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Maintenance

8.6 Maintenance schedule

S6300-01en

Edition 10/2022

Components

Replacement interval

Hard drive

3 years

CMOS buffer battery

5 years

Housing fan

3 years

Filter mat

Depending on the degree of contamination

Table 8-2:

DX site server Rack PC

Components

Replacement interval

Hard drive

3 years

CMOS buffer battery

4 years

Table 8-3:

DX site server IPC

Summary of Contents for DX2000+

Page 1: ...Operating instructions S6300 01en Edition 10 2022 DX2000 ...

Page 3: ...8 Markings and signs 17 2 9 Safety information for the personnel 18 2 10 Safety instructions for maintenance personnel 18 2 11 Additional safety information for maintenance 19 2 12 Notes on special types of hazards 19 2 12 1 Electrics 19 2 12 2 Components that can be destroyed by electrostatic discharge ESD 20 2 12 3 Noise 20 2 12 4 Vibration 21 2 12 5 IT security 21 3 Description 23 3 1 Product d...

Page 4: ...nd DX site server 41 5 3 Mounting the CMS DX2000 42 5 3 1 Electrical installation 42 5 3 2 Assembling the sensors 43 5 3 2 1 Safety information for mounting the sensors 43 5 3 2 2 Fastening vibration accelerometers 44 5 3 2 3 Fastening speed sensors 44 5 3 2 4 Installing the displacement sensor 44 5 3 3 Completing the mounting work 46 5 4 Safety guidelines 46 5 5 Electrical connection 46 5 5 1 Saf...

Page 5: ...t 65 9 1 Contact 65 9 2 Technical return address 65 10 Disposal 67 10 1 Plastics 67 10 2 Metals 67 10 3 Electrical and electronic waste 67 10 4 Scrapping 67 A Declaration of conformity 69 A 1 EU Declaration of Conformity 69 B Technical specifications 71 B 1 Rating plate 71 B 2 Technical data for the DX site server version Control cabinet 71 B 3 Technical data for thr DX site server version Rack PC...

Page 6: ...Table of contents 6 Edition 10 2022 S6300 01en Index 79 ...

Page 7: ...26 Figure 3 5 Industrial Ethernet on reader side connection 28 Figure 3 6 System interface of the temperature model 35 Figure 5 1 Installation situation for the displacement sensors 45 Figure 5 2 Example of assembly of the shield connector before 48 Figure 5 3 Example of assembly of the shield connector after 48 Figure 5 4 Connection assignment 49 Figure 5 5 Double deck terminal with example of la...

Page 8: ...List of figures 8 Edition 10 2022 S6300 01en ...

Page 9: ...Requirements for parameters 48 Table 8 1 Maintenance table 62 Table 8 2 DX site server Rack PC 63 Table 8 3 DX site server IPC 63 Table B 1 Technical data of the DX site server version Control cabinet 71 Table B 2 DX2000 control cabinet 75 Table B 3 DX site server 75 Table C 1 Certificates and approvals 77 Table C 2 Software 77 ...

Page 10: ...List of tables 10 Edition 10 2022 S6300 01en ...

Page 11: ...cal injury will occur if the relevant precautionary meas ures are not taken WARNING means that death or severe physical injury may occur if the relevant precautionary meas ures are not taken CAUTION means that mild physical injury may occur if the relevant precautionary measures are not taken NOTICE means that damage to property may occur if the relevant precautionary measures are not taken If mul...

Page 12: ...tation must be followed Trademarks All designations marked with the trademark symbol are registered trademarks of Flender GmbH Other designations in this document may be trademarks whose use by third parties for their own purposes may violate the rights of the owner Liability disclaimer We have assessed the contents of these instructions for compliance with the hardware and software described Howe...

Page 13: ... Page 65 1 4 Copyright1 4 Copyright The copyright of these instructions is held by Flender Without the authorisation of Flender these instructions may not be used wholly or in parts for competitors purposes or be given to third parties If you have any technical queries please contact the Customer Services address Page 65 ...

Page 14: ...Introduction 1 4 Copyright 14 Edition 10 2022 S6300 01en ...

Page 15: ...security Flender products and solutions undergo continuous development in order to make them even safer Flender strongly recommends that you regularly implement product updates as soon as they become available and that you only use the current product versions Use of older or no longer supported versions can increase the risk of cyber threats 2 2 The five safety rules2 2 The five safety rules In o...

Page 16: ...ed use follow the notes described in these instructions Safety Operation and control Maintenance and repair Any other use or use beyond this is considered improper The operator alone is solely liable for any resulting damage This also applies to unauthorised modifications to the DX2000 2 5 Reasonably foreseeable misuse2 5 Reasonably foreseeable misuse The following processing methods are considere...

Page 17: ... risks Follow the instructions that prevent residual risks from causing accidents or damage During the installation work it may be necessary to dismantle on site guards This creates various residual risks and potential dangers that every operator must be aware of 2 7 Description of the guards2 7 Description of the guards Protective measures Protective conductor PE and centre conductor N are routed...

Page 18: ... DX2000 when it is in perfect technical condition and for its intended pur pose in a safety and hazard conscious manner and in compliance with these instruc tions Flender accepts no liability for damage and accidents caused by non observance of the in structions Eliminate all faults immediately Keep the instructions handy on the DX2000 at all times Only reliable trained and qualified personnel of ...

Page 19: ...s with a torque spanner according to specification 2 12 Notes on special types of hazards2 12 Notes on special types of hazards 2 12 1 Electrics2 12 Notes on special types of hazards Work on the DX2000 may only be carried out by a qualified electrician or by instructed per sonnel under the supervision of a qualified electrician in accordance with the electrotechnical regulations Before opening the...

Page 20: ...nstructions below Avoid physical contact with electronic components If you must carry out essential work on electronic components wear some of the follow ing protective equipment A grounded ESD wrist strap If there is an ESD floor you can use ESD shoes or ESD shoe grounding strips Do not place electronic components near data terminals monitors or televisions Main tain a minimum clearance to the sc...

Page 21: ...via VPN software which uses a VPN server destination address with a fixed destination port port 443 is used for SSL HTTPS commu nication Specifically this refers to a transport encryption with a TLSv1 3 TLS_AES_256_GCM_SHA384 encryption Connection via IPSec is also possible The VPN server address is as follows crsp sslvpn fth p siemens com 194 138 37 194 DMZ Fuerth Ensure that the entire CMS for t...

Page 22: ...Safety information 2 12 Notes on special types of hazards 22 Edition 10 2022 S6300 01en ...

Page 23: ...als from the sensors installed in the drive train are digitised in some cases the signals are preprocessed The DX2000 control cabinet is connected to the DX Site Server via Ethernet This perman ently monitors the condition of components subject to wear and critical machine elements Tunnel software establishes a connection to the Flender Remote Service Center This en ables a monitoring service by C...

Page 24: ... mounting plate and cable bushings Top hat rails cable ducts Power supply unit SIPLUS CMS2000 basic module plus optional extension modules Optional Siemens S7 compact control Torque evaluation unit Schematic structure Depending on the connected sensors there are different hardware configurations The de tailed design is laid out in the respective control cabinet documentation ...

Page 25: ...scription 3 2 CMS DX2000 assembly units S6300 01en Edition 10 2022 25 Figure 3 2 Example of the electrical design of the DX2000 control cabinet Figure 3 3 Example of assembly of the DX2000 control cabinet ...

Page 26: ...ucture of the DX site server control cabinet 3 3 Sensors3 3 Sensors 3 3 1 Overview of compatible sensors3 3 Sensors You can connect various sensors to the DX2000 The following sensors are compatible with the DX2000 IEPE accelerometers Temperature sensors Current and voltage sensors Speed sensor ...

Page 27: ...uctions 3 3 4 Current and voltage sensors3 3 Sensors You can connect current and voltage sensors via the analogue inputs The current and voltage sensors must comply with the output ranges The output ranges are Current 0 mA 0 mA Voltage 10 V 10 V Information The technical data of the connectable voltage and current sensors can be found in the Technical data Page 71 chapter of the instructions 3 3 5...

Page 28: ...ted 8 Terminated Physical layer 10 Base T 100 Base TX only detected during device start up Duplex Half Full only detected during device start up Cable category at least CAT5 Auto Negotiation Auto MDIX yes Maximum cable length 100 m Insulation voltage 500 V DC Real time and buffering Information It is only permitted to connect shielded CAT5 cables or cables of a higher standard to the Ethernet sock...

Page 29: ...um a f Acceleration spectrum env f Envelope spectrum of acceleration Telegram frame format Length bytes Designation Data type Description 4 Time stamp unsigned long Current relative time in µs 0 3 600 000 000 4 Payload data length unsigned long Length of the payload data in bytes without the fields Time stamp Length of payload data In dex and End code 4 Index unsigned long Used to distinguish the ...

Page 30: ...n 0 Off 1 On 1 Status LED DO warning yellow unsigned char Current status of the LED and of the digital output warning yellow 0 Off 1 On 2 Flashes slowly 0 5 Hz 3 Flashes quickly 2 0 Hz 1 Status LED DO alarm red unsigned char Current status of the LED and of the digital output alarm red 0 Off 1 On 2 Flashes slowly 0 5 Hz 3 Flashes quickly 2 0 Hz 1 Active process alarms unsigned char Number of curre...

Page 31: ...ayload data of the compact telegram 12 Operating condition 8 8 Run 13 Status LED DO nor mal green 1 1 On 14 Status LED DO warn ing yellow 0 0 Off 15 Status LED DO alarm red 0 0 Off 16 Active process alarms 0 No active process alarms 17 Active system alarms 0 No active system alarms 18 Active process warn ing 0 No active process warnings 19 Active system warn ings 1 An active system warning is pend...

Page 32: ... configured Bit 1 0 Signal not detected or erroneously detec ted 1 Signal correctly detected Bit 2 0 Measured value not calculated invalid 1 Measured value calculated if applicable and valid Bit 3 0 not green 1 green measured value is being mon itored no threshold violation Bit 4 0 not yellow 1 yellow measured value is being mon itored warning threshold violated Bit 5 0 not red 1 red measured valu...

Page 33: ... Spectrum status unsigned short 64 Field with 1 status word 16 bits for each spectrum v f a f env f for indexing see following table as signment as follows Bit 0 0 Spectrum not configured 1 Spectrum configured Bit 1 0 Vibration signal not detected or erroneously detected 1 Vibration correctly detected Bit 2 0 Spectrum not calculated invalid 1 Spectrum calculated if applicable and valid Bit 3 0 not...

Page 34: ...edgement of alarm required 1 Alarm must be acknowledged for this spec trum The assignment of the bits in the high byte depends on the type of spectrum The following applies for env f Bit 8 Bit 11 Reserved Bit 12 0 Inner ring of bearing not affected 1 W A threshold for inner ring of bearing viol ated Indexing of the spectrum status information Index Measured value 0 VIB 1 v f 1 8 Reserved 9 VIB 2 v...

Page 35: ...ssion and resistance to electromagnetic influ ences This has been proven with tests based on the relevant basic technical standards or product family standards The requirements correspond to those laid down for devices used in an in dustrial environment A technical analysis and evaluation of transmission and resistance aspects has shown that neither the interference emission or the transmission of...

Page 36: ...ompatibility 36 Edition 10 2022 S6300 01en Designation SIMATIC S7 1200 CPU 1214C optional SIMATIC S7 1200 analogue input SM 1231 RTD optional SIMATIC S7 1200 analogue input SM 1231 8 AI optional Compact Switch Module CSM 1277 optional ...

Page 37: ...suspended loads Observe the following safety information when transporting the DX2000 control cabinet and DX site server by crane Carefully observe the applicable accident prevention and occupational safety regula tions Observe the instructions and regulations of the carrier Check the tight fit of the lifting equipment Attach the transport ropes to the crane hook in such a way that they do not tou...

Page 38: ...nnected devices Do not use any devices that show evidence of damage Check the complete scope of delivery for completeness before installation Unpack the DX2000 Check the scope of delivery for completeness using the packing lists enclosed with the control cabinet Complain about any missing parts with exact details according to the packing list Check the device for transport damage by visual inspect...

Page 39: ...rol cabinet and the DX Site Server in the control cabinet ver sion vertically Adhere to the permissible ambient temperature range according to the environmental conditions Page 75 The DX2000 control cabinet is suitable for mounting on a gear unit or for mounting close to the gear unit Connect the DX2000 control cabinet to the DX Site Server via Ethernet More information The dimensions of the DX200...

Page 40: ...Application planning 4 3 Application planning 40 Edition 10 2022 S6300 01en ...

Page 41: ...aterial Tighten screws only to the permissible tightening torque Use a torque spanner 5 2 Assembly of the DX2000 control cabinet and DX site server5 2 Assembly of the DX2000 control cabinet and DX site server DANGER Life threatening injuries possible Improper installation may result in electric shock for example As the operator only allow installation work to be carried out by qualified personnel ...

Page 42: ...ns on fixed beams in the building 1 900 mm Cushion and mark the head impact hazard area As the operator it is your responsibility to provide access aids Insulate steam and condensate pipes Information Design of the grid connection Refer to the electrical drawing and the rating plate on the control cabinet for the operating voltage and the design of the mains connection The cross section of the req...

Page 43: ... the CMS DX2000 DANGER Danger to life due to electric shock Electric shock results in fatal injuries Prior to starting work switch off the power supply to the system via the mains discon nection device Secure the system against being switched on accidentally Close the mains disconnection device and put up warning signs Ensure all work is carried out by trained and authorised specialist personnel o...

Page 44: ...tening speed sensors5 3 Mounting the CMS DX2000 Speed sensors with optical and inductive speed detection can be used on the DX2000 An optical sensor is based on the principle of a reflection light barrier while an inductive sensor functions according to the principle of an oscillating circuit with an electromagnetic field Both versions work contact free Clean the surface of the mounting location I...

Page 45: ... need the screws to fasten the holder 2 Plug the supplied cable onto the displacement sensor 3 Screw the displacement sensor into the reducer screw so that the measuring surface later protrudes from the holder 4 Screw the skin top feedthrough firmly into the holder 5 Feed the cable of the displacement sensor through the cable gland 6 Screw the reducer screw with displacement sensor into the holder...

Page 46: ...delines5 4 Safety guidelines Comply with the respective valid and official safety guidelines 5 5 Electrical connection5 5 Electrical connection 5 5 1 Safety information for electrical connection5 5 Electrical connection DANGER Danger to life due to electric shock Electric shock results in fatal injuries Prior to starting work switch off the power supply to the system via the mains discon nection d...

Page 47: ...the system interface ensure that this signal path has no galvanic connection to earth potential Please note that there is no galvanic isolation of the system interface in the DX2000 control cabinet Power supply When installing the device observe the country specific regulations Electromagnetic interference Ensure that adequate potential equalisation is implemented for all plants or systems in whic...

Page 48: ...e to put on their shields Attach the shields of the cables to the earth terminals using the shield connectors 1 Insulate the cable across the width of the shield connector 2 Pull the shield braid back over the cable sheath 3 Insert the connecting conductor into the shield connection terminal 4 Fix the terminal by pressing on the suspension bracket 5 Crimp the shield connector until both ends overl...

Page 49: ...n the legally valid standards and regulations for the operation of electrical systems NOTICE Risk of property damage to the DX2000 control cabinet DX site server and connec ted devices Incorrect wiring of the process signals leads to malfunctions of the DX2000 control cab inet DX Site Server and connected devices Ensure that the terminal assignment is correct Information The DX2000 product portfol...

Page 50: ...nt connecting terminals 4 Fasten the connection points of the terminal to the spring loaded connections Multi deck terminals For reasons of space double deck or triple deck terminals are installed in the control cabin ets When wiring in this case note not only the number but also its position in the level This means that you have to reverse the number sequence from one side The following figure sh...

Page 51: ...t this please get in touch with the contact person specified in the hardware installation instructions 4 Connect the two control cabinets via a LAN cable IP addresses In order for the DX2000 base unit in the DX2000 control cabinet to communicate with the DX Site Server both components must be connected to the same network If you have direct wiring between the two components you can use the standar...

Page 52: ...ollows to dismantle the unit 1 Switch off the fuse outlet used in the voltage distribution and secure it against being switched on again 2 Ensure that each pole is free of voltage 3 Earth and short circuit relevant components Insulate neighbouring live components 4 Carry out the assembly steps as described in chapter Mounting the CMS DX2000 Page 42 in reverse order ...

Page 53: ...DX site server every time the unit is started up The function test must be carried out by instructed person nel Do not put the DX2000 into operation until further action has been agreed with Flender if one of the following violations occur Contaminations Liquid penetration Presence of condensation Damage Other violations of transport or storage conditions ...

Page 54: ...Commissioning 6 1 Commissioning 54 Edition 10 2022 S6300 01en ...

Page 55: ... maintenance work carried out only when the unit is switched off voltage free and only by a qualified electrician A skilled electrician is a person who on the basis of their technical training knowledge and experience as well as knowledge of the relevant regulations can assess the work assigned to them and recognise possible hazards Note for the operator As the operator it is your responsibility t...

Page 56: ...abinet or DX site servers Report any changes that have occurred to the DX2000 control cabinet and DX Site Server that affect safety immediately to the superior in charge Immediately stop the DX2000 control cabinet and DX Site Server in the event of a mal function that affects safety Do not put the DX2000 control cabinet and DX Site Server back into operation until the fault has been rectified Do n...

Page 57: ...ults S6300 01en Edition 10 2022 57 7 4 Faults7 4 Faults Information If problems occur during troubleshooting contact Flender Customer Service You will find the necessary contact details in the chapter Service Support Page 65 ...

Page 58: ...Operator control 7 4 Faults 58 Edition 10 2022 S6300 01en ...

Page 59: ...bserve all safety instructions and the applicable accident prevention regulations Contact Service Support Page 65 with any questions about maintenance and in spection In case of repair send the DX2000 to the return address for defective units Information If you notice that the buffer memory for the time of day for the DX site server no longer func tions correctly this indicates that the battery is...

Page 60: ...Site Server and keep them in a functional condition in the long term Remove dust from the outside of the DX2000 control cabinet and DX Site Server with dry blowing air 5 bar or suction air with the aid of a brush Do not forget the surface of the roof plates above Carefully clean the ventilation attachments of the fields and ventilation slots of the doors with suction air only so as not to blow the...

Page 61: ...lity to determine the type and scope of required in spections Set the intervals for the periodic inspections so that the DX2000 control cabinet and DX Site Server can be used safely until the next specified inspection Information Inspection intervals As a general rule for electrical work equipment stationary approved inspection intervals for periodic inspections are every 4 years The test must be ...

Page 62: ...ork ensures consistent trouble free operation of the DX2000 control cabinet and DX Site Server The maintenance schedule depicts which work must be carried out at the designated points on a weekly monthly or semi annual basis Interval Work to be carried out Responsible person nel Monthly Clean all components Check components for wear and tear Maintenance person nel Every 6 months Check all electric...

Page 63: ...Replacement interval Hard drive 3 years CMOS buffer battery 5 years Housing fan 3 years Filter mat Depending on the degree of contamination Table 8 2 DX site server Rack PC Components Replacement interval Hard drive 3 years CMOS buffer battery 4 years Table 8 3 DX site server IPC ...

Page 64: ...Maintenance 8 6 Maintenance schedule 64 Edition 10 2022 S6300 01en ...

Page 65: ...Flender GmbH Am Industriepark 2 46562 Voerde Germany Tel 49 0 2871 92 1864 Email dx support flender com More information Further information about service and support can be found on the Internet Service Support https www flender com service 9 2 Technical return address9 2 Technical return address Send the defective DX2000 to the following address Flender GmbH Service Condition Monitoring Warehous...

Page 66: ...Service Support 9 2 Technical return address 66 Edition 10 2022 S6300 01en ...

Page 67: ...nd electronic waste Appliances with the electrical and electronic waste logo on the packaging or on the appliance must be disposed of separately These devices must not be disposed of with normal house hold waste You are responsible for ensuring that any electrical or electronic waste is disposed of through the appropriate channels 10 4 Scrapping10 4 Scrapping Check which materials can be recycled ...

Page 68: ...Disposal 10 4 Scrapping 68 Edition 10 2022 S6300 01en ...

Page 69: ...ications on which the Declaration of Conformity is based EN 61439 1 Low voltage switchgear and controlgear assemblies General rules EN 61439 2 Low voltage switchgear and controlgear assemblies Power switchgear and controlgear assem blies EN 60529 Degrees of protection provided by enclosures EN 60204 1 Safety of machines Electrical equipment of machines EN 61140 Protection against electric shock EN...

Page 70: ...Declaration of conformity EU Declaration of Conformity 70 Edition 10 2022 S6300 01en ...

Page 71: ...on s including issue date 8 Manufacturer documentation Country of origin 9 Hotline B 2 Technical data for the DX site server version Control cabinetTechnical data for the DX site server version Control cabinet Width 500 mm Height 500 mm Depth 210 mm Supply voltage 120 240 V AC Control voltage 24 V DC Power input 5 A Industrial Ethernet 3 x RJ 45 100 1000 Mbit s Protection class 65 IP Minimum tempe...

Page 72: ...A Industrial Ethernet 2 x RJ45 100 1000 Mbit s Fan13 Yes IP front 30 IP IP back 20 IP Minimum temperature range 0 C Maximum temperature range 40 C B 4 Technical data for the DX2000 control cabinetTechnical data for the DX2000 control cabinet Maximum width 760 mm Maximum height 760 mm Depth 300 mm Supply voltage 120 230 V AC Power input 5 A Protection class 65 IP Minimum temperature range 20 C Maxi...

Page 73: ...asuring range KTY 84 40 300 C Measuring range KTY 83 110 50 175 C Measuring range Pt 1000 50 500 C Measuring range Pt 100 50 500 C Input resistance voltage 9 MΩ Sensor current for Pt 100 typical 1 mA S7 CPU 1214CS Industrial Ethernet RJ45 100 Mbit s max S7 analogue input SM 1231 8 AI Analogue inputs 8x Current or voltage dif ferential inputs Permissible input current for current input destruction ...

Page 74: ...ule to a current detection module or current voltage detection module or to the operat ing module Sensor circuit Conversion time 500 ms Type of connection 2 wire or 3 wire connection Typical sensor current PT 100 1 mA typical PT 1000 KTY 83 KTY 84 NTC 0 2 mA typical Open circuit detection short circuit detection measuring range PT 100 PT 1000 Open circuit short circuit measuring range 50 C 500 C K...

Page 75: ...rature during storage and transport 20 C Maximum ambient temperature during storage and transport 60 C Minimum relative humidity during operation 5 Maximum relative humidity during operation 95 no condensation Type of protection 65 IP Maximum height above sea level 1 500 m Table B 2 DX2000 control cabinet Minimum ambient temperature during operation 0 C Maximum ambient temperature during operation...

Page 76: ...Technical specifications Environmental conditions 76 Edition 10 2022 S6300 01en ...

Page 77: ... RITTAL EU Declaration of Conformity Double deck clamps PHOENIX CONTACT EU Declaration of Conformity MZFKK 1 5 PHOENIX CONTACT EU Declaration of Conformity Earthing terminals STTB 1 5 SIEMENS EU Declaration of Conformity Table C 1 Certificates and approvals C 2 SoftwareSoftware The following software components are installed configured and tested on the DX site server Software Manufacturer Windows...

Page 78: ...Annex Software 78 Edition 10 2022 S6300 01en ...

Page 79: ...44 Vibration accelerometers 44 C Connecting the cable shield 48 Copyright 13 Current and voltage sensors 27 I IEPE accelerometers 27 M Maintenance intervals 62 R Replacement intervals 62 S Safety rules 15 Speed sensor 27 System design 23 T Technical specifications 71 Temperature sensors 27 ...

Page 80: ...Index 80 Edition 10 2022 S6300 01en ...

Page 81: ......

Page 82: ...DX2000 Operating instructions S6300 01en Edition 10 2022 Flender GmbH Alfred Flender Straße 77 46395 Bocholt Germany ...

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