FLENDER DX2000+ Operating Instructions Manual

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DX2000+

Operating instructions S6300-01en

Edition 10/2022

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Summary of Contents for FLENDER DX2000+

Page 1 DX2000+ Operating instructions S6300-01en Edition 10/2022...
Page 3: Table Of Contents
Table of contents Introduction...............................11 Legal information ........................11 Purpose of these instructions....................12 Information for the operator .....................12 Copyright..........................13 Safety information ............................15 Security notes ..........................15 The five safety rules .........................15 General information .........................15 Intended use ..........................16 Reasonably foreseeable misuse....................16 Residual risk ..........................17 Description of the guards ......................17 Markings and signs ........................17 Safety information for the personnel ..................18...
Page 4 Table of contents 3.3.5 Speed sensor ...........................27 Interfaces ..........................28 3.4.1 Ethernet ...........................28 3.4.2 Ethernet telegram ........................29 3.4.3 Pin assignment of system interface for temperature modules ..........35 Electromagnetic compatibility ....................35 Application planning ..........................37 Transport..........................37 Storage ............................37 Application planning.........................38 4.3.1 Scope of delivery ........................38 4.3.2 Unpacking and checking the delivery ..................38 4.3.3...
Page 5 Table of contents Safe operator control .......................55 Switching on and off, operation....................56 Faults ............................57 Maintenance ..............................59 Introduction ..........................59 Care of the DX2000+ control cabinet or DX site server ............60 Preparations for repair and maintenance work ................ 61 Safely maintaining electrical equipment...................61 Testing safety equipment on the control cabinet ..............
Page 6 Table of contents Index ................................79 Edition 10/2022 S6300-01en...
Page 7 List of figures Figure 3-1 Condition Monitoring System DX2000+ system design .............23 Figure 3-2 Example of the electrical design of the DX2000+ control cabinet ..........25 Figure 3-3 Example of assembly of the DX2000+ control cabinet...............25 Figure 3-4 Example of the electrical structure of the DX site server control cabinet ........26 Figure 3-5 Industrial Ethernet (on reader side) connection .................28 Figure 3-6...
Page 8 List of figures Edition 10/2022 S6300-01en...
Page 9 List of tables Table 2-1 Markings.............................17 Table 2-2 Markings.............................17 Table 5-1 Screw fasteners..........................43 Table 5-2 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...
Page 10 List of tables Edition 10/2022 S6300-01en...
Page 11: Introduction
Introduction Legal information 1.1 Legal information Warning system These instructions contain information you must observe for your own personal safety as well as to avoid damage to property and persons. The information regarding your personal safety is highlighted with a warning triangle. Information exclusively regarding property dam- age alone is not marked with a warning triangle.
Page 12: Purpose Of These Instructions
Please note the following: WARNING Flender products are only suitable for the uses set out in the catalogue and associated technical documentation. If third-party products and components are used, these must be recommended and/or authorised by Flender. Safe and flawless operation of the products requires proper transport, proper storage, setup, assembly, installation, commissioning, operation and maintenance.
Page 13: Copyright
1.4 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 15: Safety Information
In order to safeguard plants, systems, machines and networks against cyber threats it is ne- cessary to implement (and continually maintain) a holistic industrial security concept that cor- responds to the current state of the art. Flender products and solutions undergo continuous development in this respect.
Page 16: Intended Use
A typical area of application for the system is acquiring analogue and digital sensor signals from certain components of a drive train and transferring these to the Flender Service Centre. The DX2000+ should only be operated within the operating ranges and environmental condi- tions specified.
Page 17: Residual Risk
Safety information 2.6 Residual risk Residual risk 2.6 Residual risk 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.
Page 18: Safety Information For The Personnel
• Only use the 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.
Page 19: Additional Safety Information For Maintenance
Safety information 2.11 Additional safety information for maintenance 2.11 Additional safety information for maintenance 2.11 Additional safety information for maintenance Equipment appropriate for the work is required to carry out maintenance work. • Only carry out work and troubleshooting when the system is voltage-free. Carefully ob- serve the The five safety rules (Page 15) for this.
Page 20: Components That Can Be Destroyed By Electrostatic Discharge (Esd)
Safety information 2.12 Notes on special types of hazards • Call in an additional person who can press the emergency stop button or the mains dis- connection device in an emergency. • Only use voltage-insulated tools. Proper earthing of the electrical system must be ensured by protective conductor systems. A fixed installation is required for a leakage current to earth of PE > 3.5 mA.
Page 21: Vibration
Safety information 2.12 Notes on special types of hazards • If, due to local conditions, a higher sound pressure level occurs at the place of use of the DX2000+, you as the operator are responsible for equipping the operating personnel with the appropriate protective equipment.
Page 22 Safety information 2.12 Notes on special types of hazards Edition 10/2022 S6300-01en...
Page 23: Description
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 Condition Monitoring experts.
Page 24 Description 3.2 CMS DX2000+ assembly units • Ethernet switch (optional) Alternatively: • Rack PC Switch distribution – DX2000+ control cabinet • Switch housing, mounting plate and cable bushings • Top-hat rails, cable ducts • Power supply unit, SIPLUS CMS2000 basic module plus optional extension modules Optional: •...
Page 25: Figure 3-2 Example Of The Electrical Design Of The Dx2000+ Control Cabinet
Description 3.2 CMS DX2000+ assembly units Figure 3-2: Example of the electrical design of the DX2000+ control cabinet Figure 3-3: Example of assembly of the DX2000+ control cabinet S6300-01en Edition 10/2022...
Page 26: Sensors
Description 3.3 Sensors Figure 3-4: Example of the electrical structure of the DX site server control cabinet Sensors 3.3 Sensors 3.3.1 Overview of compatible sensors 3.3 Sensors You can connect various sensors to the DX2000+. The following sensors are compatible with the DX2000+: •...
Page 27: Iepe Accelerometers
Description 3.3 Sensors 3.3.2 IEPE accelerometers 3.3 Sensors You can use all IEPE sensors (integrated electronics piezo-electric) that fulfil the specifica- tion for the relevant sensor inputs, VIB1 to VIB16. Information The technical data of the connectable accelerometer can be found in the Technical data (Page 71) chapter of the instructions.
Page 28: Interfaces
Description 3.4 Interfaces Interfaces 3.4 Interfaces 3.4.1 Ethernet 3.4 Interfaces Figure 3-5: Industrial Ethernet (on reader side) connection PIN Pin assignment Transmit Data (+) Transmit Data (-) Receive Data (+) Terminated Terminated Receive Data (-) Terminated Terminated Physical layer 10 Base-T / 100 Base-TX only detected during device start-up Duplex Half / Full...
Page 29: Ethernet Telegram
Description 3.4 Interfaces 3.4.2 Ethernet telegram 3.4 Interfaces Actual data of the DX2000+ are sent cyclically via Ethernet telegrams. The telegram formats used in each case are defined here: • The telegram frame format of the telegrams that can be sent via Ethernet. •...
Page 30 Description 3.4 Interfaces Payload data for the compact telegram Length Designation Data type Description (bytes) Operating condition unsigned char Operating condition of the SIPLUS CMS2000 device: 3 = Error condition (“not ready”) 4 = Stop (“ready”) 5 = Measuring 6 = Teaching 7 = Run-Inhibit 8 = Run Note: Telegrams are sent in all of these operating...
Page 31 Description 3.4 Interfaces Length Designation Data type Description (bytes) System messages to unsigned char Number of system messages requiring acknow- be acknowledged ledgement that have not been acknowledged yet Reserve unsigned char Reserve fields for future use Exemplary structure of a compact telegram (fixed length: 32 Bytes) Byte Designation Value...
Page 32 Description 3.4 Interfaces Length Designation Data type Description (bytes) Measured values float (64) Field with 64 measured values / characteristic val- ues in IEEE 32-bit floating point format; Indexing of the following table (hereinafter always referred to as “measured values”) Length Designation Data type...
Page 33 Description 3.4 Interfaces Index Measured value OPR_HOURS AI 1 AI 2 TEMP 1.1 TEMP 1.2 TEMP 1.3 TEMP 2.1 TEMP 2.2 TEMP 2.3 10-17 Reserved VIB 1: RMS 19-26 Reserved VIB 2: RMS 28-35 Reserved VIB 1: DKW 37-44 Reserved WIB 2: DKW 46-63 Reserved...
Page 34 Description 3.4 Interfaces Length Designation Data type Description (bytes) Spectrum status unsigned Bit 5 0 = “not red” short (64) 1 = “Red” spectrum is being monitored, alarm threshold violated Bit 6 0 = No acknowledgement of warning required 1 = Warning must be acknowledged for this spectrum Bit 7 0 = No acknowledgement of alarm required...
Page 35: Pin Assignment Of System Interface For Temperature Modules
Description 3.4 Interfaces 3.4.3 Pin assignment of system interface for temperature modules 3.4 Interfaces Figure 3-6: System interface of the temperature model PIN Pin assignment TxD / SCL RxD / SDA MISO (=SDO) MOSI (=SDI) Electromagnetic compatibility 3.5 Electromagnetic compatibility The components listed in the table below are used in the DX2000+ control cabinet. The components conform to the basic protection requirements of the Electromagnetic Com- patibility Regulations with respect to transmission and resistance to electromagnetic influ- ences.
Page 36 Description 3.5 Electromagnetic compatibility 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) Edition 10/2022 S6300-01en...
Page 37: Application Planning
Application planning Transport 4.1 Transport DANGER Life-threatening crushing injuries during lifting and transporting Improper lifting and transporting can cause the DX2000+ control cabinet and the DX site server to tip and fall!! The weight distribution of the cabinet is asymmetrical, the main weight is in the rear part (back wall) of the cabinet.
Page 38: Application Planning
Application planning 4.3 Application planning Application planning 4.3 Application planning 4.3.1 Scope of delivery 4.3 Application planning Information DX2000+ sensors The sensors are delivered according to the order. Separate delivery is possible. The sensors can also be supplied preinstalled on the gear unit ex works. •...
Page 39 Application planning 4.3 Application planning NOTICE Risk of property damage to the DX2000+ and connected devices An incorrect location or mounting position may cause the unit to overheat, resulting in mal- function and damage. • Install the DX2000+ control cabinet and the DX Site-Server in the control cabinet ver- sion vertically.
Page 40 Application planning 4.3 Application planning Edition 10/2022 S6300-01en...
Page 41: Assembly
Assembly Introduction 5.1 Introduction Every person who is assigned to work on or with the CMS DX2000+ must have read and un- derstood these instructions in full. Ensure that each person follows all safety information. The operator must ensure that the DX2000+ control cabinet and the DX site server are sup- plied with power.
Page 42: Mounting The Cms Dx2000
Assembly 5.3 Mounting the CMS DX2000+ WARNING Warning against serious injuries Unsuitable fastening elements can cause the DX2000+ control cabinet and the DX site server to come loose. • Only use suitable fastening material. • Tighten screws only to the permissible tightening torque. •...
Page 43: Assembling The Sensors
Assembly 5.3 Mounting the CMS DX2000+ • Seal unused cable glands against dust. • For electrical insulation: Note the connection assignment. • Insulate the cables if required. • Expose the shielding and lay the shielding according to chapter Electrical connection (Page 46).
Page 44: Fastening Vibration Accelerometers
Assembly 5.3 Mounting the CMS DX2000+ 5.3.2.2 Fastening vibration accelerometers 5.3 Mounting the CMS DX2000+ • Assemble the vibration accelerometers according to the gear unit documentation in the level in which the load zone of the bearings is also located. To do this, select a location from which there are only a few material transitions to the bearing and which is as close as possible to the bearing.
Page 45: Figure 5-1 Installation Situation For The Displacement Sensors
If a displacement sensor is already installed there, the displacement sensor can also be in- stalled on the opposite shaft side. In this case, add the opening in the bearing cover. Contact (Page 65) Flender for the required information. Two holders are included in the delivery scope. Use the holder that matches the gear unit size.
Page 46: Completing The Mounting Work
Assembly 5.3 Mounting the CMS DX2000+ 5.3.3 Completing the mounting work 5.3 Mounting the CMS DX2000+ • Ensure that all screw connections are connected properly. • Once you have completed the mounting work, remove all objects, such as tools, cloths, deposits of dirt and moisture, etc.
Page 47: Requirements For Cables
Assembly 5.5 Electrical connection 5.5.2 Requirements for cables 5.5 Electrical connection DANGER Danger to life due to electric shock Risk of electric shock due to damaged cables. • Lay out the cables so that they cannot be damaged. • Ensure that the cables are suitable for the individual application. •...
Page 48: Connecting The Cable Shield
Assembly 5.5 Electrical connection Cable designation Conductor cross Comment section Ethernet CAT5 or higher Analogue input 0.14 ... 0.75 mm 26 ... 20 Digital input / output 26 ... 20 Accelerometer cable 26 ... 20 See Connecting the cable shield (Page 42) Table 5-2: Requirements for parameters 5.5.3 Connecting the cable shield 5.5 Electrical connection Figure 5-2: Example of assembly of the shield connector, before Figure 5-3: Example of assembly of the shield connector, after...
Page 49: Wiring
Ensure you have the wiring diagram that matches the sensor package and gear unit type. If in doubt, contact Flender Service and request a wiring diagram. The service and return addresses can be found in the Service and Support chapter.
Page 50: Figure 5-5 Double-Deck Terminal With Example Of Labelling
Assembly 5.5 Electrical connection 1. Before starting work, disconnect the system from the power supply and secure it against being switched on again. 2. Strip the insulation from the cables using a stripping tool. 3. Connect the stripped cable ends to the relevant connecting terminals. 4.
Page 51: Connection Of Dx2000+ Control Cabinet To The Dx Site Server
3. Parameterise the IP address of the DX2000+ control cabinet as described below. Please note the individual network configuration agreed between your company and Flender. If you have any questions about this, please get in touch with the contact person specified in the hardware installation instructions.
Page 52 Assembly 5.6 Dismantling Removal if a defect occurs If a defect occurs, remove the defective electrical unit and send it in. Proceed as follows to dismantle the unit: 1. Switch off the fuse outlet used in the voltage distribution and secure it against being switched on again.
Page 53: Commissioning
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: •...
Page 54 Commissioning 6.1 Commissioning Edition 10/2022 S6300-01en...
Page 55: Operator Control
Operator control Introduction 7.1 Introduction Anyone involved in the operation, cleaning, maintenance and repair of the DX2000+ control cabinet or DX site server must have thoroughly read and understood the chapter Operator control (Page 55). Safe operator control 7.2 Safe operator control Electrotechnical information DANGER Danger to life due to electric shock...
Page 56: Switching On And Off, Operation
Operator control 7.3 Switching on and off, operation A technically suitable person can assess and carry out the work assigned to them and recog- nise possible hazards on the basis of their technical training, knowledge and professional ex- perience as well as knowledge of the accident prevention and occupational safety regula- tions if they also fulfil the necessary personal requirements for the activity, e.g.
Page 57: Faults
Operator control 7.4 Faults Faults 7.4 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). S6300-01en Edition 10/2022...
Page 58 Operator control 7.4 Faults Edition 10/2022 S6300-01en...
Page 59: Maintenance
When repairing or ordering replacement parts, refer to the wiring diagrams included in the in- structions. You can find these in the supplied DX2000+ control cabinet and DX Site-Server or request them from Flender. In particular, liability for defects due to the following causes shall not apply: Poor mainten- ance, use of non-original replacement parts, modification without the written consent of the seller, poorly carried out repairs by the buyer or normal wear and tear.
Page 60: Care Of The Dx2000+ Control Cabinet Or Dx Site Server
8.2 Care of the DX2000+ control cabinet or DX site server Replacement parts to be used must comply with the technical requirements specified by Flender. This is always guaranteed with original replacement parts. Care of the DX2000+ control cabinet or DX site server 8.2 Care of the DX2000+ control cabinet or DX site server...
Page 61: Preparations For Repair And Maintenance Work
Maintenance 8.3 Preparations for repair and maintenance work • Clean the DX2000+ control cabinet and DX Site-Server on the inside too. Mark built-in withdrawable circuit breakers and withdrawable units and only then remove them for cleaning. Preparations for repair and maintenance work 8.3 Preparations for repair and maintenance work •...
Page 62: Testing Safety Equipment On The Control Cabinet
Maintenance 8.5 Testing safety equipment on the control cabinet Testing safety equipment on the control cabinet 8.5 Testing safety equipment on the control cabinet Information Check all safety devices and equipment according to the maintenance schedule (Page 62) or safety checklist. For details, refer to the instructions for the complete system or machine. If defects are found during safety inspections, the DX2000+ control cabinet and DX Site- Server may only be put back into operation after it has been repaired accordingly and ap- proved by a responsible person appointed by the operator.
Page 63: Table 8-2 Dx Site Server Rack Pc
Maintenance 8.6 Maintenance schedule 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...
Page 64 Maintenance 8.6 Maintenance schedule Edition 10/2022 S6300-01en...
Page 65: Service & Support
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) Technical return address 9.2 Technical return address Send the defective DX2000+ to the following address:...
Page 66 Service & Support 9.2 Technical return address Edition 10/2022 S6300-01en...
Page 67: Disposal
Disposal 10.1 Plastics 10.1 Plastics Sort the used/processed plastics as far as possible. Dispose of plastics in compliance with legal requirements. 10.2 Metals 10.2 Metals Separate the used/processed metals as far as possible. Ensure metals are disposed of by an authorised company. 10.3 Electrical and electronic waste 10.3 Electrical and electronic waste...
Page 68 Disposal 10.4 Scrapping Edition 10/2022 S6300-01en...
Page 69: Declaration Of Conformity
EU Declaration of Conformity EU Declaration of Conformity Product: DX2000+ Name and address of the manufacturer: Flender GmbH Am Industriepark 2 46562 Voerde Germany This Declaration of Conformity is issued under the sole responsibility of the manufacturer. This declaration refers to the product mentioned above.
Page 70 Declaration of conformity EU Declaration of Conformity Edition 10/2022 S6300-01en...
Page 71: Technical Specifications
Technical specifications Rating plate Rating plate The rating plate contains the most important information. Figure B-1: Rating plate Company logo Device Model Material number Year of manufacture Voltage information, current information No. of instruction(s) including issue date Manufacturer documentation / Country of origin Hotline Technical data for the DX site server –...
Page 72: Technical Data For Thr Dx Site Server - Version: Rack Pc 19
Technical specifications Technical data for thr DX site server – version: Rack PC 19″ Technical data for thr DX site server – version: Rack PC 19″ Technical data for thr DX site server – version: Rack PC 19″ Width 481.4 Height (4HE) 176.6 Depth...
Page 73 Technical specifications Technical data for the DX2000+ control cabinet • Input resistance (0 – +10 V) ≥ 100 kΩ • Cable length voltage: shielded and twis- ted, maximum • Industrial Ethernet (RJ45) 10 Base-T, 100 Base- Digital input 2x • Input voltage V DC Speed / Bero input •...
Page 74: Technical Data For Temperature Module
Technical specifications Technical data for temperature module • Resistance sensor Pt10, Pt50, Pt100, Pt200, Pt500, Pt1000, Ni100, Ni120, Ni500, Ni1000, Cu10, Cu550, Cu100, LG-Ni1000 • Resistance 150, 300, 600 Ω Technical data for temperature module Technical data for temperature module Fastening Snap-mounted onto 35 mm standard mounting rail or screw-mounted using additional push-in...
Page 75: Relevant Assumptions
Technical specifications Relevant assumptions Connection Temperature module Tightening torque Torque: 7 LB.IN … 10.3 LB.IN 0.8 Nm ... 1.2 Nm Conductor cross-sections: Solid 2 x 0.5 mm … 2.5 mm Relevant assumptions Relevant assumptions Maximum height above sea 1500 level Environmental conditions Environmental conditions Be sure to observe the following environmental conditions: Minimum ambient temperature during operation - 20 °C...
Page 76 Technical specifications Environmental conditions Edition 10/2022 S6300-01en...
Page 77: Annex
Annex Certificates and approvals Certificates and approvals Component Company Documentation SIPLUS CMS2000 SIEMENS EU Declaration of Conformity Sirius motor management and control SIEMENS EU Declaration of Conformity units SIMOCODE pro SIMATIC IPC SIEMENS EU Declaration of Conformity SITOP PSU100S SIEMENS EU Declaration of Conformity SIMATIC S7-1200 SIEMENS...
Page 78 Annex Software Edition 10/2022 S6300-01en...
Page 79 Index Assembly, 42 Displacement sensors, 44 Speed sensors, 44 Vibration accelerometers, 44 Connecting the cable shield, 48 Copyright, 13 Current and voltage sensors, 27 IEPE accelerometers, 27 Maintenance intervals, 62 Replacement intervals, 62 Safety rules, 15 Speed sensor, 27 System design, 23 Technical specifications, 71 Temperature sensors, 27 S6300-01en Edition 10/2022...
Page 80 Index Edition 10/2022 S6300-01en...
Page 82 DX2000+ Operating instructions S6300-01en Edition 10/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

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