FLENDER AIQ EMBEDDED Operating Instructions Manual
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FLENDER AIQ EMBEDDED Operating Instructions Manual

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AIQ EMBEDDED
Operating instructions A6230-01en
Edition 09/2022

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Summary of Contents for FLENDER AIQ EMBEDDED

  • Page 1 AIQ EMBEDDED Operating instructions A6230-01en Edition 09/2022...
  • Page 2 Original operating instructions A6230-01 Edition 09/2022 20/10/2022 Copyright (©2022 Flender GmbH) 10:02:22...

  • Page 3: Table Of Contents

    Table of contents Introduction..............................9 Legal information ........................9 General information .........................10 1.2.1 Gender .............................10 1.2.2 Copyright..........................10 1.2.3 Purpose of these instructions....................11 1.2.4 Warranty ..........................11 Safety information ............................13 Intended use ..........................13 Application limits ........................13 Reasonably foreseeable misuse....................13 2.3.1 Prohibited application.......................14 Network and IT security ......................14 The five safety rules .........................14 Description ..............................15 Description of the device......................15...
  • Page 4 Table of contents Programming speed-dependent vibration monitoring .............. 29 Switching on Bluetooth pairing mode..................29 PIN & device RESET .......................29 Warning and messages ......................30 Maintenance management ......................30 Connectivity ..........................30 7.6.1 WiFi connection ........................30 7.6.2 Smartphone app ........................31 Maintenance ..............................33 Maintenance, servicing ......................33 Error detection and troubleshooting..................33 Service &...
  • Page 5 List of figures Figure 3-1 Connectors and sensors ......................15 Figure 3-2 LED indicators ..........................16 Figure 4-1 Exploded drawing of the AIQ EMBEDDED ................19 Figure 5-1 Seal seat ............................21 Figure 5-2 Device surface O-ring.........................22 Figure 5-3 Screws for upper housing section ....................22 Figure 5-4 Seal upper section........................23 Figure 5-5 Electrical connection, connection pin assignment..............24...
  • Page 6 List of figures Edition 09/2022 A6230-01en...
  • Page 7 List of tables Table 3-1 Connector description ........................16 Table 5-1 Table for electrical connection, connection pin assignment ............24 Table 8-1 Troubleshooting table.........................33 Table B-1 Electrical specifications ......................41 Table B-2 Communication interfaces......................41 Table B-3 Environmental data ........................41 Table B-4 Housing ............................42 Table B-5 Digital outputs (DO1/DO2) ......................42 Table B-6 Digital output (DO3)........................43 Table B-7 Analogue outputs (AO1/AO2) ....................43 Table B-8...
  • Page 8 List of tables Edition 09/2022 A6230-01en...

  • Page 9: 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 10: General Information

    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 11: Purpose Of These Instructions

    1.2.3 Purpose of these instructions 1.2 General information The AIQ EMBEDDED described in these instructions will be referred to below simply as the “device”. To avoid personal injury or property damage, follow the safety information and notices in these instructions.
  • Page 12 Introduction 1.2 General information Edition 09/2022 A6230-01en...

  • Page 13: Safety Information

    For safe operation, observe the information and notes in these instructions as well as the in- formation on the rating plate. Otherwise, the device may be permanently damaged. If the device is not used as intended, Flender accepts no liability. The following applications are considered as intended uses: •...

  • Page 14: Prohibited Application

    Safety information 2.3 Reasonably foreseeable misuse • Application in all areas other than those approved • Use with PG-based oils (polyglycols) 2.3.1 Prohibited application 2.3 Reasonably foreseeable misuse The following applications are prohibited: • Use in potentially explosive atmospheres as well as in Ex-protected areas •...

  • Page 15: Description

    3.1 Description of the device The device captures diverse information and measured values pertaining to the operating condition of the Flender gear unit and transfers them to the (signal) outputs of the higher- level controller (PLC). In addition, this telemetry and diagnostic data can be transmitted to theFlender Portal AIQ In- side via WiFi.

  • Page 16: Operating Elements And Indicators

    Description 3.3 Operating elements and indicators Connector pin assignment Signal Analog out 1 + 24 V DC Analog out 2 Digital out 1 RPM out Front view of the connector Digital out 2 Digital in 1 Table 3-1: Connector description Sensor area: Oil sump temperature sensor and tachometer sensor The sensors that are already connected are mounted inside the gear unit.
  • Page 17 Description 3.3 Operating elements and indicators 1 Hz flashing: Check gear unit status, warning threshold reached 3 Hz flashing: Alarm, vibration values outside the parameters LINK LED Permanently lit up: Active WiFi network connection 1 Hz flashing: Active Bluetooth connection with smartphone Bluetooth pairing mode When Bluetooth pairing mode is activated, the LEDs flash one after the other in a clockwise direction.
  • Page 18 Description 3.3 Operating elements and indicators Edition 09/2022 A6230-01en...

  • Page 19: Application Planning

    – 1x sticker for sealing the screw surfaces – 2x M6x14 cylinder-head screws DIN 6912 • 2 m connection cable M12x8 pol Delivered state The device is supplied configured for a specific Flender gear unit and so cannot be used on its own. A6230-01en Edition 09/2022...
  • Page 20 4.1 Scope of delivery The device is used to monitor machine-related telemetry data. Do not use this device on a Flender gear unit other than the one configured. Use the device only in combination with the gear-unit-specific sensor mounting material.

  • Page 21: Assembly

    Assembly General notes regarding assembly 5.1 General notes regarding assembly This chapter describes how to mount the pre-assembled device on the Flender gear unit. DANGER Risk of burns when installing the device When mounting on the gear unit, there is a risk of burns from hot gear unit surfaces or from the surfaces of the device heated by the hot gear unit.

  • Page 22: Figure 5-2 Device Surface O-Ring

    11.Mount the tachometer sensor and temperature sensor with the gear-unit-specific mount- ing kits. 12.Fix the cable routing according to the specifications of the mounting kit. When using cable ties, only use materials approved by Flender. 13.Clean the bolt surfaces and seal them using the sticker supplied. Edition 09/2022...

  • Page 23: Connecting The Device

    Assembly 5.3 Connecting the device Figure 5-4: Seal upper section Sticker Connecting the device 5.3 Connecting the device 5.3.1 Note on connecting the device 5.3 Connecting the device The device may only be connected by a qualified electrician. Follow the national and interna- tional regulations for installing electrotechnical systems.

  • Page 24: Figure 5-5 Electrical Connection, Connection Pin Assignment

    Assembly 5.3 Connecting the device Figure 5-5: Electrical connection, connection pin assignment Connector, connection pin assignment and colour coding Labelling Functional value Colour code for the cable socket according to DIN 47100 Analog out 1 Oil temperature* (0...20 mA) White + 24 V DC ± 20% brown Analog out 2 *(4...20 mA)* green Out 1...

  • Page 25: Figure 5-7 Connection Example: Digital Switching Output

    Assembly 5.3 Connecting the device Figure 5-7: Connection example: Digital switching output A6230-01en Edition 09/2022...
  • Page 26 Assembly 5.3 Connecting the device Edition 09/2022 A6230-01en...

  • Page 27: Commissioning

    Commissioning General notes on commissioning 6.1 General notes on commissioning Commissioning as well as troubleshooting are carried out by a trained technician. Read these instructions before operating the device. Putting the device into operation 6.2 Putting the device into operation 1.
  • Page 28 Commissioning 6.2 Putting the device into operation Edition 09/2022 A6230-01en...

  • Page 29: Operator Control

    Operator control Programming speed-dependent vibration monitoring 7.1 Programming speed-dependent vibration monitoring The device monitors changes in the vibration behaviour of the gear unit. The system beha- viour is ascertained for different speed ranges and limit values are determined for the corres- ponding operating points.

  • Page 30: Warning And Messages

    These warnings can be reset via the smartphone app. In addition to the intervals preset by Flender at the factory, it is possible to create up to five own maintenance intervals per gear unit. This must be done in the app.

  • Page 31: Smartphone App

    Operator control 7.6 Connectivity To connect the device to an existing WiFi infrastructure, it is necessary to store the connec- tion settings of the WiFi network in the device. This can be done via the smartphone app. Figure 7-1: Device connection 7.6.2 Smartphone app 7.6 Connectivity To use the full range of functions of the device, the app is required.
  • Page 32 Operator control 7.6 Connectivity Edition 09/2022 A6230-01en...

  • Page 33: Maintenance

    Maintenance Maintenance, servicing 8.1 Maintenance, servicing No maintenance and servicing measures are required if the device is operated properly. Only the manufacturer or personnel authorised by the manufacturer may repair the device. Error detection and troubleshooting 8.2 Error detection and troubleshooting Symptom Possible cause Detection...
  • Page 34 Maintenance 8.2 Error detection and troubleshooting Edition 09/2022 A6230-01en...

  • Page 35: Service & Support

    Customer Service addresses: Flender GmbH Am Industriepark 2 46562 Voerde Germany Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544 More information Further information about service and support can be found on the Internet: Service & Support (https://www.flender.com/service) A6230-01en Edition 09/2022...
  • Page 36 Service & Support 9.1 Contact Edition 09/2022 A6230-01en...

  • Page 37: Disposal

    Check with your local council about this. • Free collection points for electrical and electronic equipment are available in your area. • Flender electrical and electronic equipment complies with the requirements of Directive 2012/19/EU – WEEE Directive.
  • Page 38 Disposal 10.1 Disposal instructions for electronic equipment Edition 09/2022 A6230-01en...

  • Page 39: Declaration Of Conformity

    Declaration of conformity EU Declaration of Conformity EU Declaration of Conformity Marking Product: AIQ EMBEDDED Name and address of the manufacturer: Flender GmbH Am Industriepark 2 46562 Voerde Germany The object of the declaration described above is in conformity with the relevant EU harmonised standards: •...
  • Page 40 Declaration of conformity EU Declaration of Conformity Edition 09/2022 A6230-01en...

  • Page 41: Technical Specifications

    Technical specifications Rating plate Rating plate The rating plate contains the most important data. Embedded Flender GmbH Am Industriepark 2 46562 Voerde 16-32V DC Made in Germany Figure B-1: Rating plate Device name Version / Protection class Electrical specifications Electrical specifications Operating voltage DC 24 V ± 20%...

  • Page 42: Housing

    Bearing temperature -40 °C... 85 °C Max. permanent oil temperature -40 °C... 10 °C Short-term oil temperature 125 °C Relative humidity 0 ... 98% Location of use Industrial environment, mounting on Flender gear unit Connecting cable 8 pol. M12 bushing < 30 m Table B-3: Environmental data Housing Housing Size (W x D x H) 70 mm x 70 mm x 35 mm Weight 60 g...

  • Page 43: Table B-6 Digital Output (Do3)

    Technical specifications Inputs and outputs Digital output (DO3) Application Connection to PLC Model OP-AMP Rated voltage 24 V Max. output current 10 mA Max. short-circuit current 25 mA Short-circuit proof Max. switching frequency 10 kHz Max. cable length < 30 m Function assignment of digital output 3 Pulse signal of speed Table B-6: Digital output (DO3) Analogue outputs (AO1/AO2)

  • Page 44: Sensor Technology

    Technical specifications Sensor technology Sensor technology Sensor technology Temperature measurement Measuring range -40 °C... 135 °C/PT1000 Speed sensor Switching frequency up to 10k Hz Vibration sensor ± 2 g/4 g/8 g/16 g Triax-MEMS / Bandwidth 1 ... 6000 Hz Table B-9: Sensor technology Battery Battery Battery type CR2032 Required temperature range -40 °C... 85 °C Recommended battery Murata CR2032X / -40 ... 85 °C Panasonic CR2032A / -40 ... 125 °C Table B-10: Battery...

  • Page 45: Index

    Index Copyright, 10 Pairing mode, 29 Safety rules, 14 Security-relevant data Secure with PIN, 29 Sensor, 20 Smartphone app, 29 Telemetry data, 20, 29 Vibration monitoring, 29 A6230-01en Edition 09/2022...
  • Page 46 Index Edition 09/2022 A6230-01en...
  • Page 48 AIQ EMBEDDED Operating instructions A6230-01en Edition 09/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

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