Schaeffler ProLink CMS User manual

1
Schaeffler ProLink CMS
User manual

2
Schaeffler Monitoring 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 Microsoft Edge are brands or registered trademarks of the Microsoft Corporation in the USA and/or
in other countries. Google Chrome™ is a trademark of Google.
The software uses the following third-party provider libraries under their respective licences:
base, binutils, burnin, busybox, clinfo, cmake, crypto, curl, dhcp, dropbear, expat, gcc-host, gdb, gettext, glibc, gmp-host,
i2ctools, gsoap, gwt, imx-gpu-viv, kexec-tools, keys, kiss_fft, kmod, libtirpc, libunwind, linux, linuxptp, log4cpp, lzo, mbedtls,
memstat, memtester, mtd-utils, ncurses, odhcp6c, open62541, openssl, paho-mqtt-embedded-c, perfmon, popt, protobuf,
readline, rescue_tools, rsync, sqlite, strace, tar, u-boot, ua-nodeset, udev, util-linux, zlib
Full licence conditions for the respective libraries can be found in the software's program directory.
Version 1.0.0
Translation of the original user guide.
© 17/06/2020 - Schaeffler Monitoring Services GmbH
Imprint

3
Contents
Contents
.................................................................................................................................................... 41 General
.............................................................................................................................................................................................. 41.1 Safety inform ation
.............................................................................................................................................................................................. 41.2 Hazard symbols and signal w ords
.............................................................................................................................................................................................. 51.3 About this guide
.................................................................................................................................................... 62 Product description
.............................................................................................................................................................................................. 62.1 Intended use
.............................................................................................................................................................................................. 72.2 Modifications by the user
.............................................................................................................................................................................................. 72.3 Technical data
.............................................................................................................................................................................................. 92.4 Scope of delivery
.................................................................................................................................................... 103 Commissioning the base system
.................................................................................................................................................... 134 Installing the ProLink modules
.............................................................................................................................................................................................. 134.1 Installation details of the ProLink m odules
.............................................................................................................................................................................................. 144.2 Dim ensions of the ProLink m odules
.............................................................................................................................................................................................. 154.3 Mounting modules
.................................................................................................................................................... 175 Layout, connections and fittings
.............................................................................................................................................................................................. 175.1 Overview of how to connect and set up the device
.............................................................................................................................................................................................. 185.2 Connection details
.............................................................................................................................................................................................. 215.3 Connecting modules via internal Ethernet netw ork
.............................................................................................................................................................................................. 225.4 Inputs and outputs of the vibration m odule
.................................................................................................................................................................................. 22Connecting the analogue inputs of the vibration module 5.4.1
.................................................................................................................................................................................. 23Connecting the digital inputs of the vibration module 5.4.2
.................................................................................................................................................................................. 25Connecting the digital sw itching outputs of the vibration module 5.4.3
.............................................................................................................................................................................................. 275.5 Connecting the pow er supply
.............................................................................................................................................................................................. 285.6 Connecting the com puter via Ethernet
.................................................................................................................................................... 296 Operation and controls of the ProLink system
.............................................................................................................................................................................................. 316.1 Reset button
.............................................................................................................................................................................................. 316.2 Teach button
.................................................................................................................................................... 327 Further information
.................................................................................................................................................... 348 Maintenance and repair
.................................................................................................................................................... 359 Decommissioning and disposal
.................................................................................................................................................... 3610 Manufacturer/support
.................................................................................................................................................... 3711 Appendix
.........................................................................................................................................................0Index

4
1 General
1.1 Safety information
The Schaeffler ProLink condition monitoring system is manufactured in accordance with the recognised standards
and guidelines (see Declaration of Conformity) 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
provided 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 Schaeffler ProLink 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
Schaeffler ProLink 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 in line with 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 Schaeffler ProLink outputs. In doing so, the limitations of use for the connected machine
components must also be observed, in addition to the Schaeffler ProLink specification. The machine owner bears
sole responsibility for this.
The ProLink device must 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 implications.
Operating personnel
Schaeffler ProLink may only be installed, operated and maintained by authorised qualified specialists 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
DANGER
Specifies the nature and source of the hazard
Explains actions to prevent the hazard.
7

5
General
Specific hazard symbols
DANGER
DANGER FROM ELECTRICAL CURRENT!
This symbol indicates a danger from electric shock that can cause personal injury or even
death, or damage to property.
Signal words used in this guide
Signal words indicate the severity of the hazard that occurs if the actions 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 ProLink 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 Schaeffler ProLink condition monitoring system also includes
the integrated Schaeffler SmartWeb software, which is dealt with in a separate manual.
To operate the Schaeffler ProLink device, you will also need the supplied Schaeffler SmartUtility Light software. This
is also dealt with in a separate manual. You also have the option of purchasing the Schaeffler SmartUtility software,
which features enhanced functionality.
Definitions
· Product: The Schaeffler ProLink 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 more 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.
5

6
2 Product description
About the Schaeffler ProLink system
ProLink is a condition monitoring system for permanent frequency selective monitoring of plants. It consists of a
processor module (CPU) and at least one vibration module (Vibration). The system can be extended to a maximum
of 4 vibration modules. Up to 4 analogue and 2 digital signals can be connected per vibration module and measured
values can be logged, recorded and analysed. After the analysis, the system can switch up to 4 digital outputs per
vibration module depending on user-defined alarm limits and report the state to an external control system, for
example.
The ProLink device can be used to cover a wide range of applications; the ProLink device can be configured to
meet your own requirements using the integrated Schaeffler SmartW eb software. There, the connected modules
with their inputs and outputs are automatically created with default configurations and can then be adapted to your
system. The ProLink device is administered using the software Schaeffler SmartUtility Light or optionally Schaeffler
SmartUtility.
With ProLink, the Schaeffler offers status monitoring that is optimised to suit your requirements.
2.1 Intended use
The ProLink system is intended exclusively for the following functions:
•Connection of the processor module (CPU) to a maximum of 4 vibration modules (Vibration)
•Connection of input signals according to the technical specification of the respective input
•Connection of output signals according to the technical specification of the respective output
•Connection of the processor module to the PC via Ethernet
•Use of the software that is approved for the Schaeffler ProLink device
The ProLink device must not be used to switch safety-relevant applications.
The ProLink device with all connected modules may be operated only within the limitations of use as specified under
Technical data .
Measured-value analyses and changes to settings may only be made using the supplied Schaeffler SmartUtility Light
software, the optional Schaeffler SmartUtility software or the integrated Schaeffler SmartWeb software.
Any other use or use beyond this shall be considered improper and the user shall bear all associated risk. The user is
responsible for the intended use of the device. This also includes observing these instructions.
7

7
Product description
2.2 Modifications by the user
The user must not make any modifications to the ProLink device. The user may only make settings on the device
itself or via the Schaeffler SmartWeb or Schaeffler SmartUtility Light/Schaeffler SmartUtility software.
The user bears responsibility for any further modifications! Should you detect a fault with your ProLink device, please
contact our Support team.
2.3 Technical data
The ProLink device must not be used in measurement voltage categories II, III or IV!
Processor module (CPU)
General
Housing
Material: PA (polyamide)
Colour: RAL 7035
Flammability class according to UL 94: V0
Fixing
Installation on 35-mm standard mounting rail
Mounting rail height: 7.5 mm
Installed on a flat mounting surface
Power consumption
800 mA
Power supply
18–30 VDC
Typical: 24 VDC
Humidity
80%
Operating altitude
<3000 m
Ambient temperature
Operation: -30 to +60°C
Storage: -30 to +55°C
Dimensions
75 mm x 139.5 mm x 120 mm (W x H x D)
Weight
600 g
Protection type
IP 20
Operating system
Embedded Linux
Software
Schaeffler SmartWeb:
· Device-own web interface
· Recommended browser: Google Chrome
· Configuration of the device and the measurement jobs, initial data analysis
Schaeffler SmartUtility Light:
· Administration of the device
Schaeffler SmartUtility (optional and chargeable):
· Administration of the device
· Detailed analysis of the measurement data
Schaeffler SmartVisual (optional and chargeable):
· Plant visualisation
Memory
8 GB eMMC Flash
2 GB DDR3 RAM
Certifications
CE
Interfaces
Control elements
1 button to start learning mode
1 Reset button
1 USB button, intended for future functions
Display elements
1 Status LED
1 Link LED
1 Alarm LED
1 USB Status LED
Details of the functions can be found in the section Operation and controls .
29

8
Communication
Ethernet 1000 Mb/s
RJ45
Connections
1 Ethernet 1000 Mb/s
1 USB A, intended for future functions
1 USB B, intended for future functions
1 interface for fieldbus communication, intended for future functions
1 RJ45 (internal Schaeffler module communication)
1 Ethernet 100 Mb/s for communication between the Schaeffler ProLink modules
1 power supply
Communication protocols
· WebServices
· SLMP
· OPC/UA (only with additional licence)
· MQTT (only with additional licence)
· Email (only with additional licence)
Measurement jobs and characteristic values
Measurement jobs
- Base configuration
- Roller bearing
- Journal bearing
- Pump
- Fan
- Classification (optional and chargeable)
- Coupling
- Gear stage
- Belt drive
- Shaft
- Condition guard
- Tracked frequency bands
- User-defined frequency bands
The user is guided through the configuration step-by-step with the help of a wizard. Depending
on the selected measurement job, all necessary characteristic values for frequency selective
monitoring are automatically created.
Characteristic values
(time range and frequency
range)
Defined characteristic values:
- DIN/ISO 10816
Calculated characteristic values:
- RMS
- Frequency selective RMS
- Direct component
- Peak
- Peak2peak
- Crest factor
- Wellhausen counter
- Condition guard
Other user-defined characteristic values are possible.
Vibration module (Vibration)
General
Housing
Material: PA (polyamide)
Colour: RAL 7035
Flammability class according to UL 94: V0
Fixing
Installation on 35-mm standard mounting rail
Mounting rail height: 7.5 mm
Installed on a flat mounting surface
Power consumption
400 mA
Power supply
18–30 VDC
Typical: 24 VDC
Humidity
80%
Operating altitude
<3000 m
Ambient temperature
Operation: -30 to +60°C
Storage: -30 to +55°C
Dimensions
50 mm x 139.5 mm x 120 mm (W x H x D)
Weight
320 g

9
Product description
Protection type
IP 20
Certifications
CE
Interfaces
Control elements
1 Reset button
Display elements
1 Status LED
2 Link LEDs
4 LEDs for analogue inputs
2 LEDs for digital inputs
4 LEDs for digital outputs
Details of the functions can be found in the section Operation and controls .
Connections
2 RJ45 (internal ProLink communication)
1 Ethernet 100 Mb/s for communication between the Schaeffler ProLink modules
1 power supply
Inputs
4 analogue inputs
Measuring range: +/-10 V
Sample rate: 51.2 kHz
Resolution: 24 bits
DC bandwidth: 0 Hz - 20 kHz
AC bandwidth: 0.1 Hz - 20 kHz
IEPE bandwidth: 0.1 Hz - 20 kHz
Maximum number of FFT lines: 12800
2 digital inputs
Measuring range: 0-24 VDC, 0.1 Hz - 50 kHz
A/B coded (speed and direction)
Sensor supply: 24 VDC, 100 mA
Maximum current consumption per sensor when powered by the device: 25 mA at 24 VDC
Outputs
4 switching outputs
Open collector, max. 25 mA, reaction time 1 ms
Subject to technical modifications!
2.4 Scope of delivery
Scope of delivery
· ProLink starter kit consisting of a processor module (CPU) with integrated software Schaeffler SmartWeb and a
vibration module (Vibration)
· Per vibration module: One jumper for power supply and one jumper for Ethernet
· Quick start guides for processor module and vibration module
· Software Schaeffler SmartUtility Light for download on the Schaeffler homepage
· User documentation ProLink, Schaeffler SmartWeb and Schaeffler SmartUtility Light for download on the
Schaeffler homepage
Optional accessories
An extensive range of optional accessories is available for the ProLink system from Schaeffler Monitoring Services
GmbH. Please contact your local Schaeffler contact person.
29

10
3 Commissioning the base system
· The ProLink device may be maintained only by persons who are verifiably qualified to do so
in accordance with the relevant rules and regulations.
· Ensure that the ProLink device is de-energised while work is being carried out.
You can start and become familiar with a fully functional basic version of the ProLink system with the components of
the scope of delivery and up to 4 IEPE acceleration sensors. The following steps are required:
· Step 1: Install the device
· Step 2: Connect acceleration sensors to analogue inputs
· Step 3: Connect the computer to the processor module
· Step 4: Configure analogue inputs on IEPE sensors
Details about these steps can be found in the following.
Step 1: Install the device
1. Before installing, turn off the power supply to the ProLink system.
2. Connect the DC power supply to the power supply connection on the processor module.
3. Connect the power supply connection of the processor module to the power supply connection of the
vibration module using the jumper supplied.
4. Connect the processor module to the vibration module using the jumper supplied to enable communication
between the modules.
Step 2: Connect IEPE acceleration sensors
Connect up to 4 analogue IEPE acceleration sensors to the analogue inputs of the vibration module :
9
10
10
11
11
27
21
22