FAG DTECT X1 s Continuous Monitoring of

Plant and Machinery

Increasing plant availability

Anyone with responsibility for themaintenance of complex plantknows the challenges involved in the planning of maintenancemeasures. Through permanent,seamless monitoring of instal -lations, the operator has access at any time to information on the condition of the most importantcomponents of his plant. It is thuspossible to avoid unplanned ma -chine downtime and the associatedcosts. At the same time, the earlydetection of damage makes it possible to implement measures at an appropriate time. This givesthe operator a high degree ofinvestment security as well as active machinery protection.

Online monitoring system FAG DTECT X1 s

The FAG DTECT X1 s is a flexibleonline system for the monitoring ofcomponents and devices, machineryand plant.

Typical applications include: • fans• gearboxes• compressors• roll stands• mills• drives.

Advantages of the FAG DTECT X1 s

– Reliable machinery protection by means of vibration diagnosis

– Space saving due to compactconstruction

– Suitable for harsh conditions (–20 °C to +70 °C, IP67)

– Diverse monitoring tasks due tolarger number of measurementchannels

– Increased reliability through combination of various processparameters

– Versatile communication inter-faces and connection options

– Increased operational securitydue to better availability of theequipment to be monitored

– Flexible and simple installation atthe location due to standardisedconnection systems

Reliable machine protection through vibration diagnosis · FAG DTECT X1 s areas of application

1

Continuous plant monitoring bymeans of vibration diagnosis

Vibration diagnosis by means offrequency-selective monitoring is ameasurement method that allowsobjective assessment of complexplant. Envelope analysis plays an im - portant role here. This can be usedto detect periodic shock impulsesfrom the vibration signal of amachine, such as those that occurin gearbox and rolling bearingdamage. Damage can be detectedat an early stage through charac -teristic patterns in the frequencyspectra of the machine vibration.By means of defined, narrow frequency bands, the amplitudes of individual components can bespecifically monitored.

FAG DTECT X1 s Examples of sectors and applications

Digital vibration monitor-ing with FAG DTECT X1 s

FAG DTECT X1 s allows connectionof all common IEPE accelerationsensors. The signal from these sen-sors is recorded and broken downinto its frequency components by means of Fast Fourier Trans -formation (FFT). It is thus possibleto monitor amplitudes within fixedand very narrow frequency bandsfor specified limit values. An alarmis triggered if these are exceeded. With FAG DTECT X1 s, two differentparameter types can be recordedfrom the vibration acceleration signal. Firstly the RMS value, whichis detected from the spectrum of the raw signal and secondly theLDZ value (bearing diagnostic parameter) which is generated fromthe envelope signal.

Depending on the width of the frequency components which are used for calculation based on the relevant spectrum, these are referred to as broadband or frequency-selective parameters. In the case of broadband parametermonitoring, the overall vibrationbehaviour of a machine is deter-mined. The condition of the individ-ual components can be analysedprecisely by means of narrowband,frequency-selective monitoring.

Digital vibration monitoring with FAG DTECT X1 s

2

FAG DTECT X1 s calculates variousparameters: • RMS• IEPE• peak value• peak-to-peak value• steady component• crest factor.

FAG DTECT X1 s has two additionalchannels, which can be used torecord process variables such as • speed • torque• temperature• pressureand can be used for validation ofthe parameters.This method is used in practice toachieve, for example, the speed-dependent tracking of the frequencybands and the setting of load-dependent and speed-dependentalarm limits.

As standard, the FAG DTECT X1 s issupplied in an IP67 housing forinstallation. The standard M12 plug-in connec-tors are advantageous in allowingsimple installation. A top hat railadapter is available as an option.

FAG DTECT X1 s

Broadband monitoring

Alarm warnings

In terms of adjustable limit values,a distinction is drawn between prealarm and main alarm thresholds. Each alarm can triggera switching relay. To avoid false alarms, a delay canbe set on the main alarm. FAG DTECT X1 s has two analogueoutputs and two relay outputs. If the limit value is exceeded, theanalogue outputs can relay theparameters to a higher level controlsystem (PLC system). The relay outputs are used for thedirect control of machinery.

A “traffic light” display on the frontpanel of the housing with red, yellow and green lights gives animmediate indication of the moni-toring condition.

The user is given further informationon a four line LCD display.

Remote monitoring withFAG DTECT X1 s

FAG DTECT X1 s allows remote monitoring of plant and machinery.

Changes to components are reliablydetected by the monitoring systemand can be reported to differentrecipients by various communicationchannels: • operator• plant manufacturer• service provider.

Advantages of remote monitoring

• Increased machine availability• Prevention of unplanned

downtime • Worldwide, economical plant

monitoring• No vibration expert required on

site• Continuous availability of

monitoring data• Immediate alarm activation via

telecommunications systems• User administration and password

protection.

Alarm warnings · Remote monitoring with FAG DTECT X1 s

3

Measurement data can be remotelyretrieved at any time and evaluatedby the actual customer or by theSchaeffler Monitoring Center.As a result, it is possible to changescan be made from any location tothe parametrisation where theseare necessary to carry out suitablemeasurements on a current problem.

FAG DTECT X1 s in use Monitoring Center

FAG DTECT X1 s –a variable system

FAG DTECT X1 s is available in twodesigns:• 2 channel system • 8 channel system

Signals with an output voltage of ±10 V can be connected, irrespective of the number of channels. The recorded signals are transmittedto the signal-processing elementsof the device via an internal multiplexer.

Monitoring configuration

Establishing a monitoring con -figuration provides the basis for subsequent evaluation. A monitoring configuration definesthe: • channel• value to be measured• type of characteristic value• size of the characteristic value• frequency bands (max. 12)• alarm thresholds.

It is possible to define several monitoring configurations for aninput channel.For each of these configurations,FAG DTECT X1 s determines charac-teristic values from the time andfrequency signals and saves themin the configuration’s ring buffer.For speed-tracked characteristicvalues, the speed is also recordedas a separate trend.

Variable system · Monitoring configuration · Data storage concept

4

Data storage concept

Large volumes of data are not aproblem for FAG DTECT X1 s. The flexible storage concept allowsthe user to decide what data he wishes to store, along with the degree of frequency.

5

Communication with a higher level system

For communication with a higherlevel system, various inputs andoutputs are available. Additional signals can be recordedusing analogue inputs and used for measurement purposes. These signals can thus be used ascommand variables for dependentsignal analysis such as alarmthreshold control. These signalscan also be used to initiate measurement tasks and thus facilitate automation of data logging in certain applications.

On the other hand, informationsuch as alarm status can be trans-ferred to a higher level system andheld there for further processing.

Communication with FAG DTECT X1 scan be carried out via the followingchannels:• network (TCP/IP)• serial• modem.

Communication

Cloud

A new addition is the free-of-chargeprogram Transfer Link, which facili-tates data transfer via conventionalCloud service providers. Theseinclude: Own Cloud, MicrosoftCloud, Google Drive or AmazonCloud Drive.If remote service from FAG isrequired, all data are stored on anin-house Cloud server in Germany.

Simple data exchange via the Cloud

6

Software

Successful vibration monitoring ofplant is dependent to a large extenton the software. In addition to simple configuration and use of thesoftware, the various analysis anddata presentation options are ofdecisive importance. In order to fulfil these requirements as well aspossible, the software Adminis -trator for FAG DTECT X1 s is dividedinto the following modules: • Configuration Manager• Remote Server• Data Link• E-Mail Link• Transfer Link

Software · Functionality

Configuration Manager: Alarm list

Configuration Manager

• Allocation of connected sensorsto particular monitoring configurations

• Allocation of additional channels(inputs/outputs) to existing configurations

• Definition of the frequency bandsto be monitored

• Definition of the alarm thresholds.

Remote Server/Data Link/E-Mail Link/Transfer Link

Remote Server is used to transferdata from FAG DTECT X1 to the software F’IS Administrator. This software module offers theoption of transmitting data oneither a time-controlled or event-controlled basis. The user can

select which measurement values(time signals, frequency spectra ortrend values) are transferred fromFAG DTECT X1 and stored in theappropriate database by means ofData Link. This functionalityensures seamless data storage. In order to provide FAG DTECT X1data held in the database to otherpeople, the E-Mail Link and TransferLink functionality is available. E-Mail Link allows the user todefine automatic data export by e-mail. The data can be sent to anynumber of mailboxes required. At the recipient’s end, all incominge-mails are checked and, if thesecontain measurement data, theyare automatically transferred to thecorresponding database. Alterna-tively, the data can be transferredusing Transfer Link via conventionalCloud services.

7

User management

• Installation and management ofusers

• Allocation of access rights• Allocation of rights to individual

program functions (Edit, StartServices, Import and Export...).

Bearing database

• Contains 20 000 bearings fromvarious manufacturers

• Reduces data analysis• Simplifies the process for deter-

mining the cause of damage inconjunction with the Viewer

• Facilitates the diagnosis of multiple bearing overrolling frequencies for a monitoring configuration, as a bearing listcan be stored for each monitoringconfiguration

• Can be extended to individualrequirements.

Software · Functionality

Trend analysis

Trend analysis is a simple and reliable method for detectingchanges in the vibration behaviourof machinery at an early stage,allowing action to be taken quickly.The trends can be based on par -ameters in broadband monitoring aswell as on narrowband parametersof individual components such as arolling bearing outer ring or a geartooth set. For example, monitoringof an outer ring may be carried out by bringing together severalnarrowband frequency bands foroverrolling frequency and the harmonics to form one parameter. Incipient damage or a forthcomingproblem becomes apparent in anincrease in the trend values for amonitored component or machine.

FFT analysis

FFT analysis subdivides the recordedsignals into their individual fre-quency components. It is thereforepossible to monitor the amplitudesof individual frequencies withinnarrow bands for specified limitvalues and trigger an alarm if theseare exceeded. It is possible to precisely allocate the frequenciesto particular components such asbearing rings, gear teeth or to phenomena such as misalignment,imbalance etc.

Alarm list

• Record of all status changes inthe Configuration Manager.

Viewer

• Diagramatic preparation of themeasured data

• Extensive analysis and displayoptions facilitate the assessmentand evaluation of measurementdata

• Intuitive operation, additionallybenefiting from various zoom andcursor functions

• Simple comparison of processdata and vibration data (temperature and vibration curve)

• Unique range of services despitesimplicity of simple operation.

Software · Functionality · Server variants

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Waterfall diagram and sonogram

The waterfall diagram is a presen -tation method in which the individ-ual FFTs are presented behind eachother „spatially“ to give a three-dimensional image. In the sono-gram, the development of the spectrum over time is presented by means of colour. The two display options also allownovices to gain a rapid graphicaloverview of the temporal develop-ment in vibration behaviour.

Expanded analysis

• Automatic detection of defectivecomponents

• Provides authoritative parameters(spectral flatness, kurtosis, ISO 10816, RMS, LDZ)

• Assists beginners and experts indata analysis.

Server variants

From software version 4.10, theAdministrator is supplied with theMicrosoft® SQL Server® 2012Express. The user then has accessto a storage capacity of 10 GB.

Viewer: Waterfall diagram

9

Versions and ordering designations

DTECTX1-S-2CH DTECTX1-S-8CH

FAG DTECT X1 s Versions and ordering designations

IEPE channels 2 8

Configurations 16 16

Frequency windows 12 12

Others Speed tracking of frequency windows,envelope detector

Speed tracking of frequency windows, envelope detector

Technical data of FAG DTECT X1 s

10

Inputs/sensors

Temperature rangeMeasurement values

Diagnostic methods

Parameters

Number of channels

FFTFilter

Outputs

Inputs for IEPE sensors power supply 24 V, 4 mAConvertible to a voltage input ±10 V (optionally coupled DC or AC)Amplifier: 1 ~ to 1 024 ~ or autoranging with switchable overvoltage detectionAdditional channel (validation) ±10 V with optional isolation amplifier 4 mA to 20 mA, 0 mA to 20 mA, 0 V to 10 V, for example for speed, load or other freely definablevaluesSpeed input for conventional speed sensors from > 1 min–1 to 30 000 min–1

Connectors with industrial M12 connectors (exception: Power)–20 °C to +70 °CMeasurement value for vibration pickups: acceleration (standard) convertible tovibration velocity and vibration displacement by means of integrationMeasurement values such as displacement, velocity, force, pressure, temperature etc.by means of appropriate sensorsOptional: oil qualityTime signal, frequency spectrum, trend analysis, frequency range monitoring (fixed or speed-tracked)Parameters in frequency range: RMS, peak, peak to peak, steady component, crest factorParameters in frequency range: effective value for vibration acceleration (RMS), vibration velocity and vibration displacement, broadband or freely definable frequency bands (DIN/ISO 10816)Effective value for demodulation (envelope generation)Broadband or freely definable frequency bandsSpeed-dependent tracking of frequency bands in RMS and demodulation includingspeed-variable alarm level2 channels or 8 channels with up to 16 monitoring configurations and, per channel, up to 12 individually adjustable frequency bands, additionally 2 trigger/validationchannels, in each case also with sensor signal2 048 lines, variable frequency rangeAnalogue antialiasing filter for band restriction, Butterworth 24 db/octave limit frequences 5 Hz, 10 Hz, 20 Hz, 50 Hz, 100 Hz, 200 Hz, 500 Hz, 1 kHz, 2 kHz, 5 kHz, 10 kHz and 20 kHz Filter for envelope analysis: high pass, Butterworth 12 db/octave switchable between 750 Hz and 2 kHz2 switching outputs for pre-alarm and main alarm2 analogue outputs 4 mA to 20 mA or 0 mA to 20 mA, all connections with industrial M12 connectors

11

FAG DTECT X1 s Administrator software

Options

Technical data of FAG DTECT X1 s

CommunicationDisplay

Control system

Memory

Housing

MountingCurrent consumptionElectromagnetic compatibility

Operating systemFeatures

Isolation amplifierTop hat rail adapter

Ethernet or RS232 for connection of modem/GSM/ISDNLCD display, alphanumeric 4 lines each with 20 characters with display of currentmeasurement and status of all monitoring configurations, LED traffic light systemred/green/yellow for alarm status3 keys for confirming alarms, call-up of current measurement values and setup ofrotational frequency inputFor device/monitoring configuration, spectrum and time signal as well as parameterstorage of up to 3 834 data records (depending on the number of parameters andadditional information)Dimensions: W�H�D = 260 mm�150 mm�90 mmProtection class: IP67Mounting by means of closed housing cover (optional top hat rail mounting)24 V: < 350 mA, 230 V: < 40 mAEN 61000-6-2/1999, EN 61326/1997, EN 55011-A

Windows 7 (32bit and 64bit); Windows 8 (32bit and 64bit)Database: Microsoft SQL-Server 2012 Express, 10 GBSoftware available in various languagesVarious connection options (Ethernet, GSM modems, fixed network modems, Internet etc.)Configurable remote operation with automatic data transmission via CloudNotification of alarm by e-mailContinuous recording and storage of all operating dataOption of data export (ASCII) for further processing by external programsOptimised Viewer for analysis of data

Ordering designation: DTECTX1-S.ISOAMP-UNIVERSALOrdering designation: DTECTX1-S.RAILMNT-AL

– CE– GOST

Approval

12

Notes

MAT

NR

0360

2311

6-00

00 /

TPI

170

/ 0

1 /

GB

-D /

201

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in G

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Every care has been taken to ensure the

correctness of the information contained

in this publication but no liability can be

accepted for any errors or omissions.

We reserve the right to make technical

changes.

© Schaeffler Technologies AG & Co. KG

Issued: 2015, December

This publication or parts thereof may not

be reproduced without our permission.

TPI 170 GB-D

Schaeffler Technologies

AG & Co. KG

Postfach 1260

97419 Schweinfurt

Germany

Georg-Schäfer-Straße 30

97421 Schweinfurt

Germany

Phone +49 2407 9149-66

Fax +49 2407 9149-59

E-Mail industrial-services@schaeffler.com

Internet www.schaeffler-iam.com