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ITT ProSmart Installation & Operation Manual

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  • Page 2 ProSmart Installation & Operation Guide This page was intentionally left blank.
  • Page 3 ProSmart Installation & Operation Guide Index Important Safety Reminder Getting Started Section 1 Communication Module Installation Section 2 Communication Configuration Mechanical Installation Power Connections Data Monitor Installation Section 3 Mechanical Installation Power Connections Class I Division 2 Cap Lock Installation...
  • Page 4 ProSmart Installation & Operation Guide This page was intentionally left blank.

  • Page 5: Safety Instructions

    The information in this section must be studied before attempting any work on or with the ProSmart Wireless Condition Monitoring System. Products manufactured and furnished by ITT Monitoring and Control will provide safe, trouble-free service when properly installed, maintained and operated.
  • Page 6 (Lockout/Tagout). Failure to do so will result in serious injury or death. The ProSmart System is designed and certified only to be installed in a non- hazardous location or a hazardous location labeled as Class I Division 2, Group A B C D T4 only.
  • Page 7 ProSmart Installation and Operation Guide for the applied equipment. The ProSmart System has been designed for safe and reliable operation when properly installed, applied and maintained in accordance with the instructions in the ProSmart Installation and Operation Guide. ITT Monitoring and Control shall not be liable for physical injury, damage or delays caused by failure to follow these instructions.
  • Page 8 ProSmart Installation & Operation Guide SAFETY INSTRUCTIONS This page was intentionally left blank.

  • Page 9: Getting Started

    The ProSmart Wireless Condition Monitoring System provides a cost effective method to monitor all types of rotating equipment all year around - 24 hours a day; 7 days a week; 365 days a year. The ProSmart System collects machine specific information and provides warnings and alarms to users. The ProSmart System is designed around ease of installation, rapid deployment, easy system expansion, and no additional IT infrastructure required.
  • Page 10 ProSmart Installation & Operation Guide GETTING STARTED ProSmart Wireless Condition Monitoring System Architecture...
  • Page 11 How to use this guide PROSMART This guide has been organized to make installation of the ProSmart System easy. Installation has been divided into three main sections that include all the information needed to get up- and-running. The four sections are:...
  • Page 12 ProSmart Installation & Operation Guide GETTING STARTED This page was intentionally left blank.

  • Page 13: Communication Module Installation

    ProSmart Installation & Operation Guide COMMUNICATION MODULE INSTALLATION COMMUNICATION MODULE INSTALLATION This section is devoted to install your ProSmart Communication Module. Step Description Communication Module Overview Communication Module Communication Overview Mechanical Installation PROSMART Power Connections Page 13...
  • Page 14 Communication signal strength between Communication Module and Data Monitor - It is recommended to optimize the communication signal from the Communication Module to each Data Monitor by having ITT or an authorized distributor perform a site survey. Reliable Internet connection for Communication Module to...

  • Page 15: Communication Configuration

    To configure the Communication Module to use a static IP the following information is needed: Static IP address IP DNS1 and IP DNS2 IP Gateway IP mask An ITT representative can either configure the Communication Module in the field or it can be preconfigured at the factory.

  • Page 16: Mechanical Installation

    ProSmart Installation & Operation Guide COMMUNICATION MODULE INSTALLATION Mechanical Installation Installation steps to be performed are: Before installing the Communication Module, please note the Mac ID from the nameplate on the right-side of the Communication Module for future reference. This will appear...

  • Page 17: Power Connections

    ProSmart Installation & Operation Guide COMMUNICATION MODULE INSTALLATION Power Connections The Communication Module needs to be powered by an externally supplied 12 VDC power supply. All electrical installation and maintenance work must be undertaken by a qualified electrician only. The Safety Instructions in this Installation and Operation Guide must be followed.
  • Page 18 ProSmart Installation & Operation Guide COMMUNICATION MODULE INSTALLATION This page was intentionally left blank.
  • Page 19 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION DATA MONITOR INSTALLATION This section is devoted to install your ProSmart Data Monitor DM22x. Step Description Data Monitor Overview Power Mechanical Installation PROSMART Warning Alarm Reset Power Connections TACH V/T-1 V/T-2 V/T-3...

  • Page 20: Mechanical Connections

    Wall mounted arrangement DM22x for mounting. The DM22x can be mounted on a floor mounted stand or a wall mounting bracket which ITT can provide. The DM should NOT be mounted on the equipment but should be mounted in near the rotating equipment.
  • Page 21 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION ‘ Power Connections For ease of electrical installation all user inputs and outputs – three analog inputs, two digital inputs, one relay output, and Electronic Board Chamber power connection are provided via terminal blocks mounted on a Terminal Board Chamber circuit board.

  • Page 22: Power Connection

    ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION The DM22x needs to be powered by an externally supplied 12-24 VDC power supply (Pmax = 6W). All electrical installation and maintenance work must be undertaken by a qualified electrician only. The Safety Instructions in this Installation and Operation Guide must be followed.
  • Page 23 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION Terminal Block Install the conduit and connection box per your local AI 1 + electrical and environmental codes. AI 1 - AI 2 + DM22x has ¾" NPT conduit hub. AI 2 -...
  • Page 24 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION Class I Division 2 Cap Lock Installation For hazardous areas classified as Class I Division 2 Group A B C D T4, Cap Lock (P/N A08569A) should be used on all plug and play...
  • Page 25 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION Cap Lock Install: DM22x Connections TACH V/T-1 V/T-2 For hazardous areas classified as Class I Division 2 Group A B C D T4, Cap Lock (P/N A08569A) Installation steps to be performed to install Class I Division 2 caps...
  • Page 26 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION Cap Lock Install: Cable to Cable Connections TACH V/T-1 V/T-2 For hazardous areas classified as Class I Division 2 Group A B C D T4, Cap Lock (P/N A08569A) Installation steps to be performed to install Class I Division 2 caps...
  • Page 27 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION Cap Lock Install: Cable to Sensor Connections TACH V/T-1 V/T-2 For hazardous areas classified as Class I Division 2 Group A B C D T4, Cap Lock (P/N A08569A) Installation steps to be performed to install Class I Division 2 caps...
  • Page 28 ProSmart Installation & Operation Guide DATA MONITOR INSTALLATION This page was intentionally left blank. Page 28...

  • Page 29: Sensor Installation

    ProSmart Installation & Operation Guide SENSOR INSTALLATION SENSOR INSTALLATION This section is devoted to install your ProSmart Sensors ST-02 and SV-03. Step Description Sensor Overview Tachometer Sensor ST-02 Overview and Considerations ST-02 Installation Vibration & Temperature Sensor SV-03 Overview and Considerations...

  • Page 30: Tachometer Sensor

    ProSmart Installation & Operation Guide SENSOR INSTALLATION Tachometer Sensor ST-02 OVERVIEW AND CONSIDERATIONS The Tachometer ST-02 is a high quality inductive proximity sensor. An inductive proximity sensor operates by measuring the Tachometer sensor oscillator circuit losses of a projected electromagnetic field.
  • Page 31 A ferrous metal target is required for the sensor to detect. Either a shaft-key, shaft keyway, or a set screw is acceptable. ITT also has special order split aluminum rotary encoders for purchase which make for easier installation. Once a suitable mounting location is identified, verify that...
  • Page 32 ProSmart Installation & Operation Guide SENSOR INSTALLATION 11. Once cap locks are properly installed and all wiring and installation is compliant with the plant and local codes, power the DM22x ON. 12. Rotate the machine shaft by hand while watching the LED on top of the tachometer sensor.

  • Page 33: Vibration & Temperature Sensor

    Piezo accelerometer power supplies. The SV-03 is also a “matched system component” and can not be replaced by or substituted for standard 100 mV/G sensors. Any attempt to do so may damage both the sensor and the ProSmart Data Monitor. SV-03 MOUNTING CONSIDERATIONS Vibration Sensor The key to accurate vibration measurement and condition diagnosis is transducer placement.
  • Page 34 ProSmart Installation & Operation Guide SENSOR INSTALLATION The orientation of the sensor must be recorded. The names of each axis on the ProNet User Interface must then be adjusted to reflect the machinery axis being measured. For example, if the Z-Axis (denoted by the...
  • Page 35 SENSOR INSTALLATION MACHINE SPECIFIC CONSIDERATIONS Bearing Location Terminology ITT uses standard terminology to describe the locations of bearings on equipment. Drive End denotes the bearing that is located closest to or connected to the powered shaft. Non Drive End denotes the bearing that is farthest from the powered shaft.
  • Page 36 Rolls Due to the lower RPM of rolls be sure to consult with a ProSmart Applications Engineer on possible limitations. ProSmart will only currently sample down to 6 Hz. With low speed applications this may miss the 1x run speed vibration but in most cases is sufficient to monitor bearing failures.

  • Page 37: Pre-Installation

    ProSmart Installation & Operation Guide SENSOR INSTALLATION SV-03 PRE-INSTALLATION Before installing the SV-03 Sensor, identify bearing locations on each machine to be monitored. Record locations on a machinery diagram for future reference. NOTE – Sensors should not be mounted in environments exceeding 190°F.
  • Page 38 ProSmart Installation & Operation Guide SENSOR INSTALLATION Thread the SV-03 sensor into the tapped hole. The preferred orientation of the sensor slot (denoting the Z – axis) is facing either the drive end (preferred) or the non drive end (alternative). This is critical to ensure that the correct vibration readings are recorded for X, Y, and Z axis.
  • Page 39 ProSmart Installation & Operation Guide SENSOR INSTALLATION The mounting adapter comes with a Loctite 330 Kit (Epoxy). Crush the activator vial between your fingers. Using the cotton tip wet the surfaces that will be in contact with the Epoxy. Break off the tip of the epoxy tube and apply the adhesive to the bottom of the mounting adapter.
  • Page 40 ProSmart Installation & Operation Guide SENSOR INSTALLATION Stud Mounting – Installation steps to be performed are: A 1.25” diameter is needed to install the MK-04 mounting plate. Mark the desired area for the mounting plate and use spot face tool to level and clean the area.
  • Page 41 ProSmart Installation & Operation Guide SENSOR INSTALLATION Magnet Mount – Installation steps to be performed are: A 1.25” diameter is needed to install the MK-04 mounting plate with the magnetic adapter. Mark the desired area for the mounting plate and use spot face tool to level and clean the area.
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  • Page 43 ProSmart Installation & Operation Guide PRONET USER GUIDE PRONET USER GUIDE This section is devoted to the ProNet Graphical User Interface. Step Description ProNet User Guide Logging into ProNet Dashboards My Machines Data and Trending Analytical Features Page 43...
  • Page 44 ProSmart Installation & Operation Guide PRONET USER GUIDE LOGGING INTO PRONET GETTING STARTED Browser Requirements: Internet Explorer v6+ The recommended display resolution is: 1280 x 1024 pixels Æ Right-click Desktop Properties / Settings DPI Setting: Normal Size (96 DPI) Æ...
  • Page 45 ProSmart Installation & Operation Guide PRONET USER GUIDE WELCOME TO PRONET Once you have successfully logged into ProNet, you will typically be greeted by the ProNet Welcome screen. This screen serves as your gateway to online monitoring and includes some key features. You may also be greeted by a dashboard screen.
  • Page 46 ProSmart Installation & Operation Guide PRONET USER GUIDE DASHBOARDS ProSmart continuous machinery monitoring system is designed for multi-plant predicitive maintenance programs. ProNet Dashboards take the abstract nature of your machine data and ties it into a visual representation of your machine. ProNet utilizes an easy to understand graphis to help quickly vizualize the condition of each machine.
  • Page 47 ProSmart Installation & Operation Guide PRONET USER GUIDE ALARM SUMMARY ICON Next to each sensor name there is a colored bulls-eye (as shown at the bottom). The bulls-eye represents the machine’s health for that particular sensor. Current Level Alarm State...
  • Page 48 ProSmart Installation & Operation Guide PRONET USER GUIDE BREADCRUMBS The Dashboard “Breadcrumbs” feature of ProNet allows the user to easily navigate back to previously viewed pages. The Dashboard link will always be available to quickly take the user to the primary dashboard.
  • Page 49 ProSmart Installation & Operation Guide PRONET USER GUIDE MACHINE NOTES “Machine Notes” is available to customers that purchase a customized dashboard. This feature allows users to post comments about the machine, alarm conditions, and other maintenance related activities. The user types a comment into the lower text box (see picture below) and then clicks “Enter Comments.”...
  • Page 50 ProSmart Installation & Operation Guide PRONET USER GUIDE MY MACHINES The My Machines page houses more information than the dashboards, which is why this page makes use of lists and tabs to organize information. When you trend sensors you are automatically navigated to the My Machines page.
  • Page 51 ProSmart Installation & Operation Guide PRONET USER GUIDE MACHINES TAB The My Machines page is the list view of equipment. It displays the machine name, the importance level, alarm summary icon, the machine type, and the company it resides under.

  • Page 52: Sensor Tab

    ProSmart Installation & Operation Guide PRONET USER GUIDE SENSOR TAB Selecting the machine’s name from the Machine tab will open the Sensors tab. This will display available sensor groups and sensor values. Sensor data can be trended, spectrum data viewed, and sensor readings requested from this single page.
  • Page 53 ProSmart Installation & Operation Guide PRONET USER GUIDE Trending & Requesting Data Icons on the right side of the screen are used for trending and requesting data (as shown below). REQUEST FFT/TWF – Request an FFT and/or Time Waveform to be taken VIEW LAST FFT/TWF –...
  • Page 54 ProSmart Installation & Operation Guide PRONET USER GUIDE MACHINE INFO TAB The Machine Info tab contains: The DM name, DM’s MAC ID, & Company Last communication time Importance level Machine type Bearing information (BPFO, BPFI, BSF, FTF) Machine Notes (Record of cleared alarms and comments.) Alarm Acknowledgements When an alarm is cleared a note will be made of what alarm was cleared, by whom, and at what time.

  • Page 55: Types Of Data

    Overall is calculated as a Root-Mean-Squared (RMS) value. Fast-Fourier Transform (FFT) ProSmart has the ability to analyze the time-waveform data collected from a vibration sensor using a Fast-Fourier Transform (FFT) Analysis in RMS (ips). Users are able to view the FFT value in Velocity (ips), Acceleration (g), and Displacement (mils) On Alarm –...

  • Page 56: View Options

    ProSmart Installation & Operation Guide PRONET USER GUIDE VIEW OPTIONS The trending windows have 3 primary ways to view the data Graph is the graphical view of the data. Grid view is a list of all the data points that make up the graph. This is where you would go to export the data points.

  • Page 57: Alarm Values

    ProSmart Installation & Operation Guide PRONET USER GUIDE ALARM VALUES ProSmart provides up to four alarm levels when monitoring data: High Alarm (Red Band) High Warning (Yellow Band) Low Warning (Yellow Band) Low Alarm (Red Band) Alarm levels are set in the ProNet platform and then sent down to the Data Monitor. (Tip: Yellow band...
  • Page 58 ProSmart Installation & Operation Guide PRONET USER GUIDE ZOOM Click on the graph to initialize the starting point of the area which will be zoomed in to. While still holding the left mouse button, drag your mouse (left or right) and let go when you have reached the end point of your desired zoomed in area.

  • Page 59: Viewing Historical Data

    ProSmart Installation & Operation Guide PRONET USER GUIDE VIEWING HISTORICAL DATA The date range selected can be changed from the top of the trend page. Orange calendar top indicates the current selection. Week (7 days) is shown below as currently selected.
  • Page 60 ProSmart Installation & Operation Guide PRONET USER GUIDE REMOVING TREND LINES It is sometimes necessary to drop one or more trend lines from a graph while analyzing data. There are two primary ways to remove trend lines from a graph.
  • Page 61 ProSmart Installation & Operation Guide PRONET USER GUIDE SECONDARY AXIS The Secondary Axis feature is used to view different data sets at the same time. As you can see from the screen shot below if temperature and vibration are graphed on the same axis, temperature will over power the vibration reading because of the difference in scales.
  • Page 62 ProSmart Installation & Operation Guide PRONET USER GUIDE ANALYTICAL FEATURES BAND ALARMS (aka window sensors) Band alarms (or windows) is a frequency span that covers particular fault frequency. This band sensor (or window) is used to monitor the progression of a given fault.
  • Page 63 FFT EVENT ICONS ProSmart will show when an FFT was taken for a trended sensor. This event icon will appear at the bottom of the vibration trend. The icon also doubles as a link. When the icon is clicked, the user will be navigated to the spectrum tab with the selected FFT displayed.
  • Page 64 ProSmart Installation & Operation Guide PRONET USER GUIDE SPECTRUM DATA OPTIONS Fast-Fourier Transform (Units) • A - Acceleration (g’s) • V - Velocity (inch/sec) • D - Displacement (mils) ProNet has the ability to make on-the-fly unit conversions to better meet the user’s preferences.
  • Page 65 ProSmart Installation & Operation Guide PRONET USER GUIDE HARMONIC CURSORS Harmonic cursors are used as a tool in vibration analysis to eliminate possible fault conditions. Harmonic cursors are used to distinguish synchronous and non-synchronous peaks as well as to view harmonics of a frequency.
  • Page 66 ProSmart Installation & Operation Guide PRONET USER GUIDE SIDEBAND CURSORS Sideband cursors are used to distinguish peaks that appear next to a primary peak. This is another tool used in vibration analysis. To use sideband cursors: Set the cursor base frequency. The cursors base frequency is typically the fault you want to view for sidebands (typically bearing faults).

  • Page 67: Data Export

    ProSmart Installation & Operation Guide PRONET USER GUIDE WATERFALL VIEW (aka 3D FFT view) After several FFTs are selected on the same graph, click the 3D view on the graphing tool bar. DATA EXPORT Graphing data, spectrums, time waveform, and user comments can all be exported into excel.
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  • Page 69: Appendix A-1 Modbus Information

    DM modules into a Modbus registry space. Alarming and device management on ProSmart, using Modbus, is not possible at this time. NOTE – Communication Module does not poll the DM module when the master requests a reading, but it uses the latest stored value.
  • Page 70 ProSmart Installation & Operation Guide APPENDIX A-1 MODBUS INFORMATION This page was intentionally left blank. Page 70...
  • Page 71 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Communication Module PROSMART Data Sheet ProSmart CM-LAN ProSmart CM OP TEMP. RANGE………………..158°F (70°C) to -22°F (-30°C) CERTIFICATIONS RATINGS..…………………….… COMMUNICATIONS CSA, FCC, CE CM LAN – Class I Division 2 Groups A B C D T4 NETWORK CONNECTION………..LAN or DSL...

  • Page 72: Front View

    ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Communication Module PROSMART Data Sheet ProSmart CM 3 ft 3 ft minimum required distance minimum required distance Communication Module PROSMART Cellular Antennas not present in CM-LAN 2.25 OBLONG 0.31" x 0.50"...
  • Page 73 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Data Monitor PROSMART Data Sheet ProSmart DM22x DATA ACQUISITION/PROCESSING CERTIFICATIONS RATINGS..……………………… CSA, FCC, CE ANALOG-TO-DIGITAL Class I Division 2 Groups A B C D T4 CONVERTER…………………...16 bit (with optional safety caps) ADVANCED ANALYSIS………...FFT Spectrum and Time Waveform...

  • Page 74: Right Side View

    ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Data Monitor PROSMART Data Sheet ProSmart DM22x 8.55 2.78 1.20 0.25 0.53 0.72 Power 7.38 PROSMART Warning Alarm 2.75 4.44 Reset TACH V/T-1 V/T-2 V/T-3 V/T-4 0.91 ¾” NPT F Conduit Connection 1.72...
  • Page 75 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Data Monitor PROSMART Terminal Connections ProSmart DM22x Table 1.0: Terminal Associations Label Description +24V +12V-24Vdc Power (+Vout) Ground (-Vout) AI1+ DI1+ RELAY Relay: Normally Closed AI1- RELAY DI1- Relay: Common...
  • Page 76 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Page 76...
  • Page 77 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Vibration / Temperature Sensor PROSMART Data Sheet ProSmart VT-03 CERTIFICATIONS RATINGS………………….………..CSA Class I Division 2 Groups A B C D T4 SPECIFICATIONS CABLE LENGTH……………..……..6.6ft (2m) TECHNOLOGY……………………..MEMS Accelerometer FREQUENCY…………………….…6-3500Hz (X, Y, and Z axis) TEMPERATURE ACCURACY……..+/-5°F...

  • Page 78: Set Screw

    ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Mounting Adapter for PROSMART Vibration / Temperature Sensor Data Sheet 0.85 ProSmart MK-04 0.22 1.25" (31.8mm) ¼ NPTF MK-04 Adapter ¼-28 UNF 1/8" Hex ¼-28 UNF x 0.50 Lg MK-04 Set Screw...

  • Page 79: Pre-Operation Check

    ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Tachometer Sensor PROSMART Data Sheet ProSmart ST-02 CERTIFICATIONS RATINGS………………….………..UL, FCC, CE, IP67 Class I Division 2 Groups A B C D T4 SPECIFICATIONS CABLE LENGTH……………..……..6.6ft (2m) PRE-OPERATION CHECK TECHNOLOGY……………………..Inductive Proximity Sensor...
  • Page 80 ProSmart Installation & Operation Guide APPENDIX A-2 PROSMART DATA SHEETS Page 80...
  • Page 81 ProSmart Installation & Operation Guide APPENDIX A-3 TROUBLESHOOTING DATA MONITOR TROUBLESHOOTING Symptoms Remedy The power status light does not come on. 1. Confirm the DM is being powered by a 12- 24VDC external power supply 2. Refer to the Data Monitor Power Installation guide in this manual for proper connections 3.

  • Page 82: Sensor Troubleshooting

    3. Confirm total cable run length does not exceed 30 meters ProNet reading does not match actual 1. Check for loose connections. value. 2. Check for moisture in connection. *If problem is not able to be resolved, then please contact your ProSmart Global Administrator Page 82...
  • Page 83 ProSmart Installation & Operation Guide APPENDIX A-3 TROUBLESHOOTING This page was intentionally left blank. Page 83...

  • Page 84: Monitoring And Control

    Leveraging our 150+ years in process machinery design, Our PumpSmart pump control systems provide real-time manufacture and operation, ITT Monitoring and Control control and protection of your centrifugal pumps while also products and services have one goal — improving your plant’s providing valuable process knowledge without the need for profitability.

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