Sensata 6VW Operation Manual

Machine health monitoring

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MACHINE HEALTH MONITORING (MHM) 6VW SENSOR

OPERATION MANUAL

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Page 2 OPERATION MANUAL Copyright © 2022 by Sensata Technologies All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated into any language in any form by any means without the written permission of Sensata Technologies. Disclaimer This manual is provided for informational purposes.
Page 3: Table Of Contents
3.1.6 Identifying Plant Hierarchy CONFIGURATION Sensata DIY App 4.1.1 Finding the DIY App and User Credentials 4.1.2 Sensata DIY User Tasks and Overview 4.1.3 Understanding Asset Layouts INSTALLATION & COMMISSIONING Device Handling Sensor Mounting Types 5.2.1 Sensor Stud Mount Installation Method (Permanent Installation) 5.2.2...
Page 4 5.3.3 Choosing the right location to install the sensor and the magnet: 5.3.4 Sensor Orientation Powering the 6VW Sensor 6VW Sensor Connection Status to the Cellular Network CELLULAR AND Wi-FI CONNECTION Connecting Sensors via Blinkup 6.1.1 Blink Up Using Wi-Fi 6.1.2...
Page 5 B-Board LED Blinking pattern SPECIFICATIONS AND REFERENCE DATA 10.1 Functional Specifications 10.2 Physical Specifications 10.3 Performance Specifications PRODUCT CERTIFICATIONS 11.1 Wireless Certifications 11.2 Certifications PRODUCT DECLARATIONS 12.1 UKCA Mark 12.2 CE Mark Copyright © 2022 Sensata Technologies, Inc. Page 5...
Page 6: General Information
• Before connecting the sensor in an explosive environment, make sure the instruments are installed in accordance with applicable field wiring practices. • Verify that the operating environment of the Sensata 6VW sensor is consistent with the appropriate hazardous locations' certifications.
Page 7: Configuration
Ensure the sensors are installed per applicable field installation practices. Please see the following sections on installing the sensors for more information. The 6VW sensors are powered whenever the battery is installed, the isolating paper tab removed, and the slide switch is in the on position.
Page 8: Battery
1.3.4 Battery The Sensata 6VW sensor uses a battery assembly that includes a Lithium Thionyl Chloride D sizes battery with a supercapacitor. Off-the-shelf Lithium Thionyl Chloride D batteries are not recommended. The supercapacitor is an important part of the system and ensures additional storage capacity when an inrush of current is required to support the modem.
Page 9 Shipping considerations for wireless products (Lithium Batteries) • The 6VW sensor was shipped to you with the battery inside but with an isolated paper tab. Remove the tab to connect the battery for proper operation.
Page 10: Introduction
Machine Learning approaches are implemented for the definition of the actual condition of the machine asset and for forecasting its longevity. Copyright © 2022 Sensata Technologies, Inc. Page 10...
Page 11: Predictive Maintenance (Pdm) Process
The Sensata PdM solution incorporates leading-edge sensing technology (the 6VW sensors) and software (Sensata IQ). The buildout of your PdM project will utilize both and you will engage with each. In the following manual sections, each section header will contain the highlighted topic in which you will be working.
Page 12: Planning
Site surveys are an important part of a proper application. In specific, the review of the cellular or Wi-Fi network can speed your results to data and insights from the Sensata solution (6VW and Sensata IQ software). The site cellular or Wi-Fi networks available may be either strong or weak.
Page 13: Assessing The Machine Asset
Sensata FAE to determine the number of sensors required. 3.1.5 Cellular/Wi-Fi connection strength The 6VW can connect to either LTE-M or Wi-Fi networks. As a default the sensors will be configured at the time of production for LTE-M connectivity. If you require a Wi-Fi connection, please review the balance of this section, and then proceed to section 6.2 Connecting Sensors via...
Page 14 RSSI: > -105 dBm If the RSSI (Received Signal Strength Indicator) of the 2G signal is below -105dBm (-106, -107, - 108 dBm…), a cellular signal booster that boosts the 2G network will be required for the 6VW sensor to operate properly.
Page 15: Identifying Plant Hierarchy
Layout adds a layer of information, which some companies find helpful. Your decision on this topic is important as the choice of Classic or Machine Layout only occurs in the Sensata DIY app with the first sensor deployment. After that, the choice will be fixed in the layout that you first chose.
Page 16: Configuration
4.1.1 Finding the DIY App and User Credentials You can find the Sensata IQ DIY app on the Apple App Store for iOS devices or Google Play for Android devices. Search for “Sensata IQ DIY” with the platform search tools. Install and open the app.
Page 17: Understanding Asset Layouts
4.1.3 Understanding Asset Layouts In the Sensata DIY App, there are 2 layouts available – classic or machine layout. On your first engagement with the DIY App, you will be allowed to select your preferred method for defining the hierarchy.
Page 18: Installation & Commissioning
5.2 Sensor Mounting Types Different machine asset types require different mounting locations. For any asset type not shown here, please contact Sensata to recommend mounting locations. In the adjacent image, the most common mounting locations for this type of device are identified.
Page 19: Sensor Stud Mount Installation Method (Permanent Installation)
6VW sensor. A second approach is to utilize the magnet and adhesive mount which allows for device mounting in just minutes.
Page 20: Sensor Magnet + Adhesive Installation Method (Permanent Installation)
5. Hold the sensor housing onto the surface for at least 60 seconds until the adhesive can support the weight of the sensor, ensuring the housing does not move or slide on the adhesive. 6. Allow full cure of the adhesive per the directions of the manufacturer. Copyright © 2022 Sensata Technologies, Inc. Page 20...
Page 21: Sensor Magnet Only Installation Method (Temporary Method)
5. Place the motor fin mount probe/pad between the motor fins at the location desired. • Correct fin machine asset mount selection is important. The probe must fit tightly in between the fins, and the bottom of the probe must contact the asset casing. Copyright © 2022 Sensata Technologies, Inc. Page 21...
Page 22: Rpm Sensor Installation
5.3.1 Needed for Installation 1. (1) Machine health sensor 2. (1) Strong neodymium bar magnet (Sensata part #6VW3-04) 3. (1) A two-part epoxy (Sensata part #6VW3-03) 4. (1) Personal protective equipment (PPE) Copyright © 2022 Sensata Technologies, Inc.
Page 23: Low-Speed Rpm Installation Safety Considerations
Installation is now complete. Take pictures of the location of the magnet and sensor so that the Sensata team can confirm the installation. Contact Sensata Product Support if you have any questions. Copyright © 2022 Sensata Technologies, Inc.
Page 24: Sensor Orientation
This shows that the sensor has positively progressed through all the appropriate stages and is ready for use. 5.5 6VW Sensor Connection Status to the Cellular Network The sensor can be connected to a cellular network. The device contains a global e-SIM which will automatically find the strongest cellular connection by which to send the data.
Page 25 After the above sequence, the sensor will go into deep sleep mode (no LEDs on to preserve battery life) and will wake up when it is time to report an anomaly or conduct a planned data upload. Copyright © 2022 Sensata Technologies, Inc. Page 25...
Page 26: Cellular And Wi-Fi Connection
Sensata team, the process for implementation of a cellular network can be managed by following the process identified below. 1. Install the Sensata IQ DIY App a. The Sensata IQ DIY app can be found in Google Play Store or Apple App Store: Search “Sensata IQ DIY” or iOS App Store Google Play Store 2.
Page 27: Sim Card Instructions For Cellular Operation
6VW SERIES MHM OPERATING MANUAL Fig: Blink up in Sensata DIY app Put the sensor face down near the phone screen before the screen flashing starts. (The battery should be oriented to you) After the flashing is complete, a 2-minute registration will occur. After registration, the App will display “Device is connected.”...
Page 28 6VW SERIES MHM OPERATING MANUAL Insert the SIM Card in the direction shown in the image below. The cut portion of the SIM should face the board. Copyright © 2022 Sensata Technologies, Inc. Page 28...
Page 29: Sensor Battery Replacement
Warning messages Messages d'avertissement Warning – Battery Replacement. Avertissement – Remplacement de la batterie • Use only Sensata supplied replacement battery assemblies. • Utilisez uniquement les ensembles de batteries de remplacement fournis par Sensata. • Batteries must only be changed in an area fee of ignitable concentrations •...
Page 30: Operation
Predictive Maintenance (PdM) can have a significant impact on your business, but you can use the insights in new and exciting ways. Using open APIs, a company can also tie the specific Sensata insights to other disparate systems, such as CMMS (Computerized Maintenance Monitoring Systems) or EAM’s, IIoT (Industrial Internet of Things) platforms, or other options and thereby...
Page 31 6VW SERIES MHM OPERATING MANUAL Sensata IQ helps your personnel meet their specific needs by providing the right information to the right contacts. The enterprise view provides personnel in supervisory roles the ability to understand the status of their plants (sites) and the health of their machine assets. At the plant or site level, the operations managers get actionable insights that they can use to reduce unplanned downtime.
Page 32 Sensata IQ dashboard called Sensata IQ App. This app is available for iOS and Android devices on the Apple App Store and on Google Play, respectively. User credentials for the Sensata IQ Dashboard, Sensata IQ DIY, and Sensata IQ App are all the same. Copyright © 2022 Sensata Technologies, Inc.
Page 33: Main Page
• Role Activities: The ability to add, delete, assign roles to various new or existing users. • Critical Information: The ability to get important manuals that support the hardware or software. Copyright © 2022 Sensata Technologies, Inc. Page 33...
Page 34: Equipment Main Page
Note The content of the navigation pane changes to show the available information based on the type of machine asset set up with the Sensata DIY app. The following sections show the typical elements 8.2 Vibration Vibration analysis is the process of measuring the vibration levels and frequencies of machinery and then using that information to determine how healthy the machine assets are.
Page 35: Vibration Peak
Bearing Inner Race, Bearing Outer Race, and Bearing Ball; to cover shaft faults, options such as unbalance, misalignment and looseness will be present. Copyright © 2022 Sensata Technologies, Inc. Page 35...
Page 36: Vibration Spectrum
• View and download the time waveform data in each of the three axes (X, Y, Z) and evaluate the data in different domains and units. Copyright © 2022 Sensata Technologies, Inc. Page 36...
Page 37: Vibration Frequency Spectrum Waterfall
• Customize the historical view by selecting the timestamps of interest • Plot the waterfall graph based on the selected timestamps of interest • Amend timestamps to add inclusive date ranges. Copyright © 2022 Sensata Technologies, Inc. Page 37...
Page 38: Ae Time Waveform
The sensor is uploading speed data and graphing the real-time RPM of the machine asset. • View and download data across a user-selectable date range in the units of your choosing. • Implement distribution time to normalize and present the data over the date range. Copyright © 2022 Sensata Technologies, Inc. Page 38...
Page 39: Upload Speed
MHM OPERATING MANUAL 8.8 Upload Speed Each sensor sends the upload speed data to the Sensata IQ dashboard for visualization. • View and download data across a user-selectable date range. • Implement distribution time to normalize and present the data over the date range.
Page 40 Amplitude: The maximum amplitude for the fault characteristic frequencies and their harmonics up to 10th order. This amplitude describes the severity of a specific fault mode. Sensata uses such amplitudes for RUL calculation...
Page 41 RMS: Root Mean Square is the square root of the averaged of the squared values of the AE waveform. RMS describes the AE energy emitted by the machine. The higher the AE energy, the higher the AE RMS is. Copyright © 2022 Sensata Technologies, Inc. Page 41...
Page 42: Health Score & Rul Calculation
The health score will be calculated by average the total score. In this case = 3 + 3 + 2 + 1 / 12 = 0.75 = 75 is the health score Remaining Useful Life: RUL Representation on the Sensata IQ Dashboard Fault Stage Predicted RUL in hours...
Page 43: Notification On Health Status Summary & Rul
The notification is sent from our CDP (Core Data Processor) with cloud computing. To achieve this kind of notification, two aspects are covered as below: • Algorithm for Self-Adaptive Fault Stage 4 Threshold to avoid false negatives • Notification Strategy for timely notifications Copyright © 2022 Sensata Technologies, Inc. Page 43...
Page 44: Algorithm For Self-Adaptive Fault Stage 4 Threshold
6VW SERIES MHM OPERATING MANUAL 8.12.1 Algorithm for Self-Adaptive Fault Stage 4 Threshold 8.12.2 Notification Details with Different Health Status Copyright © 2022 Sensata Technologies, Inc. Page 44...
Page 45: Rul Presentation
Alarm” with the following information included in the email: • Company Name; Plant Name; Equipment Name; Component Name • Current RMS/Peak value • NanoAI RMS/Peak Alarm value • Date & Time • Link to Dashboard Copyright © 2022 Sensata Technologies, Inc. Page 45...
Page 46: Notification By Email Alarm
The notification is sent from our CDP (Core Data Processor) with cloud computing. 8.12.5 Notification by Email Alarm The Email Alarm on the Sensata IQ dashboard allows the customer to set the customized threshold values on vibration RMS (in both acceleration and velocity) and Temperature.
Page 47: Sensor Operational Status Notification
8.13 Sensor Operational Status Notification Sensata provides an automatic sensor operational status check by automatically looking at the sensor data uploading status, battery voltage, and Wi-Fi RSSI strength. In case there is any deviation from the programmed data acquisition & upload schedule,...
Page 48: Notification On Real-Time Anomaly Detection By Edge Computing
MHM OPERATING MANUAL 8.14 Notification on Real-Time Anomaly Detection by Edge Computing Besides notifications sent from Cloud-based on “long-term” historical data, Sensata also provides real-time notifications on any anomaly with “pseudo-continuous” monitoring by measuring with a brief time interval, e.g., 30 s, and having the analysis by edge computing to cover any of the real-time anomaly detection.
Page 51: Troubleshooting
Once the unit is switched on, a red LED will start flashing. Sensor initialization will take 1 to 2 minutes to complete. After the initialization, the 6VW sensor will flash a super bright green LED to indicate a successful connection to the network. The sensor cover can now be put back into place.
Page 52: Check The Battery
Check the battery assembly voltage (battery outside device): • If the battery assembly voltage is below 3.3 volts. Please contact Sensata to order a new battery assembly. Check the battery assembly voltage (battery in device): • If the battery assembly voltage is below 3.3 volts.
Page 53: Check For Damage
IR sensor pointing downwards and through the hole, as shown in the below images. 9.1.5 Ensure eSIM switch • When not using a physical SIM card, assure eSim position is selected on the switch. Copyright © 2022 Sensata Technologies, Inc. Page 53...
Page 54: Cellular Connectivity
9.2.6 Connecting via PPP (Point to Point Protocol). Point-to-Point Protocol (PPP) is a data link layer (layer 2) communication protocol between two routers without any host or any other networking. It can provide connection authentication, Copyright © 2022 Sensata Technologies, Inc. Page 54...
Page 55: Checking Ppp Connection
LED blinking long on short-off. This indicates that the board has found a network and is securing a cellular connection. LED blinking quickly. This indicates that the board is transferring data to the connected network. Copyright © 2022 Sensata Technologies, Inc. Page 55...
Page 56: Specifications And Reference Data
Frequency Range: 1 Hz to 6.3 kHz in X, Y, and Z, (+/- 3dB) Temperature: Measurement range: -40 to +85C Acoustic Emission Frequency range: 0.1 to 80 kHz Speed Range: 10 to 5,000 RPM Magnetic Flux Input range: +/- 20 mT Copyright © 2022 Sensata Technologies, Inc. Page 56...
Page 57: Physical Specifications
Selector dans la zone dangereuse. ______________________________________________________________________________ Note: Sensata utilizes the Xeno Energy XL-205F battery and has the OEM (Original Equipment Manufacturer) conduct secondary work to include a 100 F, side-mounted supercapacitor attached with soldered leads. The final solution is a complete battery assembly.
Page 58 6VW SERIES MHM OPERATING MANUAL Mounting The screw thread into the sensor body is 1/4 - 28 UNF Device Weight 0.771 lb. (350 g) Device Enclosure Rating The sensor housing is rated IP68 Copyright © 2022 Sensata Technologies, Inc. Page 58...
Page 59: Performance Specifications
The device is rated for storage in the range from -40 to +85°C (-40 to + 185°F). ______________________________________________________________________________ Note Please store batteries in a clean, cool (not over +30°C), dry, and ventilated area ______________________________________________________________________________ Copyright © 2022 Sensata Technologies, Inc. Page 59...
Page 60: Product Certifications
RF (Radio Frequency) spectrum. Nearly every country requires this type of product certification. Sensata works with governmental agencies to supply fully compliant products and remove the risk of violating country directives or laws governing wireless device usage.
Page 61: Certifications
Complies with Canada ICES-003(B)/NMB-003 (B) Conditions for Safe Use Shall be powered only by Sensata battery assembly part number 6VW3-05. Under certain extreme circumstances, the non-metallic parts incorporated in the enclosure of this equipment may generate an ignition-capable level of electrostatic discharge.
Page 62 The asset the device is to be installed on must be in a safe condition before installation can begin. The device must only be installed by a competent person. 6VW - UL Class I, Division 2, Groups A, B, C, D Versions Standard Rating...
Page 63: Product Declarations
The device has been tested and complies with all relevant directives required for UKCA marking 12.2 CE Mark The device has been tested and complies with all relevant directives required for CE marking. Copyright © 2022 Sensata Technologies, Inc. Page 63...
Page 64 REGARD TO SENSATA DATASHEETS OR USE THEREOF. industrial-iot-eu@sensata.com All products are sold subject to Sensata’s terms and conditions of sale supplied at www.sensata.com SENSATA ASSUMES NO LIABILITY FOR APPLICATIONS ASSISTANCE OR THE DESIGN OF BUYERS’ PRODUCTS. BUYER ACKNOWLEDGES AND AGREES THAT IT IS SOLELY...

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