SKF Wireless Machine Condition Sensor

Transcription

1 SKF Wireless Machine Condition Sensor CMWA 8800 User Manual Part No EN Revision A WARNING! - Read this manual before using this product. Failure to follow the instructions and safety precautions in this manual can result in serious injury, damage to the product, or incorrect readings. Keep this manual in a safe location for future reference. Copyright 2014 by SKF USA Inc. All rights reserved Viewridge Court, San Diego, CA USA Telephone: (858) , Fax: (858) Customer Service:

2 SKF USA Inc. SKF is a registered trademark of the SKF Group. All other trademarks are the property of their respective owners. SKF 2014 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. SKF reserves the right to alter any part of this publication without prior notice. Patents: US 4,768,380 US 5,633,811 US 5,679,900 US 5,845,230 US 5,852,351 US 5,854,553 US 5,854,994 US 5,870,699 US 5,907,491 US 5,992,237 US 6,006,164 US 6,124,692 US 6,138,078 US 6,199,422 US 6,202,491 US 6,275,781 US 6,301,514 US 6,437,692 US 6,489,884 US 6,513,386 US 6,633,822 US 6,789,025 US 6,792,360 US 7,103,511 US 7,697,492 WO/2003/ Product Support Contact Information Product Support To request a Return Authorization, Product Calibration or a Product Support Plan, use the web page links for direct contact and support. Product Sales - For information on purchasing condition monitoring products, services or customer support, contact your local SKF sales office. General Product Information For general product information (i.e., product data sheet, accessories catalog, etc.), visit the Condition Monitoring Products page on SKF.com and select the appropriate product link. Technical Support Group Discuss/review issues of specific interest with maintenance and reliability specialists from around the world at the SKF Knowledge Centre. For technical support on issues like troubleshooting product installation, troubleshooting product performance, etc., use our technical support web page to contact one of our Technical Support Groups. Product Registration Please take a moment to register your product at to receive exclusive benefits offered only to our registered customers, including receiving technical support, tracking your proof of ownership, and staying informed about upgrades and special offers. (Please visit our website for more details on these benefits.) Tell us how we re doing! It s important that you re satisfied with the quality of our product user manuals. We appreciate your feedback; if you have comments or suggestions for improvement, please tell us how we re doing! dc

3 Table of Contents 1 Introduction 1 Scope and Purpose... 1 Related Documentation The Basics 3 The CMWA 8800 Sensor... 3 Cautions... 3 CMWA 8800 Label... 4 CMWA Long Tag... 4 Repair Service... 4 Issuing Commands to the Sensor... 5 Activate the Sensor... 5 Deactivate the Sensor... 5 Manual Commands... 6 Software Commands... 7 The Network... 8 WirelessHART Terminology... 8 The WirelessHART Network Joining Process... 9 Network Layers... 9 The Wireless Sensor Device Manager The Device Manager License Key Device Manager Configuration Parameters The P+F Gateway s Web Page 15 Accessing the Web Page Verifying the P+F Gateway s Firmware Version Known Issues with the Firmware Network ID and Join Key Parameters Preparing a Commissioning Gateway Joining the Sensors to the Commissioning Network The Production Network Settings P+F Gateway s Installation Torque Comparing P+F with Emerson Gateways SKF Wireless Machine Condition Sensor TOC-1

4 4 Wireless Sensor Device Manager 25 Device Manager Installation To Install Device Manager Known Issue #1 Cannot open database Known Issue #2 Replace the database Connecting to the Gateway Issue: Gateway Connection Failed Troubleshooting the Required Ports Importing Sensors into Device Manager Viewing the Connected Sensors Verifying the Sensor Firmware Known Issues in Device Manager Full Routing vs. Leaf Node Expert Features in Device Manager Wireless or Wired Communication Calibration Generic Command Feature Data Collection Scheduling Command 93 Example Command 9 Example Estimating the Time to Capture Waveforms Exporting the Measurement Collection Period Manual Data Collection Overall Data Waveform Data Changing the Network ID and Join Key 55 6 Troubleshooting XML Import to Analyst 57 7 Network Planning and Diagnostics 61 Network Planning Important Considerations Wireless Communication Stability Considerations. 62 Location and Signal Strength Coexistence with WLAN Network Commissioning Network Diagnostics Key Considerations Topology View Network Diagnostic Details The Network Statistics Report Troubleshooting Network Issues Issue: No Sensors Join Issue: Some Sensors Do Not Join Issue: One Sensor Does Not Join TOC-2 SKF Wireless Machine Condition Sensor

5 Issue: One Sensor Rejoins Over and Over Issue: The Gateway Becomes Non-responsive RF Interference and Solutions 77 RF Interference Sources Symptoms Solutions to RF Interference Channel Blacklisting System Maintenance 79 Adding a New Sensor into Service Editing a Sensor s Name Removing a Sensor from Service Replacing an Existing Sensor in Service Commissioning Network Available No Commissioning Network Relocating an Existing Sensor in Service Commissioning Network Available No Commissioning Network Upgrading Sensor Firmware Global Firmware Upgrade Individual Sensor Firmware Upgrade Device Status Indicators Device Status Extended Device Status Standardized Status Standardized Status Sensor Battery Status System Debugging Logs Execution Log Communication Log FAQs 93 Frequently Asked Questions APPENDIX A, CMWA 8800 System Setup Checklist 95 SKF Wireless Machine Condition Sensor TOC-3

6

7 1 Introduction Scope and Purpose The intended audience for this manual is Certified Service Technician and Technical Support personnel who provide detailed technical work to customers, either over the telephone or in person. It is assumed that these people are already familiar with the Monitoring Suite as well as Microsoft s Operating Systems for Desktop (XP, Vista, 7), Server (2008) and Windows Services. This document is intended to assist Certified Service Technician and Technical Support personnel in installing, configuring, supporting and troubleshooting the SKF Wireless Machine Condition Sensor (CMWA 8800) in WirelessHART networks. The Wireless Sensor Device Manager software application is commonly called Device Manager in this. In some directory paths and file names it is referred to as WSDM. Analyst is commonly called Analyst in this. PEPPERL+FUCHS is commonly called P+F in this. Related Documentation Document Part No. Wireless Sensor Device Manager User Manual P/N SKF Wireless Machine Condition Sensor (CMWA 8800) System Setup Guide P/N PEPPERL+FUCHS WirelessHART Gateway WHA-GW User Manual PEPPERL+FUCHS WirelessHART Adapter WHA-ADP- *-Z1(EX1) User Manual SKF Wireless Machine Condition Sensor 1

8

9 2 The Basics In this chapter, we present some general information about the CMWA 8800 sensor, the WirelessHART network, and the Wireless Sensor Device Manager software. The CMWA 8800 Sensor Cautions Do not twist the plastic top! Doing so voids the warranty and hazardous area certification. Do not open the plastic top! Mount by tightening the base never by twisting the plastic top. Storage temperature should be less than 30 C (86 F). (Note: Some battery life issues due to crystal build up have come to light under sustained high temperatures.) Figure 1. Correct Method of Mounting/Dismounting a Sensor. WARNING! To obtain proper torque when using a crowfoot wrench, you must attach the crowfoot 90 degrees of the torque wrench shaft. SKF Wireless Machine Condition Sensor 3

10 The Basics The CMWA 8800 Sensor CMWA 8800 Label The label on the base of each sensor displays the Hardware Version and the MAC address. The MAC address is assigned by SKF and it serves as a physical identification and does not change. The first ten characters of the MAC address make up the manufacturer and product s unique ID number (00-1B-1E-E1-A2) assigned by the HART (Highway Addressable Remote Transducer) Communication Foundation; the last six characters are the unique device ID assigned by SKF. The label also includes the operating temperature range, model number, bar code, mounting torque, CE certification number, FCC/IC certification number, icon indicating do not throw away the sensor as trash, and the warning Sensor shall not be opened by unauthorized personnel. CMWA Long Tag Analyst (called Analyst in this ) and the Wireless Sensor Device Manager software (called Device Manager in this ) use the asset name as the Long Tag to identify the sensor. The Long Tag contains 32 characters under the WirelessHART protocol, but Analyst permits only 20 characters so the Long Tag is truncated. If the truncated tag has a duplicate in the Analyst database, Analyst appends the names of the subsequent POINTs with.1,.2, and so on. The Long Tag identifier can be changed in Device Manager. Repair Service All repair service must be done at a certified repair center currently San Diego is the only center. The sensor will be inspected to determine whether the plastic top was twisted or opened in the field, which would void the warranty. The expected type of service is battery replacement. The sensor has no repairable parts. If the printed circuit board (PCB) is not in working condition, it can be replaced at the customer s request. The MAC address of the new PCB will be modified to match that of the original sensor. The serviced sensor will be fitted with new top, label, and O- ring. 4 SKF Wireless Machine Condition Sensor

11 The Basics Issuing Commands to the Sensor Issuing Commands to the Sensor LED Push button Figure 2. Wireless Sensor LED and Push Button. You activate and issue manual commands to the wireless sensor by pressing and holding its push button for various durations - as you count a number of LED blinks. Releasing the push button after a specific number of blinks will issue a specific command to the sensor. Activate the Sensor Firmly press and then quickly release the sensor s push button. The sensor s green LED immediately blinks once, pauses, then blinks in an accelerating manner, pauses, and then blinks a short burst to indicate the sensor is active. Deactivate the Sensor Firmly press the sensor s push button and count four blinks, then release. The sensor s green LED blinks in a decelerating manner, and then stops. The sensor is deactivated. (Counting five or six blinks will also deactivate the sensor.) SKF Wireless Machine Condition Sensor 5

12 The Basics Issuing Commands to the Sensor Manual Commands Once the sensor has been activated, you may issue manual commands to the sensor by pressing and holding its push button down for a specific number of blinks. Reference the following table: Press and hold for: To issue this command and elicit this LED response 1 blink Not used after sensor is activated None (verifies the sensor is active) 2 blinks (Not implemented at this time) Communicate with the gateway for identification purposes 3 blinks Reset (reboot) the sensor for troubleshooting purposes (wait five seconds after resetting the sensor before issuing new commands to the sensor) None Short burst 4 blinks Deactivate the sensor Blinks in a decelerating manner, then stops 5 blinks Deactivate the sensor Blinks in a decelerating manner, then stops 6 blinks Deactivate the sensor Blinks in a decelerating manner, then stops 7 blinks Set Network ID to 101, and reset sensor Short burst 8 blinks Set Network ID to 102, and reset sensor Short burst 9 blinks Set Network ID to 1229 (default setting) and set Join Key to E F524B53 524F434B and reset sensor Short burst The actions below are for Technical Service Group (TSG) use only in the Extended Operations Menu. 15 blinks Access the Extended Operations Menu (for TSG only). Confirm by 3 rapid blinks after releasing the button. 3 blinks Reset device back to normal operation. Burst of quick blinks. 4 blinks Set update period to 5 minutes (for testing only; not for production). Note that this will shorten the battery life if the sensor is left in this mode. 5 blinks Reset to factory defaults configuration. Sensor resets to normal operation. 6 blinks Reset of calibration data to factory default. Sensor resets to normal operation. 7 blinks Radio Test Menu (for testing only; not for production). A few rapid blinks. Returns to the regular menu. A few rapid blinks, then a burst; pause. Returns to the regular menu. A few rapid blinks, then a burst; pause. Returns to the regular menu. 6 SKF Wireless Machine Condition Sensor

13 Software Commands The Basics Issuing Commands to the Sensor After the Device Manager software is installed and operational, you can issue some standard procedure commands to the sensors with it. Select a sensor item in the hierarchy, and then go to the Device tab. Figure 3. Sensor / Device Tab, Commands to Sensors. Flash LED Click this button to cause the connected wireless sensor s LED to flash ten times. This can be useful if you need to identify a device in the network or check communication. Reset Device Click this button to reset the sensor. If the sensor is connected to the Device Manager software, resetting the sensor is similar to rebooting a computer; it helps to clear issues with the device. Note that the sensor will drop off the network, and then rejoin the network, which takes some time - more time the larger the network. Reset Pipe If the network manager fails to reassign the Fast pipe function, you can click this button to de-allocate the fast pipe from this sensor so the gateway can reassign the resource to other sensors as needed. However, the preferred method is to set the fast pipe on the P+F gateway s Operating Modes web page. IMPORTANT: You can verify a sensor s fast pipe assignment on the P+F gateway s Operating Modes web page. A failure of fast pipe assignment is indicated when a sensor directly connected to the gateway takes more than two minutes to complete collecting a waveform. IMPORTANT: Also on the Sensor / Device tab, entering the Machine Speed for the sensor is recommended. The value is exported to Analyst for the FAM overlay and it does not have to be entered in each FFT plot in Analyst. SKF Wireless Machine Condition Sensor 7

14 The Basics The Network The Network WirelessHART Terminology HART7 (spec155) added the Wireless command set, including network security terms such as Network ID and 32 character Join Key, and advertisement. HART7 is backward compatible. Some terms commonly used with WirelessHART networks are defined below. Term Advertisement Block transfer Burst mode Caching Fast pipe Network manager Leaf node device Link Long tag P1 profile Definition Messages sent by the network manager to announce the network s existence. Generally, HART communications are connectionless transactions. Block transfer extends the protocol to support connection oriented reliable stream service for large data blocks. Used for sending waveforms and firmware upgrades. The sensor publishes data for any of the HART commands at a regular interval. Contrary to polling, no query is made so burst mode is more efficient. Burst data for a query are saved in gateway memory. When queried by the host software, the gateway will return the cache data instead of polling the data from the sensor. This is a single device mode which establishes a direct connection to a selected device. It has four times the transfer rate of a regular connection. The network manager in the gateway grants fast pipe mode only to devices which identify themselves as high power profile devices. This can be selected manually in the gateway s Operating Modes web page or automatically by the network manager during block transfer for waveform upload or firmware download. See the section Full Routing vs. Leaf Node, Power profile. Responsible for the coordination of communication between the devices and the gateway and between devices. A device that does not participate in the mesh network. It does not help its neighbor. The full communication specification between adjacent nodes in the network; the communication parameters necessary to move a packet one hop. HART7 32-character logical name for the HART device. 256 slot superframe, 2.56 sec cycle; normal battery life, normal join process, better user interface response. P1 can be selected during your interaction with the P+F web page to speed response time. Then, when you are finished, P2 can be selected for normal network operation to conserve battery life. 8 SKF Wireless Machine Condition Sensor

15 The Basics The Network Term P2 profile Power profile Routing device Short tag Slot Security manager Superframe Definition 2048 slot superframe, sec cycle; better battery life, poor user interface response and slower join process. P2 is eight times slower than P1; the network assigns the same number of slots but eight times farther apart. High or low power device. See the section Full Routing vs. Leaf Node, Power profile. A device that participates in the mesh network, meaning it helps its neighbor when the neighbor does not have direct access. Pre-HART7 8-character logical name for the HART device. A fixed time interval that may be used for communication between neighbors. Responsible for the joining process of the device and assigning the session key to encrypt and decrypt packets. A collection of slots repeating at a constant rate. Each slot may have several links associated with it. KNOWN ISSUE: P2 profile is not working in the P+F gateway. However, it may work in gateways from other manufacturers. The WirelessHART Network Joining Process This is a simplified sequence of how the sensors join the network. The active gateway sends network advertisement signals. These are messages sent by the network manager to announce the network s existence. The network manager and security manager are contained in the gateway. The sensors respond with a Join Request, which consists of the Network ID and Join Key. The security manager authenticates the Network ID and Join Key and then allows the sensor to join the network. The security manager sends session keys to the sensors and routing and scheduling information. The sensors begin normal operation, which is publishing data (the four main variables and device status, as described below). Network Layers Physical Layer IEEE ISM band GHz 16 x 5 MHz non-overlapping channels in 80 MHz bandwidth SKF Wireless Machine Condition Sensor 9

16 The Basics The Network DataLink Layer Time Synchronized Mesh Network - Time Division Multiple Access (TDMA) There are 250 slots within one superframe. Each slot is 10 ms. Therefore, the superframe repeats every 2.5 sec. 133 bytes packet at 250 kbit/s; it takes ~4 ms for an average packet to complete within the 10 ms 16 channel * 100 slots/sec/channel = 1600 slots per sec Frequency hopping - Avoid interference and provide reliable communication by using a different frequency channel in each allocated slot. WirelessHART networks are extremely reliable in delivering packets of data. The grid below illustrates how TDMA works. Multiple slots may be allocated to a device within a superframe depending on the communication demand. Multiple devices can communicate at the same slot by using different frequencies; for example, sensor 1 and sensor 2 communicate at the same time by using different frequencies. Application Layer Figure 4. TDMA Slots and Channels Illustrated. Universal (spec127) Standard commands must be implemented by all HART devices. For example, they support four main variables PV (Primary), SV (Secondary), TV (Tertiary), QV (Quaternary) and other device variables, such as tag names, descriptor, date, final assembly number (FAN), device status. With CMWA 8800, the PV is velocity overall RMS, SV is enveloped acceleration overall Pk-to-Pk and TV is temperature. QV is not used. Common (spec151) Standard commands applicable to many devices, such as squawk for sensor identification, burst control for data publishing, and block transfer. Device Specific Vender specific commands. For example, cyclic update interval, sample. 10 SKF Wireless Machine Condition Sensor

17 The Basics The Wireless Sensor Device Manager The Wireless Sensor Device Manager Device Manager provides the user interface that enables you to set up, commission, operate and maintain the sensor system. It allows you to change the gateway settings and also propagates the settings to all sensors in the network (note: this cannot be done from the gateway s web page). After the sensors are set up, and their data collection schedules are configured and stored in the Device Manager database, you will start the batch service. The Device Manager batch service runs in the background using the stored data collection schedules to collect measurements and save them to the database. Both the UI and batch service are installed from a single installation application. WARNING! The minimum monitor resolution for Device Manager is 1600 x 900. Device Manager does not permit scrolling and some vital functions will be unavailable at lower resolution. Device Manager exports the collected data to the Analyst database. The diagram below shows the data flow from the CMWA 8800 all the way through to Analyst and other applications. Figure 5. Data Flow Export to Analyst. The Device Manager License Key Device Manager is shipped with a temporary license key that has a fixed expiration date. The temporary license key and expiration date can be found on the hot sheet inside of the Device Manager s CD case. This temporary license is good for up to 50 sensors only. When Device Manager is installed and a plant hierarchy item has been created (prior to the expiration date), then the permanent license key should be requested from SKF Customer Support Group (CSG) through the License Management dialog in Device Manager. SKF Wireless Machine Condition Sensor 11

18 The Basics The Wireless Sensor Device Manager Important points to note include: The license key is good for any number of installations on the same computer. The license key is good for future software upgrades. The customer must re-apply for the license key from CSG if the software is moved to a different computer. To obtain the license key, follow these steps: After the first plant is created, go to Help > License Management. The License Management dialog opens. Enter the temporary license key from the hot sheet to the License Key field. Click Save. The Expiration date is then displayed. Up to 50 sensors are supported in the Current column. In the Wanted column, select the number of the sensors that the purchased license supports (500 in this example). With the License Application Code now displayed, click the Copy to clipboard button to copy the code to your clipboard. Paste the code in an and then send it to CSG. CSG will return an with the new license key to the customer within 24 hours. Copy the license key from the from CSG to the clipboard. 12 SKF Wireless Machine Condition Sensor

19 The Basics The Wireless Sensor Device Manager From the License Key field, click the Paste from clipboard button and then click Save. The Current column will show the number of sensors that the license key supports and the Expiration date box will disappear. Device Manager Configuration Parameters Device Manager configuration parameters are stored in the Settings.config file on the drive on which the software is installed: For Windows XP, the default path is \Program Files\SKF-RS\Wireless Sensor Device Manager \Settings.config in the root drive. For Windows 7, the default path is \Program Files(x86)\SKF-RS\Wireless Sensor Device Manager 8800\Settings.config in the root drive. Settings.config - Stores the following information: Information Enables and disables expert features in the GUI Ports used Port range Enable/Disable communication logging Device Manager software program execution logging depth XML prefix SKF export folder name Default Setting <add key="localtest" value="false"/> <add key="gatewayport" value="20004"/> <add key="portrangestartport" value="7000"/> <add key="hartcommmode" value="true"/> <add key="debugmode" value="false"/> <add key="infomode" value="true"/> <add key="dbinfomode" value="false"/> <add key="udpinfomode" value="false"/> <add key="batchinfomode" value="false"/> <add key="queueinfomode" value="false"/> <add key="learninfomode" value="false"/> <add key="blockdatainfomode" value="false"/> <add key="commandinfomode" value="false"/> <add key="skfxmlexportprefix" value="wsdm"/> <add key="skfexportfolder" value="c:\wsdm_export\"/> SKF Wireless Machine Condition Sensor 13

20 The Basics The Wireless Sensor Device Manager Information Time Synch enable/disable Timing configuration Note: Optimized do not change Default Setting <add key="performgatewaytimesynch" value="false"/> <add key="cmdsendingdelay" value="500"/> <add key="cmdresponseretrycount" value="200"/> <add key="gwresponsetimeout" value="2000"/> <add key="keepaliveperiod" value="60000"/> <add key="gatewayreconnectdelaymilliseconds" value="60000"/> Figure 6. Example of a Settings.config File. 14 SKF Wireless Machine Condition Sensor

21 3 The P+F Gateway s Web Page The P+F gateway s web page gives field service personnel a wide range of information and possible actions to take when pursuing customer issues or questions. In this chapter, we will discuss the following: How to access the P+F gateway s web page Known issues with the gateway s firmware The significance of the Network ID and Join Key Why and how to prepare a commissioning gateway (including a gateway from another vendor) How to join the sensors to the commissioning network Comparison of features available with P+F vs. Emerson gateways Accessing the Web Page The P+F gateway s web page gives field service personnel a wide range of information and possible actions when pursuing customer issues or questions. To access this tool, follow the steps below. You will want to set up the configuration computer to join the customer s network. Verify with the customer the correct gateway IP address on the network. (The P+F gateway s factory default IP address is ) Enter the gateway s IP address into your browser s address bar to access the P+F gateway s configuration web page. The default username is admin; the default password is also admin. Figure 7. Authentication Required Dialog for P+F Gateway s Web Page. SKF Wireless Machine Condition Sensor 15

22 The P+F Gateway s Web Page Verifying the P+F Gateway s Firmware Version Known Issue You see the message, Microsoft Internet Explorer is not able to show the P&F gateway web page. Cause: The computer is missing Java to run Java Applet. Solution Download and install Java from this link Verifying the P+F Gateway s Firmware Version If the network P+F gateway was not purchased from SKF, verify that the software Revision is 2.5 or later and the software version is or later. Figure 8. Verify the Gateway s Firmware Version. Known Issues with the Firmware The following are known issues with the P+F gateway s firmware, current software release 2.5 version : Known Issue The web pages do not refresh automatically. The manual refresh is very slow if the network has many sensors (more than 50) trying to join the network. P1 or P2 profile options are offered, but P2 profile (slower) does not work. Solution Manually refresh the web pages to get updates. No solution. Wait until the refresh is complete. No solution at this time P2 does not work in the P+F gateway s firmware in the current version. 16 SKF Wireless Machine Condition Sensor

23 The P+F Gateway s Web Page Network ID and Join Key Parameters Known Issue The gateway s Time Synch function does not work. Solution Manually set the time in the P+F gateway s Setup web page. Time Synch is currently switched off in the Device Manager software Settings.config file: <add key="performgatewaytimesynch" value="false"/> Network ID and Join Key Parameters The gateway parameters that allow the sensors to join the network are the Network ID and Join Key. The following table shows the three built-in Network ID options provided by SKF USA, Inc. Type of Network Production network with built-in settings Commissioning network Network ID and Join Key Use one of the built-in Network IDs (101 or 102) and the factory default Join Key. Built-in network settings are manually selected on the sensor. A commissioning network is unnecessary to configure the sensors to join the production network. (You should not use 1229 in a production network.) Allows out-of-the-box sensors to join using the factory default Network ID (1229) and the factory default Join Key. Then, modify the default settings to the customized production network settings before deploying the sensors in the production network. (You should not use 1229 in a production network.) One of the built-in Network ID settings (101 or 102) can be used for a new production network installation. With the sensors manually set up with the selected Network ID and the gateway configured accordingly, the production network is quickly set up and a commissioning network is unnecessary. If the customer wants to use a customized production Network ID, then a commissioning network (factory default Network ID 1229) should be set up to customize the sensors network parameters and test communication between the gateway and the sensors before final installation. Pre-configuration services for a customer network can be arranged through CSG. SKF configures the sensors to join the production network with the customized Network ID and Join Key obtained from the customer. SKF Wireless Machine Condition Sensor 17

24 The P+F Gateway s Web Page Preparing a Commissioning Gateway Preparing a Commissioning Gateway The commissioning gateway always uses the SKF factory default network settings. The commissioning gateway and sensors being commissioned should be located away from the production network s signal range (both will temporarily have the same Network ID and Join Key when the new sensors are switched to the production network settings). Use the commissioning gateway to accomplish the following tasks: Configure new sensors from the factory to join the production network. (Refer to Chapter 9, System Maintenance, Adding a New Sensor into Service.) Modify the Long Tag of a sensor to monitor a different machine. (Refer to Chapter 9, System Maintenance, Editing a Sensor s Name.) Configure a new sensor to replace a sensor in the production network. (Refer to Chapter 9, System Maintenance, Replacing an Existing Sensor in Service.) To set up a commissioning gateway: On the gateway s web page, expand Parameter to enter Identification parameters for the gateway to best identify it on the local area network (LAN): Device Long Tag, Device Tag, Descriptor. Figure 9. Enter Descriptive Device Information. Next, expand Wired Communication > Interfaces. Enter a static IP address and Netmask settings for the gateway to connect to the LAN. 18 SKF Wireless Machine Condition Sensor

25 The P+F Gateway s Web Page Preparing a Commissioning Gateway Figure 10. Connect the gateway to the LAN. Click the Write Ethernet Information s >> button to update the gateway with the LAN settings. The gateway should be configured now to communicate using the LAN. Disconnect the Ethernet cable from the configuration computer and connect it directly to your LAN. Launch the gateway s web page in the Device Manager host computer to continue configuring the gateway. Modify the Ethernet / User Datagram Protocol (UDP) port number to the SKF default port of for the Device Manager connection. Figure 11. Ethernet / UDP Port Number. Verify the current network settings by expanding Parameter > Wireless Communication > Setup. If the gateway is from SKF, the default commissioning network ID of 1229 will display and the default Join Keys will be present, but masked. (The Join Keys are shown on the following page.) If the Network ID is 1229 and the Join Keys of the commissioning network are present, the network is ready for the new sensors to join the commissioning network. If the gateway is not from SKF, or you see a different Network ID, instructions for changing the network settings are provided below in the section, Steps to configure a commissioning gateway. SKF Wireless Machine Condition Sensor 19

26 The P+F Gateway s Web Page Preparing a Commissioning Gateway Figure 12. Verify the Network ID. If the P+F gateway is NOT from SKF, or if the Network ID is different, then complete the following steps. Steps to configure a commissioning gateway: Set DIP switch 8 to the up position to disable the security mode and enable the write function. Expand Parameter > Wireless Communication > Setup. Change the gateway s Network ID and Join Key to the SKF defaults for the commissioning network. Note: The gateway requires the Network ID and Join Key to be set together. Click Write Join Information and confirm the prompts. When the upload is done, return DIP switch 8 to the down position to disable the write function and enable the security mode again. SKF Factory Network ID: 1229 SKF Factory Join Key: E F524B53 524F434B 20 SKF Wireless Machine Condition Sensor

27 The P+F Gateway s Web Page Joining the Sensors to the Commissioning Network Expand Additional Functions > Reset. Click Reform Network to activate the new network settings. After the network reform is complete, the network is ready for the new sensors to join the commissioning network. Joining the Sensors to the Commissioning Network If many sensors (50 or more) will be joining the network, Global Advertising can be initiated to speed up the process. The Global Advertising (or Active Advertising) function can save considerable time when joining new sensors to the network; the joining process may be up to 16 times faster with advertising on. The only cost for the time saved is higher battery consumption temporarily on all devices in the network during the advertising phase. Because Global Advertising increases energy consumption of the network s devices, it is recommended that you use it only when needed, that is, when you expect new devices to join the network. Note that you can activate Global Advertising without reforming the network. To start Global Advertising: From the gateway s Setup web page, you can enter the number of minutes (1 to 255) to Global Advertising Timeout. Then, click Activate Global Advertising. Or From Device Manager, select the gateway hierarchy item. Click the Set Active Advertising On button. This function works only with P+F gateways. It will not work with WirelessHART gateways from other manufacturers. To start joining the sensors: Activate the sensors and let them join the commissioning network using the factory default settings. Go to the gateway s web page to check the sensors status. As the sensors successfully join the network, they will appear in the Com Stat column of the gateway s Operating Modes web page (refresh the page manually). SKF Wireless Machine Condition Sensor 21

28 The P+F Gateway s Web Page P+F Gateway s Installation Torque The Production Network Settings You can follow the same steps shown above in the section, Steps to configure a commissioning gateway, to modify the gateway s network join settings from the factory defaults to the final customized settings. However, the network settings modified in this way are applied only to the gateway. The gateway will not propagate modified network join settings to the sensors. Only the Device Manager software enables you to change the gateway settings and also propagates the new settings to all sensors in the network. This procedure is presented in Chapter 5, Changing the Network ID and Join Key. P+F Gateway s Installation Torque The table below provides a guide to tightening the cable glands and cover in order to maintain the gateway s IP rating. Installation Torque for Cable Glands 2.5 Nm (22 lb-in.) Plastic Type of Cable Glands 4.11 Nm (36 lb-in.) Nickel plated brass 4.11 Nm (36 lb-in.) Stainless steel Installation Torque for Housing Cover 2.5 Nm (22 lb-in.) 22 SKF Wireless Machine Condition Sensor

29 The P+F Gateway s Web Page Comparing P+F with Emerson Gateways Comparing P+F with Emerson Gateways The table below presents a couple of known differences between the P+F gateway versus an Emerson gateway. The compatibility of Device Manager and the Emerson gateway is still under investigation. P+F Gateway All gateway functions described for CMWA 8800 in the Wireless Machine Condition Sensor Setup Guide and the Wireless Sensor Device Manager User Manual should work. Emerson Gateway The functions in the Device Manager Gateway / Admin tab do not work. Supports Command 93 for caching measured values in gateway memory. Publishes the last 12 PV (Velocity RMS), SV (Env.Acc.Pk-Pk), TV (Temperature) values at 20 min intervals in a 60 min cycle for trending. Measurements have the accurate date/time stamp of when they were sampled. Does not cache Command 93 data. Command 9 must be used to publish trend values. The gateway date/time stamps the measurements when the values are received. The stamps may be off by as much as one cyclic update interval. SKF Wireless Machine Condition Sensor 23

30

31 4 Wireless Sensor Device Manager In this chapter, we will present details about installing Device Manager, including potential problems that may occur. We cover the process of enabling communication in the network devices and connecting to the gateway, including troubleshooting a failed connection. A table summarizing known issues with Device Manager is provided. Additional topics in this chapter include: Full routing vs. leaf node sensor function Expert features for service personnel Data collection scheduling Manual data collection Device Manager Installation Device Manager CD contents: dotnetfx45_full_setup.exe Wireless Sensor Device Manager software Wireless Sensor Device Manager User Manual P&F Gateway User Manual P&F Adapter User Manual SKF Wireless Machine Condition Sensor 25

32 Wireless Sensor Device Manager Device Manager Installation To Install Device Manager Verify dot Net 4.5 is installed. If not, install it. On the Windows 7 or Windows 2008 server, disable User Access Control (UAC) before installing Device Manager. Go to Start > Control Panel and search for uac. Change the setting to Never notify. Restart the computer to initiate this change. Install MS SQL Server 2008 R2. (The Express version is available on the Analyst CD.) Copy the Server Name string for later use. You will use the Server Name as the Database Server for Device Manager. The Microsoft Windows user account must have Administrative privileges on the local PC to install and operate Device Manager. Install Device Manager by following the Setup Wizard to completion. Reset the UAC to its original setting and restart the computer to initiate the UAC change. 26 SKF Wireless Machine Condition Sensor

33 Wireless Sensor Device Manager Device Manager Installation Known Issue #1 Cannot open database Issue: Device Manager installation appears to be complete but an error message appears when you try to launch the software. Cause: Unable to disable UAC due to IT security. Go to the Program Files/SKF- RS/Wireless Sensor Device Manager -8800/DB. Right-click the DB folder. Go to the DB Properties dialog, Security tab. Select Everyone. (Note: If Everyone does not exist, click Edit. Then, click Add to create Everyone.) Click Edit. Check Allow for Full control. Click OK. Manually attach the database to SQL Server by using the following steps: Right-click the Database. Select Attach to open the Attach Databases dialog. SKF Wireless Machine Condition Sensor 27

34 Wireless Sensor Device Manager Device Manager Installation In the Attach Databases dialog, click Add. In the search window, locate the database file under the pathway SKF-RS/Wireless Sensor Device Manager 8800/DB/. Select the.mdf file. Click OK. In the Attach Databases dialog, confirm the CMWA8800 database is the one you want to attach. Note: You must use the same Database name that was provided for the initial installation. For this example, the database name is CMWA8800. Click OK. 28 SKF Wireless Machine Condition Sensor

35 Wireless Sensor Device Manager Device Manager Installation The CMWA8800 database now appears under /Databases under the computer ID SQLEXPRESS Known Issue #2 Replace the database Issue: Device Manager installation appears to be complete but an error message appears when you try to launch the software. Cause: The installation script was prohibited from updating the database file during the installation. Manually detach the database to SQL Server by using the following steps: The database has been manually attached, but an error message complains that a column is missing in the table. Solution: (depicted below) Detach the database from SQL Server Engine. Replace the database files with known working database files. Re-attach the database. Go to the CMWA8800 folder under /Databases under the computer ID SQLEXPRESS. Right-click the CMWA8800 folder. Select Tasks > Detach to open the Detach Database dialog. SKF Wireless Machine Condition Sensor 29

36 Wireless Sensor Device Manager Device Manager Installation In the Detach Database dialog, select the check boxes Drop and Update. Click OK. Next, you must replace the database files with known working database files, such as WiMon.mdf, WiMon_log.ldf. Then, re-attach the database. Follow the steps below. In the search window, locate the database file under the path SKF- RS/Wireless Sensor Device Manager 8800/DB/. Select the.mdf file. Click OK. Note: A copy of an updated version of the database is included on the CD. Copy the database file from the CD to the DB folder before re-attaching the database file. In the Attach Database dialog, confirm the CMWA8800 database as the one you want to attach. Note: You must use the same database name that was provided for the initial installation. Click OK. 30 SKF Wireless Machine Condition Sensor

37 Wireless Sensor Device Manager Device Manager Installation The CMWA8800 database now appears under /Databases under the computer ID SQLEXPRESS SKF Wireless Machine Condition Sensor 31

38 Wireless Sensor Device Manager Connecting to the Gateway Connecting to the Gateway The first time Device Manager is launched, the system hierarchy needs to be created. Refer to the Wireless Sensor Device Manager User Manual for details. Right-click the root node SKF Wireless Machine Condition Sensor System and select New Plant to create the plant. The Plant will display the Batch Service Management tab. The Batch Service should remain Stopped at this time. Right-click the plant hierarchy item and select New Network to create the network. Right-click the network hierarchy item and select New Gateway to create the gateway. Enter the IP Address and the Port Number. In the Gateway / Properties tab, click the Gateway Communication Enable button. When communication is established with the gateway, the red area changes to green and the message text updates to Communication is enabled. The gateway connection should be established too. 32 SKF Wireless Machine Condition Sensor

39 Issue: Gateway Connection Failed Wireless Sensor Device Manager Connecting to the Gateway It may happen that communication with the gateway is enabled but the gateway is not connected. Issue: Gateway is not connected. The red message Gateway is not connected does not change. One or more of the following items may be at fault. Check each item to find the problem. Incorrect gateway IP Address Incorrect Port Number (Remote) (default is 20004) Incorrect Polling Address (must match the polling address DIP switch setting default is 0 with all switches in down position) Gateway and PC are in different subnets Gateway is faulty Network cable is faulty Faulty network hardware (card and/or cable) Firewall security is blocking the ports used by Device Manager Troubleshooting the Required Ports If the Device Manager PC is able to access the gateway s web page but Device Manager failed to connect, a network security firewall may be blocking the ports needed by the Device Manager software. The following ports are required by default: Destination: The gateway s UDP server listens at port (SKF default). You can test by connecting to the Telnet server in the gateway from the host PC. Go to to enable Telnet client in the Device Manager computer. From the Device Manager computer, in the DOS cmd window, enter Telnet <Gateway IP address> Source: 7000 to Device Manager uses ports 7000 to 7010 (SKF default) to initiate communication with the gateways in the network. Ask IT to open these ports in the firewall. Two ports in the Port Number Range are used for each gateway. The first port (7000) is used by the Device Manager UI and the next port (7001) is used by the batch service to connect with the first gateway, and so on, as shown below. SKF Wireless Machine Condition Sensor 33

40 Wireless Sensor Device Manager Connecting to the Gateway Figure 13. Source and Destination Ports for Multiple Gateways. By default, the Device Manager software initially reserves 10 ports in the network. If more than five gateways are to be installed, expand the range accordingly. Contact IT to open these additional ports in the firewall. Figure 14. Port Number Range. 34 SKF Wireless Machine Condition Sensor

41 Wireless Sensor Device Manager Connecting to the Gateway Importing Sensors into Device Manager After Device Manager is connected to the gateway, the list of sensors that are connected to the gateway need to be imported into Device Manager. Refer to the Wireless Sensor Device Manager 8800 User Manual for details. WARNING! First, make sure the batch service is stopped! The sensors must be turned on and appear green in the Com. Stat. column of the gateway s Operating Modes web page. This is the list of sensors that will be imported into Device Manager. Right click the gateway in the Device Manager hierarchy. Select the Find sensors option. The sensors stored in the gateway are uploaded to the Device Manager s database. Once imported, the sensors will display under the gateway item. The first time the hierarchy structure is built, the Device Manager software also uploads the current configuration data from all wireless sensors branching from the gateway. This may take several minutes (even tens of minutes) to complete, depending on the number of sensors. Viewing the Connected Sensors To view the connected wireless sensors in the Device Manager hierarchy: Click the + (open) next to the gateway and CMWA 8800 Sensors hierarchy icons to expand the sensor list. Figure 15. Two Wireless Sensors Displayed in the Hierarchy. SKF Wireless Machine Condition Sensor 35

42 Wireless Sensor Device Manager Verifying the Sensor Firmware The following icon color codes are used to indicate communication status: Green Indicates that the sensor is available and no active communication is taking place. Yellow Indicates that the Device Manager software and sensor are communicating with each other. Blue Indicates that the Device Manager software s batch service and the sensor are communicating, and the sensor is not currently available from the Device Manager software. Red Indicates that the sensor cannot be reached. Verifying the Sensor Firmware After Device Manager is connected to the gateway and the sensors are imported into the Device Manager database, you can verify that the sensor firmware is the latest released version. The current released version is 79 or later. Figure 16. Sensor Firmware Tab, Software Revision. 36 SKF Wireless Machine Condition Sensor

43 Wireless Sensor Device Manager Known Issues in Device Manager Known Issues in Device Manager Known Issue Device Manager shows an empty window upon opening. Cause: The GUI layout file has been corrupted. Unhandled Exception when closing the Device Manager GUI in Windows 7. Cause: Incompatible DotNet version. Gateway connection status cycles between connected and disconnected. Cause: Port conflict at the gateway. Another HART UDP master, such as another Device Manager instance in the same network has connected to the gateway and reserved the configured ports. A waveform took too long to upload. Cause #1: Gateway firmware may be an older version. A waveform took too long to upload. Cause #2: Probably related to missing fast pipe for the operation. It should take about 2.5 minutes for a one hop sensor with fast pipe to upload the time waveforms. The time increases proportionally for more hops. [See the following topic: Full Routing vs. Leaf Node.] Solution Delete the file DockPanel.config in the \Program Files\SKF-RS\Wireless Sensor Device Manager 8800 folder in the root drive and then re-launch the software. Install DotNet45. dotnetfx45_full_setup.exe is on CD from SKF. An Internet connection is required. Make sure there is only one HART UDP master in each network. Solution #1: Verify the gateway is running the latest firmware version Solution #2: Check the gateway s Operating Modes web page to see if the fast pipe is granted to the wrong sensor. If the fast pipe is granted to a sensor that is not currently sending waveform data or receiving a firmware download, deselect the check box in the Operating Modes web page to release the fast pipe. Make sure the sensor with the issue of the long waveform upload time is configured for Full routing in the Sensor > Status tab. Manually start a waveform upload and then confirm in the gateway s web page that the fast pipe is granted to the sensor. SKF Wireless Machine Condition Sensor 37

44 Wireless Sensor Device Manager Full Routing vs. Leaf Node Full Routing vs. Leaf Node The Power profile of all sensors must be set to Full routing (high power profile) mode in the Sensor > Status tab. The network manager in the gateway grants fast pipe capability only to sensors with the Full Routing power profile. Fast pipe capability is desired for waveform collection and firmware upgrades. Figure 17. Power Profile Full Routing Option. IMPORTANT! Having all the sensors serve as routers will increase sensor power consumption. See below for a solution. Having all the sensors serve as routers will increase sensor power consumption but there is a solution to this situation. The actual routing capability is set in the gateway s Operating Modes web page. In the Routing Device column, deselect the check boxes for the sensors so that the network manager will not use the sensor for routing. The sensors will instead function as leaf nodes to conserve power. 38 SKF Wireless Machine Condition Sensor

45 Wireless Sensor Device Manager Expert Features in Device Manager Expert Features in Device Manager Activate the Expert Features in Device Manager by changing the value of the LocalTest key to True in the Settings.config file (<add key="localtest" value="true"/>). Then, launch the Device Manager software. Select a sensor in the Device Manager hierarchy and open the Device tab. Figure 18. Sensor > Device Tab with Expert Features Activated. Wireless or Wired Communication At the top of the Sensor > Device tab, the expert feature Use wireless / wired communication displays. Wireless usage must be established first. Then, wired communication is started by connecting an RS485 modem cable and selecting the wired option button. Wireless communication is the standard operating mode for the sensor. Wired communication is used in the factory to talk to the sensor directly to download the firmware more quickly (about 5 minutes instead of 25 minutes wirelessly). SKF Wireless Machine Condition Sensor 39

46 Wireless Sensor Device Manager Expert Features in Device Manager Calibration Calibration is performed during manufacturing. If calibration is needed in the field, it is important that velocity is calibrated first because the sensor simultaneously makes a new calibration of the envelope based upon the Pre-calibration factor stored at manufacturing time. When the envelope is calibrated, a new Pre-calibration factor is calculated and stored in the sensor, based upon the new calibrated values of velocity and envelope. If you want to restore the original Pre-calibration factor stored at manufacturing time, you must obtain that number and enter it in Calibration value field. Click Write Pre-Calibration to restore this value. How to perform velocity calibration: Deselect the Use Cache check box in the gateway s Admin tab to disable the automatic data collection function. Set the sensor on a shaker table. Apply the velocity calibration reference at Hz. Enter the velocity reference in the Calibration value box. Click Perform Velocity Calibration. Wait 50 seconds for the calibration to take effect. Apply a different frequency and amplitude setting on the shaker. For example, 10 mm/s at 700 Hz. Manually take an overall reading to verify the velocity calibration is okay. The overall velocity should be between 8.88 to mm/s. Enter the calibration date in the Date fields. Enable the Use Cache function when calibration is complete. WARNING! Do not modify the Final Assembly Number (FAN). 40 SKF Wireless Machine Condition Sensor

47 Wireless Sensor Device Manager Expert Features in Device Manager How to perform envelope calibration: Enveloped acceleration calibration is not usually necessary. It is automatically calibrated when the velocity calibration is completed. Enveloped acceleration calibration follows the same steps as velocity. For accurate calibration of envelope, an amplitude modulated signal must be applied, for example, 9.82 m/s2 at 2 khz with % amplitude modulation. Generic Command Feature The Generic Command feature allows the expert user to send HART commands directly to the sensor. Figure 19. Sensor > Generic Command Tab. Here is an example of sending a HART command to the sensor. Command 125 Write Battery Voltage Threshold Value sets the threshold value for the Battery critically low alarm. The default value is 3.3 V. The 3.3 V threshold may need to be lowered for high temperature applications (60 to 85 C, 140 to 185 F) by using the generic command. Figure 20. Generic Command Example. As shown in the figure above, the setting for critical Power Failure is changed to 2.93 V, where 403B851E entered in the Data field is the IEEE hex format for 2.93 V decimal number. Press the Send button to send the command to the sensor. SKF Wireless Machine Condition Sensor 41

48 Wireless Sensor Device Manager Data Collection Scheduling Data Collection Scheduling With Device Manager installed, connected to the gateway and operational, refer to the Wireless Sensor Device Manager User Manual for details on continuing to build the wireless system s hierarchy, configuring the sensors and scheduling data collection. This presents some recommended setup guidelines for data collection scheduling and examples for your convenience. Coordination between settings on various setup tabs is required to properly set up your wireless sensor data collection. Setup guidelines are provided in the following table, which indicates the recommended wireless sensor setup for monitoring standard machinery running at standard speeds (between 1500 and 3600 RPM). The recommended setup shown in the table assumes that you are collecting vibration overalls, temperature, and battery measurements using burst mode. Recall that with burst mode the sensor publishes data at regular intervals and burst data are saved in gateway memory. When queried by the host software, the gateway returns the cache data. The figure following the table illustrates the recommended Sensor > Burst Control message settings as described in the table, using Trending Command 93. It shows the default setup for the wireless sensors joined to a P+F gateway. 42 SKF Wireless Machine Condition Sensor

49 Wireless Sensor Device Manager Data Collection Scheduling Recommended Wireless Sensor Settings for Standard Machinery ( RPM) Sensor > Device Sensor > Data Collection Gateway > Admin Sensor > Burst Control Sensor > Status Specify the sensor s identification (long tag name) and machine speed. Specify the sensor s vibration cyclic update interval and the trending command to use; and specify which measurements the sensor performs and the polling schedule to retrieve and store them in the Device Manager database. Vibration Cyclic Update Trending Command Velocity and Envelope Waveform Envelope Pk-Pk and Velocity RMS (vibration overalls) Enable Command 93 (CMD93) Enable Enable 1 hour Reference time user preference Reference time not configurable when CMD93 is selected Start time 00:00 (midnight) Period 24 hours Period not configurable when CMD93 is selected Temperature Enable N/A Period 1 hour When using burst mode (recommended), specify for Device Manager to retrieve vibration overalls, temperature, and battery measurement results from the gateway s cache. Use Cache Enable When using burst mode (recommended), specify which measurements the sensor bursts to the gateway s cache, and their burst interval. Burst Mode Message 0 - On Message 1 - On Update Period Command / Slot Message 2 - On 20 minutes 60 minutes 60 minutes N/A Command 93 Command 9 Slot 0 Battery Life Slot 1 Battery Voltage Slot 2 Battery Charge Slot 3 - None Each sensor s power profile should be set to Full Routing. Command 3 (optional) for HART OPC systems only Message 3- Off To preserve sensor battery life, disable the routing capability on the gateway s Operating Modes web page, in the Routing Device column. N/A SKF Wireless Machine Condition Sensor 43

50 Wireless Sensor Device Manager Data Collection Scheduling Figure 21. Recommended Burst Control Settings with P+F Gateway Command 93. Notice that the sensor publishes the primary, secondary, and tertiary variables 20 minutes apart, according to the designated Update Period. For example, velocity data are published at the top of the hour, enveloped acceleration data 20 minutes later, and then temperature data 20 minutes after that, equaling a 60 minute cycle, as illustrated below. Figure 22. One Data Publishing Cycle, Including the Update Periods. 44 SKF Wireless Machine Condition Sensor

51 Wireless Sensor Device Manager Data Collection Scheduling Note that in the preceding sensor setup table we recommend a setup that polls the sensors every 24 hours for waveform data, and that polls the gateway s cache every hour for vibration overalls and temperature data (using burst mode). Collecting overalls and temperature data hourly on noncritical machinery may seem excessive to those familiar with traditional vibration monitoring technologies. However, it is important to realize that HART process information systems working with OPC compliant host servers typically update their data in minutes, and that vibration / temperature data stored in the gateway s cache may be used by these existing process information systems. Bursting the overalls to the gateway cache hourly makes sense in these scenarios. If you wish to extend your trend intervals, you may choose to extend the Sensor > Data Collection tab s Period for the Envelope Pk-Pk and Velocity RMS / Temperature measurements to 12 hours, 24 hours, weekly, etc. (an example is provided below). WARNING! The Use Cache check box must be selected in order for burst mode to work. Device Manager will not retrieve the sensors measurement results from the gateway s cache if this function is disabled. You must turn off Use Cache temporarily when you are making any revisions to the data collection schedule or collecting data manually. Remember to enable it again for normal operation when you are done. To find the Use Cache check box: Select the gateway in the Device Manager plant hierarchy list. Select the Admin tab. The Use Cache check box is at the bottom of the Admin tab. WARNING! You must also disable the Batch Service temporarily when you are making any revisions to the data collection schedule or collecting data manually. Remember to enable it again for normal operation when you are done. To stop the Batch Service: Select the Plant in the Device Manager hierarchy list. The Plant will display the Batch Service Management tab. Click Stop if the Batch Service is running. SKF Wireless Machine Condition Sensor 45

52 Wireless Sensor Device Manager Data Collection Scheduling Command 93 Example The first example illustrates a sensor configured with Command 93 (burst mode). The sensor always bursts the last 12 measurements with accurate date/time stamps. The system can still recover the last 12 measurements (the trend) even after the gateway has been down for that period of time. Figure 23. Command 93 Burst Mode Data Collection Tab Example. In Figure 24, the last column on the right shows the trend collection schedule with the Vibration Cyclic Update set at one, two and three hour intervals, based on the respective Starting at time. The Starting at time (or Start Time, outlined in red) specifies when to take the first measurement of the day. The Vibration Cyclic Update is the time interval at which the sensor samples a new set of measurements and saves them in its memory. With the burst Update Period set to 20 minutes (see Figure 21), the publishing cycle duration is one hour, as shown in Figure 22. The Update Period of 20 minutes works fine for the 1-hour Vibration Cyclic Update interval. However, the 20 minute setting would waste battery power for the 2-hour and 3-hour Vibration Cyclic Update intervals because the sensor would burst the same set of measurements twice at one hour intervals with the 2-hour Cyclic Update and three times at one hour intervals with the 3-hour Cyclic Update. If the Update Period is modified to 40 minutes for the 2-hour Cyclic Update, and 60 minutes for the 3-hour Cyclic Update, then the sensor will burst only the new set of measurements once per Vibration Cyclic Update interval. Figure 24. Overall Trending Measurement Schedules. 46 SKF Wireless Machine Condition Sensor

53 Wireless Sensor Device Manager Data Collection Scheduling In Figure 25, the last column on the right shows the waveform collection schedules with the Vibration Cyclic Update set at one, two and three hour intervals, according to the respective Starting at time (or Start Time), Reference Time and Period. The Reference Time is when the Device Manager queries the sensor for the first measurement of the day, at 8:05 a.m. in this example. The Period is how often the query is repeated, every 24 hours in this example. The date time stamp (DTS) of the collected waveform is not at 8:05 a.m. because the sensor only returns the waveform sampled during its previous Vibration Cyclic Update, which was at 7:30 a.m. for the 1- hour and 2-hour Cyclic Updates and at 5:30 a.m. for the 3-hour Cyclic Update. Figure 25. Waveform Measurement Schedules. In Figure 26, the last column on the right shows the valid Possible Data Collection Periods of temperature data for the burst Update Periods of 20, 40 and 60 minutes. Unlike the vibration readings, the temperature sampling interval is fixed at every 5 minutes regardless of the Vibration Cyclic Update. As a result, with the burst Update Period set at 20 minutes (which equals a 1-hour burst publishing cycle), all 12 measurements collected within the hour are published to the gateway every hour. Therefore, all Collection Periods 5, 10, 15, 20, 30 and 60 minutes are valid. Only the 60 minute Collection Period makes sense with the burst Update Periods set to 40 minutes or 60 minutes, which are equivalent to 2-hour and 3-hour publishing cycles, respectively. For 2-hour and 3-hour Vibration Cyclic Updates, you must still use the 20 minute Update Period if you want to collect temperature data more often than 60 minutes apart. Figure 26. Temperature Trend Measurement Schedules. IMPORTANT: Some gateway manufacturers do not support Command 93 caching (e.g., Emmerson and Siemens gateways). If you are using non P+F gateways, you must use a Command 9 burst message to burst your vibration overalls and temperature measurement results for use with Device Manager and Analyst systems. SKF Wireless Machine Condition Sensor 47

54 Wireless Sensor Device Manager Data Collection Scheduling The timeline depicted in Figure 27 is a visual representation of the sequence of events described above using the Data Collection tab settings defined as shown in Figure 23. These settings include: The Vibration Cyclic Update is 1 hour, starting at 00:30. The waveform Reference Time is 08:05. The waveform Period is 24 hours. The temperature Period is 60 minutes. Figure 27. Timeline Representing the Sequence of Events Scheduled. 48 SKF Wireless Machine Condition Sensor

55 Wireless Sensor Device Manager Data Collection Scheduling This timeline assumes the network activity begins at 00:00 of the first day. The last event shown is the bursting of enveloped acceleration Pk-Pk data to the gateway at 23:40. The vibration measurements taken are indicated by VM and are numbered sequentially (VM1, VM2, etc.). The velocity RMS and the enveloped acceleration Pk-Pk measurements are collected at the same time. However, they are burst to the gateway separately. The black lines represent when the vibration measurements (VM#) are taken: at 30 minutes after the hour. The blue lines represent when the velocity RMS measurement data is scheduled to burst: at 20 minutes after the hour, according to the one hour Vibration Cyclic Update setting. The red lines represent when the enveloped acceleration Pk-Pk measurement data is scheduled to burst: at 40 minutes after the hour, according to the one hour Vibration Cyclic Update setting. The orange lines represent when the temperature measurement data is scheduled to burst: at the hour (60 minutes). Because the sensor always takes temperature readings every 5 minutes, the sensor can burst the most recent 12 temperature measurements after each hour. (The temperature measurements at 5 minutes apart were omitted from the timeline.) The dashed purple line represents when the most recently collected waveform data is requested by Device Manager: at 08:05 of every 24 hour period. The sequence of events for the day can be described as follows: With the system coming on line at 00:00, the first temperature reading is taken at 00:05. Subsequent temperature measurements are taken every 5 minutes and at 01:00 the total of 11 taken so far are burst to the gateway. The first vibration measurement, VM1, is collected at 00:30. VM1 velocity RMS data is burst at 01:20. VM2 is collected at 01:30. VM2 and VM1 enveloped acceleration Pk-Pk is burst at 01:40. Remember that the sensor will burst up to the last 12 measurements in memory. VM2 and VM1 velocity RMS data is burst at 02:20. At 02:00, the previous 12 temperature measurements are burst to the gateway. This is scheduled to occur on the hour, every hour, and is not mentioned again in this discussion. VM3 is collected at 02:30. VM3, VM2 and VM1 enveloped acceleration Pk-Pk is burst at 02:40. VM3, VM2 and VM1 velocity RMS data is burst at 03:20. VM4 continues this pattern. We pick up again with VM8 data collected at 07:30. VM8 through VM1 enveloped acceleration Pk-Pk is burst at 07:40. Device Manager requests the latest velocity and enveloped waveform at 08:05. The 7:30 measurement (VM8) will be sent from the sensor memory. SKF Wireless Machine Condition Sensor 49

56 Wireless Sensor Device Manager Data Collection Scheduling VM8 through VM1 velocity RMS data is burst at 08:20. VM9 is collected at 08:30. VM9 through VM1 enveloped acceleration Pk-Pk is burst at 08:40. VM9 through VM1 velocity RMS data is burst at 09:20. VM10 continues this pattern, building up a total of 12 measurements to be sent with each burst. And so on through the day. VM24, the last measurement of the first day, is taken at 23:30. VM24 through VM13 enveloped acceleration Pk-Pk is burst at 23:40. Thus ends the timeline. Not shown is the activity on the following day when VM24 through VM13 velocity RMS data is burst at 00:20. If the Period entries and the cyclic update interval do not evenly divide 24 hours, then the remaining hours do not carry over into the next day or change the timing of events. Command 9 Example The second example illustrates Command 9. If the network is using a non P+F gateway that does not support caching Command 93, then you must use Command 9 to burst the sensor s Envelope Pk-Pk, Velocity RMS, and Temperature measurement results to the gateway s cache (with less accurate date / time stamps). Figure 28. Command 9 Burst Mode Burst Control Tab. 50 SKF Wireless Machine Condition Sensor

57 Wireless Sensor Device Manager Data Collection Scheduling Figure 29. Command 9 Burst Mode Data Collection Tab. Figure 30. Overall Trending Measurement Schedule. Estimating the Time to Capture Waveforms How many waveforms can a single instance of Device Manager collect within 24 hours? Sampling is fast; sending and receiving data is much slower. It takes about three minutes to collect a waveform from a sensor with the fast pipe designation that is a single hop from the gateway. That equals 20 waveforms per hour or 480 waveforms per day. Therefore, if there are more than 480 sensors in the network, a single instance of Device Manager may not be able to collect all the waveforms within a day. This speed reflects a limitation of the system with a single instance of Device Manager. Each hop adds about three minutes (with the fast pipe), therefore two hops = about six minutes; three hops = about nine minutes. The number of hops taken can be found in the gateway s Diagnostics Details web page or the Network Statistics Report. SKF Wireless Machine Condition Sensor 51

58 Wireless Sensor Device Manager Exporting the Measurement Collection Period Exporting the Measurement Collection Period The data collection schedule in the Sensor > Data Collection tab is automatically exported to update the corresponding points in Analyst. When using Command 9 as the Trend Command in Device Manager, for velocity and enveloped acceleration point, the most frequent data collection interval between the overall and the waveform is exported to the Schedule tab in the POINT s properties in Analyst. However, when using Command 93, the waveform period is always exported even if the cyclic update period is more frequent. Manual Data Collection Overall Data If you need to collect overall data manually, follow these steps. Deselect the Use Cache check box in the gateway s Admin tab to disable the automatic data collection function. To export the manual overall data to Analyst, you must temporarily select Command 9 as the Trending Command. Select a sensor in the Device Manager hierarchy. Open the Data Collection tab. Select Command SKF Wireless Machine Condition Sensor

59 Wireless Sensor Device Manager Manual Data Collection Open the Process tab > Process Data. Click Get current values. Enabled overall vibration and temperature measurements will be collected and uploaded to the Device Manager database. The new measurement results display. If the export feature in the Plant > Export tab is enabled, then the collected measurement is also exported to Analyst. When you are done, remember to enable the Use Cache check box again for normal operation. Return the Trending Command to Command 93. Waveform Data If you need to manually collect waveform data, follow these steps. In the hierarchy, right-click the desired sensor and select Collect Waveform from the context menu. The vibration measurement is performed and the progress of the measurement is displayed. The waveform measurement data is uploaded for the selected sensor. If the export feature in the Plant > Export tab is enabled, then the collected measurement is also exported to Analyst. Figure 31. Manually Collecting Waveform Data. SKF Wireless Machine Condition Sensor 53

60

61 5 Changing the Network ID and Join Key You can change the Network ID and Join Key of the entire network in Device Manager s Gateway > Admin tab. With this method, you can change a tested commissioning network to the values of the production network and the values are propagated throughout the network to the sensors. Recall that changing the Network ID on the gateway s web page does not change the entire network. How to change the Network ID and Join Key of the entire network: Select the desired gateway in the Device Manager hierarchy. Click the Admin tab to open it. Figure 32. Exchange Network Id and Exchange Join Key Buttons. Enter the new Network ID in the Network Id field. If you click Read Network Id, the current Network ID will populate the Network Id field. Click Exchange Network Id to send the new Network ID to the network manager and its connected sensors. Enter the new Join Key in the Join Key field. Click Exchange Join Key to send the new Join Key to the network manager and its connected sensors. Wait for the network manager to propagate the new settings to all its sensors. Note: The time it takes for all the wireless sensors to update with the new Network ID and Join Key depends on the number of SKF Wireless Machine Condition Sensor 55

62 Changing the Network ID and Join Key Manual Data Collection sensors and the number of hops of the sensors to the gateway. When the gateway and the sensors are less than 6 m (20 ft.) apart with no obstruction in between, it takes at least an hour for up to 30 sensors to update with the new settings. For a large production network, it is recommended to modify the settings and leave it overnight and then reform the network the next day. Click Reform Network to activate the new settings. If a sensor fails to join after the network is reformed, take the following actions: If the sensor is within one hop of the gateway, reverse the Network ID and Join Key to the previous settings. Re-join the sensor to the network under the previous settings. (The sensors that did join under the new settings would disconnect from the network.) Then, repeat the change to the new Network ID and Join Key as described above, and wait and reform the network. If the sensor is more than one hop from the gateway, bring the sensor closer to within one hop and follow steps above. 56 SKF Wireless Machine Condition Sensor

63 6 Troubleshooting XML Import to Analyst WARNING! You must use Analyst 2012 (7400) MR2 with an XML Import fix or later version. This version fixed an issue concerning Analyst rejecting Command 93 overall or waveform measurements due to conflicting DTS. Refer to the Wireless Sensor Device Manager 8800 User Manual for full instructions on how to set up and enable data export from Device Manager to Analyst. This Service Manual offers troubleshooting tips for pursuing XML import problems in Analyst. If Analyst is not showing data for the POINTs of a sensor, follow the steps below. Start by checking the XML import setup. In Analyst, go to Customize > Configure XML Import. The XML Import Configuration dialog opens. Is the Enable processing check box selected? Yes Proceed to the next step. No Enable processing. Verify the Analyst Input directory path matches the WSDM SKFExportFolder key value in the Settings.config file. Yes Proceed to the next step. No Correct the input directory path so they match. If the Settings.config file is changed, restart Device Manager. Then, click Export node information to re-export the node data to the correct folder. (Plant > Export tab, Export node information button.) Settings.config file : <add key="skfexportfolder" value="c:\wsdm_export\"/> SKF Wireless Machine Condition Sensor 57

64 Troubleshooting XML Import to Analyst Manual Data Collection Verify the Analyst XML File prefix matches the WSDM SKFXMLExportPrefix key value in the Settings.config file. Verify the File prefix ends with an underscore on the right side. For example WSDM_. Yes Proceed to the next step. No Correct the file prefix so they match. If the Settings.config file is changed, restart Device Manager. Then, click Export node information to re-export the node data with the correct prefix. (Plant > Export tab, Export node information button.) In Device Manager, confirm that the Analyst Export is enabled. (Plant > Export tab.) Settings.config file : <add key="skfxmlexportprefix" value="wsdm"/> Yes Proceed to the next step. No Enable the Analyst Export function and verify that Device Manager is exporting files to the target input directory. Then, click Export node information to re-export the node data with the correct prefix. (Plant > Export tab, Export node information button.) In Device Manager, confirm that the Batch Service is running. (Plant > Batch Service Management tab.) Yes Proceed to the next step. No Start the Batch Service and verify that Device Manager is exporting files to the target input directory. In Analyst, confirm the Transaction Server is running. No Restart the Transaction Service. 58 SKF Wireless Machine Condition Sensor

65 Troubleshooting XML Import to Analyst Manual Data Collection If there is still a problem with getting data, check for any XML import errors reported in the Analyst event log. With all of these factors verified or corrected, wait long enough for the Transaction Service to read the files. The waiting time depends on the Period value in the XML Import Configuration dialog. (The recommended period of hours equals one minute.) SKF Wireless Machine Condition Sensor 59

66

67 7 Network Planning and Diagnostics In this chapter, we discuss general rules to follow when planning a new network or extending an existing one. Important points about the devices, network capabilities and communication stability are considered. The network diagnostic report is examined and tips for troubleshooting common network problems are provided. Network Planning First, determine the location of the gateway. Ideally, it will be in the center of the network to maximize the number of single hop connections. Elevation helps the connectivity. It is best to mount the gateway with no obstruction around the antenna, for example on a pole; otherwise, at least 15 cm (6 in.) away from the mounting wall. Next, determine the number of 1-hop sensors, 2-hop sensors, etc. You can use a scale map to place sensors (note: radio devices are also called motes) at all the required sensing points for the network. If possible, the access points should be located near the middle of the distribution of sensors to reduce latency and power usage. On the map, mark the gateway and access point location(s). Draw a circle with a 50 m (164 ft.) radius around the access point. Not all sensors within this circle will be able to communicate directly with the access point, but some sensors outside the circle will, so it will generally balance out. The number of sensors inside this circle approximates the number of 1-hop sensors in the deployment. Next, draw a 100 m (328 ft.) radius circle centered at the access point. The number of sensors in the ring between 50 and 100 m approximates the number of 2-hop sensors. Repeat this process with circles of increasing radius size until all sensors have been encircled and note how many sensors are in each hop. Three hops is the maximum recommended distance for any mesh network. Important Considerations WirelessHART documentation suggests at least 25% of the devices should have direct connection with the access point (or gateway). The more devices in direct connection with the access point the better; it improves stability and reduces latency. If possible, a sensor should have a maximum of three hops in practice or the network performance may slow considerably. Use multiple gateways if more than three hops are required. Each radio (sensor) should be within the estimated range of at least three other devices to provide alternative links in the mesh network. Disable the routing capability for the devices located at the site s perimeter to save battery power and promote security. Do this on the gateway s Operations Mode web page in the Routing Device column. SKF Wireless Machine Condition Sensor 61

68 Network Planning and Diagnostics Wireless Communication Stability Considerations Consider elevating the mesh network if ground level is too congested with obstructions. For example, elevated routers may receive the signals that are obstructed at ground level and then route them to the gateway, as shown in the following figure. Figure 33. Diagram of an Elevated Mesh Network, Red Lines Indicate Communication Paths Blocked by Obstacles. Wireless Communication Stability Considerations Location and Signal Strength Radio signal strength decreases in free space with the inverse square of the distance; an example of Free Space Path Loss (FSPL) is provided below with a link budget calculation example. In an industrial environment, there are several potential obstacles for radio waves, for example buildings, walls, pipes, or even moving obstacles like trucks. These obstacles can reflect, bend, diffuse or block radio waves. The table below lists radio signal attenuation through common obstacles (source is Dust Networks Inc.). Material Clear glass window Brick wall Solid wood door Cubicles Cinder block wall Drywall/sheetrock wood framed Marble Signal attenuation 2 db 2 to 8 db 3 db 3 to 5 db 4 db 4 to 6 db 5 db 62 SKF Wireless Machine Condition Sensor

69 Network Planning and Diagnostics Wireless Communication Stability Considerations Material Metal frame glass with reflective coating (wall or window) Interior office wall Glass window with security wire Concrete wall Signal attenuation 6 db 6 db 8 db 10 to 15 db The wireless sensor s sensitivity is approximately -90 dbm. For planning purposes, the gateway s transmitter power starts at 10 dbm and the antenna adds 2 dbi. Each obstacle subtracts from the signal strength. Link Budget Calculation Example You can estimate the Receive Signal Strength Index (RSSI) at the sensor as shown in this example. The gateway and a sensor are 50 m apart and there are two concrete walls in between them. P+F Gateway radio power 10 dbm Antenna gain +2 dbi FSPL (see note below) -74 db 2 concrete walls -15 db * 2 = -92 dbm (RSSI) Because the estimated RSSI of -92 dbm is below the sensitivity of the receiver in the sensor (-90 dbm), the connection will be marginal to bad. (Without adding the two concrete walls, the RSSI of -62 dbm is a good connection.) FSPL (db) is Free Space Path Loss. For 2.4 GHz, FSPL(dB) = 20log 10 (d) , where d = distance between the RF source and destination in meters. For 50 m, FSPL = 20log 10 (50) = 74 db. The system margins can be determined by comparing this sensitivity with the received signal level. Even with good signal strength, stability can be negatively influenced by wireless networks or other noise emitters in the 2.4 GHz band. You can check the radio RSSI and Stability on the gateway s Diagnostics > Wireless Communication > Details web page, which is discussed later in this chapter. SKF Wireless Machine Condition Sensor 63

70 Network Planning and Diagnostics Wireless Communication Stability Considerations Figure 34. The Gateway s Details Web Page With RSSI and Stability. Coexistence with WLAN The Wireless Local Area Network (WLAN) and WirelessHART networks both fully utilize the 2.4 GHz band. WLAN divides the 2.4 GHz band into 11 overlapping channels (see the figure below), whereas WirelessHART divides the 2.4 GHz band into 15 distinct channels. To avoid interference between WLAN channels, it is typical to use only channels 1, 6, and 11 within the same frequency space because they do not overlap. This allows WirelessHART to use some channels between 1 and 6, and some between 6 and 11. However, efficiency will be adversely affected. Also, WLAN does not utilize the channels on a continuous basis. This allows WirelessHART to use the full bandwidth when there is no WLAN traffic. In this case, the efficiency of WirelessHART will be severely affected in periods with a lot of WLAN activity (as transmit power for WLAN is high compared with WirelessHART). A much better solution is achieved, for example, if the frequency space between WLAN channels 7 through 11 is reserved for WirelessHART only, which is equivalent to WirelessHART channels 10 through 16. This allows for continuous activity with reasonable efficiency for the WirelessHART network. Figure 35. WLAN Channels in the 2.4 GHz Frequency Band. 64 SKF Wireless Machine Condition Sensor

71 Network Planning and Diagnostics Wireless Communication Stability Considerations Table of WirelessHART Channel Frequencies WHART Channels Frequency (GHz) WHART channel Frequency Range (GHz) Center min max Table of WLAN Channel Frequencies WLAN Channels Center Frequency (GHz) WLAN channel Frequency Range (GHz) Center min max SKF Wireless Machine Condition Sensor 65

72 Network Planning and Diagnostics Network Commissioning Network Commissioning The recommendations below support successful network commissioning. Always start up a gateway before turning on the sensors. If you do not, the sensor will turn itself off within an hour of not finding the gateway and it will not try to reconnect until the next day. A sensor will wake up to look for a network to join every 24 hours after it has searched for an hour and failed to connect. Do not use the Network ID 1229 unless it is a commissioning network. The sensor will attempt to join for one hour then shut down completely if the network is not found. It will remain off until manually re-activated by the push button. If there is commissioning network on site, make sure it is out of the signal range of the production network. Test the sensors within the 1-hop distance to the production gateway before deployment to verify the network settings are correct. Start up the sensors closest to the gateway first, that is the 1-hop sensors, and then move out in sequence to the sensors farther away from the gateway. Start up all 2-hop sensors, then all 3-hop sensors. While building the network, switch on Global Advertising in the gateway (click Activate Global Advertising in the gateway s Setup web page) and all field devices to shorten the time required for new sensors to join the network. The number of sensors joining simultaneously affects network formation time because these sensors must compete for limited join links and downstream bandwidth. So when too many sensors sync up at once they will contend for the same shared access point links which can slow down the overall network formation time. Network Diagnostics Key Considerations Is the network formation time acceptable? The formation time should be less than one hour because sensors that have not joined by then will automatically turn off. Reliability - Verify the reliability is close to 100%. This is the percentage of unique packets received relative to the number generated. (See the example in Network Diagnostics Details later in this chapter. Reliability is indicated in blue.) All network statistics require at least 15 minutes after the last mote has joined to develop. Stability The ratio of acknowledged packets to packets sent between two nodes; nodes are also known as motes. This step involves looking at all the discovered paths in the network, and making sure that every mote has enough good quality neighbors. The bare minimum is that every mote should have at least three good neighbors. A good neighbor is a neighbor that this mote can hear at greater than -75 db with better than 66 SKF Wireless Machine Condition Sensor

73 Network Planning and Diagnostics Network Diagnostics 50% path stability. (See the example in Network Diagnostics Details later in this chapter. Stability is indicated in orange.) RSSI (Received Signal Strength Index) Indicates the power of the received signal for each neighboring device. (See the example in Network Diagnostics Details later in this chapter. RSSI is indicated in purple.) Number of joins Verify in the network statistics file that the number of joins of each sensor stays the same. An increasing number indicates sensor reset, which means dropping from the network or weak signal strength. (See the example in Network Diagnostics Details later in this chapter. Number of Joins is indicated in red.) Two parents Use the gateway s web page topology view to identify at least two links that are available for each sensor. These paths do not have to be in use currently, they just have to be discovered and reported by the network. Topology View The traffic and stability data that is displayed in the topology view represents a single statistics cycle of 15 minutes. Therefore, the data is not immediately available, but displays only after a statistics cycle of 15 minutes has been completed. Use the colors (a legend is provided below) to determine if all connected field devices have good quality connections and good quality alternative paths. Go to the gateway s web page, Diagnostics > Wireless Communication > Topology View. Figure 36. Path to the Topology View. Another path to access the Topology View is through the Engineering node. Use the Engineering node path to set up the Topology View and manipulate the components on the image. In the following example, devices with green status icons (with a check mark) are linked and available. Devices with red status icons and no connection paths have no network connection and are unavailable. SKF Wireless Machine Condition Sensor 67

74 Network Planning and Diagnostics Network Diagnostics Figure 37. Example of the Topology View of a Network. The color of the connection indicates the stability of the path. A black line indicates that more time is needed to establish the statistics. Devices linked with dotted lines indicate the connection is unused and therefore communication can be switched to this alternative link if the main connection fails. The legends provided below explain how the stability and traffic of the connection are depicted in the topology view image. Stability Color Successfully received messages in % Color Successfully received messages in % 68 SKF Wireless Machine Condition Sensor

75 Network Diagnostic Details Network Planning and Diagnostics Network Diagnostics The introduction of the gateway s Diagnostics > Wireless Communication > Details web page in the firmware version , revision 2.5, or later, is the preferred way to view network diagnostics. It is easier to read than the Network Statistics Report obtained through Device Manager and contains almost the same information. Figure 38. Path to the Details Web Page. The diagnostic details are available only after a 15 minute cycle is complete in order to collect enough data to calculate the statistics. The information represents the communication status over the last 15 minutes. We recommend exporting the information (using the Export button) in the CSV format for archiving. Figure 39. Diagnostics Details Web Page. SKF Wireless Machine Condition Sensor 69

76 Network Planning and Diagnostics Network Diagnostics In this enlarged detail taken from the example above, the sensor East Building Pump 123 was expanded to show two neighbors: the gateway and the routing node CMWA_8800_ The RSSI and Stability of each neighbor is displayed. Figure 40. Sensor with Neighbors Expanded. The Network Statistics Report To access the network statics report, select the gateway in the Device Manager hierarchy. Go to the Gateway > Admin tab, and then click Get Network Statistics. The path of the file is \CMWA 8800Log\CMWA 8800StatisticLog from the root of the drive on which the software is installed. Figure 41. Gateway / Admin Tab Get Network Statistics. 70 SKF Wireless Machine Condition Sensor

77 Network Planning and Diagnostics Network Diagnostics The network statistics report documents the communication quality in terms of traffic, retransmissions, stability, and received signal levels between all connected nodes in the network. An example network statistics report follows. Figure 42. An Example Network Statistics Report. Note: Mote is another term for node. A list that maps MAC (Media Access Control) addresses with Mote IDs is also included in the report: MAC MoteID Jn Nbrs WDev State D C-41 ap [Gateway] Oper 00-1B-1E-1A-9A [8,0 ] Oper 00-1B-1E-1A-9A [9,0 ] Oper 00-1B-1E-1A-9A [4,0 ] Idle 00-1B-1E-1A-9A [2,0 ] Oper 00-1B-1E-1A-9A F [7,0 ] Oper 00-1B-1E-1A-9A [3,0 ] Oper 00-1B-1E-1A-9A C [6,0 ] Oper SKF Wireless Machine Condition Sensor 71

78 Network Planning and Diagnostics Network Diagnostics MAC MoteID Jn Nbrs WDev State 00-1B-1E-1A-9A A [0,0 ] Idle 00-1B-1E-1A-9A [5,0 ] Oper The table below describes each column header that displays in the Network Statistics Report. Column Description header ABPower The average RSSI values for transmissions from mote A to mote B. ABRx Number of packets mote B received from mote A. ABTx(Fail) Number of packets transmitted by mote A to mote B, and the number of packets for which mote A failed to receive acknowledgement. Packets may fail for a number of reasons, including RF interference or bit errors. avq Average number of packets in the mote s queue waiting to be transmitted. BAPower The average RSSI values for transmissions from mote B to mote A. BARx Number of packets mote A received from mote B. BATx(Fail) Number of packets transmitted by mote B to mote A, and the number of packets for which mote B failed to receive acknowledgement. (Not currently implemented. Acknowledgements are not sent for downstream data transmission.) Chg Charge consumption, in millicoulombs. Hop Average number of hops (number of jumps from mote to mote before reaching the gateway) for this mote s data packets to arrive at manager. Id Mote ID number. Jn Number of times the mote joined since the gateway s network manager was last reset. Late Data latency. The average time (in seconds) for a data packet to travel from the mote to the gateway manager. The gateway manager calculates data latency for each packet by subtracting the time the packet was received at the gateway manager from the packet time stamp, indicating when the packet was generated by the mote. The gateway manager averages the data latency of all packets from a mote to provide the values for network statistics. Me MAC-layer MIC (message integrity check) errors. MoteA Describes the path from mote A to mote B. MoteB mxq Maximum number of packets in the mote s queue waiting to be transmitted. Ne Network-layer MIC (message integrity check) errors. PkDrp Number of data packets dropped by the mote. Packets may be dropped because the mote s buffer was full and the mote was unable to generate a packet. 72 SKF Wireless Machine Condition Sensor

79 Network Planning and Diagnostics Network Diagnostics Column header PkDup PkFwd PkLst PkRx PkTerm PkTx(Fail) Reliability Description Number of duplicate packets received. A duplicate packet is sent if no acknowledgement is received for any hop in the packet s journey to manager. A high number of duplicate packets indicates problems with the mote-to-mote communication. Number of data packets forwarded by the mote to a neighbor. Number of data packets that manager expected, but did not receive. Total number of packets received by network motes. Number of data packets terminated by the mote. Total number of packets transmitted by network motes, and total number of packets for which no acknowledgement was received. Mote or network reliability The network statistics report shows an aggregated number for reliability, stability and latency. In addition, detailed communication information is listed for each sensor, including relative received signal strength values between communication nodes (ABPower / BAPower) measured in dbm. The wireless network s stability is a result of received signal level and background noise level (i.e., from a WLAN). In addition, traffic by people and/or vehicles may cause temporary loss of stability. As a general rule, if the stability percentage for a node is above 95%, the operational margin is OK. If it is lower, you should consider installing additional router nodes to increase signal to noise ratio, or investigate ways to reduce background noise by moving WLAN routers or changing WLAN channel usage. SKF Wireless Machine Condition Sensor 73

80 Network Planning and Diagnostics Troubleshooting Network Issues Troubleshooting Network Issues Issue: No Sensors Join If no sensors join the network, check the following items: You did not wait long enough; joining is still in progress. The sensors are not activated (powered on). The network ID and/or Join Key of the gateway security manager do not match the security credentials of the sensors. The gateway antenna may have an issue, such as: the antenna is blocked, the antenna or antenna cable is damaged, or the cable length has produced power loss if a remote antenna is used. The sensors are all placed too far away (beyond 50 m line of sight) from the gateway or access point. P+F gateways do not have an Access Control List (ACL) but other gateways may have one. If the gateway has an ACL, make sure the sensors are on the list. Issue: Some Sensors Do Not Join If some sensors join the network and others do not, you have at least established that the network manager and access point are functional. The reasons that some sensors do not join may include: Some sensors are placed too far away. If you are adding new sensors, make sure that the sensors that were previously peripheral are now enabled as routing devices. Some of the sensors do not have the correct security credentials to join this network manager (Network ID, Join Key). The maximum number of sensors on the gateway network manager (250) has been reached. If the gateway has an ACL, make sure the sensors are on the list. The join process has exceeded one hour and sensors that did not join in time have turned off. Issue: One Sensor Does Not Join If the number of sensors that fail to join is small relative to network size (such as 1 or 2 in 100), then the likely reasons include: The sensor is not activated. The sensor has an RF problem (it may be broken or the antenna is not attached). The sensor has the wrong security credentials. The sensor is placed too far away from the rest of the network. The maximum number of sensors on the network manager has been reached. 74 SKF Wireless Machine Condition Sensor

81 If the gateway has an ACL, make sure the sensor is on the list. Network Planning and Diagnostics Troubleshooting Network Issues The join process has exceeded one hour and sensors that did not join in time have turned off. Issue: One Sensor Rejoins Over and Over This can be observed in the Number of Joins column in the Details web page. Sensors should stay connected to the network indefinitely. Possible reasons for a single sensor to join and drop off the network and join again include: A power supply problem on the sensor is resetting it. The RF connectivity to its neighbors is marginal (reception is poor). The RF connectivity to neighbors is highly transient and unstable (reception is good but cuts out). The sensor is in a location where RF connectivity can be severed and then re-established (such as in an enclosure or behind a large obstacle). Issue: The Gateway Becomes Non-responsive On very rare occasions, a bottleneck may occur with commands sent to the gateway, and the gateway may become non-responsive. When this occurs, you can flush (clear) the gateway s command queue to clear the bottleneck. How to flush the gateway s command queue: In the hierarchy, select the gateway whose command queue you wish to clear. Right click the gateway s hierarchy item, and select Flush from the pop-up menu. Figure 43. Flush the Gateway s Command Queue. SKF Wireless Machine Condition Sensor 75

82

83 8 RF Interference and Solutions RF Interference Sources RF interference sources include: WiFi Bluetooth Multiple networks Microwave oven, cordless phones, miscellaneous, etc. Symptoms RF interference symptoms include: Reliability is less than 99.9%. The stability of a large number of paths is less than 60%, even when RSSI is better than -70 dbm. Sensors are within operating range (50 m) but have poor path stability, less than 50%. Upstream latency is greater than 30 seconds. Average queue occupancy is higher than one, and the maximum occupancy is higher than three. The average queue and maximum queue can be found in the Network Statistics Report highlighted in light blue. Solutions to RF Interference Potential solutions to RF interference include: Identify the source of the interference and remove it. Increase the number of neighbors. Channel blacklisting (see details below). Channel Blacklisting You can use frequency planning and blacklist those channels on the gateway known to overlap with heavily used WiFi channels. Or the reverse, study the WIFi channels in use with a laptop and a program like MetaGeek Wi-spy ISMB spectrum analyzer and software, and then determine the available frequency space and the channels corresponding within WirelessHART. If there are other wireless networks in the area SKF Wireless Machine Condition Sensor 77

84 RF Interference and Solutions Solutions to RF Interference where the WirelessHART network is located, you can make sure that those channels are not used by multiple networks simultaneously. The example below shows the usage over channels 1 to 4. Figure g and Background Noise. Use the Channel Blacklist feature on the gateway s Wireless Communication > Setup web page to disable selected channels. Blacklisting can improve communication stability and reduce power wasted due to retry attempts on fully blocked channels. Select the After Restart check box for the channel(s) to blacklist. Then, click Send to Device to send the new channel list to the gateway. Figure 45. Channel Blacklist Feature. 78 SKF Wireless Machine Condition Sensor

85 9 System Maintenance In this chapter, the following system maintenance procedures in Device Manager are presented: Adding a new sensor into service Editing a sensor s name Removing a sensor from service Replacing an existing sensor in service Relocating an existing sensor in service Upgrading sensor firmware Also described in this chapter are the resources available for device status information and system debugging: Device status indicators System debugging logs Adding a New Sensor into Service Commissioning network If the sensor is joining a commissioning network, simply switch on the sensor and it should be ready to join the network using the default settings. Production network with Network ID 101 or 102 If the production network uses Network ID 101 or 102 and the default Join Key, simply switch on the sensor and set the Network ID by using the sensor s push button and the LED flash sequence to configure the sensors to join the production network. Production network with customized Network ID If the production network uses a customized Network ID and Join Key, you need a commissioning network to configure the new sensor s network settings before it can be put into service in the production network. Follow the steps below. The alternative is to use SKF s pre-configuration service. SKF Wireless Machine Condition Sensor 79

86 System Maintenance Adding a New Sensor into Service Turn on the new sensor within the range of the commissioning network. Open the Operating Modes web page. A yellow icon with a small wrench will display while the new sensor is joining the network. Wait until the sensor joins the network. The sensor s yellow icon in the Com. Status column will turn green when it joins. The sensor will appear in the Device Manager hierarchy as the batch service runs. OR Right-click the gateway in the Device Manager hierarchy and execute a Find sensors command. In the Device Manager Gateway > Admin tab, enter the production Network ID in the Network Id field. Click Exchange Network Id to send the production Network ID to the gateway network manager and its connected sensors. Next, enter the production network Join Key in the Join Key field. Click Exchange Join Key to send the production Join Key to the gateway network manager and its connected sensors. 80 SKF Wireless Machine Condition Sensor

87 System Maintenance Editing a Sensor s Name Wait a few minutes for the gateway network manager to propagate the production network settings to the new sensor. Click Reform Network to activate the new settings. Verify the sensor has joined the network by viewing the gateway s web page. Turn off the sensor and move it out to the production network. Tip: Activate the sensor next to the production gateway to verify that is able to join the network before mounting the sensor to the machine. When the new sensor has joined the production network, its POINTs should be exported automatically to Analyst if the XML export was enabled. Editing a Sensor s Name Modify the Long Tag in the Sensor > Device tab and the name of the corresponding machine in Analyst will be updated accordingly. Figure 46. The Long Tag Identifier. SKF Wireless Machine Condition Sensor 81

88 System Maintenance Removing a Sensor from Service Removing a Sensor from Service After switching off a sensor, the gateway will determine it has lost connection with the sensor in approximately 15 minutes. You can force the sensor icon in the Device Manager hierarchy to turn red by right-clicking on the sensor to be removed and executing an Update Device Information command. The status of the corresponding machine in Analyst will switch to disabled once the status has been exported by Device Manager. Figure 47. Update Device Information Command. Replacing an Existing Sensor in Service Commissioning Network Available Switch off the sensor to be replaced in the production network. The status of the sensor will turn red in Device Manager and the corresponding machine in Analyst will be disabled in about 15 minutes or you can force the sensor icon to turn red by executing an Update Device Information command on the sensor to be replaced. Switch on the new sensor to join the commissioning network. (This process is the same as configuring a new sensor to join a production network, except in this case the name of the new sensor must be changed to match the long tag of the sensor to be replaced.) Modify the name of the new sensor to match the Long Tag of the sensor to be replaced. Modify the sensor network settings (Network ID and Join Key) to join the production network. Switch off the sensor and switch it back on to join the production network. The status of the replaced sensor will return to green and the corresponding machine in Analyst will be re-enabled. No Commissioning Network In Device Manager, go to the Plant > Batch Service Management tab and stop the batch service. Switch off the sensor to be replaced. The status indicator will turn red in Device Manager or you can force it to turn red by executing an Update Device Information command on the sensor. 82 SKF Wireless Machine Condition Sensor

89 System Maintenance Replacing an Existing Sensor in Service After the sensor s status indicator has turned red in Device Manager, the corresponding machine should be disabled in Analyst. Disable the XML Export in the Plant tab. Switch on the new sensor to join the network. After the new sensor has joined the network, it will show up in the P+F gateway s Operating Modes web page in the device list. A customized sensor must be ordered with the pre-configuration service to join the network. Right-click on the gateway in Device Manager, and then execute a Find sensors command to import the new sensor into Device Manager. Figure 48. Gateway s Right-click Menu, Find Sensors Command. Rename the Tag of the new sensor to match exactly the sensor which it is replacing. Switch off the new sensor. Its status indicator will eventually turn red in Device Manager or you can force it to turn red by executing an Update Device Information command. After the status of the new sensor has turned red, delete it from Device Manager by right-clicking the sensor and selecting the Delete Sensor command. Figure 49. Delete Sensor Command. Close Device Manager and then re-launch it. Activate the new sensor with the modified Long Tag and verify that it has reconnected to the P+F gateway. SKF Wireless Machine Condition Sensor 83

90 System Maintenance Relocating an Existing Sensor in Service Enable the XML Export in the Plant tab. Right-click on the gateway in Device Manager and perform a Find sensors command again. The replaced sensor s status indicator will now return to green in the Device Manager. The status of the replaced sensor in Analyst should return to enable (green). Perform a Collect Waveforms command on the replacement sensor, and then verify the measurements are correctly collected at the corresponding sensor in Analyst. Figure 50. Collect Waveforms Command. Relocating an Existing Sensor in Service When a working sensor is moved from one motor to a different motor, the measurements from each motor should be kept separately in different machines in Analyst. Commissioning Network Available The sensor can be moved to a commissioning network to be renamed for the new location and then re-join the production network. This allows Device Manager to create a new machine for the same sensor in Analyst while keeping the old machine in the disabled state. Just by changing the Long Tag of the sensor, we can now use the same sensor to monitor a different motor and keep the measurements from each motor under separate machines in Analyst. No Commissioning Network The Technical Service Group (TSG) will use the Long Tag Editor utility instead to replace the commissioning network when relocating a sensor to monitor a different motor as described above. The Long Tag Editor utility enables you to change a sensor s Long Tag on the fly while the sensor is still connecting to the production network. 84 SKF Wireless Machine Condition Sensor

91 System Maintenance Relocating an Existing Sensor in Service Enter the Gateway IP Address, Gateway Port and Poll Address. Click Connect to connect to the gateway. If successfully connected, the MAC addresses of all connected sensors will display in the list box on the left. (Note: The Connect button will toggle to Disconnect. If more sensors are joining the network, you can disconnect and then re-connect to the gateway at any time to see a refreshed list.) If the sensor you want to relocate appears in a short list, select it. OR You can quickly search for the sensor in a long list by entering the last numbers (the device ID) of the MAC address, and then clicking Search. The selected sensor s Long Tag appears in the box labeled: Edit the Long Tag of the Selected Sensor. Make the edits you want. Click Modify to apply the changes. A new sensor will be created in Device Manager after you execute a Find Sensors command. A new machine with that sensor s new Long Tag will be created in Analyst. The machine with the original Long Tag will be disabled. All measurements from the relocated sensor will now go to the POINTs in the new machine in Analyst. This process can be reversed. If the sensor s Long Tag is changed back to the original Long Tag with the utility, and then a Find Sensors command is executed, the original machine will be re-enabled while the new machine is disabled. All measurements from the sensor will again be saved in the POINTs of the previous machine. SKF Wireless Machine Condition Sensor 85

92 System Maintenance Upgrading Sensor Firmware Upgrading Sensor Firmware You can perform either a global sensor firmware upgrade on all of the network s sensors, or you may upgrade firmware for an individual sensor. Each process is described below. WARNING! Disable the batch service before upgrading sensor firmware. Global Firmware Upgrade In the hierarchy, select the network whose firmware you wish to upgrade. Go to the Network > Sensor Firmware tab. Click Read HEX-file to upload the firmware.hex file. Verify the correct firmware version in the New firmware > Software Revision area. Click Upgrade Sensors. The firmware download s progress displays on two progress bars, the individual sensor s progress and the overall global download progress. Note: If, for some reason, you are downgrading to an older version, you must enable the Force upgrade check box. Contact TSG for the compatibility requirements between firmware and software. 86 SKF Wireless Machine Condition Sensor

93 System Maintenance Upgrading Sensor Firmware When the Overall progress bar indicates 100% complete, the global firmware update is complete. During global firmware upgrade, the new firmware is downloaded sequentially only to those sensors that have an older firmware version. However, if Force upgrade is enabled in order to download an older version, firmware will be downloaded to all connected sensors irrespective of their current firmware version. This operation takes approximately 20 minutes to upgrade the firmware in each sensor, if it is in direct contact with the gateway. This time is doubled with each hop/router between sensor and gateway. If at all possible, it is desirable to bring all sensors to within one hop of the gateway to perform the upgrade to reduce the time required. It is recommended that you let Device Manager run until it is completed. If, for any reason, a sensor temporarily is not responding during upgrade, Device Manager skips to the next sensor in its list. After completing the list, a new attempt to update the firmware on skipped sensors is performed. For large systems, it is advisable to begin the procedure before leaving at the end of the day and then inspect the results the following day. Individual Sensor Firmware Upgrade In the hierarchy, select the sensor whose firmware you wish to upgrade. Go to the Sensor > Sensor Firmware tab. Click Read HEX-file to upload the firmware.hex file. Verify the correct firmware version in the New firmware > Software Revision area. Click Upgrade Sensors. Note: If, for some reason, you are downgrading to an older version, you must enable the Force upgrade check box. SKF Wireless Machine Condition Sensor 87

94 System Maintenance Upgrading Sensor Firmware The Sensor Status area shows the current upgrade status. The progress bar indicates the download s progress. Sensor Status Firmware download OK means the download was successful. The sensor automatically restarts (it will drop from the network and rejoin). Sensor Status Firmware download CRC error indicates the downloaded firmware is corrupted; the previous firmware version is retained. After a 15 minute delay, the Device Manager software checks if the sensor has joined the network again, reads the new firmware version from the sensor, and flags any errors. If unsuccessful, the Sensor Status is updated to Firmware update failed. When the firmware upgrade is successful, all Sensor Status options are cleared. 88 SKF Wireless Machine Condition Sensor

95 System Maintenance Device Status Indicators Device Status Indicators The Sensor > Status tab displays the implemented status bits in the Device Status byte, Extended Device Status byte, and the Standardized Status 0 byte and Standardized Status 3 byte, as specified in the HART protocol. Figure 51. Sensor > Status Tab, Status Indicators. For troubleshooting purposes, the status flags indicate the sensor s status as described in the following tables. Device Status Specified in the HART Command Summary Specification Bit No HART Definition Device Manager Implementation 0 Primary Variable Out of Limits Not used 1 Non-Primary Variable Out of Limits Not used 2 Loop Current Saturated Not used 3 Loop Current Fixed Not used 4 More Status Available Set upon any change of status variables, cleared when new status is read 5 Cold Start Set upon a device reset 6 Configuration Changed Set upon a configuration change, cleared when new configuration is stored to flash 7 Device Malfunction Set if memory error detected at restart SKF Wireless Machine Condition Sensor 89

96 System Maintenance Device Status Indicators Extended Device Status Specified in the HART Common Tables Bit No HART Definition Device Manager Implementation 0 Maintenance required Not used 1 Device Variable Alert Not used 2 Critical Power Failure Set if battery voltage is measured below 3.3 V 3 Undefined Reserved 4 Undefined Reserved 5 Undefined Reserved 6 Undefined Reserved 7 Undefined Reserved Additional Device Status (device specific information) Device Specific Status byte 0: Device Specific Status byte 1: Device Specific Status byte 2: Device Specific Status byte 3: Device Specific Status byte 4: Device Specific Status byte 5: bit 0 Not used bit 1 - Firmware download in progress bit 2 - Firmware downloaded OK bit 3 - Firmware download bad CRC bit 4 - Firmware update failed bit 5 Not used bit 6 Not used Standardized Status 0 Not used Not used Not used Not used Not used Bits used as detailed below: (on the Sensor / Sensor Firmware tab) (on the Sensor / Sensor Firmware tab) (on the Sensor / Sensor Firmware tab) (on the Sensor / Sensor Firmware tab) Specified in the HART Common Tables Bit No HART Definition Device Manager Implementation 0 Simulation Active Not used 1 Non Volatile Memory Defect Set if flashing of new firmware version fails 2 Volatile Memory Defect Not used 3 Watchdog Reset Executed Set if watchdog reset is executed, reset if Get Historic Info is executed 4 Voltage Conditions Out of Range Not used 5 Environmental Conditions Out of Range Not used 6 Electronic Defect Set if flashing of new firmware version fails 7 Undefined Reserved 90 SKF Wireless Machine Condition Sensor

97 System Maintenance Device Status Indicators Standardized Status 3 Specified in the HART Common Tables to support WirelessHART Bit No HART Definition Device Manager Implementation 0 Capacity Denied 1 Duplicate Master Detected Not used 2 3 Bandwidth allocation pending Block Transfer Pending 4-7 Undefined Reserved Sensor Battery Status Set if device is unable to acquire communication bandwidth required to support the burst messaging specified or network manager reduces the bandwidth allocated to the device. The device has asked for bandwidth from the Network Manager and is awaiting Network manager response. The device has a data set (waveform) awaiting transfer to the host or gateway. The Gateway should open the block transfer port and transfer the data. The lower section of the Sensor > Status tab contains the Battery Management area. Figure 52. Sensor > Status Tab, Battery Management. The green battery charge bar displays the estimated remaining battery capacity in percentage and mah. The sensor s firmware estimates the remaining battery capacity and life in days based on the type and number of activities that the sensor has executed. Battery life estimates are based on operation at room temperature (25 C, 77 F). A healthy battery voltage ranges from 3.5 to 3.6 V. When a loaded battery voltage lower than 3.3 V is measured, a Critical power failure message is reported on the Status tab s Extended Device Status Bit 2. The battery will need to be replaced within weeks or even days. Click Get historic info to see the history of the sensor s activities up to the last five battery replacements. SKF Wireless Machine Condition Sensor 91

98 System Maintenance System Debugging Logs Figure 53. Historic Power Info Records Dialog. The displayed dates indicate the first dates the sensor joined a network after a battery replacement. The # fields indicate the number of occurrences for each event. The # Operation Time field refers to the number of operation days (sensor activated) since the most recent battery replacement. System Debugging Logs Device Manager stores records of its execution and communication events in log files on the host computer s hard drive. These log files are useful for debugging purposes. WARNING! Both log files continue to grow larger the longer you use Device Manager and/or the batch service. Therefore it is necessary to regularly delete the files on a periodic basis, or else you will compromise hard drive space. Execution Log The execution log stores Device Manager and batch service activity as: \CMWA 8800Log\CMWA 8800Log.txt on the hard drive on which Device Manager is installed. By default, only error messages are logged for the execution events. However, the execution log s content is user determined by enabling specific commands in the Settings.config file. Communication Log A communication log that stores commands sent from Device Manager to the gateway and the gateway s response back to Device Manager is created for each gateway for each day. The communication log is stored as: \CMWA 8800Log\ GatewayIPAddress\CMWA 8800CommLogYYYYMMDD.txt. It is recommended that these historical files are deleted regularly unless they are necessary for examining system problems. 92 SKF Wireless Machine Condition Sensor