ITT ProSmart Original operating instructions

ProSmart Installation & Operation Guide
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ProSmart Installation & Operation Guide
Index
Important Safety Reminder
Getting Started Section 1
Communication Module Installation Section 2
Communication Configuration
Mechanical Installation
Power Connections
Data Monitor Installation Section 3
Mechanical Installation
Power Connections
Class I Division 2 Cap Lock Installation
Sensor Installation Section 4
Tachometer Sensor Installation
Vibration & Temperature Sensor Installation
ProNet User Guide Section 5
Logging into ProNet
Dashboards
My Machines
Data and Trending
Analytical Features
Appendices
MODBUS Information A-1
ProSmart Data Sheets A-2
Troubleshooting A-3

ProSmart Installation & Operation Guide
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ProSmart Installation & Operation Guide
SAFETY INSTRUCTIONS
IMPORTANT SAFETY REMINDER
To: Our Valued Customers
The information in this section must be studied before attempting any work on
or with the ProSmart Wireless Condition Monitoring System.
Products manufactured and furnished by ITT Monitoring and Control will
provide safe, trouble-free service when properly installed, maintained and
operated. We have an extensive network of experienced sales and service
professionals to assist in maximizing your satisfaction with our products.
Safe installation, operation and maintenance of ITT’s equipment are essential
end user responsibilities. The ProSmart Installation and Operation Guide
identify specific safety risks that must be considered at all times during the life
of the product. Understanding and adhering to these safety warnings is
mandatory to ensure personnel, property and/or the environment will not be
harmed. Adherence to these warnings alone, however, is not sufficient; it is
expected that the end user will also comply with industry and corporate safety
standards. Identifying and eliminating unsafe installation, operation and
maintenance practices is the responsibility of all individuals involved in the
installation, operation and maintenance of industrial equipment.
Safety Symbol and Signal Word Explanation:
This is the dangerous voltage alert symbol. It warns of high voltage which
can cause death or physical injury. Obey all safety messages that follow this
symbol to avoid possible injury or death
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided,
may result in minor or moderate injury.
NOTICE NOTICE used without the safety alert symbol addresses
practices which, if not avoided, may result in property damage.

ProSmart Installation & Operation Guide
SAFETY INSTRUCTIONS
With respect to ProSmart Wireless Condition Monitoring System installation,
operation, and maintenance activities the following risks bear reinforcement
above and beyond normal safety precautions:
All electrical installation and maintenance work must be undertaken by a
qualified electrician only. Failure to do so will result in serious injury or death.
During installation all equipment must be disconnected from the power supply
without any possibility of being made live (Lockout/Tagout). Failure to do so
will result in serious injury or death.
The ProSmart System is designed and certified only to be installed in a non-
hazardous location or a hazardous location labeled as Class I Division 2, Group
A B C D T4 only. The rating is contingent to proper installation of modules for
Class I Division 2. Failure to do so could result in serious injury or death.
The Data Monitor requires 12-24VDC and the Communication Module requires
12VDC. Connecting the module to AC or a higher voltage could result in
serious injury or property damage.
The Communication Module and Data Monitor are equipped with a radio
transmitter and receiver operating in the 2.4GHz band. To satisfy FCC radio
frequency exposure requirements for mobile type transmitting devices, a
separation distance of 20cm or more should be maintained between the
antenna of the Communication Module and Data Monitor and persons during
operation, with exception of hands, wrist, feet, and ankles. To ensure
compliance, operations at distance closer than 20cm are prohibited. Excessive
radio frequency exposure should be avoided.
The Data Monitor is equipped with a relay output. This relay output may be
activated as soon as power is connected to the unit. This may result in
unintended consequences. To ensure the relay activates only when desired, do
not connect the Data Monitor relay wires until the system accepting the
contact closure is ready (alarm beacon, horn, etc.).
The DC capacitors contain electrolyte and the printed circuit boards contain
lead, both of which will be classified as hazardous waste within the EU. They
must be removed and handled according to local regulations.

ProSmart Installation & Operation Guide
SAFETY INSTRUCTIONS
Due to some materials used in some electrical components, thoroughly wash
hands with soap and water after handling any electrical components. Always
use protective glasses, gloves, and clothing.
Please take the time to review and understand the safety instructions,
installation and operation guidelines provided in the ProSmart Installation and
Operation Guide for the applied equipment.
The ProSmart System has been designed for safe and reliable operation when
properly installed, applied and maintained in accordance with the instructions
in the ProSmart Installation and Operation Guide. ITT Monitoring and Control
shall not be liable for physical injury, damage or delays caused by failure to
follow these instructions.
NOTICE
No modifications should be made to the Communication Module and Data
Monitor enclosures and the cover should not be removed from the Data
Monitor Electronic Board Chamber; otherwise, the warranty will be void.

ProSmart Installation & Operation Guide
SAFETY INSTRUCTIONS
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ProSmart Installation & Operation Guide
GETTING STARTED
Page 9
INTRODUCTION
The ProSmart Wireless Condition Monitoring System provides a cost effective method to monitor all types
of rotating equipment all year around - 24 hours a day; 7 days a week; 365 days a year. The ProSmart
System collects machine specific information and provides warnings and alarms to users. The ProSmart
System is designed around ease of installation, rapid deployment, easy system expansion, and no
additional IT infrastructure required. A user needs very little training to start using the ProSmart system.
The ProSmart System consists of four core components: ProNet Server Application, Communication
Module, Data Monitor, and Sensors.
ProNet Application
An internet based system providing Graphical User Interface for Analysis Tools such as FFTs and Band
Alarms, Event and Alarm Management, and Historical Data Management. ProNet automatically alerts the
select users to alarms via e-mail or voice phone calls so that the problem can be rectified before it results
in machine failure. Data storage and maintenance is handled by ITT and requires minimal IT involvement.
Communication Module
A field mountable wireless data communication module, manages all data communication between the
Data Monitor module(s) and ProNet server application. The Communication Module supports
communication to the server via Local Area Networks (LAN), dedicated broadband connection such as
cable and DSL, GPRS, and CDMA cell modems.
Data Monitor
A field mountable wireless data monitoring module for capturing, analyzing, and processing conditions of
any rotating equipment such as pumps, compressors, blowers, fans, mixers, etc. using Sensors and
analog/digital inputs. The Data Monitor should be mounted in close proximity to the machine.
Sensors
Range of ProSmart specific industrial “Plug and Play” sensors measuring Vibration, Temperature, and
Speed. ProSmart also allows 3 analog process inputs in the form of 4-20mA to be analyzed. ProSmart will
also analyze 2 digital inputs in the form of 0-24VDC. This moves ProSmart from being just a vibration
monitoring device to a complete condition monitoring solution.
ProSmart and its related products are protected by the following patents: 6,464,464; 6,487,903
B2; 6,564,627; 6,591,697; 6,648,606; 6,681,634 B2; 6,776,584; 7,080,508 B2; 7,112,037 B2.

ProSmart Installation & Operation Guide
GETTING STARTED
ProSmart Wireless Condition Monitoring System Architecture

ProSmart Installation & Operation Guide
GETTING STARTED
GETTING STARTED
How to use this guide
This guide has been organized to make installation of the
ProSmart System easy. Installation has been divided into three
main sections that include all the information needed to get up-
and-running. The four sections are:
xCommunication Module Installation
xData Monitor Installation
xSensor Installation
xProNet User Guide
Each section has been laid out to speed you through the
installation process, while providing enough background
information to help understand the process.
1. Step Number - The step number helps to keep track of
where you are in the configuration process when used in
conjunction with the process map.
2. Process Map - The process map is a visual guide of what
needs to be done in the step.
3. Background Information - This information explains what
the upcoming steps are and why they are being performed.
Examples are provided to assist in understanding the
concept.
4. Special Notes - These highlighted sections contain
comments that are important to the installation process.
5. Illustration View - The illustration view shows installation
illustration for guidance.
PROSMART
Figure A - Typical Installation Page

ProSmart Installation & Operation Guide
GETTING STARTED
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ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
Page 13
COMMUNICATION MODULE INSTALLATION
This section is devoted to install your ProSmart Communication Module.
Step Description
Communication Module Overview
1
Communication Overview
2
Mechanical Installation
3
Power Connections
PROSMART
Communication Module

ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
Overview - Communication
When selecting an installation site for the Communication Module
two communication paths need to be evaluated:
1. Communication signal strength between Communication
Module and Data Monitor - It is recommended to optimize the
communication signal from the Communication Module to each
Data Monitor by having ITT or an authorized distributor
perform a site survey.
2. Reliable Internet connection for Communication Module to
communicate with the ProNet server - the Communication
Module can communicate using either Local Area Network,
Broadband connection such as DSL, cable modem, or cellular
modem, similar to an internet connection with a personal
computer.
The Communication Module communicates to the ProNet Server
application through a standard internet connection. The
Communication Module is equipped with an Ethernet cable to
connect into your network receptacle. The Ethernet cable for the
Communication Module exits through the same conduit hub as the
DC power.
All communication is initiated from the Communication Module.
Inbound communication requests to Communication Module are
ignored since it acts only as a client and not as a server. Factory
default configuration for the Communication Module is DHCP
(Dynamic Host Configuration Protocol). It may also be configured to
use a static IP.
The Communication Module allows only specific DMs to send data.
The Communication Module will set aside time in its polling routine
for a listed DM to communicate.
www
LAN
CDMA
GPRS DSL
PROSMART
Communication Module

ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
1
Communication Configuration
NETWORK SPECIFICATIONS
If communicating through a Local Area Network (LAN), it must be
configured to allow communication from the Communication
Module to the following URL address and through the following
ports, especially if the Communication Module must be behind a
firewall:
xdata.prosmart.ittmc.com for data management and software
downloads.
NOTE – Configure LAN network for URL address and not the
resolved IP address since IP address can change anytime.
xOutbound communication support for:
oHTTP Protocol (standard web browser protocol) via
port 80
oExternal NTP (standard Network Time Protocol) via
port 123
ProNet users must have access to www.prosmart.ittmc.com to
login to the GUI (Graphical User Interface) and interact with their
devices.
DHCP Configuration –
Default factory configuration. This is the preferred method of
network configuration (no additional information is needed).
Static IP Configuration –
To configure the Communication Module to use a static IP the
following information is needed:
xStatic IP address
xIP DNS1 and IP DNS2
xIP Gateway
xIP mask
An ITT representative can either configure the Communication
Module in the field or it can be preconfigured at the factory.

ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
Mechanical Installation
Installation steps to be performed are:
1. Before installing the Communication Module, please note the
Mac ID from the nameplate on the right-side of the
Communication Module for future reference. This will appear
similar to the following: 00:50:C2:8F:44:AA
2. When selecting a location to mount the Communication
Module following items need to be considered:
xMount Communication Module at least 15 feet
above ground
xCommunication Module antenna needs to be in
vertical upright position, and
xAt least 10 inches of area around the antenna needs
to be clear of any obstruction
3. Mount the Communication Module on a suitable mounting
surface such as a wall or pillar using fasteners that can
support the Communication Module’s weight of
approximately 15 lbs (6.8 Kg).
4. The Communication Module has ¾“ NPT conduit hub.
5. Install the Communication Module per NEMA requirements.
6. For Communication Module using a cellular modem, the
cellular antenna needs to be at least 3 ft away from the
Communication Module antenna. At least 10 inches of area
around the cellular antenna also needs to be clear of any
obstruction.
7. For ideal communication with the DM, the CM should be in
direct line of sight.
2
Communication Module - LAN
Communication Module – Cellular Modem
PROSMART
Communication Module
3 ft
minimum required distance
(+)
(- )
Ethernet Cable
Network Cable
(LAN, Cable, or DSL)
Female-to- Female Connector
Wire Key:
Power
Red
Black
PROSMART
Communication Module

ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
Power Connections
The Communication Module needs to be powered by an externally
supplied 12 VDC power supply.
All electrical installation and maintenance work must
be undertaken by a qualified electrician only. The
Safety Instructions in this Installation and Operation
Guide must be followed. Failure to do so will result in
serious injury or death.
Power must be wired using acceptable Class I Division
2 wiring methods if the hazardous area rating is to
apply. Failure to do so could result in serious injury or
death.
Steps to be performed for proper power installation are:
1. Install the conduit and connection box per your local
electrical and environmental codes.
2. Communication Module has ¾” NPT conduit hub.
3. Follow the wiring diagram shown to the right for proper
installation.
4. Use a voltmeter to measure the supplied power at the
connection box and verify that it is 12VDC.
NOTE – Before powering the Communication Module take
every precaution to ground the unit.
The Communication Module does not have an on-off
switch and will start operating as soon as power is
applied. This may result an unintended alarm
annunciation as well as an unintended activation of
relay outputs on the DM modules communicating
with the Communication Module at the time.
3
(+)
(- )
Ethernet Cable
Network Cable
(LAN, Cable, or DSL)
Female-to- Female Connector
Wire Key:
Power
Red
Black
PROSMART
Communication Module

ProSmart Installation & Operation Guide
COMMUNICATION MODULE INSTALLATION
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ProSmart Installation & Operation Guide
DATA MONITOR INSTALLATION
Page 19
DATA MONITOR INSTALLATION
This section is devoted to install your ProSmart Data Monitor DM22x.
Step Description
Data Monitor Overview
1
Mechanical Installation
2
Power Connections
Class I Division 2 Cap Lock Installation
3
PROSMART
Power
Warning
Alarm
Reset
TACH V/T-1 V/T-2 V/T-3 V/T-4

ProSmart Installation & Operation Guide
DATA MONITOR INSTALLATION
Page 20
1
Mechanical Connections
Installation steps to be performed are:
1. Before installing DM22x, please note the Mac ID from the
nameplate on the right-side of the enclosure for future
reference. This will appear similar to the following:
00:50:C2:8F:44:AA
2. When selecting a location to mount the DM22x the
following items need to be considered:
xMount the DM22x approximately four feet above
ground
xThe DM22x antenna needs to be in vertical upright
position, and
xAt least 10 inches of area around the antenna
needs to be clear of any obstruction
3. Mount the DM22x on a suitable mounting stand, four (4)
¼-20 UNC mounting holes are provided on the rear of
DM22x for mounting. The DM22x can be mounted on a
floor mounted stand or a wall mounting bracket which ITT
can provide. The DM should NOT be mounted on the
equipment but should be mounted in near the rotating
equipment.
4. For ideal communication with the Communication Module
the DM22x should be placed in direct line of sight, if
installation permitting.
2
3
Floor mounted stand arrangement
Wall mounted arrangement
PROSMART
Power
Warning
Alarm
Reset
TACH V/T-1 V/T-2 V/T-3 V/T-4
1.00"
Two0. 44 diameter holes
for wall mounting
Optional mounting bracket
47" approx.
PROSMART
Power
Warning
Alarm
Reset
TACH V/T-1 V/T-2 V/T-3 V/T-4