Schaeffler OPTIME C1 User manual

OPTIME C1
User manual

Foreword
OPTIME as solution for
automatic lubrication
The OPTIME system from Schaeffler is a solution for the smart and
automatic lubrication and condition monitoring of a large number of
machines. This concept allows cost-effective condition-based
maintenance even for subsystems, as unscheduled downtimes can
be avoided. When developing the system, particular attention was
paid to ensuring very simple start-up, easy scalability and a diverse
range of potential uses. Every single process step was designed to
be as user-friendly as possible.
OPTIME gateway and
OPTIME C1
The concept features special wireless OPTIME vibration sensors and
OPTIME C1 single-point lubricators, which combine with the OPTIME
gateway to form a mesh network. Another key element is the service
components, which run centrally in a cloud solution, the Schaeffler
IoT Hub, which is also where the data are analysed and the results
can be viewed in greater detail. At the same time, the results are also
transferred directly to the OPTIME app.
OPTIME app The OPTIME app shows the machine status directly on site according
to criticality and thus allows optimum planning of maintenance
activities. The status of the lubricators (fill level, battery capacity,
etc.) is also displayed in the app in order to prevent failures as
a result of inadequate lubrication. Each user can adapt the selection
of machines to their own remit and therefore has direct access to
all of the necessary information.

2 BA 70 Schaeffler Technologies
Page
Schaeffler OPTIME
About the user manual Symbols .................................................................................... 4
Availability ................................................................................ 4
Legal guidelines ........................................................................ 4
Advice on third party products and services ............................... 4
General safety guidelines Principles .................................................................................. 5
Marking..................................................................................... 5
Usage for the intended purpose ................................................. 5
Usage not for the intended purpose ........................................... 5
Warranty ................................................................................... 6
Selection and qualification of personnel .................................... 6
Work on electrical devices ......................................................... 6
Safety regulations ..................................................................... 7
Scope of delivery Gateway .................................................................................... 10
Lubricator OPTIME C1 ................................................................ 10
Cartridge CONCEPT1 ................................................................... 11
Required accessories................................................................. 12
Damage during transit ............................................................... 13
Defects...................................................................................... 13
Description Structure..................................................................................... 14
Planning.................................................................................... 16
Gateway .................................................................................... 16
Lubricators ................................................................................ 17
Transport and storage ................................................................................................. 18
Mounting Registering in the OPTIME dashboard......................................... 18
Install OPTIME app...................................................................... 18
Install gateway .......................................................................... 18
Install lubricator ........................................................................ 23
Replace empty CONCEPT1 cartridge ........................................... 30

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Page
Gateway configuration ................................................................................................ 32
Settings.................................................................................... 34
Using the OPTIME app Login and logout....................................................................... 35
General navigation.................................................................... 36
Manage groups......................................................................... 38
Manage machines..................................................................... 43
Manage lubricators ................................................................... 49
Add a lubricator orcartridge....................................................... 51
Add gateway............................................................................. 60
Using the OPTIME dashboard ................................................................................................ 61
Registration, login and logout ................................................... 62
General navigation.................................................................... 63
Description of dashboard.......................................................... 65
Using the dashboard levels....................................................... 66
Level Process Area .................................................................... 66
Level Department...................................................................... 67
Level Group .............................................................................. 68
Level Machine .......................................................................... 68
Level All Lubricators.................................................................. 71
Level Lubricator ........................................................................ 72
Maintenance ................................................................................................ 73
Troubleshooting and
rectification
................................................................................................ 73
Disposal ................................................................................................ 73
Technical data Gateway ................................................................................... 74
Lubricator OPTIME C1................................................................ 76
Appendix EU Declaration of Conformity

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Schaeffler OPTIME
About the user manual This user manual applies to the OPTIME C1 lubrication system.
Symbols The warning and hazard symbols are defined in accordance with
ANSI Z535.6-2011.
WARNING
In case of non-compliance, death or serious injury may occur. 
CAUTION
In case of non-compliance, minor or moderate injury may occur. 
NOTICE
In case of non-compliance, damage or malfunctions in the product
or the adjacent construction may occur.

Availability A current electronic version (PDF) of this user manual can be found
at https://www.schaeffler.de/std/1F8B.
Legal guidelines The information in this manual corresponded to the most recent
status at the close of editing. The illustrations and descriptions
cannot be used as grounds for any claims relating to devices that
have already been delivered. Schaeffler accepts no liability for
any damage or malfunctions if the device or accessories have been
modified or used in an incorrect manner.
Apps and functions may not be available in all countries and
regions. The availability of apps and functions may change.
Advice on third party products
and services
All names of products and services cited in this manual are brand
names of the respective companies. The details provided in the text
are merely indicative and provided for information purposes only.
■ Apple, App Store, Safari and their logos are registered
trademarks of Apple Inc.
■ Google, Android, Google Play, Google Chrome and their logos are
registered trademarks of Google LLC
■ Microsoft, Windows, Edge, Internet Explorer, Excel and their
logos are registered trademarks of the Microsoft Corporation
■ Mozilla, Mozilla Firefox and their logos are registered trademarks
of the Mozilla Foundation
■ Wirepas, Wirepas Mesh and their logos are registered trademarks
of Wirepas Ltd.
■ Loctite is a registered trademark of Henkel AG & Co. KGaA
The information given in this publication cannot be construed as
constituting any related liability for products and services not
produced or provided by Schaeffler. Schaeffler does not take owner-
ship of these products and services.
Other products and manufacturers’ names cited in this publication
may be the trademarks of their respective owners.

Schaeffler Technologies BA 70 5
General safety guidelines This chapter brings together all the important safety regulations.
Any person charged with working on the system must read this
chapter and observe the guidelines.
Principles The OPTIME system corresponds to the current level of technology
and the recognised rules of safety practice. If the safety guidelines
are not observed, risks to life and limb for the user or third parties
and extensive damage to other material assets may nevertheless
arise during use.
Marking Every lubricator and gateway is marked with a serial number.
The gateway nameplate contains the serial number,
manufacturer’s details and the certification markings.
This information is printed on the lubricator.
Usage for
the intended purpose
The OPTIME lubrication system is approved for use in indoor and
outdoor industrial environments. The system may only be used
in accordance with the technical data, see page 74.
Unauthorised structural modifications to the system are not
permissible. We assume no liability for any damage to machinery or
injury to persons arising from such actions.
The OPTIME C1 lubricator may only be operated with a CONCEPT1
cartridge.
Usage for the intended purpose also includes the following:
■ all guidelines in the user manual are observed
■ compliance with all relevant specifications on occupational
safety and accident prevention during the entire product life cycle
of the system
■ the necessary specialist training and authorisation of your
company for carrying out the necessary work on the system
Usage not for
the intended purpose
The OPTIME lubrication system does not provide machine
protection. It must not be used as a component of safety systems.
The OPTIME lubrication system is not classified as a safety com-
ponent in accordance with the Machinery Directive 2006/42/EC.

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Schaeffler OPTIME
Warranty The manufacturer shall assume liability for warranties in relation
to operational security, reliability and performance only under
the following conditions:
■ Installation and connection must be carried out only by
authorised and skilled personnel.
■ The system must be used in accordance with the information
in the technical data sheets. The limit values indicated in the
technical data must not be exceeded under any circumstances.
■ Conversion and repair work on the system may only be carried out
by the manufacturer.
Selection and qualification of
personnel
The OPTIME lubrication system may only be installed, commis-
sioned and operated by suitably qualified personnel. The scope of
competence, area of responsibility and supervision of personnel
must be precisely regulated by the site operator.
Designated qualified personnel:
■ are authorised to install the system
■ have all the necessary knowledge
■ are familiar with the safety guidelines
■ have read and understood this manual
If personnel do not possess the necessary knowledge, they must
be given the necessary training and instruction. Schaeffler can offer
corresponding product training on request.
Work on electrical devices Work on electrical devices and components may only be carried out
by a trained electrician.
On the basis of their technical training, knowledge and experience
as well as their knowledge of the appropriate regulations, a trained
electrician is in a position to assess the work assigned to them and
recognise possible hazards.
Do not repair any damaged system components. Please arrange for
any necessary repairs to be carried out by Schaeffler.
Any work on wiring, opening or closing of electrical connections may
only be performed while disconnected from the power supply and
in a voltage-free state.

Schaeffler Technologies BA 70 7
Safety regulations All safety specifications are described in the following sections.
Safety during installation Compliance with the user manual is essential for problem-free
and safe operation. The operator must ensure that only qualified
personnel work with the lubrication system, that the necessary
safety and maintenance regulations are observed and that
the lubrication system is used correctly and for the intended
purpose.
Proper functioning of the lubrication system can only be guaranteed
if the recommended lubricants and original Arcalub range of access-
ories are used and the installation and operating instructions are
observed. The manufacturer accepts no liability for any consequen-
tial damage if these instructions are not observed.
Handling batteries Risk of explosion, burns and of toxic gas formation due to excessive
heating of the battery pack. Impaired service life due to discharge
with premature failure of the device as a consequence of discharge
and possible consequential damage to the application.
Heating can be caused by external factors (e.g. fire) or
by chemical processes occurring internally (e.g. short circuit).
Premature discharge can be caused by dropping the battery pack.
Dropping the battery pack can cause internal damage to
the individual cells of the pack and the resulting short circuit can
lead to discharge.
Dispose of dropped battery packs immediately. Do not use dropped
battery packs. Used battery packs should never be reused or
recharged, but must be recycled. Do not open battery packs or
thrown them into a fire.
Only use new battery packs which are in their original packaging.
Only open the packaging of the battery pack immediately prior
to insertion into the device. The lubrication process can no longer
be carried out correctly with damaged, used or empty battery packs.

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Schaeffler OPTIME
Handling a pressurised
lubrication system
Risk of damage due to egress of lubricant. The uncontrolled egress
of lubricant under excess pressure can damage the lubricator.
Components of the lubrication system and adjacent construction
can become contaminated. The lubrication system operates under
pressure.
The lines and lubricator must be depressurised prior to dismantling
or for maintenance work. The lubricator can be depressurised by
detaching the drive unit on the cartridge.
Never remove a pressurised CONCEPT1 cartridge which is not yet
completely empty. The gas pressure in the cartridge could eject
the remaining grease or oil out of the container in an uncontrolled
manner and contaminate the battery compartment.
Ensure that the installation can withstand the maximum system
pressure. Only fill the OPTIME C1 lubricator prior to fitting on
the adjacent construction. When prefilling, the pressure must never
exceed 2 bar.
The OPTIME C1 lubricator may only be operated with a CONCEPT1
cartridge. Do not expose the installation to direct sunlight.
The use of high pressure or steam jets to clean the lubricator is not
permitted.
Danger of burns due to hot surfaces Danger of burns due to hot surfaces. The outer surface of a machine
can reach high temperatures that can cause injuries in the event of
direct contact.
Before performing installation work, switch off the machine and
allow it to cool down. If these instructions are not followed, serious
injuries may result.
Protection against
unsuitable ambient conditions
Risk of damage due to detrimental ambient conditions.
The lubrication system can be damaged or destroyed by heat,
high pressure, moisture, blows, contaminants and dust.
The mechanics and electronics can be damaged by the ingress of
water.
Ensure that the mounting position is protected against moisture,
blows, contaminants and dust. The OPTIME lubrication system
must be protected against temperatures  +55 °C and must not be
subjected to heat sources such as direct sunlight.

Schaeffler Technologies BA 70 9
Safe handling of
information interfaces
The OPTIME system has the following information interfaces:
■ 2G, LTE CAT M1
■ Wirepas Mesh network
■ WiFi (WLAN)
■ Ethernet
The product can be connected with other devices, components or
internal or external networks (e.g. internet) via each of these
interfaces. Devices (like data carriers) connected via information
interfaces may contain malware or execute malicious functions
undetected. This product, or potentially a company infrastructure
(e.g. the IT infrastructure), can be damaged due to the use of these
kinds of information interfaces. In addition, the company’s data
security may be compromised.
Before using our product and its information interfaces,
please familiarise yourself with the following:
■ the security features offered by the product and
its information interfaces
■ the security provisions of your company
(e.g. on IT security)
Before commissioning, please clarify with the relevant points of
contact whether and which security measures are to be taken when
using the product and its associated information interfaces.
Protection against
unauthorised use
Data encryption and secure login with individual login data are
the tools used to protect against unauthorised use of the OPTIME
app and OPTIME dashboard. Software users (users) must log in with
their user name and password. The password has to be changed at
regular intervals. A secure password must be used.
The user is responsible for keeping their login data secure.

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Schaeffler OPTIME
Scope of delivery The OPTIME C1 lubricator may only be combined with the CONCEPT1
cartridge.
Gateway Scope of delivery of the OPTIME gateway:
■ 1 OPTIME gateway
■ 1 built-in LTE stick (depending on the region)
■ 1 Gateway quick guide manual BA 68-02
Lubricator OPTIME C1 The scope of delivery includes the following components:
■ 10 lubricators
■ 10 battery packs
■ 1 quick guide manual BA 70-01
The enclosed quick guide manuals contain the following link to
this user manual BA 70, which always provides the latest version:
https://www.schaeffler.de/std/1F8B
Figure 1
Scope of delivery
Gateway
OPTIME
OPTIME
BA 68BA 68
NYM2 0,75mm2
i
www.schaeffler.de/std/1F40
OPTIME
OPTIME
A
B
C
50
OPTIME
OPTIME
OPTIME
xxxx
xx
xxx
www.schaeffler.de/std/1F41
xxxx
xx
xxx
1.
00199C5E00199C5E
Figure 2
Scope of delivery
Lubricator
OPTIME C1
OPTIME
5− 6
xxxx
xx
xxx
www.schaeffler.de/std/1F41
xxxx
xx
xxx
i
www.schaeffler.de/std/1F8B
BA 70BA 70
BA 69BA 69
www.schaeffler.de/std/1F4C
[email protected]
W17
2.
1.
0019731300197313

Schaeffler Technologies BA 70 11
Cartridge CONCEPT1 Prefilled cartridges are available, which are filled with high-
performance Arcanol lubricants from Schaeffler.
The CONCEPT1 cartridge is only referred to as a cartridge in
the context of the OPTIME system. Outside of the OPTIME system,
the CONCEPT1 cartridge functions as a standalone lubricator.
User manual BA 69, which contains important safety information on
the use of the CONCEPT1 cartridge and lubricator, can be accessed
via the following link:
https://www.schaeffler.de/std/1F4C
NOTICE
Risk of damage to the cartridge, lubricator and adjacent construc-
tion. Malfunctions with unsuitable lubricants (greases or oils).
When filling the cartridge with an internal lubricant, only use
lubricants that have been approved by Schaeffler for use in
CONCEPT1 cartridges. With greases, ensure good stability against
bleeding of the base oil and a low consistency grade (
 NLGI 2). 
Schaeffler can also supply CONCEPT1 cartridges filled with alterna-
tive greases by agreement.
If the CONCEPT1 cartridges are filled by the customer and filling is
not carried out correctly, or lubricants are used that have not been
approved by Schaeffler for these cartridges, any warranty or
other claims made by the customer against Schaeffler in connection
with a failure or malfunction of the lubrication system will be
disregarded. In case of doubt, please consult Schaeffler.
Figure 3
Scope of delivery
Cartridges
0019730500197305

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Schaeffler OPTIME
Required accessories To ensure the system is ready-to-use, the following devices and
accessories need to be provided by the customer in addition to
the gateway, lubricator and cartridge, Figure 4 :
■ mobile phone or tablet (each with LTE and NFC technology) with
installed OPTIME app
■ connection cable to supply power to the gateway
■ fasteners
The following accessories and tools are needed to install
the lubricator, Figure 5 :
■ lever grease gun
■ filling adapter
■ torque wrench
■ sealing tape (PTFE)
■ screwdriver
■ cartridge CONCEPT1
Figure 4
Required accessories for
the gateway
NYM 20,75 mm2
0017067200170672
Figure 5
Required accessories and tools for
the lubricator
BA 69BA 69
www.schaeffler.de/std/1F4C
W17
0019731100197311

Schaeffler Technologies BA 70 13
Damage during transit Any damage during transit must be reported as a complaint to
the carrier:
■ Check the delivery immediately upon arrival for any damage
during transit.
■ Report any damage during transit promptly as a complaint to
the carrier.
Defects Any defects must be reported promptly as a complaint:
■ Check the product immediately upon delivery for visible defects.
■ Report any defects promptly as a complaint to Schaeffler.

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Schaeffler OPTIME
Description
Structure The OPTIME system consists of several components which,
depending on the configuration, are designed for intelligent, auto-
matic lubrication, condition monitoring and predictive main-
tenance.
The intelligent OPTIME C1 lubricators automatically form a mesh
network that transfers data directly, or via other intelligent lubri-
cators or other OPTIME sensors, to the gateway. In the network,
the intelligent lubricators transfer the fill levels and status via
the gateway to the Schaeffler IoT Hub, where the data are analysed
and the results sent to the OPTIME app. All information is also
available in the OPTIME dashboard, which can be opened using an
internet browser (for system requirements, see page 62).
Directly after activation, the intelligent lubricator automatically
starts to measure and transfer data at pre-set intervals.
The mesh network organises itself automatically, when further
OPTIME lubricators or gateways are added or removed. The use of
several gateways in the same network is also possible.
Depending on the circumstances, existing OPTIME installations
can also be expanded subsequently to between 50 and 70 OPTIME
devices (sensors and lubricators) per gateway.
 OPTIME dashboards in
the Schaeffler IoT Hub
 OPTIME C1 lubricator
 OPTIME app
 OPTIME vibration sensors
 OPTIME gateway
Figure 6
OPTIME system
5432
1
0019961B0019961B

Schaeffler Technologies BA 70 15
Since an independent network is used to transfer the data to
the Schaeffler IoT Hub and wireless technology is used for other
communication (pre-set, optionally also WiFi or Ethernet), there is
no need for a connection to the local IT infrastructure.
Communication interfaces and
data transfer of OPTIME system
Mesh technology was selected because condition monitoring and
intelligent, automatic lubrication of machines in large industrial
plants must cover large distances and reach machines that are
difficult to access. The actively managed mesh network can estab-
lish contact to sensors and intelligent lubricators in a line of sight of
up to 100 m, ensures reliable communication and at the same time
optimises the battery service life of the intelligent lubricators and
sensors.
The standard version of the gateway already has an integrated
SIM card for use exclusively in conjunction with the OPTIME system.
If the proposed mobile phone connection is not to be used, there are
other options for connecting to the Schaeffler IoT Hub, i.e. using
a separate SIM card, a WiFi connection or connection via network
cable.
 Mesh network
 OPTIME gateway
 Schaeffler IoT Hub
 OPTIME dashboard
 OPTIME app
Figure 7
Communication between
OPTIME system components


1
2 3
5
4
00198FD400198FD4

16 BA 70 Schaeffler Technologies
Schaeffler OPTIME
Planning An installation tree, i.e. showing the allocation of sensors and
lubricators to machines and assets, does not necessarily have to be
set up beforehand. However, in the case of an entire plant this con-
siderably simplifies the installation process, as it is only necessary
to select the corresponding machine for installation of the sensors
and lubricators. An installation tree may take the form of an Excel
table imported via the dashboard menu.
Log into the OPTIME app and
OPTIME dashboard
Every customer receives an administration user account when
purchasing the OPTIME system. This user is able to create additional
users. All created users will receive their login data by e-mail.
To log into the OPTIME customer portal, please visit the following
website:
https://schaeffler-optime.com/dashboard
Gateway The gateway is located in a rugged protective housing suitable
for wall or ceiling mounting. It can also be used outdoors thanks
to its protection type and UV resistance.
Gateway connections and
indicators
The gateway has two cable glands for routing the cable to the power
supply and, optionally, feeding through the network cable,
Figure 8 .
The gateway is equipped with an LED indicator, which displays
the various operating states, see table .
LED displays
 Input power supply
 Input network connection
 LED for indicating operating status
Figure 8
Gateway connections and
indicators
OPTIME
1
2
3
00170E4000170E40
LED Function
Green light The gateway is connected to the internet.
Blue light The gateway is trying to connect to the internet.
If conditions are unfavourable, it can take 15 minutes
to establish a connection to the internet.
Flashing blue The gateway is in configuration mode.
Red light An error has occurred.
More information is provided in the web interface
on configuring the gateway.

Schaeffler Technologies BA 70 17
Put the gateway into configuration mode by pressing
the [ Configuration ] button.
Lubricators The OPTIME C1 lubricator works electromechanically on a fully
automatic basis and fits the CONCEPT1 cartridges.
The OPTIME C1 lubricator is screwed directly onto the lubrication
point or connected to a lubrication line.
A CONCEPT1 cartridge supplies the system with lubricant.
The running time of 1 to 12 months is set on the CONCEPT1 cartridge.
The device is configured and monitored using the OPTIME app.
The function is monitored by a control logic, which displays
the current operating state via the OPTIME app. Power is supplied via
a replaceable battery pack. The lubricator can be reused several
times. The OPTIME C1 lubricator is protected against excessive back
pressure by an integrated check valve.
 Button [ Configuration ]
Figure 9
Button for gateway configuration
OPTIME
1
00170E3F00170E3F
 Cartridge CONCEPT1
 Lubricator OPTIME C1
Figure 10
Lubricator with cartridge
1
2
0019730200197302

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Schaeffler OPTIME
Transport and storage The packaging used for the lubricators and gateway provides good
protection against damage under normal transport conditions.
NOTICE
Risk of damage due to strong vibrations. The electronics and
plastic components of the lubricators and gateway can be damaged
or destroyed by strong vibrations.
Avoid dropping and exposing the lubricators and gateway to severe
impacts.

Mounting
Registering in
the OPTIME dashboard
To configure the gateway and intelligent lubricators it is necessary
to register in the Schaeffler IoT Hub, so that intelligent lubricators
and gateways are automatically associated with your company,
see page 61. You can configure the components of your system,
i.e. gateway and intelligent lubricators, for your installation tree.
This can be done following completion of registration either in
the OPTIME dashboard or OPTIME app.
Install OPTIME app Before installing the components of the OPTIME system, you will
need to install the OPTIME app on your mobile phone or tablet.
The OPTIME app can be downloaded free of charge from
the App Store or Google Play. You will need login data to be able to
log on to the OPTIME app, see page 35.
Install gateway When installed for the first time, the gateway is the core of the mesh
network. First of all, the gateway is added to the mesh network. It is
then mounted at the desired location and the electrical installation
is completed.
Add gateway The OPTIME app will guide you step by step through the process of
adding the gateway to the mesh network.
 Open the OPTIME app.
 Tap the [ Login ] button.
 Enter your login data.
 Go to the [ Menu ] symbol and
tap on the [ Provision Gateway ] button.