Schaeffler OPTIME User manual

OPTIME
User manual

Foreword
OPTIME provides a complete
condition monitoring solution
The OPTIME system from Schaeffler is a complete solution for the
straightforward condition monitoring of a large number of machines.
The concept also renders condition-based maintenance economical
for ancillary equipment, as unplanned downtime can be avoided.
During the development of the system, particular attention was paid
to the very simple commissioning process, smooth expandability
and wide range of possible uses. The outlay on the part of the user
was kept as low as possible for each individual process step.
OPTIME gateway and
OPTIME sensors
The concept features special wireless OPTIME sensors, which com-
bine with the OPTIME gateway to form a mesh network. Another key
element is the service components, which run centrally on 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. Each user can adapt the selection of machines to their own
remit and therefore has direct access to all of the necessary
information.
Current version A current electronic version (PDF) of this user manual can be found at
https://www.schaeffler.de/std/1F40

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Page
Contents
About the user manual Symbols ................................................................................... 4
Availability ............................................................................... 4
Legal guidelines ....................................................................... 4
Advice on third party products and services............................... 5
General
safety guidelines
Principles ................................................................................. 7
Marking .................................................................................... 7
Usage for the intended purpose ................................................ 8
Usage not for the intended purpose .......................................... 8
Warranty................................................................................... 8
Selection and qualification of personnel ................................... 9
Work on electrical devices......................................................... 9
Safety regulations..................................................................... 10
Scope of delivery Gateway ................................................................................... 12
Sensor kits ............................................................................... 12
Required accessories................................................................ 13
Damage during transit............................................................... 13
Defects..................................................................................... 13
Description Structure .................................................................................. 14
Planning ................................................................................... 16
Gateway ................................................................................... 17
Sensors .................................................................................... 19
Transport and storage ................................................................................................ 25
Mounting Registering in the OPTIME dashboard ........................................ 26
OPTIME app installation ............................................................ 26
Mount gateway ......................................................................... 26
Mount sensor ........................................................................... 31

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Page
Gateway configuration ................................................................................................. 37
Settings .................................................................................... 38
Using the OPTIME app Login and logout........................................................................ 40
General navigation .................................................................... 41
Manage groups ......................................................................... 44
Manage machines ..................................................................... 48
Manage sensors ........................................................................ 53
Add sensor ................................................................................ 57
Add gateway.............................................................................. 60
Using the OPTIME dashboard ................................................................................................. 62
Registration, login and logout .................................................... 64
General navigation .................................................................... 65
Description of the dashboard..................................................... 67
Using the dashboard levels........................................................ 68
Level Process Area..................................................................... 68
Level Department ...................................................................... 69
Level Group ............................................................................... 70
Level Machine ........................................................................... 71
Level Sensor.............................................................................. 74
Schaeffler tab............................................................................ 77
Alarms ...................................................................................... 81
Other dashboard options........................................................... 79
Troubleshooting and
rectification
................................................................................................. 82
Decommissioning ................................................................................................. 82
Disposal ................................................................................................. 82
Technical data Technical data gateway ............................................................. 83
Technical data sensors .............................................................. 84
Appendix EU Declaration of Conformity ..................................................... 87

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Schaeffler OPTIME
About the user manual This user manual applies to the condition monitoring system
OPTIME.
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/1F40.
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 Monitoring Services GmbH
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.

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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 Monitoring Services GmbH.
Schaeffler Monitoring Services GmbH does not take ownership
of these products and services.
Other products and manufacturers’ names cited in this publication
may be the trademarks of their respective owners.

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Licences The OPTIME sensor software uses the following open source
components:
CMSIS Copyright © 2009-2015 ARM Limited. All rights reserved.
Redistribution and use in source and binary forms, with or without
modification, are permitted provided that the following conditions
are met:
■ Redistributions of source code must retain the above copyright
notice, this list of conditions and the following disclaimer.
■ Redistributions in binary form must reproduce the above copy-
right notice, this list of conditions and the following disclaimer
in the documentation and/or other materials provided with
the distribution.
■ Neither the name of ARM nor the names of its contributors may be
used to endorse or promote products derived from this software
without specific prior written permission.
This software is provided by the copyright holders and contributors
“as is” and any express or implied warranties, including, but not
limited to, the implied warranties of merchantability and fitness for
a particular purpose are disclaimed. In no event shall copyright
holders and contributors be liable for any direct, indirect, incidental,
special, exemplary, or consequential damages (including, but not
limited to, procurement of substitute goods or services; loss of use,
data, or profits; or business interruption) however caused and
on any theory of liability, whether in contract, strict liability, or tort
(including negligence or otherwise) arising in any way out of the use
of this software, even if advised of the possibility of such damage.
The original language of the licence texts is English. All other foreign
languages have been translated from the original English text.

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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 condition monitoring 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 sensor and every gateway of the OPTIME condition monitoring
system is marked with a serial number. The gateway nameplate
contains the serial number, information on the manufacturer and
the CE symbol. This information is printed on the sensor.

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Usage for
the intended purpose
The OPTIME condition monitoring 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 83.
Unauthorized structural modifications to the system are not permiss-
ible. We assume no liability for any damage to machinery or injury
to persons arising from such actions.
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 all life cycles 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 condition monitoring system does not provide machine
protection. It must not be used as a component of safety systems.
For use in environments with an explosion risk, please note
the markings on the sensors (expected to be available from 2022).
The OPTIME condition monitoring system is not classified as a safety
component in accordance with the Machine Directive 2006/42/EC.
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.

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Selection and
qualification of personnel
The OPTIME condition monitoring system may only be mounted,
commissioned and operated by qualified personnel. The scope
of competence, area of responsibility and monitoring 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
appropriate training courses on request.
Work on electrical devices Work on electrical devices 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 Monitoring
Services GmbH.
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.

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Safety regulations All safety specifications are described in the following sections.
Safety during installation Read this user manual before installing the system. Make sure you
are certain that the product is suitable without restrictions for
the relevant applications.
Before installing the components, check for any external damage.
If damage or some other defect is found, the system must not be
commissioned.
Any interventions in and modifications to the system, or the addition
or removal of components not designed to be added or removed,
are impermissible, can endanger occupational safety and may
render any warranty claim null and void.
The device may only be installed by a trained electrician who obser-
ves the national and international regulations covering the
installation of electro-technical equipment.
Handling the lithium batteries
in the sensors
The sensors contain non-replaceable lithium thionyl chloride batter-
ies, which are not dangerous provided they remain in the sensor
housing. Never expose the batteries to excessive mechanical,
thermal or electrical loads, as this would activate the safety valves
and the battery container could rupture. Do not open the sensor.
Avoid temperatures of more than +100 °C. Dispose of the sensor
in accordance with the statutory provisions.
The incorrect handling of sensors may result in leaks or the emission
of evaporated electrolyte that can cause a fire or an explosion and
lead to serious injuries or death.
Sensors must be deactivated during transport and storage.
Keep away from children Gateway and sensors are not toys and must be kept out of the reach
of children. The system contains small parts. Children must not be
allowed to play with system components.
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.

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Safe handling
of information interfaces
This product 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 your company infrastructure
(e.g. IT infrastructure) can be damaged due to the use of these kinds
of information interfaces. In addition, your 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 your 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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Scope of delivery The OPTIME condition monitoring system is available in various
combinations.
Gateway Scope of delivery of the OPTIME gateway:
■ 1OPTIMEgateway
■ 1 built-in LTE stick (depending on the region)
■ 1 gateway quick guide manual BA 68-02.
Sensor kits Scope of delivery of OPTIME 3:
■ 10 OPTIME 3 sensors
■ 10 mounting plates M6
■ 1 quick guide manual for sensors BA 68-01.
Scope of delivery of OPTIME 5:
■ 10 OPTIME 5 sensors
■ 10 mounting plates M6
■ 1 quick guide manual for sensors BA 68-01.
The enclosed quick guide manuals contain the following link to this
user manual BA 68, which always provides the latest version:
https://www.schaeffler.de/std/1F40
Figure 1
Scope of delivery
Gateway
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Figure 2
Scope of delivery
Sensor kit
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Required accessories To ensure the system is complete and ready-to-use, the following
devices and accessories need to be provided by the user in addition
to the gateway and sensors,
Figure 3 and Figure 4 :
■ mobile phone or tablet (each with LTE and NFC technology)
with installed OPTIME app
■ connection cable to supply power to the gateway
■ depending on type of installation, a suitable adhesive for fixing
the mounting plates.
A suitable adhesive for fixing the mounting plates for the sensors
is LOCTITE AA 330 with activator, LOCTITE SF 7388 or a product
with comparable properties.
■ Please follow the instructions and observe the safety data sheet
for the adhesive.
■ In particular, follow the instructions on preparing the substrate
and curing times.
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.
Figure 3
Required accessories
for the gateway
NYM 2⫻0,75 mm2
0017067200170672
Figure 4
Required accessories
for the sensors
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Description
Structure The overall system consists of several components designed
for condition monitoring and predictive maintenance:
■ OPTIME gateway
■ OPTIME sensors
■ OPTIME app
■ OPTIME dashboards in the Schaeffler IoT Hub.
The sensors automatically form a mesh network that transfers
data directly or via other sensors to the gateway. In the network,
the sensors transfer raw data on vibrations as well as key perform-
ance indicators (KPI) via the gateway to the Schaeffler IoT Hub,
where the data are analysed and the results sent to the OPTIME app.
All analyses are also available in the OPTIME dashboard. Directly
after activation the sensor automatically starts to measure and
transfer data at pre-set intervals. At the same time, learning mode is
initiated, which defines the alarm thresholds for the respective
machine.
The mesh network organises itself automatically, when sensors 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 50 to 70 sensors per gateway.
Figure 5
Condition monitoring system
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Since an independent network is used to transfer the measured 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 when monitoring the
condition of machines in large industrial plants large distances also
have to be covered and difficult to access machines need to be
reached. The actively managed mesh network can establish contact
to sensors in a line of sight of up to 100 m, ensures reliable commu-
nication and at the same time optimises the battery service life
of the 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
Figure 6
Communication between
OPTIME system components
1
23


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Planning A system tree, i.e. showing the allocation of sensors to machines
and assets, does not necessarily have to be set up beforehand.
However, in the case of an entire plant this considerably simplifies
the installation process, as it is only necessary to select the corre-
sponding machine for sensor installation. A system 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

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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.
Positioning of gateway If possible the gateway should be positioned in a central location
in the area of the installed sensors. Ideally there should be a line
of sight to five or six sensors. These can then be used as repeaters
for the remaining sensors. For optimum coverage it can be helpful
to install the gateway above the sensor level.
When choosing the mounting location, it should be noted that
reinforced concrete or larger metallic objects can block signal trans-
mission in this area. This also means that a gateway may on no
account be installed in a metal switch cabinet.
If a mobile phone connection is used for data transfer we recom-
mend checking the LTE reception at the installation location
beforehand with a mobile phone.
Figure 7
Gateway in the system,
suitable installation positions
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B
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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
Put the gateway into configuration mode by pressing the
[
Configuration ] button.
 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.
Please remember that 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.
 [ Configuration ]button
Figure 9
Button for gateway configuration
OPTIME
1
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