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 simple 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 sensors
The concept features special wireless OPTIME sensors which
combine 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 the information they
need.
Current version You will find the latest electronic version (PDF) of this user manual at:
https://www.schaeffler.de/std/1F40

2 BA 68 Schaeffler Technologies
Page
Contents
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 ................................................. 6
Usage not for the intended purpose ........................................... 6
Warranty ................................................................................... 6
Selection and qualification of personnel .................................... 7
Work on electrical devices ......................................................... 7
Warning notice .......................................................................... 7
Safety regulations ..................................................................... 9
Scope of delivery Gateway .................................................................................... 11
Sensor kits ................................................................................ 11
Required accessories................................................................. 12
Demage during transit ............................................................... 12
Defects...................................................................................... 12
Description Structure ................................................................................... 13
Planning.................................................................................... 14
Gateway .................................................................................... 15
Sensors..................................................................................... 16
Transport and storage ................................................................................................. 21
Mounting Registering in the OPTIME dashboard......................................... 22
Install OPTIME app .................................................................... 22
Install gateway .......................................................................... 22
Install sensor ............................................................................ 27

Schaeffler Technologies BA 68 3
Page
Gateway configuration ................................................................................................ 32
Settings.................................................................................... 33
Using the OPTIME app Login and logout ....................................................................... 35
General navigation.................................................................... 36
Manage groups......................................................................... 39
Manage machines..................................................................... 43
Manage sensors ....................................................................... 48
Add sensor ............................................................................... 52
Add gateway ............................................................................. 55
Using the OPTIME dashboard ................................................................................................ 57
Registration, login and logout ................................................... 58
General navigation.................................................................... 59
Description of dashboard.......................................................... 61
Using the dashboard levels....................................................... 62
Level Process Area .................................................................... 62
Level Department...................................................................... 63
Level Group .............................................................................. 64
Level Machine .......................................................................... 65
Level Sensor ............................................................................. 68
Schaeffler-Tab .......................................................................... 70
Alarms...................................................................................... 72
Other dashboard options .......................................................... 74
Troubleshooting and
rectification
................................................................................................ 75
Decommissioning ................................................................................................ 75
Disposal ................................................................................................ 75
Technical data Technical data gateway............................................................. 76
Technical data sensors ............................................................. 77
Appendix EU Declaration of Conformity..................................................... 79

4 BA 68 Schaeffler Technologies
Schaeffler OPTIME
About the user manual This user manual covers the OPTIME condition monitoring 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 structure may occur.

Availability The latest electronic version (PDF) of this user manual is available
from: 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.
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.

Schaeffler Technologies BA 68 5
General safety guidelines This chapter brings together all the important safety regulations.
Anyone tasked with working on the system must read this chapter
and follow the instructions given.
Principles The OPTIME condition monitoring system complies with the state-of-
the-art and the recognised safety rules. 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 gateway of the OPTIME condition monitoring
system is marked with a serial number. The gateway nameplate
contains the serial number, manufacturer’s details and CE symbol.
This information is printed on the sensor.

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Schaeffler OPTIME
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 76.
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.
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 06/2021).
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.

Schaeffler Technologies BA 68 7
Selection and
qualifications of personnel
The OPTIME condition monitoring system may only be installed,
commissioned and operated by suitably qualified personnel.
The accountabilities, area of responsibility and supervision of
personnel have to 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 you
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.
Warning notices Please read this document before commissioning the system.
Make sure that the product is suitable without restrictions for
the relevant applications.
The OPTIME conditioning monitoring system is not classified as
a safety component in accordance with the Machinery Directive
2006/42/EC.
Schaeffler Monitoring Services GmbH herewith declares that
the OPTIME gateway and OPTIME sensor wireless systems comply
with Directive 2014/53/EU.
The device may only be installed by a trained electrician.
Carry out the installation in accordance with the national and
international regulations covering the installation of electrical
equipment.

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Schaeffler OPTIME
Before mounting 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.
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 condition.
The use of the OPTIME condition monitoring system is only admissi-
ble within the boundaries of the conditions stated and illustrated
in the user manual.
The system may only be operated within the limits described in
the data sheet. If the system is operated outside these limits system
components may be destroyed.
Do not repair any damaged components of the OPTIME condition
monitoring system but instead please arrange to have any necessary
repairs carried out by Schaeffler Monitoring Services GmbH.
Only dismantle the OPTIME gateway with the power switched off and
in a voltage-free condition.

Schaeffler Technologies BA 68 9
Safety regulations All important safety specifications are described in the following
sections.
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.
Never expose the batteries to excessive mechanical, thermal or elec-
trical 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.
If the sensors are handled incorrectly there can be a risk of leaks
or the emission of evaporated electrolyte that can cause fire or
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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Schaeffler OPTIME
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.

Schaeffler Technologies BA 68 11
Scope of delivery The OPTIME condition monitoring system is available in various
combinations.
Gateway The scope of supply comprises, Figure 1 :
■ OPTIME Gateway
■ Quick guide manual BA 68-02.
Sensor kits Depending on the sensor kit ordered, the scope of supply comprises,
Figure 2 :
■ 10 ⫻ OPTIME 3 sensors or
10 ⫻ OPTIME 5 sensors
■ 10 ⫻ mounting plates
■ Quick guide manual 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 supply
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.
0017066E0017066E
Figure 2
Scope of supply
Sensor kit
OPTIME
OPTIME
5− 6
xxxx
xx
xxx
www.schaeffler.de/std/1F41
xxxx
xx
xxx
i
www.schaeffler.de/std/1F40
OPTIME
BA 68BA 68
2.
1.
0017071400170714

12 BA 68 Schaeffler Technologies
Schaeffler OPTIME
Required accessories To ensure the system is complete and ready-to-use, the following
devices and accessories need to be provided 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
0017071800170718

Schaeffler Technologies BA 68 13
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 KPIs 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 avail-
able in the OPTIME dashboard. Directly after activation the sensor
automatically starts to measure and transfer data at pre-set inter-
vals. At the same time this starts the learning mode, 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.
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.
Figure 5
OPTIME condition
monitoring system
00171C2C00171C2C

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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.
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 you only need to select the correspond-
ing sensor during 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 will get an administration user account when
the OPTIME system has been purchased. This user is able to create
additional users. All created users will get their login data via email.
To log into the OPTIME customer portal please visit the following
website:
https://schaeffler-optime.com/dashboard
 Mesh network
 OPTIME gateway
 Schaeffler IoT Hub
Figure 6
Communication between
OPTIME system components
1
23


00171C1D00171C1D

Schaeffler Technologies BA 68 15
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, please remember that
reinforced concrete or larger metal 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.
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 that shows various
operating statuses, see table , page 16.
Figure 7
Gateway in the system,
suitable installation positions
OPTIME
OPTIME
A
B
C
0017067600170676
 Input power supply
 Input network connection
 LED for indicating operating status
Figure 8
Gateway connections and
indicators
OPTIME
1
2
3
00170E4000170E40

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LED displays
Put the gateway into configuration mode by pressing the
[
Configuration ] button.
Sensors The OPTIME sensors are fixed to the machines and activated using
near-field communication (NFC) via the OPTIME app. The sensors are
also suitable for use outdoors.
Two different types of sensor are available.
The OPTIME 3 sensor has a bandwidth of 10 Hz to 3 kHz and is
therefore suitable for the following applications:
■ motors
■ generators
■ fans
■ plummer block bearings.
The OPTIME 5 sensor has a bandwidth of 10 Hz to 5 kHz and can
therefore also be considered for monitoring the following
applications:
■ pumps
■ geared motors
■ gear box
■ compressors.
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
00170E3F00170E3F

Schaeffler Technologies BA 68 17
The OPTIME system is suitable for machines that run continually
or partly continually. Machines that are only operated for short
phases during the day are less suitable for monitoring by OPTIME.
In addition, the machine should normally run in a stable operating
condition (speed and performance) for a period of around one
hour. With OPTIME 3 sensors, machine speeds of 100 min
–1
to
3 000 min
–1
can be monitored, and with OPTIME 5 sensors up to
5 000 min
–1
. When choosing the suitable combination of machines
and sensor, there are certain factors that need to considered,
see table .
Combination of machines and
sensors
1)
Please consult Schaeffler if your machine is not listed.
Application
1)
Other
characteristic
Sensor
type
Quan-
tity
Mounting location
Electric motor ⬍ 0,5 m OPTIME 3 1 ■ Bearing position
on motor drive side
■ Centrally on the motor
■ In the centre at the base
of the motor
⬎ 0,5 m OPTIME 3 2 ■ Drive side and
non-driven side of motor
■ Base of drive side and
non-driven side of motor
Fans Overhang OPTIME 3 1 ■ Plummer block housing
Between
bearings
OPTIME 3 2 ■ Plummer block housing
directly
coupled
OPTIME 3 1 ■ Drive side of motor
Compressor –OPTIME 5 2 ■ Bearing position
Plummer
block
bearings
–OPTIME 3 1 ■ Bearing position
Pump –OPTIME 5 2 ■ Bearing position
Geared motor ⬍ 0,5 m OPTIME 5 1 ■ Gearbox
⬎ 0,5 m OPTIME 3
OPTIME 5
1
1
■ Motor
■ Gearbox
Extruder –OPTIME 3 2 ■ Bearing position
Calenders –OPTIME 3 2 ■ Bearing position
Belt drive –OPTIME 3 2 ■ Bearing position
Saws –OPTIME 5 1 ■ Bearing of saw blade
Shaft –OPTIME 3 1 ■ Bearing housing
Gearbox –OPTIME 5 2 ■ Input and output

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Mounting position on machine Ideally the sensors should be mounted in the vicinity of the bearing
arrangements of the machine, if possible in a radial layout
(in the load zone). The precise mounting location is not too critical;
a sensor can still be located effectively at some distance from
the ideal position. If, for example, the bearing area of a motor is
not accessible, the sensor can alternatively be fixed to a suitable
flat area on the motor housing or even at the base of the motor.
If possible the sensor should not be shielded on several sides by
metal parts.
The vibration monitoring process measures the structure-borne
sound of machines, which is why there needs to be a fixed connec-
tion to the bearing arrangements. This means that machine cladding
components are not suitable as a mounting location.
When attaching sensors to the machine it helps to use
the overviews, Figure 10 to Figure 13 , page 19.
Figure 10
Examples of
mounting positions with
OPTIME 3 sensor
0017073700170737
Figure 11
Examples of
mounting positions with
OPTIME 5 sensor
0017073D0017073D
Figure 12
Examples of
mounting positions for
large and small motors
MM
⬎0,5 m
2⫻
MM
⬉0,5 m
1⫻
0017073000170730