SKF MTx User manual

SKF Österreich AG
Condition Monitoring Centre - Steyr, Seitenstettner Strasse 15, A 4401 Steyr, Austria,
Phone [phone], Fax [phone],
E-mail [email protected], Web www.skf.com/cmc-steyr
Technical manual
SKF Machine Tool Observer
MTx

MTx TABLE OF CONTENTS
SKF Condition Monitoring Centre – Steyr 1 - 6 - 1
TABLE OF CONTENTS
1. VERSION OF MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. ABOUT THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1.1. Typographic instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2. DETAILED INFORMATION ABOUT INPUTS. . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1. Acceleration sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2. Rotation sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.3. Switching sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.4. Voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.5. Current sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.6. Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3. SWITCHING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4. CONNECTION PLAN AND JUMPER SETTINGS . . . . . . . . . . . . . . . . . . . . . . 23
3.4.1. Supply voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4.2. Speed sensor sine/cosine 1 Vpp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4.3. Speed sensor 5 Vpp or 24 Vpp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.4. Standard industrial sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.5. Triax accelerometer [CMSS-ONL-1500E-2] . . . . . . . . . . . . . . . . . . . . . . . . 24
3.4.6. Ethernet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4.7. Switching output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4.8. Switching output 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4.9. Universal sensor input connector (n here can be 1 to 10) . . . . . . . . . . . . . 25
4. SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1. MTx SERVER SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1.1. Server intallation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1.2. Server configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1.3. Server monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.2. MTx CLIENT SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.1. Client installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.2. Uninstall software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.3. Choosing the network interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2.4. Start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2.4.1. Connect to device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2.5. MTx device panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.5.1. File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2.5.2. Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.5.2.1. Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.5.2.2. Input configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2.5.2.3. Matrix configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.5.2.4. Switching output configuration . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.5.2.5. User Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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4.2.5.3. Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.2.5.3.1. Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.5.3.2. Alert settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.5.3.3. Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2.5.4. Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.5.4.1. About MTx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2.6. Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2.6.1. Monitor mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2.6.2. Matrix and events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2.6.3. Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1. CHANGING IP-SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2. APPROVED SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.1. Acceleration sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.2. Rotation sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.3. Switching sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.4. Voltage sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.2.5. Current sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2.6. Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.3. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.4. DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.5. DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

MTx VERSION OF MANUAL
SKF Condition Monitoring Centre – Steyr 1 - 6 - 3
1. VERSION OF MANUAL
VERSION DATE CHANGES
Manual Software Manual
1 1.4 24.07.2014

VERSION OF MANUAL MTx
1 - 6 - 4 SKF Condition Monitoring Centre – Steyr
Room for notes

MTx INTRODUCTION
SKF Condition Monitoring Centre – Steyr 1 - 6 - 5
2. INTRODUCTION
The tooling industry has a growing need to increase productivity, machine availability, pre-
cision and reliability.
As a result it is increasingly important to avoid unplanned downtime, adopt effective main-
tenance approaches, and support quality and process improvements.
The SKF Machine Tool Observer MTx is a stand alone data logger system for machine tools
and machine tool spindles which offers benefits to both OEM and end users. It can easily be
integrated into new machines or retrofitted as an upgrade for existing machines.
The MTx can log measurements from your critical machine tools, and is capable of collecting
data from a wide range of sensors such as vibration, speed, temperature, humidity, eddy
probes and oil streak. The user and the machine control system are alerted if a value is de-
tected out with pre-defined boundaries. All events which exceed thresholds, or spindle
crashes, are logged with an accurate time stamp and sensor values, and are stored in a per-
manent flash memory.
The SKF Machine Tools Observer MTx can continuously log data over 10 years. High speed
relay outputs can stop the machine in milliseconds and the e-mail warning system can im-
mediately send a warning to the supervisor for a corrective action.
A multilevel access system provides a high level of recorded data security, and a server and
client software package for live data display, data distribution and administration is also in-
cluded with the system.
2.1. ABOUT THIS MANUAL
This manual deals with the SKF MTx hardware and software.
For simple cross reference we have divided the manual into chapters and sections.
MTx hardware,
and software
We assume that the reader has a basic knowledge of Windows computer programs.
We will not explain every possibility the software has. However, we will try to exactly explain
the principles. If the use of a display page is self-evident, we will only take a typical usage
as an example. We will explain more complex proceedings in detail.
2.1.1. Typographic instructions
• Paragraphs which are marked with this symbol describe the lists.
* Paragraphs which are marked with this symbol describe the functions which you have
to fulfil in order to solve a certain task.
CAPITALS show keys to press on the keyboard, like for example: Press ALT+F4.
'..............'
Expressions in inverted commas display operating steps on the display menu, like for exam-
ple: 'Save - file'.
Paragraphs marked in this way are there to make the reader aware of an important point
of the area just dealt with.

INTRODUCTION MTx
1 - 6 - 6 SKF Condition Monitoring Centre – Steyr
This is a summary. A summary of the subject just dealt with can be quoted in the left margin in grey letters.

MTx HARDWARE
SKF Condition Monitoring Centre – Steyr 1 - 6 - 7
3. HARDWARE
SKF has developed a new stand-alone online condition monitoring device, which actively
monitors, records and observes the history and maximum events of machine tool spindles.
The system consists of a microcontroller based electronics with internal memory for data
storage with real time clock and supports a wide range of different types of sensors, where
a maximum of 14 of these sensor types can be connected at the same time.
• Vibration in three axis by triax accelerometer or standard industrial accelerometer
(maximum 3 channels)
• Spindle speed sensors (5 V, 24 V or 1 Vpp)
• 10 universal sensor inputs (voltage 0 to 24 V, current 4 to 20 mA or switching sensors 0
to 24 V)
The system has also two digital relay outputs for alarm or emergency stop on free program-
mable limits on two independent channel basis. The same programmable limits are also
used to report data and status to any configurable email addresses. A green LED on the
electronics shows voltage status and a red LED indicates recorded incident. The electronics
is preferable installed inside the electrical cabinet for machine tool, while the triax acceler-
ometer should be connected as close as possible to the spindle head by using a M5 screw,
magnet or special glue. The maximum supported cable length between MTx electronics and
accelerometer is 12 m.
Fig. 3/1... SKF Machine Tool Observer MTx
Electronics [CMON 1502]

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1 - 6 - 8 SKF Condition Monitoring Centre – Steyr
Fig. 3/2
Fig. 3/3
1
8
2 3 4 5 6 7
9
1 ....... Supply voltage
2 ....... Rotation sensor 1 Vpp
3 ....... Rotation sensor 5 V, 24 V
4 ....... Industrial acceleration sensors (3×)
5 ....... Triax acceleration sensor (1×)
6 ....... Ethernet connector
7 ....... Switching output (2×)
8........ Universal sensor inputs (10×)
Switching or voltage sensor
Current 4 to 20 mA sensors
Pt100 or KTY84-130 temperature
sensors
9........ Status LED’s
green: power on
green flashing: working
red: event
Power supply [CMON 1503]

MTx HARDWARE
SKF Condition Monitoring Centre – Steyr 1 - 6 - 9
Fig. 3/4 ... Accessories
Fig. 3/5 ... Mounting example
Triax accelerometer
[CMSS-ONL-1500E-2]
Triax accelerometer extension cable
[CMSS-ONL-1500EXT-10]

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3.1. GENERAL DESCRIPTION
The SKF Machine Tool Observer MTx can handle up to six different types of sensors, where
14 of them can be connected at the same time.
• Acceleration sensors:
- Triax accelerometer [CMSS-ONL-1500E-2]
- SKF Vibration Sensors
- Standard industrial sensor
Please check the sensor-datasheet for compatibility of standard industrial acceleration
sensors.
• Rotation sensors:
- 0 V to 24 V rectangle
-0Vto5Vrectangle
-1Vpp
• Switching sensor (On/Off, 0/1), which connected to the offered 24 V supply voltage from
0 V to 24 V. In this document these inputs will be called PNP-Inputs.
• Voltage sensor, 0 V to 24 V, e.g. an Eddy Probe sensor for force/load measurement.
• Current sensor, 4 mA to 20 mA sensor which represent all sensors with a current-out-
put, e.g. humidity sensor (0 to 100% relative humidity)
• Temperature sensors
- KTY84-130
-Pt100
Please find a list of approved sensors in the appendix, section 5.2.

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SKF Condition Monitoring Centre – Steyr 1 - 6 - 11
3.2. DETAILED INFORMATION ABOUT INPUTS
Before the input can be used the correct Jumper positions have to be set up for each input
’X1-1’ to ’X1-10’.
If any input isn't in use there it is recommended to set them as PNP. In this case they can
be disabled in the software (switch configuration) and not cause any undesired alarms.
Jumper position
1. Voltage sensor (e.g. Eddy Probe), switching sensors 0 to 24 V
2. Current sesnor (e.g. humidity) 4 to 20 mA
3. Pt100 or KTY84-130
4. Reserved
5. Reserved
Input filter information please see section 5.3., Inputs.
3.2.1. Acceleration sensors
There are three types of acceleration sensors available with this system:
1. Triax accelerometer [CMSS-ONL-1500E-2]:
Fig. 3/6
It is a small, low power, complete 3-axis accelerometer with signal conditioned voltage out-
puts. It can measure the static acceleration of gravity in tilt-sensing applications, as well as
dynamic acceleration, resulting from motion, shock, or vibration.
Specifications:
• Supply voltage: 1,8 to 3,6 +0,3 Vdc
• Bandwidth X, Y: 800 Hz
• Bandwidth Z: 600 Hz
• Max. range: ±16 g PkPk
• Max. shock survival: 10 000 g
•Sensitivity:34mV/g
The maximum supply voltage of 3,6 +0,3 Vdc must not be exceeded, otherwise the triax
sensor will be destroyed.
IYI
IXI
IZI

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Fig. 3/7 ... Connection example
2. SKF vibrations sensors
Fig. 3/8
The acceleration sensor is versatile, reliable and the most popular vibration sensor for ma-
chinery monitoring. For a given mechanical acceleration level, piezoelectric accelerometers
have a constant signal over a wide frequency range, typically up to 20 kHz, and are very
useful for all types of vibration measurements. Acceleration integrated to velocity can be
used for low frequency measurements.
Acceleration signals in the high frequency range added with various signal processing tech-
niques like Acceleration Enveloping (gE) are very useful for bearing and gear measure-
ments.
The basic acceleration sensor has a good signal to noise ratio over a wide dynamic range.
They are useful for measuring low to very high frequencies and are available in a wide va-
riety of general purpose and application specific designs.
When combined with vibration monitors capable of integrating from acceleration to velocity,
accelerometers can be useful components in a multi-parameter monitoring program.
3. Industrial acceleration sensors:
Standard industrial accelerometer identifies sensors that incorporate built-in, signal-con-
ditioning electronics. The built-in electronics convert the high-impedance charge signal that
is generated by the piezoelectric sensing element into a usable low-impedance voltage sig-
nal that can be readily transmitted, over ordinary two-wire or coaxial cables, to any voltage
readout or recording device. The low-impedance signal can be transmitted over long cable
distances and used in dirty field or factory environments with little degradation.
Usually these sensors only can provide one axis acceleration measurement.

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To activate the standard industrial sensor supply current the following jumpers need to be
set:
Fig. 3/9
Fig. 3/10
Warning: If you use non standard industrial sensors without disabling the supply-current
(by setting the jumpers to ’standard industrial sensors’) the sensor can be destroyed.
Please find a connection plan and the appropriate jumper settings in section 3.4.
Jumper
Z, Y, X
Connector
GND, Z Y, X
Jumper set inactive
standard industrial sensor
Jumper
Z, Y, X
Connector
GND, Z Y, X
Jumper set active
standard industrial sensor

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Fig. 3/11 ... Connection example
Parameters in software
1. Sensitivity:
The sensors sensitivity has to be named here.
2. Gain:
All sensors are supplied with 3,3 V. This value is halved to get a positive and negative signal
for acceleration. With the supported sensors a gain of 1 is necessary because they already
deliver
If the sensor delivers less than the signal can be amplified to gain a better
resolution.
If another sensor is used which e.g. delivers the signal can be amplified by 2.
But be aware, if the input exceeds the the ADC will stuck at his maximum and maybe
information will be lost without any error.
3.2.2. Rotation sensors
There is a possibility to connect three different types of rotation sensors to the MTx. As
mentioned the device provides rectangle signals where the pulses represent the rotation
velocity. The number of pulses to be one turn can be adjusted in software.
The rotation-input can measure up to 600 kHz input frequency no matter which input is
used.
Be careful: Frequencies higher than 600 kHz cause failure in measurement and further can
overload the controller.
Because of performance issuses a accuracy of ± 60 rpm is possible.
165V165V
33
2
---------V165V=
07V
165V

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SKF Condition Monitoring Centre – Steyr 1 - 6 - 15
Fig. 3/12 ... Possible assembly with eight pulses/turn
Although it is very often used in SKF the MTx also provides signals coming from a interface
(Siemens, VS-Sensorik und Heidenhain).
And the 5 V coming from this interface can be directly connected to the MTx and also the
pulses/turn can be adjusted in software.
For avoiding influences to the system, this input is galvanic divided and very high-resist-
ance.
Parameters in software
1. Pulse per turn:
Define how much pulses occur at one rpm.
2. Counter start level:
If the machine monitored by the MTx runs at more than the specified value (in rpm), a coun-
ter will add up the time in this working condition.
Speed input
Sensor ......... Pulses per turn (ppt)
Spindle......... maximum speed (vmax) [rpm]
Signal
frequency..... (fSignal) [Hz
Conditions.... vmax < 65 000 rpm
fsignal < 600 000 Hz
Examples
Spindle with maximum speed of 40 000 rpm, two sensors: Sensor one with 1024 pulses
and Sensor two with 512 pulses.
Condition one is ok: 40 000 < 60 000
Condition two for sensor one:
682 667 < 600 000!!! - condition failed
fSignal ppt vmax
60
-------------
=
1024 40000
60
---------------
682667=

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Condition two for sensor two:
341 333 < 600 000 - condition ok
Fig. 3/13 ... Connection examples
3.2.3. Switching sensor
PNP input
This input option supports all sensors with a switching output such as pressure of fluids,
force, supply voltage inspection, (end) position sensors, ...
The MTx therefore can provide switching voltages up to 24 V.
If the desired sensor is a simple switch the 24 V sensor-supplies can be used of course.
Internal the 24 V input then will be down converted to 3,08 V and then amplified (by one)
for the ADC. For that purpose a voltage divider which divides the input by 7,8 is used. The
ADC can handle a maximum of 3,3 V.
There is a possibility to connect other sensors with a switched voltage-output less than the
24 V. Thereto the gain of the input-amplifier is adjustable (see the example calculation in
voltage (Eddy Probe) input).
Also the switching-level (referring to 24 V) can be adjusted in software where you can also
choose a high- or low-active usage.
Parameters in software
1. Active on:
Defines high- or low-active usage.
2. Switching level:
Defines the threshold-level (referring to 24 V) in %.
3. Gain:
Defines pre-amplification as described in the text above.
512 40000
60
---------------
341333=

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Switching input
Input ............ Umax = 24 V
Sensor ......... Voltage of HIGH level UHigh [V]
Voltage of switching level USL [V]
Gain depends on calculated x:
Switching level (SL) [%]
Examples
Sensor with 10 V high level. The chosen switching level voltage is 7 V
Gain = 2 (x = 24/10 = 2,4)
Sensor with 5 V high level. The chosen switching level voltage is 4,2 V
Gain = 4 (x = 24/5 = 4,8)
Fig. 3/14 ... Connection example
3.2.4. Voltage sensor
General information
Sensors connected to this input can provide 0 V to 24 V.
As described above a voltage divider which divides the input by 7,8 is used because the ADC
can only handle a maximum of 3,3 V.
Gain
1 < x < 2 1
2 < x < 4 2
4 < x < 5 4
5 < x5
xUmax
UHigh
-----------------=
SL USL Gain
Umax
------------------------------ 100=
SL 72
24
------------100== 58%
SL 424
24
------------------100== 70%

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There is a possibility to connect other sensors with a voltage-output less than the 24V.
Thereto the gain of the input-amplifier is adjustable. By using the amplifier there is a pos-
sibility to get better resolution on the ADC.
For example:
Your sensor delivers only 0 V to 10 V the ADC will be used in a range of
so 0 V to 1,28V. If the amplifier with a gain of two (adjustable in the software) is used there
are 0 V to 2,56 V at the ADC and so a better resolution in the digital-converted results.
But be aware, if the input exceeds the 3,3 V the ADC will stuck at his maximum and maybe
information will be lost without any error.
Parameters in software
1. Name:
Description of the voltage sensor
2. Unit:
Unit description of the sensor
3. Sensitivity:
Defines the sensitivity of the used sensor in mV/measured unit.
4. Offset:
Defines the offset of the sensor in the measured unit
5. Gain:
Defines pre-amplification as described in the text above.
Voltage input
Input ............ Umax = 24 V
Sensor ......... maximum signal voltage USignalmax [V]
Gain depends on calculated x:
Examples
USignalmax = 10 V -> chosen gain: 2
USignalmax = 7 V -> chosen gain: 2
USignalmax = 3 V -> chosen gain: 5
Gain
1 < x < 2 1
2 < x < 4 2
4 < x < 5 4
5 < x5
10V
78
----------128V=
xUmax
USignalmax
--------------------------------=
x24
10
------24==
x24
7
------34==
x24
3
------8==