Timken StatusCheck User manual

StatusCheck™ Operators Manual
StatusCheck™ 2.4GHz

Disclaimer:
This manual is provided for infor-
mation purposes. Timken makes no
warranty of any kind with regard to
this material. Timken will not be
held liable for omissions or incon-
sistencies that may be found within
this manual or for incidental or
consequential damages in connec-
tion with this manual. Information
in this manual is subject to change
without notice. The information in
this manual is not all-inclusive.
Product Support:
Should you have any questions
regarding this material or items
that were not covered in this
manual please contact Timken's
StatusCheck™ product support
group at [phone] or at
conditionmonitor[email protected].
In the event that you are not able to
solve a problem related to this
product, technical help is available
for those who purchased the
product support package from
Timken. Product support is available
for one year from date of purchase.
To better serve you, please have
the hardware serial numbers and
software version of your system
available. Be prepared to explain
the exact nature of the problem.
Returns:
A Return Goods Authorization
(RGA) number is required for all
product returns. Please call the
Product Support Group at +1-330-
471-3369 for an RGA# and return
shipping instructions.
Internet:
www.timken.com
Software:
You have the non-exclusive right to
use this software on only one
device at a time. For network
systems, you have the non-
exclusive right to install this
software on only one server per
license purchased. Read/write
access is limited to the number of
licenses purchased.
Software upgrades will periodically
be made available to the registered
users. These upgrades will be free
to registered users who have
purchased the product support
package offered with this system.
To purchase a support contract,
please contact your Timken sales
representative.
StatusCheck™ Quick Start Guide and
Operators Manual

StatusCheck Quick Start Guide
This guide assumes that you have all of the components supplied with this
system including a serial or USB cable, a controller, at least one
StatusCheck™ end node, and a monitoring software installation disk.
To install this system you will need your own PC running Windows®2000 (or
above) that has a CD drive and at least one available serial or USB port. You
also will need at least one machine or device that needs monitoring.
As an overview of the installation, you will mount StatusCheck end nodes
on the machines or devices that need monitored. Next, you will connect
the controller to the PC with a serial cable. Then install the monitoring
software on your PC and configure the monitoring software to recognize
the StatusCheck components in your system. After which, you will test the
monitoring system.
1. Mount the StatusCheck end nodes on the machines or devices that
you want to monitor. Make a note of each StatusCheck end node’s ID
so that you can configure the software that you will install in step 3.
You can use the magnetic mounting option to place each StatusCheck
end node, see the Hardware Operations Manual for more details or for
other mounting methods. Using the toggle switch on the bottom of the
end nodes, turn the units on before you mount them. When the units
are turned on, you will see a light blink on the top of the end nodes.
Once the locations are verified, you may want to permanently mount
the units and adjust the data collection interval as desired. Please see
the hardware manual for additional details on mounting and data
collection interval adjustments.
2. Insert the software installation disk in the CD drive of the PC. The
installation software should auto load, if it does not, run the
executable file on the installation disk called SCCMS_X_XX_XXX.exe.
The X’s are replaced by version numbers on the software CD. Follow
the installation instructions as they appear on the PC screen. Taking
all the defaults will produce a functional system. Do not forget to
remove the installation CD from the drive when this step is done.
3. Install the serial or USB cable between the controller and the PC, see
operators manual for controller data interface details. Connect the line
cord, supplied with the controller, to line power. Turn the controller’s
power switch on (to the right). The LED in the power switch will
illuminate when power is applied.
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Note: The controller, when interfaced with a PC, must be configured
properly; open the hinged lid and ensure the router/controller switch
inside the box is set to “controller.” Close and secure the lid.
4. After step 3 is complete, double click the StatusCheck icon that
appears on the PC’s desktop. The
icon will appear after the
software installation step is
completed.
A dialog box will appear telling you
that your software needs configured.
Click the OK button on the dialog
box. A window with multiple tabs will
appear. See Figure 1.
Figure 1 ————————————
Select from the menu File, then
select Load Quick Start Options.
See Figure 2.
Figure 2 ————————————
After the options have loaded, click
the Data Acquisition Module tab.
You will see five generic end node
ID’s, from FEE0001 to FEE0005, in the
end node table. These need to be
replaced by the ID numbers specific
to your system. See Figure 3.
Figure 3 ————————————
5. Select the row with end node ID FEE0001. Click the Replace button. A
dialog box will ask you for the new end node ID. Enter the ID from one
of the end nodes you installed in step 1. If you have installed more end
nodes, repeat this step for each end node using rows with end node
IDs FEE0002, FEE0003, and so on. If there are rows present that do not
represent end nodes you have placed in the field, double click on the
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activation/deactivation field column for each non-functional end node.
The Yes field will change to No. Also, note that if more than five units
are being installed, you must add rows to represent these additional
units. See the
Software Operations Manual for more details.
6. Select the first row in the
controller table. Click the Delete
button. Click the Find button. A
Notepad file is displayed
showing all of the com ports
scanned in finding the controller.
The Notepad display can show
you information about your
computer that can help diagnose
problems with com ports. See
Figure 3.1.
Figure 3.1 ———————————
7. Cancel the Notepad display. The controller’s table should now contain
the address and com port that your controller is attached to. Select
the location field and enter the location of the controller for
documentation purposes. If the Find procedure did not locate your
controller, add a row to the controller table and fill in the fields
accordingly.
8. To complete the software configuration select from the menu File then
Generate System. After the system has been generated, select from
the menu File and Exit.
9. To run the system, double click the StatusCheck icon on the PC’s
desktop. This time the monitoring software will execute. The controller
window will be displayed. See Figure 4 below. To see if all of your
installed devices are working click the Show radio button under
System Monitor on the controller window. If you want to see the real-
time data being gathered, click the Show radio button under Grapher.
If you need additional information on how to configure or use the
monitoring software, please refer to the
Software Operations Manual .
If some devices in your system are not working, see the
troubleshooting guide in the
Hardware Operations Manual .
Figure 4 ————————————
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4
StatusCheck Operators Manual
System Overview:
This manual provides the necessary documentation for the installation and
operation of the Timken StatusCheck™ Condition Monitoring System. The
StatusCheck System is a cost-effective online monitoring system for
predicting the health and operating condition of machinery components.
The StatusCheck end node is self-contained with battery powered sensors
and electronics. The end node attaches directly to the outer frame or
housing of a machine. It uses wireless radio frequency (RF)
communications to transmit sensed physical characteristics (vibration
parameters and temperatures) of the machine. A transmission distance of
up to one kilometer (1⁄2mile) line-of-sight (open field) or 300 meters (328
yards) in a typical plant environment can be achieved. Multiple
StatusCheck end nodes (up to 100) can be in use on one or more
machines, all of which send their signals back to a controller.
The controller connects through a serial, USB or Ethernet port to a PC that
displays the data. The data consists of ambient temperature, probe
temperature and vibration parameters from a dual axis accelerometer in
acceleration or velocity. The StatusCheck software is used for real-time
monitoring, data logging and triggering alarms once the collected data
exceeds user-defined thresholds indicated by yellow and red conditions.
By observing the data over time, the user can evaluate the operating
condition of the machines. The data plotted in Figure 5 versus time either
can be operating temperature or a vibration measurement. The machine
measurement trends increase as the machine approaches a failure mode.
The yellow line indicates a warning condition, whereas the red line
represents a critical alarm condition. The goal is to detect conditions that
require maintenance action before a problem becomes severe and causes
unplanned machine downtime or collateral damage.
Applications:
The StatusCheck monitoring system is suitable for a wide range of
applications. The machines that can be monitored include pumps, fans,
rolls, gearboxes, motors, bearings or other industrial applications requiring
the measurement of steady-state temperature and vibration.

5
Figure 5: Operation of StatusCheck™
How it Works:
The StatusCheck system collects
temperature and vibration signals for
a one second period during a
transmission cycle. The vibration signal consists of 4,096 data points over
this time interval. The vibration data is then statistically parameterized into
five main statistical readings for each accelerometer axis. This
parameterized data, along with the temperature readings, is transmitted to
a controller, which connects to a PC for analysis. The StatusCheck real-
time tracking software compares the parameterized data to adjustable
user-defined thresholds and to trigger alarms. This technique allows easy
interpretation of a machine’s operating condition over time.
It is important to note that this system will not indicate the exact system
problem only that a problem exists. A more advanced diagnostic system
can be used once a problem is identified. This system is fully turn-key and
installs quickly, with minimal required training, for a simple assessment of
a machine’s operating condition.
System Components:
At a minimum, the system is composed of one controller, one end node
and one software package. Routers may be required to extend the range
from the end node(s) to the controller. The system can be composed of a
maximum of 100 end nodes per controller. Mounting fittings, mounting
plates, spare o-rings, cabling and spare batteries also are available from
Timken. Contact your Timken representative to obtain these items.
End Node:
The StatusCheck end node operates in the 2.4 GHz ISM band and is a
direct sequence spread spectrum. There are many benefits to using a
spread spectrum transmission scheme. The StatusCheck device complies
with FCC- and EU-based RF requirements and will typically not interfere
with other wireless devices.
Testing has been successfully performed in plant environments without
significant loss of data. Transmission distance is decreased and data loss
is increased with obstructions and noise interference.

6
Figure 6: StatusCheck
end node and a listing of the
main components.
Accelerometer Type and Measurement Axes:
The accelerometer is a dual axis, 18 G,
cantilevered beam, MEMS device and is
located on the center post of the end node.
The accelerometer is used for sensing
mechanical vibrations. The two axes of
measurement are referenced in Figure 7.
Figure 7: Vibration Sensing Axis Designation
Data Collection Intervals:
Five different data collection intervals are available for use with this
product. For example, a 15-second data collection interval denotes that
once every 15 seconds the end node will activate and collect 4,096 data
points over an approximate one second period. Next, it will parameterize
and transmit data prior to returning inactive. A 60-second data collection
interval denotes that once every 60 seconds the end node will activate
and collect 4,096 data points over an approximate one second period.
Next, it will parameterize and transmit data prior to returning inactive.
The data collection interval and environmental conditions will determine
the life of the battery. The factory interval setting is every 15 seconds. It is
recommended that you initially retain the factory setting for network
configuration then switch to a longer data collection interval to conserve
battery life.
LED Indicator
Lid
Base
Battery
Gasket
Transmitter
Board
Signal Processing
Board
Temperature
Probe

7
The six data collection intervals for the StatusCheck end node and the
approximate battery lives are depicted in the table below:
Interval Setting Data Collection Interval Approx. Battery Life
15 (Default Setting) Every 15 seconds 4.5 Months
30 Every 30 seconds 9 Months
60 Every 60 seconds 1.5 Years
300 Every 5 minutes 3 Years
600 Every 10 minutes 4.5 Years
The data collection interval is adjusted using dip switches located on the
signal processing board inside the end node case. As shown in Figure 8,
the dip switches are located on the left side of the board and can be
switched on or off using a pencil tip or small screwdriver (the ON position
is up). These switches are adjusted according to the tables below to
obtain the desired data collection intervals.
Caution: Turn the unit power OFF before adjusting the dip switches and
use a non-conductive tool to adjust. Do not place unnecessary stress on
the boards while moving the dip switches.
The 15-second interval setting is obtained by positioning the internal dip
switches as follows:
Switch 1234
On
Off
I
X
I
X
I
X
I
X
The 30-second interval setting is obtained by positioning the internal dip
switches as follows:
Switch 1234
On X
Off
II
X
I
X
I
X

8
The 60-second interval setting is obtained by positioning the internal dip
switches as follows:
Switch 1234
On X
Off
I
X
II
X
I
X
The five-minute interval setting is obtained by positioning the internal dip
switches as follows:
Switch 1234
On X X
Off
III
X
I
X
The 10-minute interval setting is obtained by positioning the internal dip
switches as follows:
Switch 1234
On X
Off
I
X
I
X
II
X
Caution: Do not move switch four to the ON position (up); this position is
used for calibration only.
Figure 8: StatusCheck
Dip Switch Location ——
Location of Dip Switches