Xylem optimyze User manual

Installation, Operation, and
Maintenance Manual
P2007013_1.0
optimyze™

Table of Contents
1 Introduction and Safety........................................................................................................ 3
1.1 Introduction....................................................................................................................3
1.2 Safety terminology and symbols....................................................................................3
1.3 User safety.................................................................................................................... 4
1.4 Protecting the environment............................................................................................4
1.5 Battery safety and disposal........................................................................................... 4
1.6 Spare parts.................................................................................................................... 5
2 Transportation and Storage................................................................................................. 6
2.1 Examine the delivery..................................................................................................... 6
2.1.1 Examine the package............................................................................................. 6
2.1.2 Examine the unit..................................................................................................... 6
2.2 Storage guidelines.........................................................................................................6
3 Product Description..............................................................................................................7
3.1 Usage............................................................................................................................ 7
3.2 Features........................................................................................................................ 7
3.3 Compatibility.................................................................................................................. 7
3.4 Parts.............................................................................................................................. 7
4 User Interface.......................................................................................................................8
4.1 Common icon................................................................................................................ 8
4.2 Main menu.....................................................................................................................9
4.3 Asset health menu.........................................................................................................9
4.4 Asset details menu........................................................................................................ 9
5 Installation.......................................................................................................................... 11
5.1 Precautions..................................................................................................................11
5.2 Mounting options......................................................................................................... 11
5.3 Requirements.............................................................................................................. 11
5.3.1 Standard magnetic mounting................................................................................ 11
5.3.2 Flat plate mounting............................................................................................... 12
5.3.3 Sensor...................................................................................................................12
5.4 Install the standard magnetic mounting.......................................................................12
5.5 Prepare the flat plate mounting................................................................................... 12
5.6 Install the flat plate mounting.......................................................................................12
5.7 Install the sensor......................................................................................................... 13
6 Operation........................................................................................................................... 14
6.1 Precautions..................................................................................................................14
6.2 Download the optimyze application............................................................................. 14
6.3 Register the user......................................................................................................... 14
6.4 Start the application.....................................................................................................14
6.5 Activate the sensor...................................................................................................... 14
6.6 Set up the configuration mode.....................................................................................15
6.7 Connect a mobile phone to the sensor........................................................................15
6.8 Configure the sensor................................................................................................... 15
6.9 Configure the asset..................................................................................................... 16
6.10 Vibration threshold selection..................................................................................... 16
Table of Contents
optimyze™ Installation, Operation, and Maintenance Manual 1

7 Maintenance.......................................................................................................................17
7.1 Replace the battery..................................................................................................... 17
7.1.1 Remove the battery...............................................................................................17
7.1.2 Clean the gasket groove....................................................................................... 17
7.1.3 Install the battery...................................................................................................18
7.1.4 Install the cover.....................................................................................................18
8 Troubleshooting................................................................................................................. 19
8.1 Symptoms and remedies.............................................................................................19
9 Technical Specification...................................................................................................... 21
9.1 Dimensions..................................................................................................................21
9.2 Approvals.....................................................................................................................21
9.3 Environmental requirements........................................................................................21
9.4 Surface temperature measurement.............................................................................21
9.5 Vibration measurement............................................................................................... 22
9.6 Power.......................................................................................................................... 22
9.7 Wireless communication..............................................................................................22
9.8 Physical properties...................................................................................................... 22
9.9 Part numbers............................................................................................................... 22
10 Product Warranty............................................................................................................. 23
11 Cybersecurity................................................................................................................... 24
12 Certifications.................................................................................................................... 25
12.1 For US and Canada only........................................................................................... 25
12.1.1 FCC/IC statement............................................................................................... 25
12.1.2 CAN ICES-3 (A)/NMB-3(A)................................................................................. 25
12.1.3 FCC / IC RF radiation exposure statement.........................................................25
12.1.4 UL and cUL listed (E516095)..............................................................................25
12.2 For EU countries........................................................................................................25
12.2.1 RF radiation exposure statement........................................................................25
12.2.2 WEEE 2012/19/EU Notice.................................................................................. 26
13 Declaration of Conformity.................................................................................................27
13.1 EU Declaration of Conformity.................................................................................... 27
Table of Contents
2 optimyze™ Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide the necessary information for working with the unit.
Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the unit.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. This includes any modification to the equipment or use of parts not provided
by Xylem. If there is a question regarding the intended use of the equipment, please contact
a Xylem representative before proceeding.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not
personal injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
1 Introduction and Safety
optimyze™ Installation, Operation, and Maintenance Manual 3

Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
• Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by the
site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves and
shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
1.5 Battery safety and disposal
WARNING:
Do not crush, puncture, short, or expose batteries to a temperature above +85°C (185°F).
Only use batteries supplied by Xylem Inc. for replacement. Do not ingest batteries, chemical
burn hazard.
This product contains two replaceable lithium batteries. Consult the product instruction
manual for replacement guidelines. All batteries must be disposed in an environmentally
sound manner according to local regulations. Consult your local waste-management officials
for information on how to safely dispose of used batteries.
NOTICE:
This product contains an external 5V DC power connector which is currently not supported.
Do not connect a 5V DC power connector to this product.
1 Introduction and Safety
4 optimyze™ Installation, Operation, and Maintenance Manual

1.6 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty components.
The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as
void the warranty.
1 Introduction and Safety
optimyze™ Installation, Operation, and Maintenance Manual 5

2 Transportation and Storage
2.1 Examine the delivery
2.1.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
4. If the product has been picked up at a distributor, make a claim directly to the distributor.
2.1.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If there is any issue, then contact a sales representative.
2.2 Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
2 Transportation and Storage
6 optimyze™ Installation, Operation, and Maintenance Manual

3 Product Description
3.1 Usage
optimyzeTM 1 is a condition monitoring application that gives health guidance and predictive
maintenance advice for the following rotating and fixed assets:
• Pumps
• Heat exchangers
• Motors
• Steam traps
The cloud stores the data of asset health as a backup and shares the information with
multiple users.
3.2 Features
• Periodic measurement of asset vibration (three axis) and temperature
• Uses the Bluetooth® wireless technology 2 to communicate the health and operating data
to a smart device
• Shares data automatically with other local users through cloud
• Shows the asset health by using a traffic light warning system
• Graphical trending and waveform analysis
• Generates reports
• Shows maintenance logs
• Library of product documentation (IOM, data sheet, and parts)
• Schedules the routine preventive maintenance of assets
3.3 Compatibility
• iOS
• Android
3.4 Parts
1234
5
67
8 WS013241A
1. Upper cover
2. QR code
3. LED
4. Bluetooth® icon
5. Axis alignment guide
6. Lower cover
7. Infrared (IR) sensor window
8. Magnetic feet
1optimyze™ is a trademark of Xylem, Inc. or one of its subsidiaries. All other trademarks or registered trademarks are
property of their respective owners.
2The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks
by Xylem Inc is under license. Other trademarks and trade names are those of their respective owners.
3 Product Description
optimyze™ Installation, Operation, and Maintenance Manual 7

4 User Interface
4.1 Common icon
The following icons are shown on the home page:
Icon Color Description
- Show the following pages:
•Dashboard
•View reports
•View reminders
•Setting
•Contact us
- Allows the user to email information
- Displays the notifications and warnings
- Allows the user to add new asset or sensor
Green Shows that the asset health is satisfactory
Yellow Shows that the asset health has deteriorated
Red Shows that the asset health has become critical
Green Shows that the asset temperature is normal
Red Shows that the asset temperature is more than the
recommended limit
Green Shows that the asset vibration is normal
Yellow Shows that the asset vibration has increased to warning
level
Red Shows that the asset vibration has increased to critical level
Green Shows that the battery level is normal
Red Shows that the battery level is low
- Shows that the new data has been uploaded from the sensor
today
- Shows that the new data has not been uploaded from the
sensor today
- Shows the following parameters in the asset details menu:
•Reports
•Maintenance
•Reminders
•Asset Setting
•Documents
- Allows the user to edit the information
- Allows the user to delete the information or item
- Allows the user to select a calendar date
- Shows the drop-down list
- Allows the user to capture or upload photo
Blue Allows the user to enable feature
Gray Allows the user to disable feature
- Allows the user to change the language of the application
4 User Interface
8 optimyze™ Installation, Operation, and Maintenance Manual

4.2 Main menu
The icon contains the following tabs:
Icon Tab Function
Dashboard Shows the following parameters of the assets and sensors:
• Health of the assets
• Battery life of the sensor
• Status of the data synchronization
View reports Allows the user to view and share the reports
View reminders Allows the user to view the maintenance reminders
Setting Allows the user to edit the user profile information and
application settings
Contact us Shows the email ID and phone number of the local sales and
service representative
Allows the user to send the log history to the local sales and
service representative
4.3 Asset health menu
The menu show the following parameters of sensors and assets:
Parameter Description
Temperature Shows the last recorded temperature
Allows user to access the trend chart
Vibration
Radial, Axial, and Horizontal
Shows the last recorded RMS vibration level
Allows user to access the vibration trend charts for RMS,
Kurtosis, and FFT
Battery life Shows the last recorded battery level
Allows user to access the trend chart
Force read Forces the sensor to collect the last data read by the
device immediately
Each asset shows the following parameters:
• Asset picture
• Name
• Location
• Sensor icon
The sensor icon changes color according to the health of the asset.
For more information, see Common icon on page 8.
4.4 Asset details menu
The icon contains the following tabs:
Tab Function Description
Reports Allows the user to create, view, and share
reports for a specific asset
-
Maintenance Allows the user to create and view the
maintenance logs for a specific asset
-
Reminders Allows the user to create and view the
maintenance reminders for a specific
asset
Notifications must be turned on in the
settings to create and receive reminders
4 User Interface
optimyze™ Installation, Operation, and Maintenance Manual 9

Tab Function Description
Asset Setting Asset setting shows the following
parameters:
• Image of the asset
•Asset name
•Manufacturing date
•Model
• Sensors
• The sensor setting page shows the
following parameters:
–Learning mode
–Manufacturing date
–Sensor Placed on
–Sensor placed on the part
–Vibration Standard
–Classification
–Asset size
–Sampling frequency
• Allows the user to select one of the
following options for the Sensor placed
on the part:
–NDE Bearing (Non-drive end)
–DE Bearing (Drive end)
–Motor and Other
• The asset size and classification
selects the approved vibration
thresholds for normal operation.
For more information, see Vibration
threshold selection on page 16.
• If an incorrect power rating or
classification is selected, the sensor
may show the inaccurate warnings or
alarms.
•Learning mode reads the natural
steady state properties of the asset.
• The normal condition is selected during
the learned time period that displays on
the temperature and RMS plots as
other color bands.
• After initial setup, the sensor must be in
configuration mode to edit the sensor
settings.
For more information, see Set up the
configuration mode on page 15.
Documents Shows the product-specific information,
literature, and data
-
4 User Interface
10 optimyze™ Installation, Operation, and Maintenance Manual

5 Installation
5.1 Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety on page 3 have been read and understood.
WARNING:
All work must be performed by qualified personnel trained in the proper application,
installation, and maintenance of the equipment.
WARNING:
Always disconnect and lock out power to the sensor before you perform any installation or
maintenance tasks. Failure to disconnect and lock out power will result in serious physical
injury or property damage.
WARNING:
Failure to follow all instructions can result in a fire hazard which may cause personal injury or
property damage.
WARNING:
Magnetic Hazard. Magnetic fields can damage cardiac pacemaker and other medical
implants.
WARNING:
The magnets in the sensor feet are extremely powerful. Beware of serious injury to fingers
and hands. When not in use, keep magnetic (ferrous) components and magnetized tools
apart by a minimum of 1 m (3 ft).
5.2 Mounting options
One of the following mountings must be used to install the sensor on a pump or motor:
Standard magnetic mounting Flat plate mounting
5.3 Requirements
5.3.1 Standard magnetic mounting
• The standard magnetic mounting must be installed on ferrous metals.
• The sensor must be mounted near bearings or other sources of vibration and increase in
temperature.
• The standard magnetic mounting cannot be installed on special alloys or stainless steels.
• Before the sensor is installed, the pump or motor surface must be cleaned.
• If there is no correct surface to install the standard magnetic mounting, use the flat plate
mounting.
5 Installation
optimyze™ Installation, Operation, and Maintenance Manual 11

5.3.2 Flat plate mounting
• The flat plate mounting can be used where the mounting surface is non-ferrous.
• The sensor must be mounted near bearings or other potential sources of vibration and
increase in temperature.
• For true close-coupled pumps, the mounting location must be near the motor bearings.
• There must be sufficient space to remove the sensor and mounting plate safely without
harm or injury.
5.3.3 Sensor
• The infrared sensor window must be in direct line of sight with the surface of the asset
being measured.
• Avoid installation of the sensor on any sheet metal enclosures surrounding the asset.
• The sensor must be mounted near bearings or other potential sources of vibration and
increase in temperature.
• Follow the correct sensor orientation guidelines.
For more information, see Install the sensor on page 13
5.4 Install the standard magnetic mounting
1. Install the standard magnetic mounting on one of the following surfaces of the asset:
– Flat and dry
– Curved: The minimum diameter must be 180 mm (7 in).
2. Check that the mounting is stable on the asset surface.
5.5 Prepare the flat plate mounting
1. On the asset, locate the surface to install the mounting.
2. Put the mounting plate on the location.
3. Use the outer most holes in the mounting plate to mark the position of holes on the
surface of the asset.
4. Drill the holes at the marked position.
– The flat plate mounting requires a size M6 or 1/4 in -20 tap.
– The diameter of the hole must be 5 mm or 13/64 in.
– The depth of hole must be 13 mm or 1/2 in.
– The distance between the holes must be 105 mm (4.1 in).
5. Deburr the holes.
6. Use a M6x1 (1/4 in - 20) threading to tap the holes.
5.6 Install the flat plate mounting
1. Remove the magnetic mounting feet from the sensor.
2. Put the sensor face down.
The infrared sensor window must not be blocked.
3. Put the flat plate mounting on the sensor.
The countersunk holes must face away from the sensor.
4. Align the four screw holes of the flat plate mounting and four blind holes of the sensor
housing.
For more information, see Install the sensor on page 13.
5. Install the screws.
6. Use a torque wrench to tighten the screws.
The torque must be 0.88 Nm (7.8 lbf.in).
7. Install the flat plate mounting and sensor on the pump.
5 Installation
12 optimyze™ Installation, Operation, and Maintenance Manual

8. Tighten the screws.
9. Check that the mounting is stable on the asset surface.
The mounting must be stable to obtain the accurate vibration data.
5.7 Install the sensor
Install the sensor on the pump or motor surface in one of the following correct positions:
Table 1: Default position
Axis Align Position
X Axially to the shaft
Y Horizontally to the shaft
Z Radially to the shaft
Table 2: Alternate positions
Table 3: Incorrect position
Axis Align Position
X Not aligned to major vibration axis
Y
Z
5 Installation
optimyze™ Installation, Operation, and Maintenance Manual 13

6 Operation
6.1 Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety on page 3 have been read and understood.
6.2 Download the optimyze application
Download the optimyze application by using one of the following methods:
– Search for the Xylem optimyze application in the application store.
– Scan the QR code by using the mobile camera to go to the application store.
6.3 Register the user
1. On the landing page, tap the Register button.
2. If the user already has a Xylem cloud account, register by using the existing details.
3. On the Register page, follow these steps.
a) Type the following information:
–Email ID
–Phone number
b) Select the Country code.
c) Tap Register.
An email with the verification link is sent to the user.
4. Click the verification link to validate the email address.
A set password window appears.
5. Type the password.
6. Click Set Password.
6.4 Start the application
1. Go to the optimyze application.
2. Type the following information:
– Email address
– Password
3. Tap Login.
6.5 Activate the sensor
Put the magnet in the handle of the supplied screwdriver on the Bluetooth® icon to
activate the sensor.
The LED blinks white light shows that the sensor is awake from the sleep mode.
6 Operation
14 optimyze™ Installation, Operation, and Maintenance Manual

The LED blinks yellow light until the sensor is put in configuration mode.
If the sensor is not set to configuration mode in 2 minutes, the sensor goes into sleep
mode.
6.6 Set up the configuration mode
Hold the magnet in the handle of the supplied screwdriver on the Bluetooth® icon to set
up the configuration mode.
The LED blinks pink light shows that the configuration mode is on.
6.7 Connect a mobile phone to the sensor
1. Before connecting the mobile phone to sensor, check that the following procedures are
completed:
1. Bluetooth wireless technology is enabled.
2. Camera permission is allowed for the optimyze application.
2. On the Asset health page, tap the icon.
3. On the Add a sensor page, select one of the following options:
Entry Action
QR code Use the mobile phone camera to scan the QR code on
the sensor.
Manual entry Type the nine-digit serial number
The serial number is located below the QR code.
4. Tap Enter.
A blinking blue LED shows that the mobile phone is connected to the sensor.
5. On the Bluetooth Pairing Request screen, tap the Pair button.
6.8 Configure the sensor
On the Sensor configuration page, follow these steps to configure the sensor.
a) Select the Installation date.
b) Select the following parameters from the drop-down list:
–Sensor Placed on
–Sensor placed on the part
c) Select one of the following Vibration Standard:
–ISO
–ANSI/HI
For more information, see
Vibration threshold selection on page 16.
d) Select the following parameters from the drop-down list:
Parameter Description
Classification Defines the vibration monitoring threshold
For more information, see Vibration threshold
selection on page 16.
Asset size
Sampling frequency Shows the period in which sensor collects the
data
Set up axis for vibration For more information, see Install the sensor on
page 13.
e) Tap on Add an asset button.
6 Operation
optimyze™ Installation, Operation, and Maintenance Manual 15

6.9 Configure the asset
On the asset configuration page, follow these steps to configure the asset.
a) Type the asset name.
b) Select the Manufacturing date.
c) Select the asset location from the drop-down list.
d) Tap the icon to add an image of the asset.
e) Select the asset model from the drop-down list.
f) Tap Save button.
6.10 Vibration threshold selection
Pump
category
Standard Pump type Vibration velocity (mm/s) and LED color
LED Power rating
≤200 kW
Power rating
>200 kW
1 ISO 10816-7 Category 1 -
critical
Green ≤ 4.0 ≤ 5.0
Yellow Between 4.0 and
6.6
Between 5.0 and
7.6
Red > 6.6 > 7.6
2 ISO 10816-7 Category 2 -
general
Green ≤ 5.1 ≤ 6.1
Yellow Between 5.1 and
8.5
Between 6.1 and
9.5
Red > 8.5 > 9.5
3 ANSI/HI 9.6.4 End suction,
vertical inline,
split case, and
horizontal
multistage
Green ≤ 4.9 ≤ 6.2
Red > 4.9 > 6.2
4 ANSI/HI 9.6.4 Vertical turbine
and vertical
multistage
Green ≤ 4.3 ≤ 5.6
Red > 4.3 >5.6
6 Operation
16 optimyze™ Installation, Operation, and Maintenance Manual

7 Maintenance
7.1 Replace the battery
7.1.1 Remove the battery
1. Use the supplied T10 screw driver to remove the screws from the casing.
123
4 WS013247A
1. Screw
2. Upper cover
3. Gasket
4. Gasket groove
2. Remove the upper cover.
3. Pinch the white connector tips. Carefully remove the battery leads.
Damage to the printed circuit board (PCB) must be avoided.
4. Carefully remove the battery clip by using a small flat head screwdriver.
1
2
3
WS013248A
4
1. Battery clip
2. Lower cover
3. Adhesive foam strip
4. Batteries
5. Remove the batteries.
6. Dispose the batteries in accordance with the local regulations.
Batteries must not be reused.
7. Remove the gasket from the groove of lower casing.
8. Dispose the old gasket.
Gasket must not be reused.
7.1.2 Clean the gasket groove
1. Use a small cotton bud and rubbing alcohol to clean the gasket groove in the lower
cover.
2. Repeat this procedure for the upper cover.
7 Maintenance
optimyze™ Installation, Operation, and Maintenance Manual 17

7.1.3 Install the battery
1. Install the batteries into the battery holder.
The positive terminals of the batteries must face the power connectors on the PCB.
The negative terminals of the batteries must face the 5 V power connector located
opposite of the battery connection pins.
2. Attach the battery clip on the batteries.
3. Check that the battery clip engages correctly.
4. Attach the supplied adhesive foam strips on the top of both the batteries.
Distance must be 0.5 cm (1/4 in) from the end of each battery.
5. Plug the white connectors of batteries on the PCB.
7.1.4 Install the cover
1. Install the new gasket in the gasket groove of the lower cover.
2. Carefully install the upper cover on the lower cover.
The outer rim of the cover must surround the lip of the lower cover.
The Xylem logo must align with the external power supply connector.
3. Use the T10 screw driver to install the screws on the cover.
4. Tighten the screws diagonally opposite of one another to prevent rolling or pinching of
the gasket.
5. Use a torque wrench to tighten the screws of the cover.
The torque must be 0.88 Nm (7.8 lbf.in).
7 Maintenance
18 optimyze™ Installation, Operation, and Maintenance Manual