FLIR Systems SV87-KIT User manual

User Manual

Vibration Monitoring
Solution

SV87–KIT (GW65 Remote Monitoring Gateway and SV87
Vibration / Temperature Remote Sensors)

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User Manual
Vibration Monitoring
Solution

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Table of contents

1 Advisories............ ..... ................................ ..... .................... 1

1.1 Copyright.... ..... ..... ..... ..... ................. ..... ..... ..... .......... 1

1.2 Quality Assurance .... ..... ..... ..... ................. ..... ..... ..... ... 1

1.3 Documentation .................. ..... ..... ..... ................. ..... ... 1

1.4 Disposal of Electronic Waste .............................. ..... ...... 1

2 Introduction..... ................. ..... ..... ..... ...................... ..... ..... ... 2

3 Safety ........... ..... ..... ..... ..... ............ ..... ..... ..... ..... ................. 5

4 Product Descriptions ..... ..... ...................... ..... ..... .................7

4.1 Product Call-Out Description ............... ..... ..... ..... ..... ...... 7

4.2 Remote Monitoring Gateway GW65 Overview.... ..... .......... 7

4.3 SV87 Remote Sensor Overview ..... ...................... ..... ..... 7

4.4 Mobile App Overview .... ..... ..... ..... ............ ..... ..... ..... .... 8

4.5 Windows PC App Overview ............. ..... ........................8

5 Quick Steps . ................. ..... ..... ..... ................. ..... ..... ..... .......9

5.1 Quick Steps for Stand-Alone Operation ...... ..... ..... ..... ...... 9

5.2 Quick Steps for Windows PC Operation..... ..... ............... 13

6 Sensor Installation ........ ..... ..... ...................... ..... ..... ..... ..... 18

6.1 Sensor Placement Considerations.... ..... ................. ..... . 18

6.2 Mounting the Sensors....... ..... ........................... ..... .... 18

6.3 Where Sensors should not be placed............ ..... ..... ..... . 21

6.4 Determining the Number of Sensors to Place on

6.5 Documenting Sensor Locations ........ ..... ...................... 22

7 Mapping a Test Site ..... ..... ..... ................. ..... ..... ..... ............ 23

7.1 Assets..... ..... ..... ..... ................. ..... ..... ..... ................ 23

7.2 Sensor Groups....................... ..... ........................... .. 23

7.3 Test Points ................. ..... ........................... ..... ........ 23

7.4 Sensor Identification. ..... ................. ..... ..... ..... ............ 23

8 Communication Preparation ... ..... ..... ..... ............ ..... ..... ..... .. 24

8.1 Communication Basics ............... ..... ..... ..... ................ 24

8.2 Choosing PC-based or Stand-Alone Control......... ..... ..... 24

8.3 Preparing a Communications System...... ..... ..... ............ 26

8.4 Preparing the Mobile App ..... ..... ..... ..... ................. ..... . 27

Equipment ... ..... ..... ..... ................. ..... ..... ..... ............ 21

8.2.1 How To Decide ...... ........................... ..... ........ 24

8.2.2 Stand-Alone System Block Diagram......... ..... ..... 24

8.2.3 Windows PC Operation Block Diagram.. ..... ........ 25

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Table of contents

8.5 Preparing the Windows PC App................... ..... ........... 28

8.6 ‘Historical Sensors’ Option.. ................. ..... ..... ..... ........ 29

8.7 Preparation for Sensor Placement.. ..... ..... ..... ............... 29

9 Mobile App ........... ..... ................................ ....................... 30

9.1 FLIR Mobile App Screens............ ..... ..... ..... ................ 30

9.2 Trend Charts. ..... ............ ..... ..... ..... ..... ............ ..... ..... 34

10 Windows PC App.................. ..... ..... ..... ................. ..... ..... ... 37

10.1 Windows App Opening Screen .. ..... ............ ..... ..... ..... .. 37

10.2 Exporting Measurement Data as .csv Formatted

10.3 Sensors Tab .. ................. ..... ..... ..... ................. ..... .... 39

10.4 Alarm Status Tab ... ................. ..... ..... ..... ................. .. 41

10.5 Archived Sensors ............... ..... ..... ..... ................. ..... . 42

11 Fast Fourier Transform (FFT) ... ..... ..... ................. ..... ..... ..... . 43

11.1 Background............ ..... ..... ..... ................. ..... ..... ..... .. 43

11.2 Time-Domain and Frequency-Domain Methods .............. 43

11.3 Determining Machine Defects by Vibration

12 Toggling Stand-Alone and Local Server Modes ... ..... ..... ........ 45

13 GW65 Field Firmware Updates ............. ..... ..... ..... ................ 47

13.1 Firmware Update Procedure using the Mobile

14 Three-Year Limited Warranty ... ........................... ..... ............ 48

15 CUSTOMER SUPPORT .......... ..... ..... ..... ................. ..... ..... ... 49

16 Specifications.......................... ..... ........................... ..... .... 50

16.1 GW65 Remote Monitoring Gateway

16.2 SV87 Remote Sensor Specifications ..... ..... ................. .. 51

File.. ..... ..... ..... ................. ..... ..... ..... ................. ..... . 38

Characteristics.. ...................... ..... ..... ...................... . 43

App ............ ..... ........................... ..... ...................... 47

Specifications ............. ..... ..... ..... ................. ..... ..... ... 50

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As with most electronic products, this equipment must be disposed
of in an environmentally friendly way, and in accordance with existing
regulations for electronic waste. Please contact your FLIR Systems
representative for more details.

Advisories

1.1 Copyright

©2020 FLIR Systems, Inc. All rights reserved worldwide.

No parts of the software including source code may be reproduced, transmit­ted, transcribed or translated into any language or computer language in any
form or by any means, electronic, magnetic, optical, manual or otherwise,
without the prior written permission of FLIR Systems.

The documentation must not, in whole or part, be copied, photocopied, repro­duced, translated or transmitted to any electronic medium or machine-read­able form without prior consent, in writing, from FLIR Systems. Names and
marks appearing on the products herein are either registered trademarks or
trademarks of FLIR Systems and/or its subsidiaries. All other trademarks,
trade names or company names referenced herein are used for identification
only and are the property of their respective owners.

1.2 Quality Assurance

The Quality Management System under which these products are developed
and manufactured has been certified in accordance with the ISO 9001 stand­ard. FLIR Systems is committed to a policy of continuous development; there­fore, we reserve the right to make changes and improvements on any of the
products without prior notice.

1.3 Documentation

To access the latest manuals and notifications, go to the Download tab at:

. It only takes a few minutes to register online. In the
download area you will also find the latest releases of manuals for our other
products, as well as manuals for our historical and obsolete products.

1.4 Disposal of Electronic Waste

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Figure 2.1 Monitoring vibration and temperature in motors.

Figure 2.2 Monitoring vibration and temperature in fans.

Figure 2.3 Monitoring vibration and temperature in conveyors.

Introduction

The FLIR Vibration Monitoring Solution allows you to monitor machinery for
excessive vibration and over-temperature conditions using a mobile device
exclusively (stand-alone) or a combination of Windows PC and mobile device.
Accelerometers in the Remote Sensors measure changes in vibration. Ther­mometers in the Remote Sensors measure surface Temperature.

This product can check for balance issues, eccentricity, misalignment, and
looseness. Examples of equipment that can be monitored are shown below.

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Figure 2.4 Monitoring vibration and temperature in chillers.

Figure 2.5 Vibration frequency (left), amplitude (centre), and acceleration (right)

Introduction

Vibration measurements look at the frequency (velocity), amplitude (strength),
and acceleration (intensity) of the vibration.

Vibration measurements provide insight into potential mechanical issues. This
device is well suited for identifying imbalances, eccentricity, loose parts, and
misalignment. In addition, Remote Sensors include a surface temperature
thermometer that identifies potential over-heating issues. Excessive vibration
and over-temperature conditions can shorten the life of machinery and com­ponents, pose safety hazards, and create excessive noise.

Acceleration is measured in ‘g’ units (gravitational constant). Velocity is repre­sented in mm/s (millimeters per second) and in/s (inches per second) units
and is derived from FFT (Fast Fourier Transform) analysis of Acceleration
measurements. Temperature measurements are presented in ℃ and ℉ units.

The Remote Sensors attach directly to machinery, using the supplied double­sided tape, and transmit data to the Remote Monitoring Gateway via Blue­tooth which in turn communicates to a mobile device and Windows PC. Adhe­sive alternatives are available commercially that could be more reliable on
some machinery (see the Specifications section for details). The system con­sists of the following components:

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Introduction

• GW65 Remote Monitoring Gateway. Communicates with Remote Sen-

sors over Bluetooth and transmits measurement data over Wi-Fi. Multiple
Gateways can be used for optimum coverage of large test sites.

• SV87 Remote Sensors. Attach to machinery and transmit measurement

data and battery status via Bluetooth to the Remote Monitoring Gateway.

• Mobile application (app) for iOS and Android devices. Communicates

with the Remote Monitoring Gateway on a Wi-Fi network.

• Windows PC application. Communicates with Remote Monitoring Gate-

ways and mobile devices on a Wi-Fi network.

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WARNING! Hazardous conditions.

Double Insulation.

Certified by ETL to North America safety standards.

Conforms to European Union directives.

Conforms to Australian Safety and EMC standards.

Complies with WEEE Directives.

Safety

Warnings identify conditions that expose the user to danger. For safe opera­tion, and to avoid the potential for electrical shock and fire, read and under­stand all operational instructions and safety warnings and cautions. Failure to
do so can cause personal injury and damage to equipment.

• Please read all safety information and user manual instructions before us-

ing these devices.

• No user serviceable equipment. Please contact FLIR for all service and re-

pair inquiries.

• Use these devices only as described in the provided documentation. Fail-

ure to do so can impair the devices’ built-in protections.

• These devices are intended for indoor use only.

• Do not use any of these devices if they appear damaged or if they do not

function normally. Contact FLIR for service.

• Avoid wet or overly damp locations for installation or when using these

devices.

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WARNING

Applicability: Class B digital devices.

This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reason­able protection against harmful interference in a residential installation. This equipment
generates, uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If
this equipment does cause harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the re­ceiver is connected.

• Consult the dealer or an experienced Radio / TV technician for help.

Safety

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Figure 4.1 Remote Monitoring Gateway GW65 (left) and SV87 Remote Sensor (right).

Product Descriptions

4.1 Product Call-Out Description

1. GW65 AC plug side

2. GW65 Power LED (blue light when powered)

3. GW65 Communications LED (green for active communications; amber for
inactive communications)

4. SV87 ‘xyz’ axes graphic

5. SV87 serial number label

6. Low battery LED (glows red when battery is low)

4.2 Remote Monitoring Gateway GW65 Overview

Gateways communicate with sensors over Bluetooth and transmit measure­ment data over a Wi-Fi network. Gateways are AC powered and can be
plugged directly into an AC receptacle (100 V to 240 V AC 50 / 60 Hz).

4.3 SV87 Remote Sensor Overview

SV87 sensors attach to machinery using the supplied double-sided tape. Ad­hesive alternatives are available that could be more reliable on some machi­nery (see the Specifications section for details). When attached, sensors
measure Acceleration in gravitational units (g) and surface temperature in ℃
or ℉ units.

Velocity data is derived from the Acceleration measurements using FFT (Fast
Fourier Transform) and displayed in mm/s or in/s units (millimeters or inches
per second).

Measurement data is transmitted from the sensors to Gateways over Blue­tooth. Sensors also transmit battery status data. Coordinates (x, y, z) for vibra­tion axes and serial number are printed on the sensor housing.

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Product Descriptions

4.4 Mobile App Overview

The mobile app is available from the FLIR website (link below), the App Store
(iOS devices), or Google Play (Android devices). With the mobile app you can
communicate with Gateways over a Wi-Fi network.

The mobile app allows you to configure and organize Gateways and sensors
into complete test systems, link sensors into groups, document asset types
and classifications, monitor readings digitally and graphically, set alarms, and
more.

4.5 Windows PC App Overview

The Windows PC app (link below) allows you to monitor and control test sys­tems from your PC. Communication takes place over a Wi-Fi network. The
app displays measurement data in trend graphs and digitally. The app can
send email alerts when alarm thresholds have been exceeded and can export
measurement data as .csv files for use in spreadsheets.

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Quick Steps

The Vibration Monitoring Solution is a powerful set of tools that require careful
attention and a fair number of steps, even for a quick start, to setup. Once set­up is complete, however, the tools are automated and do not require adjust­ment unless changes to the setup are needed.

Follow the quick steps in Section 5.1, below, for Stand-Alone operation (mo­bile device use only), or Section 5.2 if you are using a Windows PC and a mo­bile device. Refer to Section 8.2, Choosing PC-based or Stand-Alone Control,
to help you decide which route to take.

These steps will take you through the process of establishing communication
with the devices in your system. Once communication is established you can
continue with the remaining sections of this manual to setup sensors and ex­plore the other capabilities of the monitoring system.

NOTE

• The mobile device must be within 12 inches (30 cm) of the Gateway during setup.

• The sensors must be kept within 5 feet (1.5 m) of the Gateway during setup.

5.1 Quick Steps for Stand-Alone Operation

1. Plug the Gateway into an AC outlet. The blue power LED and amber com­munication LED will light. The communication LED turns green when com­munication is established with the Wi-Fi network.

2. Download the FLIR Remote Monitoring app for Android (Google Play) or
iOS device (App Store).

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4. Tap the + Add Gateway command.

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Quick Steps

3. Open the app on your mobile device and tap ‘STAND-ALONE’ on the
opening app screen.

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6. The STEP 1 screen will appear. Tap CONNECT.

7. The Gateway name should appear on the Gateway List.

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Quick Steps

5. A three-step information screen will appear. Tap START.

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9. Tap CONTINUE.

10. Tap the name of your network in the Wi-Fi Router List.

11. Type the network password when prompted.

12. Tap NEXT when communication is successful. If not successful, repeat
the above steps; contact FLIR if issues persist.

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Quick Steps

8. Tap the displayed Gateway name. The STEP 2 screen will appear. Note
that STEP 3 is the Sensor activation step (not covered in these quick
steps). See Section 9, Mobile App, for instructions.

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Quick Steps

13. The Stand-Alone communication is now operational, and the system is
ready for adding sensors; see Section 9, Mobile App.

5.2 Quick Steps for Windows PC Operation

1. Connect the Windows PC to the local Wi-Fi server network.

2. Download, install and open the FLIR Gateway Windows app.

3. The user name, password, IP address, and port number are shown on the
app’s opening screen.

4. If Gateways have been connected before, you’ll see them on the Gateway
List in the app. If Gateways have been archived, you’ll see the ARCHIVED
box (red) next to the archived Gateway. To export data in .csv format from
an archived or active Gateway, click the Export button on the opening app
screen.

5. Plug the GW65 into an AC power source.

6. The blue (power) LED and amber (communications) LED will light. The
communications LED is amber when not communicating to the Wi-Fi net­work. When communication is established, the LED will turn green.

7. Download , install, and open the mobile app on your smart device, and
select Local Server from the opening screen. For Android devices use
the Google Play store and for iOS devices go to the App Store to obtain
the mobile app.

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9. In the mobile app, tap on the Server IP field and type the IP address that
matches the address on the Windows app screen.

10. Tap the User name field and type the user name that matches the user
name in the Windows app screen.

11. Tap the Password field and type the password that matches the password
in the Windows app screen.

12. If necessary, tap the Port field and enter the number that matches the
number in the Windows app screen.

Quick Steps

8. Tap +Add Server to begin the process of connecting to the Wi-Fi network,
unless you see the PC machine name already on the Server List (as
shown in the image below). If so, tap the machine name and continue with
step 14.

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14. Tap the PC name on the mobile app and tap the +Add Gateway com­mand when prompted. A three-step information screen will appear.

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Quick Steps

13. Tap Continue in the mobile app. After several seconds your PC machine
name should appear on the mobile app.

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16. The STEP 2 screen will appear, tap Continue. Note that STEP 3 is the
Sensors activation step, not covered in these quick steps. See Section 9,
Mobile App, for instructions.

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Quick Steps

15. Tap Start. The STEP 1 screen will appear. Tap Connect.

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18. A list of Wi-Fi networks will appear, tap your network’s name.

19. When prompted, type the Wi-Fi network password and then tap NEXT.
When communication is successful, press NEXT again to continue.

20. The Gateway that you plugged in earlier should now appear on the Win­dows app Gateway list. Click the Refresh button and repeat these steps if
you do not see the Gateway on the list. Contact FLIR if issues persist.

21. When the Gateway appears on the list you are ready to add sensors as ex­plained in Section 9, Mobile App.

Quick Steps

17. The Gateway that was powered up earlier in this procedure will appear in
the mobile app. Tap the Gateway name.

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6

Sensor Installation

NOTE

Do not permanently affix sensors to assets until you’ve allowed sufficient time to ensure sta­ble communication between sensors and Gateways in their temporary positions.

6.1 Sensor Placement Considerations

When considering test point sensor locations, the individual parts of the
equipment and its operation should be well understood. Basic rotating equip­ment will have a combination of bearings, shafts, shaft coupling equipment,
fans, pumps, compressors, etc. Note that this unit is not suitable for monitor­ing bearing or gearbox vibration as this would require a higher frequency
range (this product has a maximum frequency of 1 kHz).

For personal and equipment safety, do not affix sensors where they can inter­fere with machine operation. Affix sensors to solid metal. Refer to the dedi­cated section below for a list of areas where sensors should not be affixed.

6.2 Mounting the Sensors

Sensors should be placed on structural parts of the equipment that signifi­cantly respond to the overall vibration and dynamic forces (example photos
below).

For best results, clean the area where the sensor is to be attached.

Confirm stable communication between sensors and Gateways before com­mitting to a permanent installation. Move the Gateway closer to the sensors if
necessary and use multiple Gateways if greater coverage is required.

Although the maximum distance between sensors and Gateway is 213 ft. (65
m), the range is affected by concrete, metal, etc. in the line-of-sight. Multiple
Gateways can be used for wider coverage.

Sensors must be installed where they cannot interfere with the operation of
the machinery under test or where they will interfere with machine operators.
Attach the sensors to the equipment using the supplied double-sided tape.
Adhesive alternatives are available commercially that could be more reliable
on some machinery (see the Specifications section for details).

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Figure 6.1 Examples of areas to place sensors.

Sensor Installation

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Figure 6.2 SV87 Sensors shown mounted on machinery.

Sensor Installation

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CAUTION

Do not mount sensors on the following locations:

• Motor winding areas

• Middle of motor

• Pump casing

• Cooling fan fins/covers

• Coupling belt guards, gearboxes

• Seal locations

Figure 6.3 Examples of places you should not mount sensors.

Sensor Installation

6.3 Where Sensors should not be placed

6.4 Determining the Number of Sensors to Place on Equipment

The larger the equipment under test, the greater the number of sensors re­quired; this is because vibrations can go undetected if the sensors are posi­tioned too far from the source of vibration. Vibration is absorbed by the
equipment after travelling approximately 3.3 ft. (1 m), so you’ll want to situate
sensors to maximize coverage.

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6

Sensor Installation

Ensure that coverage of equipment is sufficient regarding the number of sen­sors. Ten (10) sensor will work in most circumstances, given no obstruction
between Gateway and sensor. The key factor is obstruction since, with no ob­struction, it is possible to have more than ten sensors operating normally. Use
multiple Gateways to accommodate more sensors and to ensure proper cov­erage of a test site.

For larger equipment, more sensors may be needed, as discussed earlier.
Use a sufficient number of sensors to provide good surface-area coverage of
assets.

6.5 Documenting Sensor Locations

It is important to document the sensor and test point locations for all equip­ment in a test system, as discussed in Section 7, Mapping a Test Site. A
spreadsheet is ideal for documenting Gateways, test points, sensors, sensor
groups, etc.

Having accurate documentation helps locate, track, and assess equipment
easily for preventive maintenance programs and servicing.

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7

Mapping a Test Site

To best maintain a test site, it is important to keep a list of asset (equipment)
names and their types, classifications, and locations. Depending on the size
of the operation, a site map may also be needed to show machine locations
and the test points where sensors are attached to assets.

7.1 Assets

The term ‘asset’ is used when referring to a piece of equipment under test.

Log as much information as possible for each asset so that maintenance and
configuration can be handled quickly and accurately. Keep track of locations,
names, categories, and test points/sensors.

7.2 Sensor Groups

When using the mobile and Windows apps, sensors are grouped for easy
tracking and monitoring. Groups should be appropriately named for clarity
and easy identification.

7.3 Test Points

A test point is a location on an asset where a sensor is attached. Test point lo­cation is a critical part of the vibration monitoring strategy. Refer to Section 6,
Sensor Installation, for important information and instructions.

7.4 Sensor Identification

Sensor serial numbers are printed on their housings. The mobile and Win­dows apps will show the serial number of sensors and Gateway hardware
when communication is established. Names of sensors and other compo­nents in the system can be customized.

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Communication Preparation

8.1 Communication Basics

As discussed below, the first decision you’ll make is whether to use the stand­alone method (mobile smart device exclusively) or a combination of Windows
PC and mobile device.

If you’ll be communicating exclusively from a mobile device, you’ll need only
the mobile remote monitoring app. If you’ll be communicating using a Win­dows PC, you’ll need the Windows PC app and the mobile app.

The mobile app is available from the App Store, Google Play, or FLIR website
(link below). The Windows app is available from the FLIR website.

8.2 Choosing PC-based or Stand-Alone Control

8.2.1 How To Decide

As mentioned, the first decision to be made when planning and configuring a
test system is whether to run a stand-alone system or a system that incorpo­rates a Windows PC for monitoring and control. The table below lists the ad­vantages for each method. Block diagrams are provided later in this section
showing how the system components, Wi-Fi, Bluetooth, and direct connec­tions interact.

STAND-ALONE METHOD WINDOWS PC METHOD

Simple setup and portability. Convenient, comprehensive dashboard

View measurements, trends, alarms, and
FFT directly on a smart phone.

Easy updating of firmware and app. Automatically sends email alert when alarm

Data is easily transportable and retrievable. Unlimited data storage on PC.

and monitoring console.

Text files (.csv) of measurement data can
be exported for data analysis.

set points are exceeded.

8.2.2 Stand-Alone System Block Diagram

The diagram below provides an overview of the Stand-Alone system. Subse­quent sections of the manual provide details and specifics regarding test sys­tems that will be controlled by a smart device only.

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Figure 8.1 The Gateway (GW65) is shown communicating with a Wi-Fi network and a smart

phone. The SV87 sensor is shown communicating with the Gateway via Bluetooth.

Communication Preparation

This diagram shows how a test system is configured using a smart device.
The sensor, on a monitored asset, automatically sends vibration and tempera­ture data to the gateway every 90 seconds (via Bluetooth).

The Gateway transmits sensor data to the smart phone using Wi-Fi. The
smart device alerts the user to abnormal vibration or temperature readings.

Ten (10) or more sensors can pair with one Gateway system depending on
the severity of obstructions that exist between sensors and Gateway.

8.2.3 Windows PC Operation Block Diagram

This diagram below shows how a test system can be configured using a PC.
The PC provides up-to-the-minute measurement status (digitally and graphi­cally) and alerts the user to abnormal vibration or temperature readings.

The Windows app can automatically send email when an abnormal reading is

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registered. The PC can also export sensor data as .csv formatted files for use
in spreadsheets.

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Figure 8.2 Block diagram of a system controlled by a Windows PC. The GW65 Gateway

communicates with the SV87 Sensor using Bluetooth and with the smart phone through a Wi­Fi router. The PC is shown communicating with the network using a direct Ethernet
connection.

Communication Preparation

8.3 Preparing a Communications System

During setup, the Gateways, sensors, and mobile devices must be in close
proximity. As detailed below:

• The mobile device must be within 12 inches (30 cm) of the Gateway during

setup.

• The sensors must be kept within 5 feet (1.5 m) of the Gateway during setup.

When planning a test configuration it is useful to understand the equipment hi­erarchy, as you will be prompted in the applications for equipment names,
classifications, types, etc. The hierarchy and definitions are as follows:

• Group: Sensor groups are collections of sensors in a test area.

• Assets: Machinery under test. Assets require names, types (pump, for ex-

ample), and ISO 2372 classification (see chart in the mobile app). Photos
of assets can be added by mobile device during configuration.

• Test Points: Location and position of sensors on an asset.

With the information covered in this section, a site map and equipment list
should be created and maintained. This will ensure that you know where all
Gateways, sensors, and other equipment are located when performing

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Figure 8.3 FLIR mobile app installed on mobile device (above, left) and opening screen

(above, right).

Figure 8.4 Adding a new network or selecting an existing one.

Communication Preparation

preventive maintenance and if you need to locate equipment quickly in an
emergency. See Section 7, Mapping a Test Site, for more information.

8.4 Preparing the Mobile App

1. After downloading the mobile app, as described earlier, you’ll see the FLIR
app on your mobile device, as shown in Figure 8.3 above.

2. When you open the app you’ll see a start-up screen (Section 5, Figure

5.1). Select the option for stand-alone operation.

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Figure 8.5 Windows PC app opening screen.

Figure 8.6 Add a new server or select an existing one. Note that references to a server indi-

cate that the Windows PC app is being used.

Communication Preparation

3. Select a Wi-Fi network from the list or tap + Other Network to add a new
network (see Figure 8.4 above).

4. The next screen prompts for a network password. Enter the password and
tap NEXT.

5. Communication to the network should now be established.

6. If you are unable to connect to the Wi-Fi network, please verify that the
credentials are correct. Contact FLIR support if connection issues persist.

7. Once the setup and preparation are complete, follow the detailed instruc­tions in Section 9, Mobile App.

8.5 Preparing the Windows PC App

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Communication Preparation

To maintain a test site using a Windows PC, download the Windows app and
mobile app (for iOS or Android) from the FLIR support site shown below. Fol­low the preparation steps below and then continue with the instructions in
Section 10, Windows App.

1. Open the Windows app on your PC. The opening screen is shown in Fig­ure 8.5 above (shown with the Information tab selected).

2. Open the mobile app on your mobile device, as described earlier.

3. Tap + Add Server in the mobile app to setup a new network or select an
existing one from the list as shown in Figure 8.4 above.

4. The next screen prompts for the network user name and password. Tap
Continue when done.

5. Network connection should now be established.

6. For connection issues, verify that the credentials are correct. Contact FLIR
support if connection issues persist.

7. Refer to the dedicated instructions in Section 9, Mobile App and Section
10, Windows PC App.

8.6 ‘Historical Sensors’ Option

Select the ‘Historical Sensors’ option from the opening screen in the mobile
app to view previous sensor configurations. You can also select archived, his­torical sensor configurations in the Windows PC app.

8.7 Preparation for Sensor Placement

1. Once communication between all components in the system (Gateways,
sensors, PC and mobile devices) is established, the sensors can be
moved into position temporarily. Do not permanently affix the sensors at
this point.

2. With the sensors in their desired locations, allow time to ensure that the
communications between all system components is stable. If you notice
intermittent problems you may have to move the Gateway closer to the
sensors.

3. When stable communication is verified, follow the instructions in Section 6,
Sensor Installation, for details on permanently attaching sensors to equip­ment. To verify stable communications, ensure that there are no connec­tion drop-outs, weak signals, or connection display errors.
Evidence of spotty communications would be Gateway communication
light toggling amber and green colors, alarm set points false triggering,
and displayed data and graphs on mobile device or PC showing no data.

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1. Tap an existing Gateway from the list or tap + Add Gateway to add a new
Gateway.

2. Tap + Add Sensor to configure a new sensor or tap Monitoring List to
view existing configurations.

3. List of existing sensor groups.

4. Informational page. Tap Continue.

5. Sensor installation definitions page.

6. Connected sensors. Tap a sensor on the list to continue.

7. Selected sensor indicated by checked box.

Mobile App

9.1 FLIR Mobile App Screens

Once communication between all devices in the test system is verified, follow
the instructions below. The numbered steps below correspond to the

numbered screen shots.

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9. Sensor Settings. The top blue box shows the selected sensor and its cur­rent reading, tap the X to remove it. Tap the lower blue box to continue with
the sensor group, asset, and test point setup.

10. Tap + Add Group to add a new sensor group.

11. Type a group name and tap NEXT.

12. Tap + Add Asset to add a new asset or tap an existing asset.

13. ISO Standard 2372 machine classification table.

14. Name the asset, describe its type, and select its class. Tap NEXT.

15. Assign the selected sensor to an asset. Tap + Add Asset to create a new
asset or tap an existing one.

Mobile App

8. Naming Assets and Setting Test Points (informational page). Tap
Continue.

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17. View the test point name and photo. When satisfied, tap Save.

18. Configuration screen. View the sensor ID, Gateway name, asset/group
names, test point name, and vibration/temperature units of measure. Tap
a pencil icon to edit a field.

19. Tap Add Alarm to program an alarm, or tap Continue to bypass.

20. Select an alarm type and tap NEXT or tap Cancel.

21. Select the low and high alarm thresholds. Tap Save to continue.

22. Select a threshold for another Alarm. Tap Save to continue.

23. Edit an existing alarm (pencil icon), delete an alarm (X), or add an alarm.
Tap Continue.

Mobile App

16. Name the test point, take a photo, and tap Continue when done.

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25. For a successful installation, tap Finish Setup. If there is an error, retry
the setup steps.

26. List of installed sensors. Tap Finish Setup.

27. Tap the Local Server (for Windows PC mode) or Stand-alone tab to switch
between configurations. You will need to follow a process, however, as ex­plained in Section 12, Toggling Stand-Alone and Local Server Modes, to
switch from one mode to the other.

28. View the trend chart, change measurement units, and edit the alarm setup.

29. Continue as with the previous trend screen. Tap End Session to stop the
test. Tap the alarm bell icon to view alarm activity.

30. Tap the Recent or Expired tab to view recent or historical alarms.

Mobile App

24. Tap a pencil icon to edit a field. Tap Install Sensors to complete the setup.

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4. Tap any area of a chart to select a region, the measurement and time
stamp for the region will appear. To add and remove measurement data
from the graph, tap a measurement type in the MAX/MIN table (below the
graph).

5. FFT data screen. See FFT Section 11 for technical FFT information.

Mobile App

9.2 Trend Charts

As shown in screens 28 and 29 above. The mobile app shows a representa­tion of logged data on a trend chart and in a MAX/MIN data table (below the
graph). Additional trend chart details are provided below. The numbered

steps below correspond to the accompanying numbered screen shots.

1. Tap an installed sensor as shown in screen 1 (below), to open the trend
chart.

2. Tap the Acc. tab to view acceleration measurement data. Note that you
can tap the three dots or the alarm icon, on the upper right corner of the
app screen, to see other options.

3. Tap the FFT icon to view the Fast Fourier Transform screens.

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7. Select Velocity measurement data by tapping the Vel. tab as shown.

8. Velocity data is shown on the trend chart. Tap a region of the chart to open
its measurement and time stamp information. To add and remove meas­urement data from the graph, tap a measurement type in the MAX/MIN ta­ble (below the graph).

9. Tap the FFT icon to view the Fast Fourier Transform screens.

10. FFT data screen. See FFT Section 11 for technical FFT information.

Mobile App

6. FFT data screen. See FFT Section 11 for technical FFT information.

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Mobile App

11. FFT data screen. See FFT Section 11 for technical FFT information.

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Windows PC App

To monitor a test site using a Windows PC, download the Windows applica­tion from the FLIR support site (link below). Open the application and follow
the instructions below.

Ensure that all devices (mobile device, Gateway, and sensors) reside on the
same IP sub-network, assigned from the shared router or AP (access point).
The mobile device configuration, when identifying the PC, must match the IP
address shown in the Windows screen.

Note that you may need to obtain system information and credentials from
your IT department to connect to a network.

10.1 Windows App Opening Screen

Refer to the call-out numbers in Figure 10.1, below, for this numbered list.

1. Click REFRESH to initiate or refresh a connection.

2. Click EXPORT to export data as a .csv file.

3. User name, password, IP address, port and other information. Click the
user name to open the credentials setup screen.

4. Information, Sensors, and Alarm tabs. Click a tab to open. The Information
tab is selected in Figure 10.1 below.

5. Click to edit the Gateway name.

6. Alarm and other messaging appear here.

7. Archived Gateway. Click the red ARCHIVE tab to open the data window
for the archived Gateway.

8. Active Gateway.

9. Sampling rate (how often readings are taken).

10. Wi-Fi network name.

11. Email alerts setup.

12. Click to archive the selected Gateway.

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Figure 10.1 Windows App opening screen with Information tab selected.

Figure 10.2 Exporting measurement data as .csv file.

Windows PC App

10.2 Exporting Measurement Data as .csv Formatted File

Export data as .csv file for use in a spreadsheet.

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Figure 10.3 Example .csv data file.

Figure 10.4 Sensors tab screen.

Windows PC App

10.3 Sensors Tab

Click the Sensors tab to view sensor information and battery status. Refer to
Figure 10.4, below, for this numbered list.

1. List of alarm types.

2. Click to open the alarm threshold editing utility.

3. Click to open the Trend Chart.

4. Click to update (refresh) the displayed data.

5. Click to toggle inch/s and mm/s units.

6. Click to toggle temperature units (℃/℉).

7. Click to close this window.

8. Current maximum and minimum alarm threshold settings.

9. Click the Miscellaneous tab to view test start date and display update rate.

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Figure 10.5 Using the edit tool to configure sensor alarms.

Figure 10.6 Opening a Trend Chart. Click on a point on a graph line to see instantaneous

date/time and measurement values.

Figure 10.7 To open an FFT graph, as shown in this figure, double-click on any measure­ment point from a Trend Chart (shown in Figure 10.5).

Windows PC App

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Figure 10.8 Configuring the system to send automatic alarm email alerts.

Windows PC App

10.4 Alarm Status Tab

Click the Alarm tab to view alarm activity. Refer to Figure 10.9, below, for this
numbered list.

1. Refresh the screen.

2. Mark the selected alarm as ‘read’.

3. Mark alarm as ‘unread’.

4. Delete alarm instance.

5. Click a check box to select one or more alarm instances.

6. Time of alarm instance.

7. Alarm details.

8. Sensor where alarm occurred.

9. Sensor group name.

10. Name of asset where sensor is mounted.

11. Test point name.

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Figure 10.9 Alarm Status tab screen.

Figure 10.10 Archived Gateway screen.

Windows PC App

10.5 Archived Sensors

Configurations can be archived for future reference by clicking on ARCHIVE
in the Information tab as shown at the start of this section in Figure 10.1. In
Figure 10.10, below, the archive screen is shown when an archived configura­tion is selected.

1. Click the Archive to see the archived information.

2. Archived information.

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Fast Fourier Transform (FFT)

11.1 Background

In simple terms, FFT is a mathematical algorithm that converts a data presen­tation (graph, for example), shown as a function of time, into a data presenta­tion shown as a function of frequency and vice versa.

This is useful in the representation of vibration measurements. For example,
Velocity graphs, in the FLIR mobile and Windows apps, are derived from FFT
analysis of Acceleration measurements.

11.2 Time-Domain and Frequency-Domain Methods

Time and frequency domain vibration measurement methods can both be em­ployed to study vibration measurements.

The time domain method provides a glimpse into the source of vibration but
not ideal for analyzing multiple frequency vibration signals.

The frequency domain method is more effective; especially when evaluating
amplitude and phase characteristics of vibration signals. The frequency do­main method is effective finding bearing defects and identifying shock pulses
and friction activity.

11.3 Determining Machine Defects by Vibration Characteristics

Each defect causes vibrations having unique characteristics. You can deter­mine, more easily, the root cause of a problem if you understand these char­acteristics, and that’s where FFT comes in handy.

You can determine a lot about an asset, even when it is working normally, by
looking at FFT data graphs. For example, in normal operation, the shaft rota­tion frequency (fundamental) will be represented on the graph on the left fol­lowed by a series of harmonics whose amplitude will be approximately a third
the amplitude of the fundamental.

Additional signals are present in a normal system representing the vibrations
of the structure that the machine is mounted on.

For faulty systems, the following changes in FFT graphs may appear.

• Shaft balance issues cause large radial variations and marked increase in

amplitude of the fundamental frequency.

• Misalignments are shown as an increase in frequency amplitude at the 2nd

harmonic.

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Figure 11.1 Graph on left shows a normal system; Centre graph shows a balance issue;

Graph on right shows a misalignment issue.

Figure 11.2 Graph on left shows a loose equipment issue (additional frequencies near the
fundamental); Graph on right shows an impulse vibration (between 3rd and 4th harmonic) .
Frequency of the impulse will vary from machine to machine (speed, size, etc.).

Fast Fourier Transform (FFT)

• Looseness is evidenced by a marked increase in the number of harmonics.

If there is looseness in the main support of the asset, an increase in the
fundamental frequency amplitude will also be noticed.

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Figure 12.1 Switch from the Local Server mode to the Stand-Alone mode.

Toggling Stand-Alone and Local Server Modes

Once you set up your test system as either a ‘Stand-Alone’ or ‘Local Server’
configuration, switching to the opposite mode requires a few steps prepara­tion. If you attempt to setup in Local Server mode, after you’ve setup in Stand­Alone mode, for example, you’ll receive an error message on the mobile app.

To switch from the Local Server mode to the Stand-Alone mode, follow these
steps and view the screens below.

1. Navigate to the opening mobile app screen and select Local Server mode.

2. Step to the + Add Server screen, where your PC’s machine name will be
shown.

3. Check the box next to the PC name.

4. Tap the DELETE command at the top of the screen.

5. Confirm the deletion, when prompted.

6. Now return to the mobile app opening screen, select the Stand-Alone
mode, and follow the instructions for configuring a test system in Stand­Alone mode as previously described.

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Figure 12.2 Switch from the Stand-Alone mode to the Local Server mode.

Toggling Stand-Alone and Local Server Modes

To switch from the Stand-Alone mode to the Local Server mode, follow these
steps.

1. Navigate to the opening mobile app screen and select Stand-Alone mode.

2. Step to the + Add Gateway screen, where the currently connected Gate­way name will be shown.

3. Tap the trash icon at the top of the screen.

4. Confirm the deletion, when prompted.

5. Now return to the mobile app opening screen, select the Local Server
mode, and follow the instructions for configuring a test system in Local
Server mode as previously described.

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13

Figure 13.1 GW65 Gateway Firmware Update Using Mobile App.

GW65 Field Firmware Updates

13.1 Firmware Update Procedure using the Mobile App

To update the GW65 Gateway firmware, connect to the network with the mo­bile app, and then follow the steps below:

1. Select ‘Local’ or ‘Stand-Alone’ mode in the app and connect to the same
network as the GW65.

2. Navigate to the ‘Gateway Settings’ screen in the app and tap the ‘FW Up­date’ box.

3. When prompted, tap on an available update file and tap ‘UPDATE’.

4. The app will show the ‘Update Complete’ message when done.

5. The GW65 will reboot and operation will continue normally. If you have
questions or update issues, please contact FLIR.

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16

Specifications

16.1 GW65 Remote Monitoring Gateway Specifications

Operating and Storage
Temperature

Operating Relative
Humidity

Altitude 6562 ft. (2000 m)

Data back-up 32 MB flash memory available for power outages. 5 days of

Power 100 ~ 240 V AC 50/60 Hz

Bluetooth Type: BLE 4.2

Wi-Fi Type: IEEE 802.11 b/g/n

IP Rating IP 40

Drop-proof 3.3 ft. (1 m)

Safety Certifications: ETL / IC / FCC / CE / RCM

Dimensions 2.26 in x 1.55 in x 1.82 in.

Weight 1.2 oz. (35 g)

-13 ℉ ~ +149 ℉ (-25 ℃ ~ +65 ℃)

10 ~ 95% non-condensing

data for 4 sensors or 20 days of data for one sensor can be
stored maximum.

Gateway-to-Sensor Range: 213 ft. (65 m) line-of-sight

Antenna: -3 dBm, single antenna,

Frequency Range:

Output power:

Antenna: 0 dBm, single antenna, om-

Signal strength: -65 ~ –70 dBm

(57.3 mm x 39.3 mm x 46.1 mm)

omni-directional

2.4 GHz

< 100 mW

ni-directional

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Specifications

16.2 SV87 Remote Sensor Specifications

Measurements Acceleration: ± 32 g (gravitational constant)

Velocity data (mm/s or in/s) displayed in the mobile and
Windows apps, derived from FFT.

Contact temperature trend range: –22℉ ~ +176℉ (–30℃ ~
+80℃)

Frequency Range 10 Hz ~ 1 kHz

Sampling rate One data point captured / 90 seconds

Sensor attachment method Double-sided tape (supplied). Order Tesa® 4957 double-

Number of sensors per
Gateway

Operating Temperature -22 ℉ ~ +176 ℉ (-30 ℃ ~ +80 ℃)

Operating altitude 6562 ft. (2000 m)

Battery 3.6 V 2400 mAh Lithium battery (battery life: 4 years,

Bluetooth Type: BLE 4.2

IP Rating IP 67

Drop-proof 3.3 ft. (1 m)

Safety Certifications: ETL / IC / FCC / CE / RCM

Dimensions 2.42 in x 0.95 in. (61.5 mm x 24 mm)

Weight 1.4 oz. (28 g)

sided general purpose PE-foam tape from your local sup­plier for additional tape.

Adhesive alternatives are available on the market that
could be more reliable on some machinery. Epoxy (Loctite
AA 330 + Loctite SF 7387/8) may give a more rigid and
long lasting bond.

Ten (10) sensors will work in most circumstances, given no
obstruction between Gateway and sensor. The key factor is
obstruction since, with no obstruction, it is possible to have
more than ten sensors operating normally.

nominal)

Sensor-to-Gateway
Range:

Output power:

213 ft. (65 m) line-of-sight

< 10 mW

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