ITT ProSmart Installation & Operation Manual

ProSmart Installation & Operation Guide

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ProSmart Installation & Operation Guide

Index

Important Safety Reminder

Getting Started Section 1

Communication Module Installation Section 2

Communication Configuration

Mechanical Installation

Power Connections

Data Monitor Installation Section 3

Mechanical Installation

Power Connections

Class I Division 2 Cap Lock Installation

Sensor Installation Section 4

Tachometer Sensor Installation

Vibration & Temperature Sensor Installation

ProNet User Guide Section 5

Logging into ProNet

Dashboards

My Machines

Data and Trending

Analytical Features

Appendices

MODBUS Information A-1

ProSmart Data Sheets A-2

Troubleshooting A-3

ProSmart Installation & Operation Guide

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ProSmart Installation & Operation Guide

SAFETY INSTRUCTIONS

IMPORTANT SAFETY REMINDER

To: Our Valued Customers

The information in this section must be studied before attempting any work on
or with the ProSmart Wireless Condition Monitoring System.

Products manufactured and furnished by ITT Monitoring and Control will
provide safe, trouble-free service when properly installed, maintained and
operated. We have an extensive network of experienced sales and service
professionals to assist in maximizing your satisfaction with our products.

Safe installation, operation and maintenance of ITT’s equipment are essential
end user responsibilities. The ProSmart Installation and Operation Guide
identify specific safety risks that must be considered at all times during the life
of the product. Understanding and adhering to these safety warnings is
mandatory to ensure personnel, property and/or the environment will not be
harmed. Adherence to these warnings alone, however, is not sufficient; it is
expected that the end user will also comply with industry and corporate safety
standards. Identifying and eliminating unsafe installation, operation and
maintenance practices is the responsibility of all individuals involved in the
installation, operation and maintenance of industrial equipment.

Safety Symbol and Signal Word Explanation:

This is the dangerous voltage alert symbol. It warns of high voltage which
can cause death or physical injury. Obey all safety messages that follow this
symbol to avoid possible injury or death

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

DANGER indicates a hazardous situation which, if not avoided,
will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided,
may result in minor or moderate injury.

NOTICE

NOTICE used without the safety alert symbol addresses
practices which, if not avoided, may result in property damage.

ProSmart Installation & Operation Guide

SAFETY INSTRUCTIONS

With respect to ProSmart Wireless Condition Monitoring System installation,
operation, and maintenance activities the following risks bear reinforcement
above and beyond normal safety precautions:

All electrical installation and maintenance work must be undertaken by a
qualified electrician only. Failure to do so will result in serious injury or death.

During installation all equipment must be disconnected from the power supply
without any possibility of being made live (Lockout/Tagout). Failure to do so
will result in serious injury or death.

The ProSmart System is designed and certified only to be installed in a non­hazardous location or a hazardous location labeled as Class I Division 2, Group
A B C D T4 only. The rating is contingent to proper installation of modules for
Class I Division 2. Failure to do so could result in serious injury or death.

The Data Monitor requires 12-24VDC and the Communication Module requires
12VDC. Connecting the module to AC or a higher voltage could result in
serious injury or property damage.

The Communication Module and Data Monitor are equipped with a radio
transmitter and receiver operating in the 2.4GHz band. To satisfy FCC radio
frequency exposure requirements for mobile type transmitting devices, a
separation distance of 20cm or more should be maintained between the
antenna of the Communication Module and Data Monitor and persons during
operation, with exception of hands, wrist, feet, and ankles. To ensure
compliance, operations at distance closer than 20cm are prohibited. Excessive
radio frequency exposure should be avoided.

The Data Monitor is equipped with a relay output. This relay output may be
activated as soon as power is connected to the unit. This may result in
unintended consequences. To ensure the relay activates only when desired, do
not connect the Data Monitor relay wires until the system accepting the
contact closure is ready (alarm beacon, horn, etc.).

The DC capacitors contain electrolyte and the printed circuit boards contain
lead, both of which will be classified as hazardous waste within the EU. They
must be removed and handled according to local regulations.

ProSmart Installation & Operation Guide

SAFETY INSTRUCTIONS

Due to some materials used in some electrical components, thoroughly wash
hands with soap and water after handling any electrical components. Always
use protective glasses, gloves, and clothing.

NOTICE

No modifications should be made to the Communication Module and Data
Monitor enclosures and the cover should not be removed from the Data
Monitor Electronic Board Chamber; otherwise, the warranty will be void.

Please take the time to review and understand the safety instructions,
installation and operation guidelines provided in the ProSmart Installation and
Operation Guide for the applied equipment.

The ProSmart System has been designed for safe and reliable operation when
properly installed, applied and maintained in accordance with the instructions
in the ProSmart Installation and Operation Guide. ITT Monitoring and Control
shall not be liable for physical injury, damage or delays caused by failure to
follow these instructions.

ProSmart Installation & Operation Guide

SAFETY INSTRUCTIONS

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ProSmart Installation & Operation Guide

GETTING STARTED

INTRODUCTION

The ProSmart Wireless Condition Monitoring System provides a cost effective method to monitor all types
of rotating equipment all year around - 24 hours a day; 7 days a week; 365 days a year. The ProSmart
System collects machine specific information and provides warnings and alarms to users. The ProSmart
System is designed around ease of installation, rapid deployment, easy system expansion, and no
additional IT infrastructure required. A user needs very little training to start using the ProSmart system.

The ProSmart System consists of four core components: ProNet Server Application, Communication
Module, Data Monitor, and Sensors.

ProNet Application

An internet based system providing Graphical User Interface for Analysis Tools such as FFTs and Band
Alarms, Event and Alarm Management, and Historical Data Management. ProNet automatically alerts the
select users to alarms via e-mail or voice phone calls so that the problem can be rectified before it results
in machine failure. Data storage and maintenance is handled by ITT and requires minimal IT involvement.

Communication Module

A field mountable wireless data communication module, manages all data communication between the
Data Monitor module(s) and ProNet server application. The Communication Module supports
communication to the server via Local Area Networks (LAN), dedicated broadband connection such as
cable and DSL, GPRS, and CDMA cell modems.

Data Monitor

A field mountable wireless data monitoring module for capturing, analyzing, and processing conditions of
any rotating equipment such as pumps, compressors, blowers, fans, mixers, etc. using Sensors and
analog/digital inputs. The Data Monitor should be mounted in close proximity to the machine.

Sensors

Range of ProSmart specific industrial “Plug and Play” sensors measuring Vibration, Temperature, and
Speed. ProSmart also allows 3 analog process inputs in the form of 4-20mA to be analyzed. ProSmart will
also analyze 2 digital inputs in the form of 0-24VDC. This moves ProSmart from being just a vibration
monitoring device to a complete condition monitoring solution.

ProSmart and its related products are protected by the following patents: 6,464,464; 6,487,903
B2; 6,564,627; 6,591,697; 6,648,606; 6,681,634 B2; 6,776,584; 7,080,508 B2; 7,112,037 B2.

Page 9

ProSmart Installation & Operation Guide

GETTING STARTED

ProSmart Wireless Condition Monitoring System Architecture

ProSmart Installation & Operation Guide

GETTING STARTED

GETTING STARTED

How to use this guide

This guide has been organized to make installation of the
ProSmart System easy. Installation has been divided into three
main sections that include all the information needed to get up­and-running. The four sections are:

x Communication Module Installation

x Data Monitor Installation

x Sensor Installation

x ProNet User Guide

Each section has been laid out to speed you through the
installation process, while providing enough background
information to help understand the process.

1. Step Number - The step number helps to keep track of
where you are in the configuration process when used in
conjunction with the process map.

2. Process Map - The process map is a visual guide of what
needs to be done in the step.

3. Background Information - This information explains what
the upcoming steps are and why they are being performed.
Examples are provided to assist in understanding the
concept.

4. Special Notes - These highlighted sections contain
comments that are important to the installation process.

5. Illustration View - The illustration view shows installation
illustration for guidance.

PROSMART

Figure A - Typical Installation Page

ProSmart Installation & Operation Guide

GETTING STARTED

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ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

COMMUNICATION MODULE INSTALLATION

This section is devoted to install your ProSmart Communication Module.

Step Description

Communication Module Overview

Communication Module

1

2

3

Communication Overview

Mechanical Installation

Power Connections

PROSMART

Page 13

ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

Overview - Communication

When selecting an installation site for the Communication Module
two communication paths need to be evaluated:

1. Communication signal strength between Communication
Module and Data Monitor - It is recommended to optimize the
communication signal from the Communication Module to each
Data Monitor by having ITT or an authorized distributor
perform a site survey.

2. Reliable Internet connection for Communication Module to
communicate with the ProNet server - the Communication
Module can communicate using either Local Area Network,
Broadband connection such as DSL, cable modem, or cellular
modem, similar to an internet connection with a personal
computer.

The Communication Module communicates to the ProNet Server
application through a standard internet connection. The
Communication Module is equipped with an Ethernet cable to
connect into your network receptacle. The Ethernet cable for the
Communication Module exits through the same conduit hub as the
DC power.

All communication is initiated from the Communication Module.
Inbound communication requests to Communication Module are
ignored since it acts only as a client and not as a server. Factory
default configuration for the Communication Module is DHCP
(Dynamic Host Configuration Protocol). It may also be configured to
use a static IP.

The Communication Module allows only specific DMs to send data.
The Communication Module will set aside time in its polling routine
for a listed DM to communicate.

CDMA

GPRS

www

LAN

Communication Module

PROSMART

DSL

ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

1

Communication Configuration

NETWORK SPECIFICATIONS

If communicating through a Local Area Network (LAN), it must be
configured to allow communication from the Communication
Module to the following URL address and through the following
ports, especially if the Communication Module must be behind a
firewall:

x data.prosmart.ittmc.com

downloads.

NOTE – Configure LAN network for URL address and not the
resolved IP address since IP address can change anytime.

x Outbound communication support for:

o HTTP Protocol (standard web browser protocol) via

port 80

o External NTP (standard Network Time Protocol) via

port 123

ProNet users must have access to www.prosmart.ittmc.com
login to the GUI (Graphical User Interface) and interact with their
devices.

DHCP Configuration –

Default factory configuration. This is the preferred method of
network configuration (no additional information is needed).

Static IP Configuration –

To configure the Communication Module to use a static IP the
following information is needed:

x Static IP address

x IP DNS1 and IP DNS2

for data management and software

to

x IP Gateway

x IP mask

An ITT representative can either configure the Communication
Module in the field or it can be preconfigured at the factory.

ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

2

Installation steps to be performed are:

1. Before installing the Communication Module, please note the

2. When selecting a location to mount the Communication

Mechanical Installation

Mac ID from the nameplate on the right-side of the
Communication Module for future reference. This will appear
similar to the following: 00:50:C2:8F:44:AA

Module following items need to be considered:

x Mount Communication Module at least 15 feet

above ground

x Communication Module antenna needs to be in

vertical upright position, and

x At least 10 inches of area around the antenna needs

to be clear of any obstruction

3. Mount the Communication Module on a suitable mounting
surface such as a wall or pillar using fasteners that can
support the Communication Module’s weight of
approximately 15 lbs (6.8 Kg).

4. The Communication Module has ¾“ NPT conduit hub.

5. Install the Communication Module per NEMA requirements.

6. For Communication Module using a cellular modem, the
cellular antenna needs to be at least 3 ft away from the
Communication Module antenna. At least 10 inches of area
around the cellular antenna also needs to be clear of any
obstruction.

7. For ideal communication with the DM, the CM should be in
direct line of sight.

Communication Module

PROSMART

Wire Key:

Power

(+)

Red

( - )

Black

Communication Module - LAN

minimum required distance

Communication Module – Cellular Modem

3 ft

PROSMART

Ethernet Cable

Female- to- Female Connector

Network Cable

(LAN, Cable, or DSL)

Communication Module

ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

3

The Communication Module needs to be powered by an externally
supplied 12 VDC power supply.

Power Connections

All electrical installation and maintenance work must
be undertaken by a qualified electrician only. The
Safety Instructions in this Installation and Operation
Guide must be followed. Failure to do so will result in
serious injury or death.

Power must be wired using acceptable Class I Division
2 wiring methods if the hazardous area rating is to
apply. Failure to do so could result in serious injury or
death.

Steps to be performed for proper power installation are:

1. Install the conduit and connection box per your local
electrical and environmental codes.

2. Communication Module has ¾” NPT conduit hub.

3. Follow the wiring diagram shown to the right for proper
installation.

4. Use a voltmeter to measure the supplied power at the
connection box and verify that it is 12VDC.

NOTE – Before powering the Communication Module take
every precaution to ground the unit.

PROSMART

Wire Key:

Power

(+)

Red

( - )

Black

Communication Module

Ethernet Cable

Female-to- Female Connector

Network Cable

(LAN, Cable, or DSL)

The Communication Module does not have an on-off
switch and will start operating as soon as power is
applied. This may result an unintended alarm
annunciation as well as an unintended activation of
relay outputs on the DM modules communicating
with the Communication Module at the time.

ProSmart Installation & Operation Guide

COMMUNICATION MODULE INSTALLATION

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ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

DATA MONITOR INSTALLATION

This section is devoted to install your ProSmart Data Monitor DM22x.

Step Description

Data Monitor Overview

1

Mechanical Installation

PROSMART

Warning

Power

Alarm

2

3

Power Connections

Class I Division 2 Cap Lock Installation

TACH V/T-1

Reset

V/T-2 V/T-3 V/T-4

Page 19

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

1

Mechanical Connections

Installation steps to be performed are:

1. Before installing DM22x, please note the Mac ID from the
nameplate on the right-side of the enclosure for future
reference. This will appear similar to the following:
00:50:C2:8F:44:AA

2. When selecting a location to mount the DM22x the
following items need to be considered:

x Mount the DM22x approximately four feet above

ground

x The DM22x antenna needs to be in vertical upright

position, and

x At least 10 inches of area around the antenna

needs to be clear of any obstruction

3. Mount the DM22x on a suitable mounting stand, four (4)
¼-20 UNC mounting holes are provided on the rear of
DM22x for mounting. The DM22x can be mounted on a
floor mounted stand or a wall mounting bracket which ITT
can provide. The DM should NOT be mounted on the
equipment but should be mounted in near the rotating
equipment.

4. For ideal communication with the Communication Module
the DM22x should be placed in direct line of sight, if
installation permitting.

2

3

Power

V/T-2 V/T-3 V/T-4

PROSMART

TACH V/T-1

Warning

Alarm

Reset

V/T-2 V/T-3 V/T-4

Power

Warning

Alarm

Reset

PROSMART

TACH V/T-1

Wall mounted arrangement

47" approx.

Optional mounting bracket

Two 0. 44 diameter holes

for wall mounting

1.00"

Page 20

Floor mounted stand arrangement

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

2

‘ Power Connections

For ease of electrical installation all user inputs and outputs –
three analog inputs, two digital inputs, one relay output, and
power connection are provided via terminal blocks mounted on a
circuit board.

NOTE – The DM22x Process Board Section is not to be accessed
by the user or the product warranty will be voided.

OPENING THE TERMINAL SIDE OF THE DM22X

Installation steps to be performed are:

1. Using a Phillips head screw driver, remove the four screws
located in each corner of the cover.

2. Using an 1/8” Allen wrench pry up on the corners of the
cover to break the seal.

a. Using the Allen wrench feel for the gasket that

separates the cover from the DM22x housing.

b. Take caution not to damage the threads in the

screw connections

c. Using the gap where the gasket is located pry

up the cover.

d. Slow constant force will aid in breaking the seal.

e. Take a look at the other corners and slowly pry

up on them to release the overall tension
holding the face plate.

PROSMART

TACH V/T-1 V/T-2 V/T-3 V/T-4

Data Monitor – DM22x

J32

J34

AI1+

6

1

DI1+

AI1-

5

DI1-

2

AI2+

4

DI2+

3

AI2-

3

DI2-

4

AI3+

2

Relay NC

1

AI3-

1

Relay COM

2

Relay NO

3

+24V GND

J35

1 2

J30

J36

Terminal Board Chamber

Electronic Board Chamber

Terminal Board Chamber

Power

J32

J34

AI1+

6

DI1+

1

Warning

AI1-

5

DI1-

2

Alarm

AI2+

4

DI2+

3

AI2-

3

DI2-

4

AI3+

2

Relay NC

1

AI3-

1

Relay COM

2

Relay NO

3

+24V GND

J35

1 2

J30

J36

Reset

Two Digital Inputs

Three Analog Inputs

One Form - C Relay Output

12-24 VDC Power Input

#8-32 screw for Saftey Grounding

#4-40 screw for Shield Connection

¾” Conduit Conn ection

The face plate edges of the DM housing may be sharp
due to the manufacturing process, and should be
handled carefully. Failure to take precautions may
result in minor or moderate cuts and injury.

NOTICE

Although it is preferred that an 1/8” Allen wrench be
used in accessing the terminal side of the DM, other
tools can be used. The Allen wrench has worked the
best in field applications and resists damage more
than other possible instruments.

Page 21

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

The DM22x needs to be powered by an externally supplied 12-24
VDC power supply (Pmax = 6W).

All electrical installation and maintenance work must
be undertaken by a qualified electrician only. The
Safety Instructions in this Installation and Operation
Guide must be followed. Failure to do so will result in
serious injury or death.

Power and Relay must be wired using acceptable
Class I Division 2 wiring methods if the hazardous
area rating is to apply. Failure to do so could result in
serious injury or death.

POWER CONNECTION

Installation steps to be performed are:

3. All terminal blocks are labeled and color coded:

Power (J30) – RED

Analog Inputs (J32) – LIGHT GREY

Digital Inputs (J34) – DARK GREY

Relay Output (J35) – BLUE

NOTE - Relay Output can be configured as NO or NC and
rated at max 0.5A at 125VAC, 2A at 30VDC

4. Inside the terminal side of the Data Monitor there are 3
screws provided for shielding and grounding of the unit for
saftey.

NOTE – For ground shield two (2) #4-40 screws are
provided and for Tie down one (1) #8-32 screw is provided.

5. If analog inputs are used, connect the analog input shield
to the DM22x enclosure #4-40 shield screw (see diagram).
For analog and digital inputs wiring use shielded 22AWG,
300V cable with minimum temperature rating of -20C to
80C.

NOTE – Analog inputs are not optically isolated. If
necessary, use universal signal conditioning module (P/N
A08968A) for each analog input.

NOTE – Digital inputs are non-powered dry contact type.

NOTE – Terminal connection diagram is also provided on
the back-side of the DM22x front cover for reference.

12-24V

DC

DC Common

Power Connections on DM

Terminal

J32

Terminal Block

AI 1 +

6

AI 1 -

5

AI2 +

4

AI 2 -

3

AI3 +

2

AI 3 -

1

J30

Terminal Block

+ 24

GND

VDC

2

1

= +24Vdc
= Ground

= Ground

N = Neutral

DC ok

24 -28V

Power Supply

100-240Vac 1.0A

NL

DC

ok

50W

L = Live

110-240Vac

Single Power Supply for Process

Transmitter and Data Monitor

Page 22

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

6. Install the conduit and connection box per your local
electrical and environmental codes.

7. DM22x has ¾" NPT conduit hub.

8. Use a voltmeter to measure the supplied power at the
connection box and verify that it is within the 12-24VDC
range.

NOTE – Before powering the DM22x take every precaution
to ground the unit.

The Data Monitor does not have an on-off
switch and will start operating as soon as
power is applied. This may result an
unintended alarm annunciation as well as an
unintended activation of Relay Outputs on
the Data Monitors communicating with the
Communication Module at the time. To
ensure the relay activates only when desired,
do not connect the Data Monitor relay wires
until the system accepting the contact closure
is ready (alarm beacon, horn, etc.).

9. After completing the electrical connection, fasten the
DM22x front cover.

NOTE – The DM22x is delivered with protective caps on all
connectors. The caps shall remain in place on all
connectors that do not have a sensor cable connected.
Failing to follow this instruction may lead to damage of the
connector and subsequent damage to the internal
electronic boards.

DC ok
24 -28V

Power Supply

100-240Vac 1.0A

NL

DC
ok

50W

N = Neutral

= +24Vdc
= Ground

= Ground

L = Live

110-240Vac

Separate Power Supply for Process

Transmitter and Data Monitor

A08968A

1

2

3

7
8

9

10

11

12

DC

ok

DC ok
24 -28V

Power Supply

100-240Vac 1.0A

NL

50W

= +24Vdc
= Ground

6

5

4

3

2

1

6

5

4

3

2

1

Terminal Block

+24

VDC

1

J32

Terminal Block

J32

Terminal Block

J30

GND

DC ok
24 -28V

Power Supply

100-240Vac 1.0A

NL

AI 1 +

AI 1 -

AI 2 +

AI 2 -

AI 3 +

AI 3 -

AI 1 +

AI 1 -

AI 2 +

AI 2 -

AI 3 +

AI 3 -

2

DC
ok

50W

Page 23

= Ground

N = Neutral

L = Live

Universal Signal Conditioning

Module Wiring

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

3

For hazardous areas classified as Class I Division 2 Group A B C D
T4, Cap Lock (P/N A08569A) should be used on all plug and play
connections of the Data Monitor, whether there is a sensor
connected or only a protective screw cap, to prevent the event of
an open receptacle.

Class I Division 2 Cap Lock Installation

Unit must have tool removable cap-locks installed
according to Installation and Operation manual or the
system is not Class 1 Division 2 compliant. Failure to
comply with Class 1 Division 2 instructions could
result in serious injury or death.

CapLocks are to be used on the following areas for Class 1
Division 2 applications:

A. DM22x connections (includes unused inputs).

B. Cable to cable connection points.

C. Sensor cable to sensor housing connection.

1

C

2

!

k

c

i

l

Page 24

3

ProSmart Installation & Operation Guide

DATA MONITOR INSTALLATION

Cap Lock Install: DM22x Connections

For hazardous areas classified as Class I Division 2 Group A B C D
T4, Cap Lock (P/N A08569A)

Installation steps to be performed to install Class I Division 2 caps
are:

1. Unit should not be powered until all Cap Locks are
installed and the installation is compliant with Class 1
Division 2 and local electrical standards.

2. Cover the installed sensor, extension cable connection, or
protective screw cap with the Class I Division 2 Cap Lock.

3. Connect the 2 halves of the cap lock around the
connection point. After it snaps together secure the cap
lock to the cable (if applicable) by inserting the arrow
through the ring.

TACH V/T-1

V/T-2

A

B

C

For Non-hazardous

TACH V/T-1

V/T-2

Page 25

For C1D2 Rated

TACH V/T-1

V/T-2

ProSmart Installation & Operation Guide

s

1

D

d

DATA MONITOR INSTALLATION

Cap Lock Install: Cable to Cable Connections

For hazardous areas classified as Class I Division 2 Group A B C D
T4, Cap Lock (P/N A08569A)

Installation steps to be performed to install Class I Division 2 caps
are:

1. Unit should not be powered until all cap-locks are
installed and the installation is compliant with Class 1
Division 2 standards.

2. Cover the cable connections with the Class I Division 2
Cap Lock.

3. Connect the 2 halves of the cap lock around the
connection point. After it snaps together secure the cap
lock to the cable (if applicable) by inserting the arrow
through the ring.

4. Each connector requires a Cap Lock, therefore cable to
cable connections will have 2 Cap Locks.

TACH V/T-1

V/T-2

A

B

C

For Non-hazardou

For C

Page 26

2 Rate