BDI STS4 Wireless Intelliducer Node User Guide

BDI STS4 Wireless Intelliducer Node

Structural Testing System

The Structural Testing System (STS4) is a rugged, wireless and battery-powered device developed by BDI since the early 1990s. The STS4 includes the latest wireless and battery power technology while maintaining ease of use in difficult field-testing conditions.

Warranty Information

For any technical support or warranty-related queries, please contact BDI Technical Support at 740 S Pierce Ave Unit 15 Louisville CO 80027 or call +1.303.494.3230.

Table of Contents

• Introduction
  • PC Requirements
  • Manual Information
• System Architecture
• Setting up the hardware
• STS-LIVE Support
  • STS-LIVE Help Guide
  • Training Videos

Compatible STS Hardware

The following components are compatible with the STS4 system:

PC Requirements

The PC requirements for using the STS4 system are not mentioned in the manual.

Manual Information

No part of this operations manual may be reproduced, by any means, without the written consent of BDI. The information contained within this manual is believed to be accurate and reliable. However, BDI assumes no responsibility for errors,omissions, or misinterpretations. The information herein is subject to change without notification.

Product Usage Instructions

To assemble and operate a basic STS4 system, follow the step-by-step procedure outlined in the Quick Start Guide. The guide includes the following steps:

1. Check if all components listed in Table 1 are available
2. Assemble the hardware components as per the instructions provided
3. Turn on the wireless base station and connect it to your PC
4. Install and configure STS-LIVE for running tests with an assembled STS4 system
5. For further assistance in configuring STS-LIVE and running tests, refer to the instructional videos available on the BDI website.

The manual also contains critical information highlighted with special symbols. Pay close attention to these symbols to avoid damaging the device or for successful device operation and/or settings and configuration.

INTRODUCTION

Thank you for purchasing our latest and most advanced Structural Testing System (STS4). BDI has been developing and refining rugged STSs since the early 1990s. This 4th generation system includes the latest wireless and battery power technology while maintaining ease of use in difficult field- testing conditions.
This Quick Start Guide outlines the step-by-step procedure for assembling and operating a basic STS4 system consisting of the components listed in Table 1.

Table 1: Compatible STS Hardware

For further assistance in configuring STS-LIVE and running tests with an assembled STS4 system, please refer to the extensive series of instructional videos available on the BDI website at: https://bditest.com/product/training- support/video-tutorials/sts-live/

PC REQUIREMENTS
BDI recommends that a personal computer (PC) with a minimum of a Dual Core Intel i5 processor supported with 8Gb RAM and Windows 10 Pro) be used to operate STS4 systems consisting of 100 data channels or less. For higher channel count STS4 systems, please get in touch with BDI for recommended PC capabilities. It is also highly recommended to dedicate one PC for running the STS4 rather than having to configure the Windows Firewall and other third- party internet security applications that often block the STS-LIVE application on various computer operating systems.

MANUAL INFORMATION
The following highlighted message blocks will appear throughout the manual, containing critical information the user should review.

STOP: This symbol and corresponding message represents information that if not followed could lead to damaging the device. Pay close attention to this message!

WARNING: This symbol and corresponding message represents information that is critical for the successful device operation and/or settings and configuration.

INFORMATION: This symbol and corresponding message represents helpful tips for successfully configuring and operating the device.

SYSTEM ARCHITECTURE

Figure 1: System Architecture

SETTING UP THE HARDWARE

STS4 WIRELESS BASE STATION

The STS4 Wireless Base Station (STS4-WBS) system is comprised of the Control Unit, dual-band wireless Access Point (AP), and the mounting tripod. The Control Unit provides power to the Access Point, allowing the system to power itself independently off an AC outlet with the supplied Power Supply. The Control Unit and Access Point utilized are connected via an industrial Ethernet cable provided with the system. If the optional Automatic Load Position Tracker (ALPT) is purchased with the system, an internal receiving radio will be supplied with the STS4-WBS and paired with the transmitting radio within the ALPT.

STS4-WBS Components

Table 2: STS4-WBS Components

STS4-WBS Assembly Procedure

1. Attach the four Antennas (1 & 2) into Antenna Receptacles on Wireless Access Point (3). Be sure to identify the Antenna type and attach it to the matching receptacle (2.4 GHz vs. 5.0 GHz). Thread clockwise until Antenna is secure. Do not over-tighten.
2. Slide dowel on the back of Wireless Access Point (3) into Wireless Access Point Tripod Mounting Bracket (4) socket with metal slide handle and secure. Do not over-tighten.
3. Slide the adjustable Control Unit Tripod Mounting Bracket (5) to the midpoint of the Tripod Vertical Pole (6) and lightly tighten the clamp.
4. Attach Tripod Vertical Pole (6) into Tripod Base (7) and extend the three support legs to be 120˚ apart. Extend the Tripod Vertical Pole (6).
5. Attach the Wireless Access Point Tripod Mounting Bracket (4) to the top of the Tripod Vertical Pole (6) and tighten it. The angle of the Wireless Access Point can be adjusted as required to ensure the best signal coverage.
6. Attach the Control Unit (8) to the Control Unit Tripod Mounting Bracket (5).
7. Using the Wireless Access Point to Control Unit Ethernet Cable (9), connect the Wireless Access Point (3) to the Control Unit (8) AP receptacle.
8. If using the ALPT, attach the Antenna (12) to the ALPT receptacle on the Control Unit (1).
9.  If communicating with the STS network in wired mode, using the Computer to Control Unit Ethernet Cable (10), connect between the PC and the Control Unit (8).
10. If the Control Unit (8) needs to be charged, connect the Power Supply (11) to an AC source and then plug it into the Control Unit (8) power input receptacle.

WBS Operation

1. Charge Battery: Connect Power Supply (11) to Power Input Receptacle on (1) and plug into 90-220 VAC supply until the unit is fully charged. The battery charge level will be indicated by briefly depressing and releasing the power button on the front of the Core (1). The battery icon LEDs will provide a simple display of the remaining charge.
2. Power: Turn the power on by holding the button down until the indicator light turns green (~2 seconds). This initiates the internal network circuitry, and the unit will require approximately two minutes to “boot up” and begin broadcasting the “STS” wireless network (SSID). The LED on the side of the Access Point (2) will be illuminated when the unit begins broadcasting the 2.4GHz SSID. When STS-Live has been installed on the PC, the STS4 WBS will automatically attempt to connect to the network and, when successful, will appear in the Hardware Tab.
3. Turn off the WBS by holding down the Power button until the LED turns red (~2 seconds).

STS4 NODES

The STS4 node is used to power sensors and transmit data from the sensors to the test computer running the STS-LIVE application. The node can accommodate four sensors and communicate over a wired or wireless TCP/IP network.

STS4 Node Components

Table 3: STS4 Node Components

STS4 Node Assembly Procedure

1. Thread Antennas (1) onto the receptacle in the back of the STS4 node (2).
2. Connect four Intelliducer-based sensors into the mating receptacle and rotate the sleeve until it snaps into place. Note that any Intelliducer sensor may be plugged into any receptacle since STS-LIVE automatically detects the sensor’s location within the system to apply its unique settings properly.

STS4 Node Operation

1. Charge Battery: Connect Power Supply (3) to the power input receptacle on the back of the STS4 node (1) and plug into the 90-220 VAC supply. The battery charge level will be indicated when initially plugging the Power Supply in and briefly depressing and releasing the power button located on the front of the STS4 node (1). The battery status LEDs will display the remaining charge.
2. Power: Depress the power button until the LED turns green (~2 seconds). The blue LED will indicate the Node’s connection status as one of the four possible states outlined in Table 4.
3. When STS-LIVE has been installed on the PC and is open, the STS4 node will automatically attempt to connect to the application. It will appear in the Hardware Tab when successfully connected.
4. If a connection is not established, the STS4 node will enter a low-power Snooze cycle (2 minutes) and then attempt to connect again.
5. Turn off the node by depressing the power button until the power LED turns red (~2 seconds).

Table 4: Blue LED Responses

Solid On

| Powered on and searching for a connection to STS-LIVE. The node will remain in this state for two minutes until it establishes a connection to STS-LIVE. If two minutes pass and the node cannot establish a connection, the node will go into a Snooze cycle for two minutes.

Off

| Powered down, Snoozing, or Sleeping. If the power LED flashes orange when the power button is depressed, the node is in the Snooze or Sleep cycle. Wake up the node by depressing the power button until the power LED turns green. If the power LED flashes red, the node is turned off.
Slow Flashing| Connected to STS-LIVE and ready for configuration and test initiation
Rapid Flashing| Testing underway, recording and storing data

AUTOMATIC LOAD POSITION TRACKER (OPTIONAL)

The Automatic Load Position Tracker (ALPT) uses either a 900MHz or 2.4 GHz (depending on geographic region) wireless connection to connect to the STS4-WBS and consists of two primary components: the ALPT transmitter (main unit with wheels); and the receiving radio, which is integrated into to the STS4-WBS. In addition to the main components, the ALPT is provided with mounting hardware to use in connecting the ALPT Main Unit to the load truck. Note that the ALPT and STS4-WBS receiving radio will be configured by BDI prior to use and are not compatible between different STS4-WBS devices.

Table 5: ALPT Components

ALPT Assembly Procedure

1. Attach the Antenna (3) to the ALPT Main Unit (1). Do not over-tighten.
2. Insert the hollowed circular slot on (4) into the circular base at the top of (1). Align and secure with the supplied screws until they resist torque. Ensure mounting hardware and ALPT transmitter are securely connected.

ALPT Operation

1. Charge Battery: Connect Power Supply (5) to Power Input Receptacle on (1) and plug into 90-220 VAC supply until the unit is fully charged. The battery charge level will be indicated by briefly depressing and releasing the power button located on the front of the ALPT (1). The series of LEDs will provide a simple display of the remaining charge.
2. Power: Depress and hold the power button down until the indicator light turns green (~2 seconds). The charge level is displayed during this process. The battery charge level can be checked at any time by activating the power button for approximately one second.
3. When STS-LIVE has been installed on the PC and opened, the ALPT will automatically attempt to connect to the application and will appear as “PULSEWHEEL” in the Hardware Tab when successfully connected.
4. Turn off ALPT by depressing the power button until the power LED turns red (~2 seconds).

Installing the ALPT on the Test Vehicle

1. Place the bracket opening at the end of item 4 in a secure location on the truck’s rear side.
2. Secure the bracket to the truck using the C-clamps. Tighten the C-clamps until the ALPT assembly is securely attached to the truck.
3. The ALPT bracket should be mounted so that the ball joint connecting the bracket and the extension pole is in a neutral position. If the ball joint is maxed out in any one direction, the range of motion of the extension pole and ALPT becomes restricted (See Figure 8).
4. The ALPT must be mounted so that the angle between the mounting hardware and the ground is between 25° to 45°. Angles outside this range may cause the ALPT to bounce and skip while being pulled, resulting in inaccurate readings.

INFORMATION: The above mounting scenario will vary depending on the test vehicle. The bracket/ball mount should allow the unit to be adapted for most situations. Some user creativity may be required for some applications, meaning it is good practice to determine the configuration of the test vehicle’s rear bumper prior to running the test as delay may occur.

INSTALLING STS-LIVE

NETWORK SETTINGS
To operate the STS-LIVE application, the PC’s Internet Protocol Version 4 (TCP/IPv4) address must be set according to Figure 10. The IP address used by STS-LIVE is the same for all Windows® operating systems; however, navigating to the settings may vary depending on the operating system version.

WARNING: It is important that the computer Network Settings are correct before launching the STS-LIVE application and attempting to establish connections with STS4 components. This is often the first suspect in case a connection cannot be established. Please ensure the TCP/IPv4 settings are as follows:

• IP address: 192.168.10.2
• Subnet mask: 255.255.0.0
• Default gateway: Blank
• DNS Settings: Blank

INSTALL STS-LIVE ON PC

1. Insert a USB drive into the laptop port or download the latest STS-LIVE Installer from the BDI website.
2. Double-click “Setup” to begin the installation.
3. Install STS-LIVE to the recommended default hard drive location.
4. Accept the License Agreement to continue with the installation.
5. The National Instruments LabView® application will be automatically installed if it is not already installed on the PC. Two license agreements required by National Instruments must be accepted.
6. The summary of files to be installed is displayed. Note that it may take up to 15 minutes to complete installation.
7. After STS-LIVE successfully installs, the STS-Configuration application will launch to import sensor calibrations.
   • Select the folder icon and navigate to the sensor calibration file supplied on a USB drive or otherwise supplied by BDI.
   • After the file appears in the Source Sensor File text box, select “Import Sensor File.” The sensor settings will be imported into the base sensor calibration file.
   • Exit the calibration file importer window.
8. Launch the STS-LIVE application.

INFORMATION: A detailed video that outlines the STS-LIVE installation is available on our website:
https://bditest.com/product/training-support/video-tutorials/sts-live/

If USB drive is unavailable, the latest STS-LIVE version is available online. Files are downloaded into a “Zip” file that should be extracted to the hard drive prior to installation. https://bditest.com/?smd_process_download=1&download_id=4549

COMPUTER SECURITY SETTINGS

Ensure that ALL Internet security and firewalls are turned off or enter STS- LIVE as a trusted program within any third-party Internet security software (i.e., Norton Internet Security) and Windows® firewall. In most cases, when the STS4 system has communication problems, the issue results from the computer’s firewall blocking communication. For more details regarding the disabling of security programs, please refer to the operation guide for the specific security program installed on the computer.

ASSEMBLE SYSTEM & COLLECT DATA

STEP 1: ESTABLISH A CONNECTION BETWEEN PC AND STS4-WBS

1. Turn on the STS4-WBS and wait for the boot-up sequence to complete. The wireless network “STS” should be visible by the computer’s network adapter.
2. If you are using wireless communication, establish a connection to the “STS” network, as shown in Figure 11.
3. If using the wired connection, plug a cable into the STS4-WBS Ethernet port and the other end into the computer’s Ethernet port.
4. Once a connection is established, Windows® will display the connection status in the taskbar. The status will include a warning symbol, indicating that the network is not identifiable and that an Internet connection is unavailable, which is ok since this is a closed network.

STEP2: LAUNCH STS-LIVE

Table 6: Main Tab Descriptions

Table 7: System States and Descriptions

STEP3: ESTABLISH CONNECTION TO THE STS4 NODES & ALPT

1. Connect sensors to STS4 nodes.
   INFORMATION: Although the STS4 hardware contain electronic protection, it is recommended to always connect sensors when the hardware is powered OFF.

2. Power on all STS4 nodes.

3. A few minutes may be required for all nodes to establish a connection to STS-LIVE.

4. If using the optional ALPT, power the unit on.

5. All STS4 components should appear in the Hardware Tab. Verify that STS4 components and sensors are accounted for.

Table 8: Node Connection Icons and Sensor Type Icons

INFORMATION: The most common reason for nodes to lose connection is due to disruptions with the wireless network or faulty connection in a wired network. If a node loses connection, check all network devices to ensure that the network infrastructure is intact. When using wireless networks, ensure that STS4 nodes have a clear line of sight to the STS4-WBS for a more stable connection. It is also good practice to have the test computer located close to the STS4-WBS when operating wirelessly. Often, the weak link is the PC to STS4-WBS link due to an improperly-configured PC network adapter, or a low- cost wireless network adapter within the PC.

STEP 4: RUN TEST
Now that the hardware has successfully connected to STS-LIVE, you are ready to collect data. Data collection can be started from either the Hardware Tab or the Display Tab. However, if you want to view graphical data, that can only be done from the Display Tab.

Table 9: Test Panel Buttons and Descriptions

STEP 5: REVIEW DATA
Follow the file path saved under the Settings Tab to view recorded data. By default, this location will be C:\STS_UserData\Data. STS-LIVE automatically creates a month folder at this location and a date folder within the month folder that corresponds to the test computer’s current date and time information. STS-LIVE data is saved in a TDMS file format that can be viewed using BDI’s STS-VIEW software or opened directly in Microsoft Excel. STS-LIVE can also save the raw data in an ASCII text file (Settings Tab).

INFORMATION: For a more complete explanation of the TDMS file structure, please visit the National Instruments website: http://www.ni.com/white- paper/3727/en/
To view TDMS files with older versions of Microsoft Excel you may need to install the TDMS file reader extension for Excel: http://www.ni.com/example/27944/en/

STS-LIVE SUPPORT

STS-LIVE HELP GUIDE
Additional user support is available through the online STS-LIVE Help Guide by selecting the question mark icon, as seen in Figure 15. Note that when the Help Guide is open, all other STS-LIVE functions are disabled. Depress the Help icon a second time to exit the Help Guide.

INFORMATION: W hen the help guide is active, the help icon remains depressed and the mouse pointer changes to indicate that the help system is active. There are many active hyperlinks throughout the STS-LIVE application, clicking on various items will automatically take you to that portion of the help guide. If an active hyperlink does not exist, try using the search function.

TRAINING VIDEOS
This Quick Start Guide has been developed to assist users in assembling, initiating, and testing out any size STS4 system with the least amount of effort and training. Due to the nature of structural testing, many more options and test configurations are available, which are described in further detail through training videos available in our online video library accessed through the Resources tab on our website and Youtube.com.
https://bditest.com/product/training-support/video-tutorials/sts-live/
https://www.youtube.com/channel/UCUX3keE_3I3YOtgOHw6gQkQ

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LOUISVILLE CO 80027

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support@BDITEST.COM
+1.303.494.3230

No part of this operations manual may be reproduced, by any means, without the written consent of BDI.
The information contained within this manual is believed to be accurate and reliable. However, BDI assumes no responsibility for errors, omissions, or misinterpretations. The information herein is subject to change without notification.
Copyright © 2015 – 2022
Bridge Diagnostics, Inc. (dba BDI)

References

• Structural Health Monitoring and Structure Diagnostic Testing
• Support - BDI Structural Testing & Monitoring Systems
• TDM Excel Add-In for Microsoft Excel Download - NI
• NI TDMS File Format - What is a TDMS File? - NI
• Applications Tutorials - BDI Structural Testing & Monitoring Systems

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