Sensoteq WMVM ANTR2006 Intelliwear Monitoring Systems Installation Guide

Document: DOC-00898
Publish Date: 23/08/2023
Authors: Ciarán Caldwell / Martin McNeill
Installation Guide

Sensors for Intelliwear monitoring systems
Sensor Model: WMVM
Gateway for Intelliwear monitoring systems
Gateway Model: ANTR2006

Sensoteq Ltd
8 Cromac Avenue
Belfast BT7 2JA UK
Copyright Sensoteq Ltd 2022

References

Versions

Nomenclature

Safety and Regulatory Information

WARNING: A WARNING indicates a potential property damage, personal injury, or death Battery Safety
WARNING: The WVMVM sensor contains a battery. The battery is enclosed within the product however if the batteryis damaged then the sensor should not be used.
Safety and Regulatory Information
You can find additional Safety Best Practices and information on REACH, Electromagnetic Compatibility (EMC), Ergonomics, Transportation, and Tuners on the Regulatory Compliance page, www.sensoteq.com/regulatory_compliance.
WARNING: Use of controls, adjustments, procedures, connections, or signal types other than those specified in your documentation may result in exposure to shock, electrical hazards, and/or mechanical hazards.

• Sensoteq products are not designed for use in hazardous environments unless purchased as ATEX certified Sensoteq products. If you require ATEX certified products contact Sensoteq for appropriate part numbers.
• Sensoteq product are not designed for use in operating or calibrating machinery. Sensoteq products are monitoring equipment only.

WARNING: Do not operate your equipment disassembled.
The product should remain as purchased with backing plates and bases etc. installed
AC Power supplies are not IP rated and must be protected from water ingress.

• Do not use damaged equipment, including exposed, frayed, or damaged power cords.

WARNING: Do not attempt to service the equipment yourself, except as explained in your Sensoteq documentation or in instructions otherwise Power and Adapter Safety
WARNING: RISK OF FIRE or ELECTRICAL SHOCK when using a main plug adapter that is not specified. Use only the Sensoteq-provided AC adapter approved for use with this device. Use of another AC adapter may increase the risk of fire or explosion.

• Check the voltage rating before you connect the equipment to an electrical outlet to ensure that the required voltage and frequency match the available power source.

The AC adapter may become hot during normal operation of our product. Ensure adequate ventilation and use care when handling the adapter during or immediately after operation of your device.
CAUTION: Your AC adapter has no accessible earthed metal parts, so it is not possible to perform an Earth Continuity Test.
The low voltage DC Output Connector Is not an earthed part and should not be subjected to the Earth Continuity Test as this may give an incorrect result and could damage the AC adapter.

Location of Radio Regulatory Labels
For some products, the radio regulatory labels may be found on the bottom or rear of the equipment
Recycling Information
Sensoteq recommends that customers dispose of their used sensors, gateways, and other peripherals in an environmentally sound manner. Potential methods include reuse of parts or whole products and recycling of products, components, and/or materials.
For specific information on Sensoteq’s worldwide recycling programs, see: www.sensoteq.com/recycling.

Waste Electrical and Electronic Equipment (WEEE) Directive
**** In the European Union, this label indicates that this product should not be disposed of with household waste.
It should be deposited at an appropriate facility to enable recovery and recycling. For information on how to recycle this product in your country, please visit: www.sensoteq.com/recycling.

Battery Disposal
The WMVM/VSM/VHM sensor contains a Li-SOCI2 (lithium based) battery and must be recycled according to local regulations.
The Gateway can be recycled as electronic waste according to local regulations.
SIMPLIFIED DECLARTION OF CONFORMITY FOR RADIO EQUIPMENT DIRECTIVE 2014/53/EU
Sensoteq Ltd. declares that all CE Marked Sensoteq products incorporating Radio Equipment functionality are in compliance with Directive 2014/53/EU.
The Full text of the EU declaration of conformity is available at the following internet address: www.sensoteq.com/regulatory_compliance.

**** In the European Union, this label indicates that the batteries in this product should be collected separately and not be disposed of with household waste.
Substances in batteries can have potential negative impact on health and environment and you have a role in recycling waste batteries, thus contributing to the protection, preservation, and improvement of the quality of the environment. You should contact your local authority or retailer for details of the collection and recycling schemes available. Alternatively visit: www.sensoteq.com/recycling.
Registration, Evaluation, and Authorisation of Chemicals (REACH)
REACH is the European Union (EU) chemical substances regulatory framework. Information on substances of very high concern contained in Sensoteq Products in a concentration above 0.1% weight by weight (w/w) can be found at: www.sensoteq.com/REACH.

Regulatory Notices
For Electromagnetic Compatibility (EMC), see www.sensoteq.com/regulatory_compliance.

This device complies with Part 15 of the FCC Rules Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation.
WARNING: Changes or modifications not expressively approved by the party responsible for compliance could void the user’s authority to operate the equipment.
This device contains licence-exempt transmitter(s)/receiver(s) that comply with Innovation, Science and Economic Development Canada’s licence-exempt RSS(s). Operation is subject to the following two conditions:

1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause undesired operation of the device.

Installation Process

A typical installation follows the process below:

1. Check equipment
2. Download Install App
3. Connect gateway(s) to PLC
4. Gateway setup
5. Using the Sensoteq Install App
6. Assign sensors to gateway(s)
7. Install the sensor(s)
8. Test and install gateway(s)

The best method is to connect each gateway in turn (and add sensors) as the installation progresses, then move onto the next gateway.

Checking Equipment

When you receive the Sensoteq equipment please check:

• None of the equipment has been visually damaged during transport
• You have the following equipment:

o Hose / Spool Kit
▪ Sensor only
▪ Hose or Spool connection interface (+ seal)
▪ 4-Way Connector with x4 crimp contacts
▪ Sensor ID label sticker

o Gateway Kit
▪ Gateway (with DIN rail bracket)
▪ External Antenna (with bracket)
▪ SMA-SMB RF adapter
▪ 12V power cable
▪ 2m ethernet cable (Cat 5E / Cat 6)

• You have at least one gateway per group of sensors
o Typically, one per physical room or large piece of equipment
o A maximum of 40 sensors per gateway
• A power supply (or connector) for each gateway

Physical Identification

Weld fit to Spool
Order code| Product Kit| Purpose
---|---|---
WM-K0H| Hose kit| Hose Monitoring sensor kit – transmit RF data
WM-K0P| Spool kit| Spool Monitoring sensor kit – transmit RF data

Sensors for Intelliwear monitoring systems

Gateway

Bolted or DIN Rail

PLC via Modbus

Type Identification

Additional Equipment
• Tools to affix the gateway or sensors to the equipment
o Allen key
o Spanner
o Paper clip (or Ø1mm x 25mm long tool, e.g. Allen key)
o DIN rail inside Gateway installation cabinet (not essential)
• A Mobile Device
o Any phone or tablet running Android OS 9, 10 or 11
o An iPhone

Download Install App

• The VHM Install app is required to complete the full installation process. This is available from:
o Android – Google Play Store
o iOS – App Store

Connect Gateway to PLC system

Power gateway using the 12V power supply provided and connect ethernet cable (Cat 5E / Cat 6) from gateway to PLC.
Data from the gateway can be read via the Modbus serial communications protocol.
Modbus is a master-slave system, where the master communicates with one or multiple slaves. In this instance, the PLC is the master, and the gateways are the slaves. The PLC requests (polls) the sensor data from the gateway via ethernet.

Gateway Setup

General process
• Have to hand:
o Paper clip (or Ø1mm x 25mm long tool, e.g. Allen key)
o Gateway Unique Part ID
o Android phone or tablet
It is important to setup the gateway correctly before installing any sensors, as this will ensure that the gateway can successfully receive data from any sensors that are intended to be assigned to it.

Installation Guidelines

Place the gateway close to the proposed location where the gateway will be installed. This exercise is to ensure the proposed gateway location is sufficient to receive data coming from the linked sensors.

• The gateway should be as close to the equipment being monitored as possible

• Place the gateway as high as possible above the level of the equipment

• Direct line-of-sight to the equipment works best, but is not essential

• Objects between equipment and the gateway
  o The gateway will still work with objects between the gateway and the equipment/sensors
  o The thickness, metallic properties and number of objects will have an impact on the ability of the gateway to receive signals from the sensors
  o High voltage/current power lines close to the gateway will negatively impact range

• It may be necessary to move the gateway after the sensors are installed to ensure optimum signal strength

• Further information is available in the following sections

Gateway Modes
The first step in setting up a gateway is to understand what mode it is currently in.

1. Power gateway using 12V power cable provided
2. Connect ethernet cable from gateway to PLC
3. Check gateway LED for connection status

Gateways have several modes denoted by the LED colour:

The device is connected to Ethernet with no internet connection.
BLE Listening Mode The gateway is in advertising mode.
| Dark blue Pulsing| No Wi-Fi Credentials
No WiFi configured, please connect to the device and set WiFi credentials.
| Cyan Slow “Breathing”| Connected to Cloud Working as expected.
| Cyan Fast blink| Searching for Cloud
The device is connected to WiFi and internet is available. Attempting to connect with Sensoteq cloud services
| Bright Green Fast blink| Searching for WiFi
The device is attempting to connect to WiFi. If it remains in this state for more than 3 minutes please see your IT administrator.
| Magenta Fast blink| System: Firmware Updating The gateway is performing an update of its firmware. This is an automatic process.
| Red
Fast blink or Slow Flash| System: Fault Detected
The gateway will attempt to restart automatically. If this pattern persists, please contact Sensoteq.

Do not disconnect the Gateway power while Firmware update is in progress (Magenta)

Using the Sensoteq VHM App

• Download the Weir VHM App from:
o Available apk
o Google Play Store
o App Store

• Open the Weir VHM App

• From the VHM Installation home screen, there are options to either Scan for Gateways or Scan for Sensors

a) Connect to a Gateway

• Press the Scan for Gateways button on the VHM Installation home screen

• Press the Scan button on the Scanning for Gateways screen

• Gateways that have been found will appear in a list. These can be pressed to select or use the scan button to rescan for gateways

• When a gateway has been selected, it will display details of the gateway and also the sensors associated to it

• The gateway and sensor details can be modified by selecting the chosen option

• On the Sensor Association list:
  a. Sensors highlighted in Blue indicate that sensor data has been updated
  b. Sensors highlighted in Grey indicate that the sensor has not been seen for 120 minutes or more
  c. Sensors highlighted in Purple indicate that the sensor battery level is low. The low battery tag will take priority over the blue or grey tags

• To disconnect from the gateway, press the Disconnect button at the bottom of the screen

b) Connect to a Sensor

• Press the Scan for Sensors button on the VHM Installation home screen
• Press the Scan button on the Scanning for Sensors screen
• Sensors that have been found will appear in a list. These can be pressed to select or use the scan button to rescan for sensors
• When a sensor has been selected, it will ask you to confirm that you wish to connect to the sensor. Press the Connect button
• When a sensor is connected, it will display details of the sensor and some configuration options
• Live Incoming Messages are displayed at the bottom of this screen

c) Select Sensor Mode

1-Wire Mode

• To put the sensor into 1-wire mode, press the 1-Wire button
• When a sensor mode has been selected, it will ask you to confirm that you wish to update the sensor mode to ‘1-Wire’. Press the Continue button
• The sensor mode will update to 1-Wire after a period of time, and the Incoming Messages will show the sensor is set to Rst1 when there are no valid resistances across either coil
• The sensor mode will change to ‘OkC1’ or ‘OkC2’ when 6 valid resistance samples are detected across either Coil 1 or Coil 2 respectively, and the Green LED will flash

2-Wire Mode

• To put the sensor into 2-wire mode, press the 2-Wire button
• When a sensor mode has been selected, it will ask you to confirm that you wish to update the sensor mode to ‘2-Wire’. Press the Continue button
• The sensor mode will update to 2-Wire after a period of time, and the Incoming Messages will show the sensor is set to PRST when there are no valid resistances across either coil
• The sensor mode will change to ‘OK’ when 6 valid resistance samples are detected across Coil 1 and Coil 2, and the Green LED will flash

d) Sensor Diagnostic Commands

• To select a sensor diagnostic command, press the Diagnostic Commands button
• The diagnostic commands are shown below. Incoming messages are also displayed at the bottom of this screen
• When an option is selected, the button will turn red for a few seconds. The sensor will transition to the selected diagnostic state after 6 valid samples

e) Upgrade Sensor Firmware

• To load new firmware onto the sensor, press the Upgrade Firmware button from the Connected to Sensor screen
• On the Upgrade Firmware screen, press the Select File button
• Select the appropriate zip file
• Press the Update Firmware button and the firmware will begin updating. The Sensor will have the Yellow LED on for a few seconds during this operation. Once finished, the Update Complete message will appear

Understanding RF Range

Line of Sight (LoS)
Direct line of sight between the sensor and gateway will work up to 100m in optimum conditions. As distance increase the RF energy will decrease.

Indirect or structural blockage
Any object that blocks the path from the sensor to the gateway will reduce the range. It is best to place the gateway on the same side of the structure as the sensor.

Sensor within protective housing
If the protective housing is made from plastic or a thin gauge metal with ventilation or other holes then there is a good possibility that RF will be received outside the housing. Range will be impacted.

Line of Sight with metal surroundings
Any additional metal surrounding the sensor will attenuate the signal, even if you still have direct line of sight. Range will be impacted.

Sensor Configuration

The sensor measures the resistance of the wires embedded in the hose/spool. Resistance values of ~12 ohms or less indicate that the wire is unbroken. Values over 12 ohms indicate a broken wire.
The sensor can be configured to measure either 2 wires or 1 wire embedded in the hose/spool depending on the system requirement.
Using the VHM app, BLE commands can be sent to the sensor to configure it into the desired mode. These are listed in the following flowcharts (i.e. SETUDX with the X replaced by a number).
Below are a list of the BLE commands that can be sent to the sensor to configure into the desired mode.

There is a delay of around 5 minutes from Reset to normal mode to allow handling time of the sensor.
The Sensoteq VHM app includes buttons pre-set with the above commands and allows for firmware upgrades. The VHM app also allows switching between 1-wire and 2-wire modes.
Note: Sensors are shipped in Transit mode for battery saving. When wires are connected and the sensor measures a valid resistance, it will stay in Transit mode for 10 minutes (Green LED flashing every 30 seconds) and then transition automatically to Normal mode.

2-Wire Mode
In 2-Wire mode the sensor measures the resistance/inductance of 2 wires which are embedded at thicknesses of approximately 50% and 75% in the hose/spool.

1-Wire Mode
In 1-Wire mode the sensor measures the resistance/inductance of 1 wire which is embedded at a thickness of approximately 80% in the hose/spool.

Install the Sensor

Sensor on Hose
Below is an example of the hose sensor after installation, the sensor should be screw down until it is hand tight. For further instruction refer to OEM documentation.

Sensor on Spool
Below is an example of the spool sensor after installation, the sensor should be screw down until it is hand tight. For further instruction refer to OEM documentation.

Wire terminal connection to hose/spool

Connecting the wear cable/wire from inside the hose/spool to the Sensor.
The supplied terminals and connector are shown below.

Use the correct crimp tool to crimp the terminal to the hose/spool wear indicator wire.
Deutsch Tooling part number HDT-48-00
The hose/spool will have 4 wear indicator wires protruding from the sensor mount area.
These are paired as a coil 1 and coil 2 and are to indicate partially worn and fully worn.
The picture below shows the correct way to connect the wear indictor wires for the sensor to detect wear.

Connector locations 1 and 2 are to be connected to 1 of the wear indicator wires and locations 3 and 4 should be used for the remaining wear indicator wear.

Install each Gateway

Now that the sensors have been installed, affix the gateways in a more permanent manner.
The gateway has two mounting options:

• Bolted/screwed
• DIN Rail

The gateway is powered via a 12v connection. Please use the power supply connection cable provided.
If using an external power source, such as that within an enclosure or panel, ensure that it has capacity to provide 2A@12vdc.

Troubleshooting

Please refer to the customer service email address below for additional support. support@sensoteq.co.uk

Regulatory Information

Note the label is located on the base of the sensor.
FCCID: 2ANL3SPR433TA ICID: 23633-SPR433TA
Note : The approvals number label is located on the inside of the back cover This device complies with part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
WARNING: Changes or modifications not expressively approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This device contains licence-exempt transmitter(s)/receiver(s) that comply with Innovation, Science and Economic Development Canada’s licence-exempt RSS(s). Operation is subject to the following two conditions:

1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause undesired operation of the device.

Radiation Exposure Statement:
This equipment complies with FCC/ ISED radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with greater than 20cm between the radiator & your body.

Sensoteq Ltd
Unit 23 Ormeau Business Park,
Belfast BT7 2JA Northern Ireland UK
Copyright Sensoteq Ltd 2023

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