Installing an Enwatch Surveillance System
Objectives –
To cover the installation process from the initial selection of machines to be monitored through
the software links required in Emonitor Odyssey and the Emonitor Online Module.
To discuss the considerations when picking a spot for an Enwatch box, understanding the
network interface and why your Information Technology or Information Services group will have to
be involved.
To deal with the nuts and bolts of installing an Enwatch including the local setup of the unit and
the software configurations needed to make a connection and route the data to the correct
location in the Odyssey database.
Considerations when planning to install an Enwatch System
Which Assets to monitor
The first consideration is to determine which machines warrant surveillance monitoring as
compared with walk around or protection monitoring. Figure 1 gives a good representation of
where surveillance monitoring has typically fallen in a condition-monitoring program.
E ntek IR D Internation
C ost vs . S can R ate
“Critical”
$$$ Co ntinuou s
C os t o f L os t P roduc tio n
M onitoring and
Protection
“Essential”
System s
O n-lin e
$$ Surveillance
System s
W alk -A rou nd
“BOP ”
Data Collec tors
and An alyzers
$
Y ea rs M o nths W e ek s Days H o urs M in utes S eco n ds
G radual Degradation Sudden O nset Failure
T im e to Failure / R eq uired S can R a te
Figure 1
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As the graph represents, on-line surveillance systems are used on assets that are not only costly
to maintain, but more so when not in service due to the cost associated with lost or decreased
production. The other factor that comes into play is the anticipated time from the first indication of
a developing problem to the actual onset of failure, if the asset is more likely to fail in days or
weeks than an on-line surveillance system is the most cost effective approach. Research shows
that Enwatch becomes more cost effective than walk around when the required data collection
interval more frequent that every four weeks. Note, however that because of its multiplexed
single channel design, the Enwatch surveillance system is not intended to take the place of a
protection system. The other application for on-line surveillance is represented in Figure 2.
International
Cost vs. Scan Rate
“Critical”
$$$
of Lost Production
“Essential”
Online Surveillance
$$
Systems
Dangerous
→
h
a tc
IRD
“BOP”
&
w
En
Inaccessible
Entek Cost
Locations
$
←
Years Months Weeks Days Hours Minutes Seconds
Gradual Degradation Sudden Onset Failure
Time to Failure / Required Scan Rate
Figure 2
Dangerous and inaccessible locations have increasingly become a common use of surveillance
systems. Machinery that had been left out of programs in the past due to the expense of manual
data acquisition in dangerous and inaccessible locations are now being added, because of the
decrease in the cost per point and ease of installation of surveillance systems.
Location and installation costs
In the past, the prime reason for selecting a surveillance unit’s location was at the point of
utilization due to the cost per point of the system and the desire to utilize all the channels. When
you’re considering locations and the number of Enwatch boxes, factor in all of your costs. Often a
single centralized box is more costly than 2 localized boxes due to the cost of running the signal
cables possibly being higher than adding a second box. Also, check with your Information
Technology or Information Services department on the availability of network drops in the areas
that you are planning to locate your units.
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Getting Information Technology or Information Services (IT/IS) Involved
Getting your IT/IS department involved during the planning stage is important. They usually are
owners of the site network and will have a vested interest in the project. They will have questions
like how much traffic will be produced, what speed it will be running at and what protocols are
being used. They will also hold the key to your local area network (LAN), its configuration and
limitations. They will be the ones who can help with the connection to the network, and should be
able to answer specific local questions. The IT/IS department will need to help determine if a
simple hub is all that is required, if there is an available router, will you create your own LAN for
the Enwatch system or will an Ethernet switch or bridge be required. They will also be the ones
that provide the static network addresses which are required, such as IP addresses and Subnet
Masks. Having the IT/IS department involved up front will better allow you budget the job, be
better prepared when the time comes to install the system, and help to create a smooth running
system from the start.
System Architecture
RS232
RS232
database
Server Station
Odyssey Station
Ethernet Ethernet
Ethernet
Ethernet
enwatch unload
station/Analysis
Station
206.112.221.178
enwatch enwatch enwatch
206.112.221.191 206.112.221.192 206.112.221.190
Figure 3
Physical installation of an Enwatch unit and Sensors
Guidelines for installing permanent sensors for an on-line system
If you have never mounted sensors permanently before there are some things to be aware of
before you start. First, consider how many sensors to use at each location. Three sensors per
bearing would be optimal. Sometimes physical restrictions or budgetary limitation do not allow for
the optimum. If faced with this problem, here are some things to think about:
• Data should be taken at each bearing,
• If limited to only one radial per bearing look at previous data if available or the design
of the machine for the direction most likely to give you the first warning of a problem,
and
• Consider at least one axial sensor per solid shaft to look for problems only identified
from energy in that direction.
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When permanently mounting sensors, you should mechanically attach them to ensure that they
stay where you want them. If physical changes are not allowed, such as drilling and taping, an
alternative would be to epoxy the sensors in place.
Wiring Alternatives from the Sensors to the Enwatch Box
Most new vibration sensors utilize twisted shielded pair cabling to minimize Electro-Magnetic
Interference (EMI). The twisted pair is used to carry the signal and are connected from the
transducer directly to the input terminal. The shield must only be attached at one end to keep
from creating a ground loop and allow it to perform its function of protecting the signal. Other
vibration sensors, as well as some process parameter sensors may only have coaxial cable,
which should be wired directly to the input. If you have chosen to centralize the Enwatch box to
utilize it for several machines, you may want to consider remote junction boxes and multi-pair
cable to help minimize the cost.
Connections on the Enwatch Board
Figure 4 below is a representation of the connections to an Enwatch board.
Figure 4
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Connectors J1 and J2, at the bottom of figure 4, are terminal blocks utilized for dynamic signal
input, each accepts 8 channels.
Figure 5 shows the corresponding channels for each of the terminal blocks as well as a
representation of an analog input configuration jumper. The jumpers are used to setup each
channel for the type of input that is being applied. With the jumper across the first 2 pins the
channel will support an ICP type transducer, the most common type used today. A jumper
across the last 2 pins will support a DC coupled device and no jumper will allow the input and
support of an AC coupled device. The Enwatch is setup to be a constant current device. If
required, modifications can be done to support constant voltage type transducers. Note that the
Weidmuller terminal blocks used on the Enwatch board allow quick disconnection without
unwiring if the board ever needs to be removed.
Figure 5
Connectors J3 – J6, upper right in Figure 4, are trigger input channels that are compatible with
CMOS/TTL type devices. Any voltage input in the range of 5-24V can be accommodated.
Figure 6 shows the pin-outs for the 4 connectors. Board supply voltage is available on pin one to power an
external trigger device, if required. The voltage on pin 1 is equal to the input from the power supply.
A jumper is supplied for each trigger channel to allow it to be isolated or non-isolated, the common of the
trigger input able to be tied to the common of the Enwatch, or not, at the user’s discretion. Note that if you
plan to power your device from pin one, then the jumper corresponding to that trigger channel must be
connected to provide a ground return path for the sensor power.
J3 – J6: External Trigger
Signal Pin No. Notes
Power Supply 1 Power to supply external device
Input 2 CMOS/TTL type or 5-24V
Ground 3
Figure 6
Connector J8, upper left in Figure 4, is a standard RJ-45 Ethernet modular type connection.
Enwatch supports Ethernet 10BASET the most common speed network found in business today.
There are also 4 LED’s on the Enwatch board, upper middle in Figure 4, that indicate the status
of Ethernet communication. These illuminate as follows:
OB: Enwatch is accessing LAN controller
LK: communication link is established between Enwatch and network
RX: data is being received
TX: data is being transmitted
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Connector J9, upper right corner in Figure 4, is the supply voltage input. Supply voltage should
be in the range 7-12Vdc. Incoming AC mains supply voltage to the power supply can be 80-240
Vac / 50 or 60 Hz. Approximate power consumption is 500mA with no ICP transducers connected
or 750mA with 16 transducers supplied from the board. In order to minimize heat dissipation on
the heat sink, it is suggested that the input voltage be set to 9Vdc, especially when the board is
supplying power to all 16 transducers.
Connector J11, top of Figure 4, is an RS232 compatible serial port, it provides local
communication with the board (i.e. independent of the network). A null-modem type cable
must be used. An on-board software monitor is provided which communicates via the serial
port.
Configuration of the Enwatch Firmware for Communications with your
Network
Monitor Mode
Enwatch incorporates an on-board monitor program for checking the unit and modifying the
systems addresses. When a jumper is inserted into JP21, center in Figure 4, the Enwatch will
operate in its internal monitor mode. This enables you to change the Enwatch IP address as well
as modify its options. Before installation, make sure you have plant specific IP network
addresses, Subnet Mask , Gateway IP(if it is available) available for each Enwatch.
To invoke the monitor mode:
1. Attach the Enwatch to the test computer via the RS-232 (serial) port using a null modem
cable.
2. Make sure the jumper in the middle of the Enwatch board is shorted (JP21)
3. Start up any terminal program (Winterm, QVT/Term, Procomm, Hyper Terminal etc…)
and set it up to communicate through the serial port at 9600 Baud, No parity, 8 data bits,
and 1 stop bit.
4. Turn on the Enwatch. It should display its configuration, then a configuration menu in the
terminal window, see Figure 7.
.
--------- Start monitor com port: COM1 9600 N81
Intelligent Transducer Adapter Type 1) V 1.2
Copyright Icon Research Ltd 1998/99
Main Menu:
1 - Exercise Hardware Control
2 - Exercise Memory Devices
3 - Exercise Ethernet Controller
4 - Exercise Combined Sub-Systems
5 - Configure Adapter Settings
6 - Enter Download Mode
Make your selection (1-6) : 5
Figure 7
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By selecting option 5 you will be able to adjust all the needed communications settings. Figure 8
shows the selections that are available.
Select the Configure Adapter Settings
Intelligent Transducer Adapter Type 1) V 1.2
Copyright Icon Research Ltd 1998/99
Configure Adapter Menu:
1 - Default Settings
2 - Assign Host MAC
3 - Assign Host IP
4 - Assign Host UDP Port
5 - Assign Subnet Mask
6 - Assign Gateway IP
7 - Assign Name
8 - Assign Network Option
9 - Assign Debug Level
ESC - Back to Main Menu
Figure 8
Selection 2 allows you to check and set the MAC or hardware address of the board. The address
is identified on the board.
Selection 3 lets you assign the plant specific IP address for this unit. This needs to be an
individual number and should be supplied by your network administrator. Note that unlike many
software programs the Enwatch firmware requires that all 12 digits of the IP address need to be
entered, including leading zeros.
Selection 4 is the Host UDP Port, it is required to be set at the default value of 4242.
Selection 5 lets you assign the plant specific Subnet Mask to be used by this unit. Again this
needs to be supplied by your Network Administrator.
Selection 6 lets you assign the plant specific Gateway IP to be used by this unit if your network
requires one. Again this needs to be supplied by your Network Administrator.
Selection 8 needs to be set to Ethernet 10 Base T as your network option
Selection 9 – leave the Debug level off unless you are asked to specifically select it by an Entek
Customer Service representative for problem investigation purposes. Debug modes other than
zero cause the system to run slowly.
When all of your communication settings are in:
• Shut down the Enwatch by removing the AC power, and turn it back on. Look at the
configuration settings and make sure the MAC and IP address are the same as what you set
them to.
• Shut down the Enwatch again, by removing the AC power, remove the jumper in the center of
the board, and connect the board to an active Ethernet connection.
• Open a DOS prompt on a networked computer. Type “ping” then a space, then the first IP
address. You should get a return response from the Enwatch.
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If you get a response disconnect from the RS-232 port and you are ready to setup the Odyssey
Online Module.
Setting Up Odyssey Online for use with Enwatch
Hardware Setup
Hardware Setup is the program used to configure your online system. Remember that data
collection parameters are still controlled from Odyssey just as you would for your walk around
points.
The first step is to identify which computer will be your Enwatch unload station. The unload
station is the computer that gets data from the Enwatch, processes it and delivers it to the
database only when told to. Figure 9 shows the first dialogue box when setting up an unload
station, you are required to select the type of unload station based on the instruments that you
are going to attach. Although an unload station has the ability to support many instruments they
do have to be all of the same type.
Figure 9
The second dialogue box, Figure 10, has you identify the unload station by it’s IP address and
also gives you a text field to give a descriptive name to the computer. Once you’ve completed
your entries, click finish and a new unload station will be added to the hierarchy on the main
screen. Once the system refreshes, the icon for this unload station in the hierarchy should
indicate ‘on’.
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Figure 10
The next step is to insert an instrument to be used with this unload station, you can insert either
by a right click the edit pull down. Once inserted an Enwatch properties dialogue box appears,
Figure 11, allowing you to setup your Enwatch box.
Figure 11
The General tab in Figure 11 allows input of a text description for identification of this Enwatch
box within the program and the IP address of the Enwatch box.
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Figure 12
Figure 12 shows the channel tab, this is where you map the Enwatch channel to the Odyssey
Location. By double clicking in the “Machine or Location” fields, you are given a location browser
to navigate with in the Odyssey hierarchy to find the point that this channel will be tied to. Note
that you will need to create the points in Odyssey prior to mapping the Enwatch. Once you have
selected the point, Hardware Setup will fill the “Machine and Location” location fields. The trigger
channel allows you to select which trigger to apply to this channel, or select 0 for no trigger.
By double clicking on the validate box the dialogue box shown in Figure 13 appears.
Figure 13
This validate dialogue box allows selection of any channel and measurement, that if outside of a
specified range, prevents the data that is collected for this channel from being stored to the
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database. This keeps the system from saving data taken on a non-running machine or only when
a certain driver is driving it.
The trigger channel tab allows for the setting of a timeout and number of pulses per revolution for
each trigger channel, as shown in Figure 14.
Figure 14
The Timeout parameter is the number of seconds before trigger times out, skiopping
acquisition for that channel. The default is 5 seconds.
The number of pulse per revolution can be in the range of 1 to 999. The default is 1, which
will be most common. Multiple pulses can be accommodated and will be used when you are
looking at a multi-toothed gear as your speed reference input.
The schedule tab allows you to set the date and time for the Enwatch to begin taking data, as
well as how often you want the route to be run.
A note field is also provided to help keep track of any changes made to the system.
Once the configuration is complete and the system refreshes the hierarchy icon for this
Enwatch should change to ‘on’. You now need to load the route into the Enwatch unit. This is
done one of the following 3 ways; the load push button on the button bar, right clicking the
Enwatch you want to load in the hierarchy or the control pull down.
Other options that you have within Hardware setup are:
• Manual Acquire – forces the Enwatch into starting it’s route,
• Unload – starts the unload process manually, and
• Refresh - allows manual initiation of system refresh.
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Scheduler
The “Scheduler” allows you to build a profile on when and how you want your data to move from
the unload station.
There are 3 options for getting the data from the unload station to the database.
You can set up Scheduler to periodically, such as once an hour, have your database updated.
You may want to work around heavy network traffic times and have your database updated at
lunch or on the back shift. With this selected a frequency tab is made available allowing you to set
the time and date to start transferring data as well as how often.
If you want data to move to your database as quickly as possible select the “File Change
Notification” option. This sets the Scheduler to transfer the data from a directory that the unload
station uses immediately upon seeing the file arrive. With the File Change Notification selected a
settings push button is made available allowing you to identify which file type to watch for
changes.
The last option is Manual Launch. With this checked, a button appears when the profile is
selected allowing you to override the time schedule and transfer the data immediately. Along with
this goes a check box that choose from advancing the schedule to the point of Manual launch and
reset the clock or leave the schedule as is.
The last part of setting up the scheduler is the Event tab. This is where you define the event that
will be executed whenever the launch condition is meet. For on-line surveillance systems, for the
data to get transferred to the Odyssey database, the executable that is required is
“didaemon.exe” that is in your Odyssey or Enshare directory. A command line that will point the
transfer to the right database and should be set to “odonline.edi” which is also in your Odyssey
directory.
Setup Complete / Start taking data
Once the installation, firmware configuration and software setups are complete you are ready to
start taking data. All that is require to be running on the unload station computer to collect and
store data to the database is the “Scheduler” and the “Unload Station Manager”(USM). Note that
USM has no user configurable parts. It simply controls communications and logs all tasks that
are performed between the Enwatch and the Enwatch Unload Station. It uses the schedule
information that you entered in Hardware Setup to determine when to unload which Enwatch box
in the field.
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