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Smart Sensor FAQ

ABB Ability™ Smart Sensor is a compact condition monitoring sensor that can be attached to the frames of induction motors and electric pumps. No wiring is needed. Using on-board algorithms, based on ABB’s decades of motor expertise, the ABB Ability™ Smart Sensor relays information about the motor’s health, via a smart device and over the internet, to a secure server. This solution turns electric assets into smart devices, enabling them to benefit from intelligent services.

Installation
Usage, Support & Security
User Management
Gateway
Knowledge Base
Installation documents: 
Activating Sensors and Adding Assets 
App Initialization and User Management 
Smart Sensor Installation Manual (ENG) 
Smart Sensor Installation Manual (GER)
Smart Sensor Installation Manual (Clamp Bracket) 

What are the technical requirements for the installation and use of the Smart Sensor? 

The Smart Sensor works with Bluetooth® 4.0 and up. If the Smart Sensor App is not listed in the application store it means that the smart device is not fulfilling these requirements. 

List of supported operating systems: 

iOS 10.0 or higher 
Android 5.1 or higher (Bluetooth® Low Energy support required) 

List of tested smart devices: 

iPad 2*
iPad Mini 2*
iPhone 7, 7+*
iPhone 6, 6+*
iPhone SE*
Samsung Galaxy S8, S8+ 
Samsung Galaxy S7
Samsung Galaxy A7   
Sony XPERIA L1 
Huawei P9 

*not suitable for sensor activation by vibration

List of latest Internet browsers on Windows Operating System for tested usage of the Smart Sensor Portal: 
Google Chrome 67.0.3396.87 
Microsoft Edge 42.17134.1.0 
Microsoft Internet Explorer 11.2248.14393.0 
Mozilla Firefox 60.0 

  

What is myABB?

myABB is a personalized channel for ABB services, helping to maximize equipment availability, optimize the lifecycle of assets and improve operational efficiency and performance. myABB account is required for use of the Smart Sensor Portal and the Smart Sensor App.  



Does the Smart Sensor require subscription to work?

Yes. Every Smart Sensor comes with a 60-day free trial period. After the trial, a subscription is needed to access the data gathered by the Smart Sensor. Subscriptions are available at the moment for 1 or 2 year periods. 



My Smart Sensor package is missing parts or some parts are faulty?

If you notice any faults on the Smart Sensor or other parts, please contact your Smart Sensor supplier. 



My asset’s bearing is not found from the Smart Sensor App’s list when I activate the Smart Sensor?

Please select the closest bearing option from the Smart Sensor App and contact Smart Sensor Support to inform the details of the missing bearing. 



The asset nameplate is missing some required information. Can some fields just be left blank?

If essential asset information is missing from the nameplate, please contact the asset manufacturer for details. It is vital that all of the required fields are filled with exact information, since the interpretation of the data relies on correct initial data.  



The system says that the Subscription Code has expired or has already been used?

The Subscription Code’s expiration date is announced in the Subscription Code sheet. In case of other questions, please contact Smart Sensor Support Team at support.smartsensor@abb.com



My Smart Sensor's mount doesn't fit to my asset!

The mount has to be a correct size to enable correct functioning of the Smart Sensor. If the mount doesn’t fit properly, please contact your local ABB Service.


Can the Smart Sensor be removed from the asset?

The Smart Sensor itself can be removed from the bracket and reinstalled with two screws. The sensormount is more difficult to remove and it is not recommended to do so.

Notice that removing the sensor mount might damage the motor frame and expose it to corrosion. Always use extra caution if removing has to be done.


Can the Smart Sensor be transferred to another asset?

Yes, the Smart Sensor can be moved to another asset. This requires the Smart Sensor to be first deleted from the old organization with the Smart Sensor App. During that procedure you can also choose whether the Smart Sensor's internal memory is reset or not. After deleting the old asset, you can normally recommission the Smart Sensor to a new asset. 



I'm having connection problems with my Smart Sensor!

The Bluetooth connection might be exposed to distractions generated by for example obstacles between the device and the Smart Sensor. Besides environment, the coverage area also depends on the Smart Sensor's and the smart device’s Bluetooth capabilities.

If retrying the connection or data transfer doesn’t solve the problem, please contact Smart Sensor Support Team at support.smartsensor@abb.com

Usage, Support & Security documents: 
End User License Agreement 
Smart Sensor Datasheet 

Does the Smart Sensor require an internet connection?

Gathering data from the asset to the Smart Sensor doesn’t require internet connection. Internet connection is required for the data transfer from Smart Sensor to the cloud server. 

 

What kind of batteries does the Smart Sensor use? Can the batteries be replaced?

There are four lithium batteries inside the Smart Sensor and they cannot be replaced. Opening the Smart Sensor's cover results in warranty void. Expected lifetime of the Smart Sensor’s batteries is up to 5 years depending on the operating temperature, measurement interval and other factors. 



In which kind of electric motors can the Smart Sensor be used?

The Smart Sensor can be used with both ABB and non-ABB motors up to 6000 Volts with rib-cooling and a maximum frame size of 450 due to the mounting part variables. The Smart Sensor supports monitoring of Direct Online Drive (DOL) and Variable Frequence Drive (VFD, Low-Dynamic Load) electric motors.  



How often does the Smart Sensor measure data and can the measuring interval be modified?

By default, the Smart Sensor measures data every one hour. The interval can be modified for each asset to a minimum of 5 minutes and maximum of 12 hours, but it is worth to mention that modifying the interval can drastically extend or shorten the lifetime of your Smart Sensor’s battery. 


How can I contact Smart Sensor Support?

The Smart Sensor Support can be contacted via support.smartsensor@abb.com


Which standards and certificates does the Smart Sensor utilize?

Please see the Smart Sensor Datasheet .



I'm having problems with updating the Smart Sensor's software?

The software updates are important for the Smart Sensor to utilize all of its features. During the update process the smart device has to be constantly within the Smart Sensor’s Bluetooth range. Please try a different smart device if the problem continues. Be aware, that the update process can be safely repeated if it fails.  



I suspect that the data given by the Smart Sensor is inaccurate?

Please make sure that the Smart Sensor is mounted properly. Also make sure that the asset details are correct in the Smart Sensor App and that they match the correct asset plate. It’s vital that all of the fields are filled with exact information, since the interpretation of the data relies on correct initial data. If some of the asset information is missing, please contact the asset manufacturer for details. If you still suspect that the data is inaccurate, please contact your local ABB Service. 


Where is the data storaged and processed?

The data is stored and processed in the Smart Sensor, user's smart device as well as on the server. Algorithms stored in the Smart Sensor perform the primary analysis, with further analysis and processing by algorithms stored on the ABB secure cloud server. 

Measurements done by the Smart Sensor are used together with algorithms that have been developed to evaluate operational parameters and these are then related to specific motor defects. For example, the solution analyzes a combination of measurements in the time and frequency domain to determine whether the bearings are defective. 

In this example, since motor-specific bearing manufacturer and type have been provided by the user it is possible to clearly determine whether the defect-related measurements are coming from the motor bearings themselves. 



Is the data transmitted to the ABB server in an encrypted form?

Industry standard encryption protocols are used to secure data transfer to the ABB cloud. The entire cloud server implementation is fully compliant with ABB’s cyber security guidelines. 

Data is stored in an encrypted form in the ABB cloud. The ABB portal uses a role-based access to ensure that the data is available only to the users with correct authorization. The connection to the ABB portal is secured with standard encryption protocols.  



Does ABB use the data provided by the Smart Sensors?

Through user consent given in the End User License Agreement ABB holds the rights to use the data provided by the Smart Sensors for development and big data analysis purposes.  

User Management documents: 
App Initialization and User Management 

Where can I track my asset's trend data?

By making the following selections in the Smart Sensor Portal:  

→ "Asset Details" (Top-page menu)
→ "Asset Detail" 
→ Select organization, asset group and asset 
→ Select desired dates and parameters to illustrate the graph 

 

What are the differences between the app and the portal?

The Smart Sensor App is required to activate, commission and delete assets. It also provides asset usage functions for users who choose not to join an organization. The most recent asset measurements are also visible in the App.

The Smart Sensor Portal provides access to organizations and further analyzed asset data. Through the portal, organization’s admin users can also manage Asset and User Groups.  

Portal and App share some functionalities for usability convenience.  

 

Do I have to join to an organization?

No, you don’t. Smart Sensor can be activated and used without an organization. However, by joining an organization it is possible to share the Smart Sensor's data with other users inside the same organization. 



Can I change my organization?

Yes, you can. User’s organization can be changed from the Smart Sensor App. If user belongs to multiple organizations, the active organization’s data is shown in the portal and the app.  



How can I delete an asset from my organization?

Assets can be deleted with the Smart Sensor App. 



What are Asset and User Groups?

Asset Groups are used to gather up and categorize assets and to manage their access rights. An Asset Group always belongs to an organization. Master Asset Group (*Organization name* Master) is an automatically generated Asset Group when a new organization is created. 

A User Group is a set of users within the same organization that can be given an access to certain Asset Group(s). 


How can I change the asset’s Asset Group?

Asset Group can be changed from the Smart Sensor App by selecting “Transfer Asset” from the asset's drop-down menu or from the Portal’s Organization Management → Asset Groups.  


How can I find “My Assets” from the Smart Sensor Portal?

By making the following selections in the Smart Sensor Portal:  

→ "Asset Details" (Top-page menu)
→ "Asset Detail" 
→ Select organization and "Other Assets"

Gateway documents: 
Gateway Installation Manual 
Gateway User Guide (Cassia)

Is there a Gateway solution available for automated sensor reading? 

Yes, Gateway is available to order and it can be used with different Smart Sensor types. Please contact your local ABB Service.  

 

How do I know which Smart Sensors are within my Gateway's range? 

Please see the Gateway Installation Manual.  Note that the first readings can take up to 3 hours after the installation of the Gateway and the adding of new sensors to the Gateway's reading cycle can take up to 24 hours after the sensor has been brought to the Gateway's range. 

 

What is the BLE range of the Gateway? 

The Bluetooth Low Energy range depends on the Gateway's environment and obstacles. The range estimate for factory environment is 25-65 meters.  

 

What else do I need for the use of the Gateway? 

Internet connection: 

An available internet connection without VPN (open network). Connection options are PoE (Power-over-Ethernet), ethernet cable or WiFi.  

Power Supply: 

In case PoE connection is not available, a power supply (PoE injector) for the Gateway is needed. 

Ethernet cable: 

1 ethernet cable is needed for PoE or for WIFI connection options.
2 ethernet cables are needed in case of ethernet cable connection. 

Computer: 

Computer with WiFi adapter is needed to configure the gateway for customer network. 

 

What is the required bandwidth for data transfer between a Gateway and the ABB cloud? 

The required bandwidth is very low. The expected data volume is about 1 MB per asset per month.

 

How do I know if my Gateway is online? 

Your Gateway's online time can be viewed from its internal setup pages. You can also check if your Smart Sensor's data has been transferred to the Smart Sensor Portal within the next 24 hours from the installation of the Gateway. 

 

Why isn't my Gateway reading measurements regularly / within stable intervals?

Gateway is configured in a way that it tries to connect to every Smart Sensor once every hour. However, it usually uploads measurements to the Smart Sensor Portal even only once per day. This is due to the Gateway's environment, internet connection stability and other variables. Since the Smart Sensor itself stores measurements internally by the user-defined measurement interval, no measurements are lost even if the Gateway doesn't upload them to the Smart Sensor Portal every hour. 

The Smart Sensor is not designed to act as a real-time measurement device and it's operating principle as a long-term condition monitoring device causes the Smart Sensor's value being created from stable and long-term asset's operating monitoring. Therefore the Gateway's possible irregular measurement upload intervals do not affect the measurements and analytics performed by the Smart Sensor. 


Terminology & Features

Asset Group:

Asset Groups are used to gather up and categorize assets and to manage their access rights. An Asset Group always belongs to an organization. Master Asset Group (*Organization name* Master) is an automatically generated Asset Group when a new organization is created.  

Bearing condition:

The bearing condition indicator is a joint reflection of the severity of defects along with the stresses existing in the motor. Motors that are operating at lighter load and/or lower speeds would have lower stresses, but if the bearing has significant defects, the same can be detected. Using a combination of parameters to describe the health also means that values could even reduce during operation depending on load changes or maintenance such as lubrication. The bearing health indicator cannot be used as a prognostic measurement, but one could generally say that when the warning or alert levels are crossed, the bearing is in the last 20% of its lifetime. Warning or alert levels are set at 6 (arbitrary units) and alarm levels are set at 10 (arbitrary units). 

KPI:

Key Performance Indicator

Condition indexes: 

Every Condition Index has a value between 0 and 10; a value of 0 represents the unhealthiest status, 10 the healthiest status.

  • Availability: Status of the KPIs indicating the quality of the asset of being able to be used or obtained. Showing characteristic of the asset that is committable, operable or usable upon demand to perform its designated or required functions. 
  • EnvironmentStatus of the KPIs indicating the current impact of external and internal environmental parameters to the operating of the asset. E.g. the internal and / or external temperature and the humidity in relation to the asset and / or asset type specific defined maximum or threshold values. 
  • Reliability: Status of the KPIs of the asset indicating the quality of being trustworthy to perform its intended or required function consistently without degradation or failure. Includes the degree to which the result of a KPI measurement and calculation can be depended on to be accurate. Example KPIs are any kind of asset maintenance advices or the number of asset failures in the past operating period. 
  • StressStatus of the KPIs indicating the current load and performance of the asset regarding the main functionality in relation to the asset type specific maximum value of the load. E.g. the current power of the motor in relation to the maximum power. 

Dimension factor:

A bearing information which tells each bearing ball's center's distance from the center of the bearing circle. The Dimension Factor can be simply calculated by adding the outer and inner bearing radiuses together and dividing the sum by 2.

Energy consumption:

Tells how much energy your asset is consuming. Only available to calculate for DOL motors. 

Health trend:

Shows the percentage amount of non-healthy assets of the assets that the user has an access to.

Misalignment:

Misalignment between the asset's and the load's shafts can be identified based on the trend data of asset's vibration parameters. For healthy condition, the misalignment status is 0 and for detected misalignment condition the status is 1.

Motor Supply Frequency:

Frequency of the AC voltage from the asset's electric supply, measured in Hz. Maximum value at the moment ~70Hz.

Number of starts:

Tells the number of on-off-on cycles of your asset. 

Overall vibration:

The maximum vibration measured by combining all three vibration axles.

Regreasing advice:

The asset’s relubrication interval can be manually added to an asset from the Smart Sensor App. The regreasing advice is an reminder which takes the asset’s usage and environment into notice.

Set measured current:

Asset's current under nominal conditions can be manually measured. Using the manually measured current instead of the nominal current given on the nameplate makes the Smart Sensor's energy consumption calculation more accurate.

Speed:

The asset shaft's rotational speed (rpm).

Subscription code:

A subscription is needed for the full-functional use of the Smart Sensor Portal. For subscription purchases, please contact your local ABB Service.

User Group:

A User Group is a set of users within the same organization that can be given access to certain Asset Group. 
 

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