PROGNOST- Predictor

User Manual
List of Contents
1 Preliminaries ...................................................................................................................................................3
1.1 Introduction ............................................................................................................................................................................... 3
1.2 Overview ..................................................................................................................................................................................... 4
1.3 System Architecture ................................................................................................................................................................ 4
1.3.1 Sensors ............................................................................................................................................................................... 4
1.3.2 PROGNOST-Predictor rack ......................................................................................................................................... 4
1.3.3 Server Computer ............................................................................................................................................................ 4
1.3.4 Client Computer ............................................................................................................................................................. 5
1.4 PROGNOST-Predictor rack .................................................................................................................................................. 5
1.4.1 Controller Card ................................................................................................................................................................ 5
1.4.2 Accelerometer Card ....................................................................................................................................................... 6
1.4.3 Proximity Card ................................................................................................................................................................. 6
1.4.4 AC Card .............................................................................................................................................................................. 6
1.4.5 DC Card .............................................................................................................................................................................. 7
1.4.6 Tachometer Card ............................................................................................................................................................ 7
1.4.7 Key Card............................................................................................................................................................................. 8
1.4.8 Relay Card ......................................................................................................................................................................... 8
2 System Functionality ......................................................................................................................................9
2.1 System Diagnostics ................................................................................................................................................................. 9
2.2 DC Measurement ..................................................................................................................................................................... 9
2.3 Standard Spectrum ................................................................................................................................................................. 9
2.4 High Frequency Envelope (HFE) Analysis ........................................................................................................................ 9
2.5 Time Synchronous Averaging (Gear Imaging) ............................................................................................................... 9
2.6 Sleeve Bearing Gap Analyses ............................................................................................................................................... 9
2.7 Sleeve Bearing Shaft Centerline Analyses ....................................................................................................................... 9
2.8 Sleeve Bearing Orbit Analyses ........................................................................................................................................... 10
2.9 Confidence analysis .............................................................................................................................................................. 10
3 Graphical Status ........................................................................................................................................... 11
3.1 Navigation Tree ...................................................................................................................................................................... 11
3.2 Graphical Controls ................................................................................................................................................................. 12
4 Notification Log ........................................................................................................................................... 14
4.1 Machine Status Notifications ............................................................................................................................................. 14
4.2 System Diagnostic Notifications ....................................................................................................................................... 15
5 Watch List ..................................................................................................................................................... 17
5.1 Page Layout ............................................................................................................................................................................. 17
5.2 Print Summary Report .......................................................................................................................................................... 18
6 Confidence Analysis .................................................................................................................................... 20
7 Machine Status ............................................................................................................................................. 23
7.1 Component Centric Tree ..................................................................................................................................................... 23
7.2 Analysis Centric Tree ............................................................................................................................................................. 25
7.3 Machine Status Tree Dialogs .............................................................................................................................................. 26

PROGNOST Systems GmbH Preliminaries 1

 7.3.1 Machine Group Dialog ............................................................................................................................................... 26
7.3.2 Add Machine Dialog.................................................................................................................................................... 26
7.3.3 Machine Dialog ............................................................................................................................................................. 27
7.3.4 Machine Element Dialog ........................................................................................................................................... 29
7.3.5 Analysis Wizard ............................................................................................................................................................. 31
7.3.6 Signature Wizard .......................................................................................................................................................... 32
8 Hardware Status ........................................................................................................................................... 36
8.1 Panel Layout ............................................................................................................................................................................ 36
8.2 Hardware Status Tree Dialogs ........................................................................................................................................... 37
8.2.1 Site Dialog....................................................................................................................................................................... 37
8.2.2 Processor ......................................................................................................................................................................... 40
8.2.3 Card................................................................................................................................................................................... 41
8.2.4 Channel ........................................................................................................................................................................... 41
8.2.5 OPC Server ...................................................................................................................................................................... 41
8.2.6 OPC Channel .................................................................................................................................................................. 42
9 Data Viewer ................................................................................................................................................... 43
9.1 Page Layout ............................................................................................................................................................................. 43
9.2 Trend Summary ...................................................................................................................................................................... 44
9.3 Analysis Views ......................................................................................................................................................................... 45
10 Miscellaneous ............................................................................................................................................... 49
10.1 List of Figures .......................................................................................................................................................................... 49

2 Preliminaries PROGNOST Systems GmbH

1 Preliminaries
1.1 Introduction
This publication is provided for informational purpose only and is subject to
change without notice. No part of it may be reproduced or transmitted by any
means or in any form, without prior written consent from PROGNOST Systems
GmbH.
PROGNOST Systems GmbH makes no warranty of any kind with regard to ma-
terial, including, but not limited to, the implied warranties or merchantability
and fitness for a particular purpose. PROGNOST Systems shall not be liable for
errors, omissions or inconsistencies which may be contained herein or for in-
cidental or consequential damages in connection with the furnishing, perfor-
mance, or use of this material. Information is furnished under a license agree-
ment or nondisclosure agreement with PROGNOST Systems GmbH or a third
party vendor. Any software may be used or copied only in accordance with
the terms of the agreement.

All product names mentioned in this manual are trademarked or copyrighted

by their respective manufacturers.

PROGNOST Systems GmbH

All rights reserved.

Rheine, December 2014

PROGNOST Systems GmbH Preliminaries 3

1.2 Overview
The PROGNOST-Predictor Monitoring System is an automatic machine health
advisory system for detecting developing machine faults or process abnormal-
ities. This easy to use, on-line system not only monitors and diagnoses various
existing or impending process and machine conditions, but also provides end
user guidance to help characterize the severity of the fault condition.
The foundation of this system is state-of-the-art digital signal processing used
for precise diagnosis of machine component condition. The benefits of this
technology are:
- Early detection allows more time for maintenance planning to mini-
mize lost production
- Substantial cost savings and improved productivity through extended
component lifetime
- Early warning reduces the risk of catastrophic failure and improves em-
ployee safety

1.3 System Architecture

The system consists of sensors mounted on the monitored machinery,
PROGNOST-Predictor rackPROGNOST-Predictor rack which analyze these
sensor signals, a server computer which stores the PROGNOST-Predictor rack
analysis results, and client computers to display machine status to system us-
ers. The PROGNOST-Predictor rackPROGNOST-Predictor rack, server and cli-
ent computers communicate over the LAN.

1.3.1 Sensors
- ( 30 V) DC Voltage and 4-20 mA current loop sensors
- Accelerometers
- Velocimeters
- Proximity probes
- Pulse Tachometers
- Key phase probes
- Shaft Torque
- Up to 15 V AC sensors

1.3.2 PROGNOST-Predictor rack

- Provides power to transducers
- Maintains schedule of analyses to be performed
- Performs signal acquisition and processing, analog and digital
- Interfaces to tachometer or key phase signals for RPM determination
and synchronous processing
- Computes machine condition measures, maintains measurement
- Applies thresholds to measurements and declares alarms
- Capable of annunciating alarms

1.3.3 Server Computer

- Maintains SQL Database and runs system software on Windows 2008
Server platform
- Only one server is required per system regardless of the size of the sys-
tem
- Not intended for operator or analyst use
- Provides a TCP/IP interface to a plant network.

4 Preliminaries PROGNOST Systems GmbH

 - Installed in a control room environment in an isolated area such as a
control/equipment room

1.3.4 Client Computer

- Operator and Analyst computer
- Connected to PROGNOST-Predictor Server with via network

1.4 PROGNOST-Predictor rack

The PROGNOST-Predictor rack consists of a controller card which performs
the sensor analyses and communicates with the server and client computers;
and up to 12 individual sensor cards.

Fig. 1 PROGNOST-Predictor rack

The PROGNOST-Predictor rack is mounted in a cabinet, placed in a nearby

equipment room or in a stainless steel enclosure near the monitored machin-
ery.

Chassis Dimensions Height 10.4, 256 mm

Width 17.4, 442 mm
Depth 7.0, 180 mm
Input Power 110 240 V AC 50/60 Hz, 2/1 A max-
imum
Slots 1 double width controller card slot
12 single width sensor card slots

1.4.1 Controller Card

The Controller card performs the analysis functions of the PROGNOST-
Predictor rack. It acquires digitized data from each installed sensor card
through the backplane data bus, analyzes these signals, assesses the machine
component condition, and communicates the results to the server for storage
over the TCP/IP LAN connection.

Dimensions Height 10.4, 256 mm

Width 2.4, 61 mm
Depth 7.0, 180 mm
Input Power 24 V DC powered through the chassis backplane
Environmental 0 - 50 C (32 F 122 F), non-condensing

PROGNOST Systems GmbH Preliminaries 5

 Interfaces 1 RJ45 Ethernet port
IIC backplane card control
12 slots of TDMA card data transfer

1.4.2 Accelerometer Card

The Accelerometer card powers each connected accelerometer or velocimeter
sensor, samples the sensor signal at the programmed sample rate, and trans-
mits the digitized data to the controller card over the backplane data bus.
Card and individual channel diagnostics are performed and status conditions
reported by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 300 mA powered through the chassis
backplane
Sensor Power 24 V DC, 4 mA constant current, applied program-
matically
Inputs 8 channels
Display 1 Card status LED
8 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control
12 slots of TDMA card data transfer

1.4.3 Proximity Card

The Proximity card supplies -30 V power to each proximitor powering a prox-
imity probe. It samples the sensor signal at the programmed sample rate and
transmits the digitized data to the controller card over the backplane data
bus. Card and individual channel diagnostics are performed and status condi-
tions reported by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 300 mA powered through the chassis
backplane
Sensor Power -30 V DC, applied programmatically
Inputs 8 channels
Display 1 Card status LED
8 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control
12 slots of TDMA card data transfer

1.4.4 AC Card
The AC card accepts a voltage signal from any dynamic AC signal, samples the
sensor signal at the programmed sample rate and transmits the digitized data

6 Preliminaries PROGNOST Systems GmbH

 to the controller card over the backplane data bus. Card and individual chan-
nel diagnostics are performed and status conditions reported by the status
LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 300 mA powered through the chassis
backplane
Sensor Power None supplied
Inputs 8 channels, -15 to +15 V range
Display 1 Card status LED
8 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control
12 slots of TDMA card data transfer

1.4.5 DC Card
The DC card accepts a voltage or current loop signal from any DC signal. Card
and individual channel diagnostics are performed and status conditions re-
ported by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 150 mA powered through the chassis
backplane
Sensor Power None supplied
Inputs 16 channels as 8 isolated pairs. -30 to +30 V DC or 0 -
20 mA current loop
Display 1 Card status LED
16 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control

1.4.6 Tachometer Card

The Tachometer card powers a pulse type tachometer and measures the peri-
od between successive pulses. Card and individual channel diagnostics are
performed and status conditions reported by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 370 mA powered through the chassis
backplane
Sensor Power +24 V DC, applied programmatically

PROGNOST Systems GmbH Preliminaries 7

 Inputs 8 channels, -20 to +20 V range
Display 1 Card status LED
8 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control
12 slots of TDMA card data transfer

1.4.7 Key Card

The Key card powers a proximity type key probe to measure the period be-
tween successive pulses Card and individual channel diagnostics are per-
formed and status conditions reported by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 370 mA powered through the chassis
backplane
Sensor Power -30 V DC, applied programmatically
Inputs 8 channels
Display 1 Card status LED
8 individual channel status LEDs
Environmental 0 - 50 C (32 F 122 F), non-condensing
Interfaces IIC backplane card control
12 slots of TDMA card data transfer

1.4.8 Relay Card

The Relay card controls the state of 12 output relays. The relay state is report-
ed by the status LEDs.

Dimensions Height 10.4, 256 mm

Width 1.2, 30.5 mm
Depth 7.0, 180 mm
Input Power 24 V DC , 30 mA powered through the chassis back-
plane
Sensor Power 12 channels normally open or normally closed relays
controlled programmatically
Inputs 1 Card status LED
12 individual channel status LEDs
Display 0 - 50 C (32 F 122 F), non-condensing
Environmental IIC backplane card control
Interfaces 24 V DC , 30 mA powered through the chassis back-
plane

8 Preliminaries PROGNOST Systems GmbH

2 System Functionality
2.1 System Diagnostics
The system performs regularly scheduled self-diagnostics to confirm the
proper operation of the individual cards in a PROGNOST-Predictor rack. Addi-
tionally the signal from each sensor is evaluated every second to verify good
signal quality. Any failed or failing sensor is flagged so that it cannot lead to
false alarms.

2.2 DC Measurement
DC sensors are measured and evaluated every second.

2.3 Standard Spectrum

The standard spectrum uses the Fast Fourier Transform (FFT) algorithm to
compute frequencies and energy of signals coming from the machine. Faults
or defects in the machine components will generate excess energy at specific
frequencies. Bands are constructed around these frequencies of interest, and
the software tracks the energy contained within each band over time. If the
amount of energy exceeds a predetermined level and the confidence analysis
(see 2.9) confirms the fault, then an alarm is activated to indicate a problem or
impending component failure.

2.4 High Frequency Envelope (HFE) Analysis

HFE analyzes high frequency bursts of energy. These bursts of energy are iso-
lated to calculate their repetition rate, which is directly related to a failing
component. Consequently, HFE spectral analysis can provide early warning of
impending failures, often long in advance of standard spectrum analysis. HFE
analysis is especially useful for early detection of gear and bearing defects.
Like Standard Spectral Analysis, HFE can have band and alarm setups for
trending over time.

2.5 Time Synchronous Averaging (Gear Imaging)

Time Synchronous Averaging is a technique used to detect developing gear or
nipped roll cover defects. The technique uses a tachometer to provide de-
tailed rotation timing and accelerometers to measure the component vibra-
tion. By averaging a large number of turns, the signals not associated with the
component average out permitting the isolation of the fault signature.

2.6 Sleeve Bearing Gap Analyses

The proximity probe gap voltage are monitored at a 1 second interval and
compared to acceptable thresholds.

2.7 Sleeve Bearing Shaft Centerline Analyses

The bearing clearances are monitored during run up, coast down events and
during normal operation.

PROGNOST Systems GmbH System Functionality 9

2.8 Sleeve Bearing Orbit Analyses
The shaft orbit for each sleeve bearing is monitored during run up and coast
down events and during normal operation. Direct, 1X, 2X and other harmonics
are evaluated.

2.9 Confidence analysis

Confidence analysis compares the expected spectral harmonic structure of a
signature to the actual structure to quantify the similarity. This is a powerful
technique for filtering out false alarms and identifying missed alarms due to
incorrect thresholds.

10 System Functionality PROGNOST Systems GmbH

3 Graphical Status
The Graphical Status panel shows the status of the monitored machines in a
graphical form as a series of navigable pages. Active controls within a page
show machinery status and allow the navigation to other more detailed pag-
es. Other active controls show sensor amplitudes such as pressure, tempera-
tures, or machine speed. Active machine component controls navigate to the
detailed status for that component. Alarm conditions are indicated by blue,
yellow, orange, or red color to indicate unknown, warning, alert and alarm
levels respectively.

Fig. 2 Graphical Status

3.1 Navigation Tree

To the left of the graphics is the navigation tree. The tree may be collapsed as
in the figure above. Hovering the mouse over the collapsed tree will open it as
shown below. You have the option to pin this tree or hide it when not in use.

Fig. 3 Pin navigation tree

The navigation tree shows the title for each available page with status lights
indicating the warning, alert, and alarm status of the contents of the page.
You can click on the tree selection and go to the selected graphic page.

Above and to the left of the graphics page are next and previous buttons that
navigate back or forward through the displayed page history.

PROGNOST Systems GmbH Graphical Status 11

 Fig. 4 Navigation Tree

3.2 Graphical Controls

There are a number of different controls that can be placed on a graphics
page to provide the user status and value information.
Status Buttons indicate the status of a page or
machine element. Blue represents unknown,
green good, yellow warning, orange alert, and
red alarm. Hovering over a status button linked to
a machine element will show a pointer to the
linked element. Clicking on the button navigates
to the Data Viewer for a machine element or nav-
igates to the linked graphics page.
Some components show an active status. For
example a shaft, bearing, or gear will be in a nor-
mal neutral color if good, but turn yellow, orange,
or red at the corresponding alarm level.
Meters display the current value of a signature or
machine sensor value.

12 Graphical Status PROGNOST Systems GmbH

 Fig. 5 Graphical controls

If you hover over a component of the graphics it will describe the component
in more detail.

Fig. 6 Tooltip Gear

PROGNOST Systems GmbH Graphical Status 13

4 Notification Log
The Notification Log consists of 2 grids, the top grid collects the information
about machine status changes and the bottom grid contains system diagnos-
tic information. Each section heading has a collapse button to the left of the
heading which opens or collapses the grid. Presence of a new entry is indicat-
ed by the blinking red Notification Log tab. The grids consist of many column
headings providing useful information about each message. These can be
configured by the user by right clicking on the heading and selecting which
columns to show. This selection is retained as a user preference. Columns can
be sorted by left clicking on the heading and re-arranged by dragging the
heading to the new position. Entries remain in the log until removed by a user
or when they age beyond the retention age. Deleted entries go into the ar-
chive and can be retrieved later when needed.

Fig. 7 Notification Log

Machine Status Notifications (see chapter 4.1)

1 Column Headings
2 Menu Functions
System Diagnostic Notifications (see chapter 4.2)
3 Column Headings
4 Menu Functions

4.1 Machine Status Notifications

The Machine Status Notification grid displays individual signatures that have
entered a new status state. If an alarm has an associated relay activated, it can
be cleared.

14 Notification Log PROGNOST Systems GmbH

 Column Headings
In Watch List This column is checked if the signature has
been added to the Watch List
Has Machine Relay This column is checked if there is an active
Machine Relay associated with this alarm
event
Machine Element Machine Element name which can be ex-
panded to show the parents
Measure Name Name of measuring loop
Sensor / Analysis Sensor / Analysis names
Current Date / Time Date / time of last measurement
Current Status Status of last measurement
Current Confidence The confidence meter provides a measure of
the current confidence the system has in the
alarm status.
Current Value Signature value of last measurement
Current Machine RPM Machine RPM of last measurement
Current Analysis RPM Analysis RPM of last measurement
Initial Date / Time Date / time of the initial measurement
Initial Status Status of the initial measurement
Initial Confidence The confidence meter provides a measure of
the initial confidence the system has in the
alarm status.
Initial Value Signature value of the initial measurement
Initial Machine RPM Machine RPM of the initial measurement
Initial Analysis RPM Analysis RPM of the initial measurement
% Growth % growth of the signature value from the
value at the time of the initial alarm
2nd Opinion Indicates whether another sensor saw the
same alarm
Baseline Value Baseline value
Viewed By User name of the user which opened the
alarm log when the tab was blinking
Viewed Date Date and time when the log was viewed
Context menu
View Data Opens the Machine Element Data Viewer
and displays the analysis and trend for the
signature
Add to Watch List Adds the Machine Element to the watch list
Print Report Opens the report wizard
Clear Relay Event Clears the associated machine relays
Show Relay Activation Shows the history of the activated relays
History
Archive Entry Deletes the entry and moves it to the archive
Show Archive Entries Shows archived entries
Hide Archive Entries Hides archived entries

4.2 System Diagnostic Notifications

The System Diagnostic Notifications grid displays messages indicating a prob-
lem with PROGNOST-Predictor system itself. These may be sensor faults, or
processor or processor card faults. If any of these fault conditions have an as-

PROGNOST Systems GmbH Notification Log 15

 sociated relay that is active (See the site dialog chapter 8.2.1) then the asso-
ciated relay will be activated. A menu function is available to clear the relay.
Column Headings
Processor Name Name of the processor
Card Name Name of the card
Channel Name Name of the current channel
Current Date / Time Date / time of last assessment
Current Status Status of last assessment
Initial Date / Time Date / time of the initial assessment
Initial Status Status of the initial assessment
Viewed By User name of the user which opened the alarm
log when the tab was blinking
Viewed Date Date and time when the log was viewed
Context menu
View Channel Trend Shows the trend of current sensor data if the en-
try is a channel
Clear Relay Event Clears the associated machine relays
Archive Entry Deletes the entry and moves it to the archive
Show Archive Shows archived entries
Entries
Hide Archive Entries Hides archived entries

16 Notification Log PROGNOST Systems GmbH

5 Watch List
The Watch List displays information about Machine Elements that users have
identified as worth special attention. These are usually elements that have
known faults and the user wants to be able to quickly access their current
condition. There are many column headings providing useful information
about the entry. These can be configured by the user by right clicking on the
heading and selecting which columns to show. This selection is retained as a
user preference. Columns can be sorted by left clicking on the heading and
rearranged by dragging the heading to the new position.

5.1 Page Layout

Fig. 8 Page Layout

1 Column Headings
2 Menu Functions
Column Headings
Priority User assigned priority
Machine Element Machine Element name which can be expand-
ed to show the parents and children
Days on List Number of days the entry has been in the
Watch List
Current Date / Time Date / time of last measurement
Current Status Status of last measurement
Current Value Signature value of last measurement
Current Confidence The confidence meter provides a measure of
the current confidence the system has in the
alarm status.
Current Analysis RPM Analysis RPM of last measurement
Current Machine RPM Machine RPM of last measurement
% Growth % growth of the signature value from the value
at the time of the initial alarm

PROGNOST Systems GmbH Watch List 17

 % Growth From Base- % growth of the signature value from the base-
line line value
Initial Date / Time Date / time of the initial measurement
Initial Status Status of the initial measurement
Initial Value Signature value of the initial measurement
Initial Confidence The confidence meter provides a measure of
the initial confidence the system has in the
alarm status.
Initial Machine RPM Machine RPM of the initial measurement
Initial Analysis RPM Analysis RPM of the initial measurement
Baseline Value Baseline value
Context menu
View Data Opens the Machine Element Data Viewer
Assign Priority Assign the entry priority, one is the lowest and
three the highest
Print Summary Report Opens the report wizard
Archive Entry Archive the entry
Delete Entry Deletes the entry and moves it to the archive
Include Archive Shows archived entries
Entries
Hide Archive Entries Hides archived entries

5.2 Print Summary Report

A report wizard configures a status report with selected alarm trends.

Fig. 9 Report Wizard

In the upper screen you can choose which analyses should be included in the
report. Simply mark them and choose Next. The following dialog comes up.

18 Watch List PROGNOST Systems GmbH

 Fig. 10 Final Report Wizard
In this dialog an overview is given which could be printed, copied (as image),
saved (as PDF), emailed (as PDF) or deleted by the user.

PROGNOST Systems GmbH Watch List 19

6 Confidence Analysis
The PROGNOST-Predictor system implements an innovative analysis called
Confidence Analysis. Confidence Analysis is a pattern recognition technique
that quantifies the similarity of the measured spectral peaks to the expected
fault peaks. The confidence provides a strong indicator of whether a meas-
urement really represents a real fault or damage. If the confidence is low, it
most likely means that the specific fault is not present, but if the confidence is
high, then it is likely that the fault indicated is real. The results of the signature
calculation and the confidence are graphed in a confidence plot.
The plot is a data mining tool to identify false alarms and faults which are pre-
sent but still are in a good status (false pass). The signature amplitude is nor-
malized relative to the threshold values and the amplitude is plotted vertically
and the confidence horizontally (See figure below). The plot is populated with
the most recent amplitude / confidence pairs for each signature in the data-
base. This plot is a convenient method to display whether a significant signa-
ture is present and also that the amplitude is larger than normal indicating
that a component fault is developing.

Fig. 11 Confidence Analysis

The four corners of the scatterplot correspond to different possible situations.
Points in the bottom left corner are signatures with low amplitudes relative to
alarm levels, and a low confidence. These signatures are in a good status.
The bottom right corner contains signatures with low amplitudes relative to
alarm levels, but a high confidence. These points are false passes and require
immediate attention and likely have alarm thresholds that are set too
high. These signatures, if left unattended, would be missed alarms in a typical
monitoring system since their alarm thresholds are too high to alarm even
though a fault signature is present. The user should analyze each of these
points and adjust alarm thresholds as necessary to monitor the upcoming fail-
ure.
The top left corner contains signatures with high amplitudes relative to alarm
levels, but a low confidence. These points are false alarms that need analyst at-
tention and possibly their alarm thresholds increased.

20 Confidence Analysis PROGNOST Systems GmbH

 The top right corner contains signatures with high amplitudes relative to
alarm levels, and a high confidence. These signatures should be managed
carefully to avoid machine failures. They show true component faults.
The scatter plot is divided into alarm regions Warning, Alert, and Alarm. The
user can define additional informational regions. For each trend a signature
amplitude and confidence is computed. If the new pair of values falls into a
defined region that status is assigned to the trend.
Hovering over a point in the scatter plot will show a popup of information
about that point. Double clicking while the popup is open moves the selected
point into the list to the right. This is a convenient place to save important
points for analysis.
Rolling element bearing signatures are considered emergent signatures be-
cause the spectral lines are not present when the bearing is in good condition
and begin to emerge from the spectrum as a fault develops. Some other sig-
natures such as imbalance or gear mesh are persistent signatures since even
when the component is in an acceptable condition, these spectral lines are
present. The two classes of signatures are displayed in separate scatter plots.
Other signatures such a temperatures are direct signatures and have no con-
fidence analysis.

Fig. 12 Confidence Analysis

1 Scatter plot context menu

2 Selected point context menu
Scatter plot menu functions
Configure Re- Configure the region positions
gions
View Data Show the detail data for the selected signature

Selected point context menu functions

View Data Show the detail data for the selected signature
Highlight this Highlight the point in the scatterplot associated with
signature only this signature
Highlight all Highlight all the points in the scatterplot associated
signatures for this with this measure
Measure

PROGNOST Systems GmbH Confidence Analysis 21

 Highlight all Highlight all the points in the scatterplot associated
signatures for this with this machine element
Machine
Element
Add this Machine Add this Machine Element to the watch list
Element to the
watch list
Remove Remove this selection from the list
selection

22 Confidence Analysis PROGNOST Systems GmbH

7 Machine Status
The Machine Status Tree shows a hierarchy of the monitored machinery. This
panel is used to define what machinery is to be monitored and displays the
current status of the monitored machine components. The panel can show
either the Component Centric Tree which hides the details of the types of anal-
yses performed to assess the component status or the Analysis Centric Tree
which shows the analysis details. To switch between the views simply use the
context menu (right click) of the Machine Status.

Fig. 13 Machine Status Tree

7.1 Component Centric Tree

The levels in the Component tree are:
Site The root of the tree is the name of the site.
Machine Group The monitored machinery can be organized
into any number or depth of machine groups.
Machine An individual machine.
Machine Element A specific shaft, gear, bearing, or other com-
ponent internal to the machine.
Measure A measurement property associated with the
parent machine element. For example, a bear-
ing will have cage, roller, outer race, and inner
race measures.
Signature A specific combination of analyses and sensors
used to compute the measure. For example, an
outer race measure may have an acceleration
and HFE spectral analyses assigned to 2 differ-
ent sensors all computing the outer race
measure.

PROGNOST Systems GmbH Machine Status 23

 Context menu

Level Menu entry Description

Site View All View the complete Machine tree
View Faults View the Machine tree with any faults expanded
and good levels collapsed
Refresh Refreshes the tree. The tree is also automatically
refreshed as new data is added to the database.
Component Centric Tree Display the Component centric tree
Analysis Centric Tree Display the Analysis centric tree
Add Machine Group Add a Machine Group to the selected tree node
Machine Group Add Machine Add a Machine to the selected tree node
Reorder Machine Groups Changes the order of the Machine Groups
Add Machine Group Add a Machine Group to the selected tree node
Modify Machine Group Modify the selected Machine Group
Delete Machine Group Delete the selected Machine Group
Machine View Real-time Shaft Centerline Display the real-time shaft centerline plots for
Plots this machine
View Machine Sensor Trends View the machine sensor trends for this machine
Start Start monitoring this machine
Suspend Suspend monitoring this machine
Resume Resume monitoring this machine
Compute on/off Threshold Recompute the on / off threshold
Recompute Baseline Recompute the trend baselines for this Machine
Reorder Machines Changes the order of the Machines
Modify Machine Modify the selected Machine
Delete Machine Delete the selected Machine
Calibrate Sleeve Bearing Rest Execute this function to calibrate the sleeve
Position bearing positions so that they appear at the rest
position in the Shaft Centerline plots when the
machine is off
Machine Element View Data Opens the Data Viewer to view the analysis and
trend data for this Machine Element
Recompute Baseline Recompute the trend baselines for this Machine
Element
Add to Watch List Add this Machine Element to the Watch List
Reorder Machine Elements Changes the order of the Machine Elements
Modify Machine Element Modify the selected Machine Element
Measure View Data Opens the Data Viewer to view the analysis and
trend data for this Measure
Recompute Baseline Recompute the trend baselines for this Measure
Reorder Measures Changes the order of the Measures
Signature View Data Opens the Data Viewer to view the analysis and
trend data for this Signature
Recompute Baseline Recompute the trend baselines for this Signa-
ture
Reorder Signatures Changes the order of the Signatures

24 Machine Status PROGNOST Systems GmbH

7.2 Analysis Centric Tree
The levels in the Analysis Centric tree are:
Site The root of the tree is the name of the site.
Machine Group The monitored machinery can be organized into
any number or depth of machine groups.
Machine An individual machine.
Machine Element A specific gear, bearing, or other component
internal to the machine.
Machine Element A sensor that is assigned to monitor its parent
Sensor machine element
Analysis An analysis, typically a DC measurement, spec-
tral analysis, time synchronous average, shaft
centerline or orbit analysis applied to the sensor
signal
Signature A signature value computed from the parent
analysis which is associated with a measure in
the Component tree
Context menu
The Site, Machine Group, Machine, and Machine Element menu items are
identical to those for the Component Centric Tree. The differences begin at
the Machine Element Sensor level.
Level Menu entry Description
Machine Ele- View Data Opens the Data Viewer to view the analysis and trend data
ment Sensor for the parent Machine Element
Recompute Baseline Recompute the trend baselines for all Signatures which
derive from this sensor
Reorder Machine Element Changes the order of the Machine Element Sensors
Sensors
Delete Machine Element Deletes the sensor and all data associated with it.
Sensors
Add Analysis Invokes the Analysis wizard to add a new analysis
Analysis View Data Opens the Data Viewer to view the analysis and trend data
for this Analysis
Perform Immediate Analy- Abort currently executing Analyses and perform this one
sis
Recompute Baseline Recompute the trend baselines for all Signatures which
derive from this analysis
Reorder Analyses Changes the order of the Analyses
Modify Analysis Modify the selected Analysis
Delete Analysis Deletes the Analysis and all data associated with it.
Add Signature Invokes the Signature wizard to add a new Signature
Signature View Data Opens the Data Viewer to view the analysis and trend data
for this Signature
Recompute Baseline Recompute the trend baseline for this Signature
Reorder Signatures Changes the order of the Signatures
Modify Signature Modify the selected Signature
Delete Signature Deletes the Signature and all data associated with it.
Force Status to Good Forces the status of this signature to good. Use this func-
tion if a sensor is removed or disabled to clear an old un-
wanted status

PROGNOST Systems GmbH Machine Status 25

7.3 Machine Status Tree Dialogs
The tree is generated by defining the different nodes in the tree through a se-
ries of dialogs

7.3.1 Machine Group Dialog

The tree can be organized as a nested series of groups of machines. A Machine
Group can have children that are Machines or other Machine Groups.

Fig. 14 Machine Group

Name Name of Machine Group

7.3.2 Add Machine Dialog

Machines are added to the tree by the Add Machine menu function. A library
of machine templates is supplied which have the internal arrangement of
Machine Elements already configured.

Fig. 15 Add Machine

Name Name of Machine
Machine Template Machine Template to use to construct the subtree
for this Machine. The Machine elements are added
automatically.

7.3.2.1 Add Machine Wizard

Fig. 16 Add Machine Wizard

Once the template is selected, the installed sensors are associated with the
suggested sensors from the template

26 Machine Status PROGNOST Systems GmbH

 Fig. 17 Add Machine Wizard

Pressing Finish will build the machine tree as shown in Fig. 13.

7.3.3 Machine Dialog

Once the Machine has been added by the Add Machine dialog, the properties
of the Machine can be further defined.

Fig. 18 Machine (advanced view)

PROGNOST Systems GmbH Machine Status 27

 Name Name of Machine
Is RPM fixed? Specifies whether the RPM is fixed or variable
Fixed RPM If the RPM is fixed, the RPM value.
Low RPM The machine will be monitored if the RPM is at or
above this value
High RPM The machine will be monitored if the RPM is at or
below this value
Are events enabled? Enables run up and coast down event analysis for
sleeve bearing analysis.
Maximum event Maximum allowed duration for an event.
duration (sec)
Event low RPM A run up event starts when the RPM exceeds the
threshold low RPM threshold and a coast down event stops
when the RPM is below the low threshold
Event high RPM A run up event stops when the RPM exceeds the
threshold high RPM threshold and a coast down event
starts when the RPM is below the high threshold
Pretrigger time (sec) The event data analysis will start the pretrigger
time before the RPM threshold trigger
Posttrigger time The event data analysis will stop the posttrigger
(sec) time after the RPM threshold trigger
RPM step A new shaft centerline and orbit will be comput-
ed each time the RPM changes by this amount
Event analysis time A new shaft centerline and orbit will be comput-
step (sec) ed each time the elapsed time from the previous
analysis changes by this amount
Id The database table Id is not editable
Primary Shaft The shaft designated as the primary shaft for
which the Machine RPM is taken
DC database update Suggested interval for updating the database
interval (sec) with machine sensor analysis results. This value is
used to prevent the database from being updat-
ed too often making it too large.
Highest RPM Highest RPM for event processing. For superposi-
tion gearboxes, this is the highest RPM for the
primary shaft
Superposition Shaft The shaft designated as the superposition shaft
for superposition gearboxes
Low Superposition For superposition gearboxes, this is the lowest
RPM RPM for the superposition shaft
Highest For superposition gearboxes, this is the highest
superposition RPM RPM for the superposition shaft
Enable or- Defines whether the sampled data should be
der sampling? resampled for order analysis. (Not shown in the
figure since this feature is disabled for superposi-
tion machines)
Enable triggered Defines that a trigger is assigned to this machine
monitoring? to indicate it is OK to monitor
False Alarms in Noti- Adds any false alarms associated with this ma-
fication Log? chine to be added to the Notification Log.

28 Machine Status PROGNOST Systems GmbH

7.3.3.1 Machine Sensors and Relays
Machine Sensors can also be associated with the Machine. These are often
process or load signals that describe how the Machine is operating and are
not associated with the status of an individual Machine Element. Motor Load
would be a typical example. Relays can also be assigned and configured to be
activated on a defined machine status criterion.

Fig. 19 Machine Sensor(advanced view)

Name Name of Machine

Sensor Opens the Channel Selector
Processor name Name of Processor (filled automtically after use of
Channel Selector)
Card name Name of the Card (filled automtically after use of
Channel Selector)
Channel name Name of the Channel (filled automtically after use
of Channel Selector)

Channel Selector

Fig. 20 Channel Selector

7.3.4 Machine Element Dialog

The dialog has 2 tabs, one to define the properties of the machine element
and the other to define which sensors are assigned to monitor that element.

PROGNOST Systems GmbH Machine Status 29

 Fig. 21 Machine Element

Name Name of Machine Element

Component type Type of component. For example a shaft, bearing,
or gear
[Component This is a variable number of rows where compo-
specific nent specific information is defined. For the depict-
properties] ed bearing example, the bearing model is specified.
For a gear, the number of gear teeth would be en-
tered
Id Database table Id. This is not editable
Database update Suggested interval for updating the database with
interval (sec) analysis results. This value is used to prevent the
database from being updated too often making it
too large.
Required base- A baseline is computed for each signature as an
line tests average value over a duration of time. The value
determines the minimum number to average
Required base- The minimum duration in days for the baseline
line days period.
Required consec- Number of consecutive entries into an informa-
utive informa- tional region before an informational status is de-
tional entries clared.
Required consec- Number of consecutive entries into a warning re-
utive warning gion before a warning status is declared.
entries
Required consec- Number of consecutive entries into an alert region
utive alert entries before an alert status is declared.
Required consec- Number of consecutive entries into an alarm region
utive alarm en- before an alarm status is declared.
tries

The Sensors tab allows the association of the suggested sensor locations with
the actual installed sensors connected to the channel inputs on the cards in
individual processors. Suggested sensors that are not present can be deleted
and other sensors that are present can be added.

30 Machine Status PROGNOST Systems GmbH

 Fig. 22 Configure machine element

7.3.5 Analysis Wizard

The Analysis wizard allows the modification of an existing analysis parameters
or the addition of a new analysis.

Fig. 23 Analysis wizard

Name Name of Analysis

Target resolu- The target resolution is used to compute the
tion (orders) number of spectral lines if the Calculate from
target resolution option is selected in the Num-
ber of spectral lines field. Otherwise the field is
ignored.
Number of averages The number of averages to perform or, for some
analyses, this field is replaced by the number of
turns
Maximum frequen- The maximum frequency to display for the analy-
cy (Hz) sis. A value can be explicitly selected or the value
can be automatically calculated at analysis execu-
tion time if the selection is Calculate from signa-
tures. In this case the frequencies of the signa-
tures are calculated based on the current RPM
and a frequency is selected to accommodate that
frequency requirement. Specific fixed frequencies
are also available from 50 to 40000 Hz.

PROGNOST Systems GmbH Machine Status 31

 HFE frequency (Hz) The High Frequency Enveloping range can be
None for direct analysis or other ranges from 500-
1000 to 20000-40000 Hz
Number of spec- The number spectral lines for the analysis. This
tral lines value can be automatically calculated at analysis
execution time if the selection is Calculate from
target resolution based on the maximum fre-
quency and the target resolution. Specific num-
ber of lines is also available from 40 to 12800.
Display as Vibration sensors can displace their spectral am-
plitude in Displacement, Velocity, or Acceleration
units independent of the sensor type. For exam-
ple an accelerometer may be used to display a
velocity spectrum.
Id Database table Id. Not editable
Enable or- Defines whether the sampled data should be
der sampling? resampled for order analysis.
Enable Han- Defines whether the Hanning window should be
ning window? applied before the spectrum is computed.
Once the analysis parameters are defined, the scope of application of the
changes can be selected from:
Make the change to this analysis instance only
Make the change to this sensor and all similar sensor types assigned
to this machine element
Make the change to this sensor and all similar sensor types assigned
to this machine element on all machines generated from this ma-
chine template

7.3.6 Signature Wizard

The Signature wizard allows the modification of an existing signature parame-
ters or the addition of a new signature. The wizard has 2 tabs, a properties and
threshold tab.
Tab Properties

Fig. 24 Signature wizard

32 Machine Status PROGNOST Systems GmbH

 Id Database Id. Not editable
Available Some fields below accept numeric values or the sym-
property bolic properties of the machine element listed in this
parameters field
Base frequency Base frequency in units of CPM, Hz, or Orders
units
Base frequency The base frequency can be entered as a center and half
entry width or as a low to high range
Base frequency Base frequency of the signature in the base frequency
units can be a numeric or symbolic value. In the exam-
ple the base frequency is the BPFI, the ball pass fre-
quency of the inner race
Base frequency The half width around the base frequency to include in
half-width the signature
Base harmonic A list of harmonics of the base frequency to include in
factor list the signature. The list has the format 1-3,5,7-10
Include Determines whether the base frequency harmonics are
base bands? included in the signature. This is usually yes, but may
be no if only the sidebands are in the signature
Include side- Determines whether sidebands are included in the
bands? signature
Sideband fre- Sideband frequency in units of CPM, Hz, or Orders
quency units
Sideband Sideband frequency of the signature in the side-
frequency band frequency units can be a numeric or symbolic
value. In the example the sideband frequency is 1 or-
der
Sideband The half width around the sideband frequency to in-
frequency half- clude in the signature
width
Sideband A list of harmonics of the sideband frequency to in-
harmonic factor clude in the signature. The list has the format 1-3,5,7-
list 10
Required con- Number of consecutive entries into an informational
secutive region before an informational status is declared. This
informational overrides the value in the machine element dialog
entries
Required con- Number of consecutive entries into a warning region
secutive warn- before a warning status is declared. This overrides the
ing entries value in the machine element dialog
Required Number of consecutive entries into an alert region
consecutive before an alert status is declared. This overrides the
alert entries value in the machine element dialog
Required Number of consecutive entries into an alarm region
consecutive before an alarm status is declared. This overrides the
alarm entries value in the machine element dialog

PROGNOST Systems GmbH Machine Status 33

 Tab Thresholds

Fig. 25 Filling of signature

The Signature has four classes of thresholds to define the medium, high and
high-high level status levels.
Relative rising thresholds are triggered when the signature value is
above the value computed by multiplying the baseline value by the
threshold multiplier.
Absolute rising thresholds are triggered when the signature value is
above the threshold value.
Relative falling thresholds are triggered when the signature value is
below the value computed by multiplying the baseline value by the
threshold multiplier.
Absolute falling thresholds are triggered when the signature value is
below the threshold value.
Signature Relays can be defined that are activated if a signature enters a de-
fined status.

34 Machine Status PROGNOST Systems GmbH

 Tab Relays

Fig. 26 Signature Relays

Name Name of the relay

Processor name Processor associated with the assigned relay

Card name Card associated with the assigned relay

Channel name Channel associated with the assigned relay

Relay activation Status level to activate the relay
level
Activate on higher If yes, the relay will be activated on higher status
statuses also levels also
Enabled ? Enable or disable the relay

PROGNOST Systems GmbH Machine Status 35

8 Hardware Status
8.1 Panel Layout
The Hardware Status panel defines the processors, cards, and channel inputs
to the system. If an OPC interface is enabled, then this connection and tags are
also defined. The tree shows the self-diagnostic status for each node and the
last date and time when this status changed.

Fig. 27 Panel Layout

Context menu
Site View All View the complete Hardware tree
View Faults View the Hardware tree with any faults expanded and
good levels collapsed
Refresh Refresh the tree
Add Processor Invokes the processor configuration tool to add a pro-
cessor
Configure Site Configure Site parameters
About PROGNOST- Shows the about box with the software version number
Predictor
Processor View Recent Processor Log The processor saves messages in the database indicat-
Messages ing important events or error conditions. This menu
function displays the messages.
Reboot Processor Reboot the processor
Reload Processor Force the processor to reload its configuration
Configure Processor Invoke the processor configuration tool
Delete Processor Delete the processor
Card Configure Processor Invoke the Processor configuration tool with the focus
on the selected card
Delete Card Delete the card
Test Relay If the card is a relay card this menu item will appear and
invoke the test relay dialog
Channel View Recent Sensor Trend The exact wording of this menu item varies depending
on the type of card. A 60 second trend of the average
signal level is displayed.
Configure Processor Invoke the processor configuration tool with the focus

36 Hardware Status PROGNOST Systems GmbH


Delete Channel
Processor Relay Assignment
on the selected channel
Delete the channel
A processor relay is one which is activated based on pro-
cessor self-diagnostic errors. This menu function desig-
nates the relay as a Processor Relay and defines the acti-
vation criteria.

8.2 Hardware Status Tree Dialogs

The tree is generated by defining the different nodes in the tree through a se-
ries of dialogs

8.2.1 Site Dialog

The site dialog has four tabs for defining system wide site parameters, user
preferences, user privileges, and sensor properties.
8.2.1.1 Tab Site

Fig. 28 Site Configuration - Tab Site

Site Name Name of site

Display displacement
Spectral amplitude as
Display velocity spec-
tral amplitude as
Display acceleration
spectral amplitude as
Display default
spectral amplitude as
Notification Log auto
archive duration (days)
Notification Log auto
archive count
Selects the spectral amplitude standard for
displacement amplitudes
Selects the spectral amplitude standard for
velocity amplitudes
Selects the spectral amplitude standard for
acceleration amplitudes
Selects the spectral amplitude standard for
non-vibration amplitudes
Notification log entries are remove from the
log after this duration has expired
The oldest notification log entries are remove
from the log if this count of entries is exceed-
ed

8.2.1.2 Tab User

Users can have user or administrative privileges. No login to
PROGNOST-Predictor is required. The login is implicitly made by comparing
the computer user login name to the User Name in the database. If no match

PROGNOST Systems GmbH Hardware Status 37

 can be made the user is admitted under the guest account with user privileg-
es.

Fig. 29 Site Configuration Tab User

Name User Name

User name Computer login account name
Email Address Email address to send configured email alerts
Phone number Phone number to send configured phone alerts
Web account name Account name to access the
PROGNOST-Predictor web site
Web account pass- Account password to access the
word PROGNOST-Predictor web site
User role Role can be user or administrator. User privileg-
es allow the examination of status and data, but
not the modification of setup and configuration
parameters
Display Units for the display of displacement data
displacement as
Display velocity as Units for the display of velocity data
Display Units for the display of acceleration data
acceleration as
Display Units for the display of frequency data
frequency as
Units standard Units standard for the display of non-
vibration data
Starting Starting graphics page for this user
graphics page
Days to show trend Default number of days to show when opening
a trend plot
Days to show Default number of days to show when opening
default summary a summary trend plot

38 Hardware Status PROGNOST Systems GmbH

 trend
Default Machine Status On startup show the Component or Analysis
tree centric machine tree
Is graph toolbar visi- Sets whether the plot toolbar is automatically
ble? shown when the plot has the focus

8.2.1.3 Tab Sensors

Fig. 30 Site Configuration Tab Sensors

Name Sensor name

Sensor type Type of sensor
Is sensor powered Is the sensor powered by the card?
Sensitivity Nominal sensor sensitivity
Offset Nominal sensor offset
Signal encoded as Units the signal is encoded
Is ICP sensor Is this sensor an ICP sensor which has a signal rid-
ing on a bias level?
English units English units for the signal
Metric units Metric units for the signal
Metric conversion Factor to multiply the English unit to convert to the
factor Metric unit
Metric conversion Offset to add to convert to the Metric unit
offset

8.2.1.4 Tab System Diagnostics

Specific processor card or channel fault conditions can be selected in the Sys-
tem Diagnostics tab for entry into the system diagnostic notification log.

PROGNOST Systems GmbH Hardware Status 39

 Fig. 31 Site Configuration Tab System Diagnostics

8.2.2 Processor
The processor configuration tool is used to configure the controller, IO cards,
and channels.

Fig. 32 Configure Processor

Name Name of processor

Network Name Network computer name of processor
Network Address Network address of processor
URI String Universal Resource Identifier string has the format

40 Hardware Status PROGNOST Systems GmbH

 http://[network name or IP]:8888/DPServices
or alternatively
net.tcp://[network name or IP]:8888/DPServices
Over Tempera- Controller card temperature limit to shut down the
ture Limit processor to prevent overheating

8.2.3 Card
The card type is specified by right clicking on a card slot position and select-
ing the card type from the list. The channel specification grid below will then
be invoked for that card.

8.2.4 Channel
The channel specification grid is specific to the channel type. The example be-
low is for an accelerometer card.

Fig. 33 Channel configuration

Id Database Id for that channel

Channel Channel input position within the card
Name Name of the channel
Sensor Type Type of sensor model
Enabled Indicates whether the channel is enabled
Sensitivity Sensor sensitivity
Max OK Value Maximum 1 second average value for a signal to
be considered to have valid data.
Min OK Value Minimum 1 second average value for a signal to
be considered to have valid data.
Range OK Value Maximum 1 second value range for a signal to
be considered to have valid data.

8.2.5 OPC Server

The PROGNOST-Predictor system can be configured to be an OPC Client to re-
ceive, store, and trend DC data from an OPC server. This data is often process
data or bearing temperatures and oil pressures.

PROGNOST Systems GmbH Hardware Status 41

 Fig. 34 OPC Server

Name Name assigned in the Hardware tree

OPC Server Name Network name of the OPC server
OPC Server Domain Domain name of the OPC server
Name
OPC Server Account OPC server login account name
Name
OPC Server Account OPC server login account password
Password
Connection String Connection string to the OPC server
Units Standard Units standard is English or SI for data sup-
plied by the OPC server

8.2.6 OPC Channel

Once the server is specified the data tag values are defined.

Fig. 35 OPC Channel

Name Signal name

OPC Tag OPC Tag
Sensor Model Sensor Model
IS Enabled? Indicates whether the channel is enabled
Minimum valid value Minimum value for a signal to be considered to
have valid data.
Maximum valid value Maximum value for a signal to be considered to
have valid data.

42 Hardware Status PROGNOST Systems GmbH

9 Data Viewer
The Data Viewer panel shows the data analysis results and trends for a Ma-
chine Element. The plots have analysis tools to extract useful information
about the data and the user can configure the layout to compare multiple
analyses.

9.1 Page Layout

The panel consists of a view selector area at the left and a view container re-
gion at the right. The container consists of a grid of available view locations.
The selector can be hidden and retrieved by pressing the View Selector button
at the far left. In the figure below the container is configured as a 1x2 grid and
is currently empty. A view is a collection of plots associated with an analysis.
For example a Spectrum view has plots for the confidence, spectrum, time
waveform, signature trend, and RPM trends. The 4 buttons at the top of the se-
lector area clear the container, allow 1 plot in the container, allow 2 plots side
by side, or invoke a small dialog that defines a grid of up to 4x4 plots. The se-
lector consists of a region of favorites with the default Trend Summary button,
The analysis subtree for the selected Machine Element, and the full Machine
tree. Individual plots can be displayed by clicking on a favorites button or by
dragging an analysis or signature from the selector trees into the container
region.

Fig. 36 Page Layout

By using the buttons below the user is able to change the analysis window.

Fig. 37 Page Layout buttons

Clear Workspace Cleans up the whole workspace

Single Cell Workspace The workspace is not divided

Double Cell Workspace The workspace is divided into two cells

PROGNOST Systems GmbH Data Viewer 43

 Select Workspace The workspace could be layouted as the
Layout user likes

The Fig. 38 shows the container filled with 2 analyses for comparison and the
View Selector collapsed.

Fig. 38 Page Layout - Double Cell Workspace

9.2 Trend Summary

When first invoked, the Data Viewer shows a summary of all signature trends
associated with the Machine Element. Also, pressing the Trend Summary but-
ton under Favorites shows the plot. At the top left of the container is the Ma-
chine element button. Pressing this button shows all trends associated with
the machine element. This allows a quick visual scan to identify trends that
might be important to analyze further. To the right of this button is a row of
Measure buttons. Pressing one of these buttons shows signature trends only
for that Measure. The summary trend plots are buttons that when pressed in-
vokes the full view for that analysis and signature.

Fig. 39 Trend Summary

44 Data Viewer PROGNOST Systems GmbH

9.3 Analysis Views
Dragging an analysis from the selector to the container shows a display as the
figure below. The arrangement of the plots in each view depends on the
analysis type. The figure shows a spectrum view with the time waveform and
RPM trends hidden. The view header consists of a dragging point indicated be
the hatch lines in the top left corner, a layout button, a delete view button,
followed by the full name of the analysis, annotation of the Analysis RPM, and
a button that invokes an analysis results properties list providing useful
information about the analysis, signature, and sensor. Below the header are
the plots of the view. Views can be re-arranged within the container by drag-
ging from the same corner and dropping into the new location. The specific
plots shown within the view can be selected by pressing the layout button. A
particular view can be removed from the container by pressing the x button.
By using the Graph Selector
button in the upper left corner,
the dialog below opens. This
selector and analysis views
could be enabled or disabled by
clicking.

Fig. 40 Analysis Views

The plots can be configured by positioning the mouse above the middle of
the plot to invoke the toolbar where the plot can be scaled in various ways
and the cursor type adjusted from single, difference, sideband, and harmonic.

Fig. 41 Analysis View scaling

Restore Previous Scale Manual Scale

Compress X Scale Single Cursor

AutoScale X Difference Cursor

Expand X Scale Sideband Cursor

Compress Y Scale Harmonic Cursor

PROGNOST Systems GmbH Data Viewer 45

 AutoScale Y Display Cursor Readout

Expand Y Scale Lock Toolbar

Each view has additional configuration functions and tools specific to that
view. For example, the Spectrum View has the following context menu items.
Select Spectral For vibration spectra this selects between
Amplitude Units showing the spectrum in displacement, ve-
locity or acceleration units
Select Spectral Selects from CPM, Hz, and orders
Frequency Units
Select Waveform Selects from msec, sec, and turns
Time Units
Select Displayed Add frequency position markers to display
Machine Frequencies other signature frequencies associated with
the machine. This is useful to identify the
source of a peak in the spectrum.
Recompute Baseline Recompute the trend baseline for this Signa-
ture trend
Modify Thresholds Open the modify threshold dialog
Perform Immediate Schedules this analysis for execution
Analysis
Listen to Sensor Sound Plays the raw sensor signal to the computer
speakers
Add Machine Element Adds Machine Element to Watch List
to Watch List
Delete Trend Data Deletes data from the trend plots
Copy to Clipboard Copy the current plot to the clipboard

Shaft Centerline Analysis

The shaft centerline analysis tracks the position of the center of the shaft rela-
tive to the clearance circle of sleeve bearing. The data view shows the shaft
centerline plot and trends of the X and Y gaps, eccentricity, and RPM. This
analysis is applied at intervals during startup and coast down and periodically
during normal running.

Fig. 42 Shaft Centerline

46 Data Viewer PROGNOST Systems GmbH

 The context menu functions available from this analysis are:
Reset Shaft Centerline Resets the shaft centerline plot to the dia-
Plot Scale metrical clearance scale
View Full Trend View the full trend of data
View Isolated Event Adjust the trend scale to show only data
from the selected event
Mark Event as Refer- Mark the event as a reference event so it can
ence be recalled later
Modify Thresholds Open the modify threshold dialog
Recompute Baseline Recompute the trend baseline for this Signa-
ture trend
Perform Immediate Schedules this analysis for execution.
Analysis
Add Machine Element Adds Machine Element to Watch List
to Watch List
Delete Trend Data Deletes data from the trend plots
Copy to Clipboard Copy the current plot to the clipboard

Orbit Analysis
An Orbit analysis is computed for sleeve bearings with X Y probe pairs. The
orbit plots the instananeous position of the shaft center relative to the bearing
clearance. Trends of the X and Y vibration amplitudes and the filtered 1X and
2X amplitudes and phases are computed. The data view shows the orbit plot,
which can be configured to show the raw orbit as well as the 1X and 2X
filtered orbits, the individual X and Y waveforms, and the selected trend and
RPM trend. This analysis is applied at intervals during startup and coast down
and periodically during normal running.

Fig. 43 Orbit

The context menu functions available from this analysis are:

Select Waveform Selects from msec, sec, and turns
Time Units
Reset the Orbit Scale Resets the orbit plot to the diametrical clear-
ance scale
Modify Thresholds Open the modify threshold dialog
Recompute Baseline Recompute the trend baseline for this Signa-

PROGNOST Systems GmbH Data Viewer 47

 ture trend
Perform Immediate Schedules this analysis for execution
Analysis
Listen to Sensor Sound Plays the raw sensor signal to the computer
speakers
Add Machine Element Adds Machine Element to Watch List
to Watch List
Delete Trend Data Deletes data from the trend plots
Copy to Clipboard Copy the current plot to the clipboard

48 Data Viewer PROGNOST Systems GmbH

10 Miscellaneous
10.1 List of Figures
Fig. 1 PROGNOST-Predictor rack .................................................................................. 5
Fig. 2 Graphical Status ..................................................................................................... 11
Fig. 3 Pin navigation tree ................................................................................................ 11
Fig. 4 Navigation Tree ...................................................................................................... 12
Fig. 5 Graphical controls ................................................................................................. 13
Fig. 6 Tooltip Gear ............................................................................................................. 13
Fig. 7 Machine Status Tree ............................................................................................. 23
Fig. 8 Machine Group ....................................................................................................... 26
Fig. 9 Add Machine ........................................................................................................... 26
Fig. 10 Add Machine ......................................................................................................... 27
Fig. 11 Machine Element................................................................................................. 30
Fig. 12 Configure machine element............................................................................ 31
Fig. 13 Analysis wizard ..................................................................................................... 31
Fig. 14 Signature wizard.................................................................................................. 32
Fig. 15 Filling of signature .............................................................................................. 34
Fig. 16 Signature Alarm relay ........................................................................................ 35
Fig. 17 Panel Layout ......................................................................................................... 36
Fig. 18 Site Configuration Tab Site ........................................................................... 37
Fig. 19 Site Configuration Tab User ......................................................................... 38
Fig. 20 Site Configuration Tab Sensors ................................................................... 39
Fig. 21 Site Configuration Tab System Diagnostics ............................................ 40
Fig. 22 Configure Processor ........................................................................................... 40
Fig. 23 Channel configuration....................................................................................... 41
Fig. 24 OPC Server ............................................................................................................. 42
Fig. 25 OPC Channel ........................................................................................................ 42
Fig. 26 Notification Log ................................................................................................... 14
Fig. 27 Page Layout........................................................................................................... 17
Fig. 28 Confidence Analysis ........................................................................................... 21
Fig. 29 Page Layout........................................................................................................... 43
Fig. 30 Page Layout........................................................................................................... 44
Fig. 31 Trend Summary ................................................................................................... 44
Fig. 32 Analysis Views ...................................................................................................... 45
Fig. 33 Analysis View scaling ......................................................................................... 45
Fig. 34 Shaft Centerline ................................................................................................... 46
Fig. 35 Orbit ......................................................................................................................... 47

PROGNOST Systems GmbH Miscellaneous 49

PROGNOST Systems GmbH
Daimlerstr. 10
48432 Rheine
Germany
+49 (0)59 71 - 8 08 19 0
+49 (0)59 71 - 8 08 19 42
info@prognost.com
www.prognost.com
PROGNOST Systems, Inc.
1018 Hercules
Houston, TX, 77058
USA
+1 - 281 - 480 - 9300
+1 - 281 - 480 - 9302
infousa@prognost.com