Machine Up Time Monitor Datasheet

Device Overview

Figure 1: Device Overview

Status LED

The Status LED is used to indicate errors or other sensor diagnostics.

LED blinks once – Message was sent successfully and no error in last sensor read as well in data transmission.

LED blinks twice and then one more time – Message was sent successfully but there was an error in last sensor read.

LED blinks thrice – MCU is having issue communicating with the radio module.

Sensor Specifications

SpecificationsMinimumNominalMaximumNotes
Width3.54"
Length4.52"
Height2.16"
Enclosure RatingIP65, NEMA 1,2,4,4X,12,13, UL-508
Temperature Rating-40° C23° C85° CComponent Rating
Tested Temperature0° C23° C40° CAs Tested by NCD Staff
Probe Temperature-40° C23° C85° CAs Tested by NCD Staff
InputsDigital, Acceleration, Magnetic, Current
Opto-input Voltage3.3 V24V

Printed Circuit Board Specifications

ParameterMinimumNominalMaximumNotes
Trace Width0.007 inch0.012 inch0.25 inchTrace Width depends on the Trace Type
Layer Count2L - RigidTop and Bottom Layer
Material TypeFR-4 TG170FR-4 TG170FR-4 TG180
Surface FinishENIG 2u"
IPC StandardIPC CLASS 2
Finished Copper Foil1.0/1.0 OZ
Finished Thickness0.062 inc
Fine line <4.0/4.0milNo
Blind & Burried ViasNo
Non-Conductive ResinNo
Conductive ResinNo

Mechanical Drawing

Figure 3: Mechanical Drawing

RF Module Specifications

Parameter868MHz900MHz2.4GHz
Frequency Band863 MHz to 870 MHz902 to 928 MHzISM 2.4 GHz
Transmitter PowerUp to 13 dBm ERPUp to 24 dBmUp to 8 dBm
Receiver Sensitivity-106 dBm at 80 Kbps-101 dBm at 200 Kbps-103 dBm at 250 Kbps
Range (dense urban)up to 2 milesup to 2 milesup to 750m
Range (open area)10+ miles10+ miles10+ miles
Data Rate80 Kbps200 Kbps250 Kbps
Networking ProtocolDigi XBee® DigiMesh®Digi XBee® DigiMesh®Digi XBee® DigiMesh®
Encryption128-bit AES128-bit AES128-bit
Reliable Packet DeliveryRetries/acknowledgementsRetries/acknowledgementsRetries/acknowledgements
IDsPAN ID and addresses, cluster IDs and endpoints (optional)PAN ID and addresses, cluster IDs and endpoints (optional)PAN ID and addresses, cluster IDs and endpoints (optional)
CertificationCE/RED, ROHS CompliantFCC (America), IC (Canada), C-Tick (Australia), Anatel (Brazil), IDA (Singapore)FCC (America), IC (Canada), RCM (Australia), Anatel (Brazil), Teleck MIC (Japan), KCC (South Korea)

Probes Specifications

There are 4 types of probes: Bare wire for digital inputs, Current sensor, Accelerometer, and Magnetometer.

Digital Inputs

The Industrial Digital Input and Sensor Reader is a compact and robust device tailored to interpret signals from various digital inputs and sensors prevalent in industrial settings, including brake sensors, photo reflectors, and on/off signals. With high accuracy and reliability, it offers real-time data acquisition and monitoring, seamlessly integrating into existing industrial automation systems. Its user-friendly interface and flexible configuration options ensure easy setup and compatibility with diverse applications, enhancing operational efficiency, equipment reliability, and production optimization. Ideal for conveyor systems, packaging machinery, and robotic systems, it empowers industrial operators with streamlined data interpretation and control capabilities, minimizing downtime and maximizing productivity.

Note: When using a digital input sensor the Rising edge of the pulse is used for the cycle count by default, however you can configure it to be a falling edge instead (via software configuration of the sensor).

Accelerometer Sensor

The Cycle and Uptime Tracker is an innovative device engineered to monitor and record the number of cycles and total uptime of machinery or equipment in industrial environments. Leveraging advanced acceleration sensing technology, users can set customizable acceleration thresholds to precisely detect cycle initiations. This allows for accurate tracking of machine activity while minimizing false readings. The device captures and stores data, providing insights into equipment usage patterns and overall uptime. With its user-friendly interface and customizable settings, operators can easily configure acceleration thresholds to suit specific machinery requirements. Ideal for diverse industrial applications, the Cycle and Uptime Tracker enhances maintenance planning, optimizes production scheduling, and improves operational efficiency.

Magnetometer Sensor

Magnetic Field-Based Machine On/Off Detection System is meticulously engineered to precisely discern the operational status of machinery that emits magnetic fields during operation. Employing cutting-edge magnetic field sensors, this system offers unparalleled accuracy in identifying whether the machine is active or inactive. With its robust design and reliable performance, there’s no need for user adjustments, ensuring hassle-free operation. Real-time monitoring capabilities enable proactive maintenance planning and energy conservation, enhancing operational efficiency. Seamlessly integrating into various industrial setups, this system represents a pinnacle of reliability and professionalism in machine monitoring solutions.

Current Sensor

Industrial Machine Uptime and Cycle Counter, a cutting-edge solution that accurately measures total machine uptime and cycle counts using advanced current sensor technology. With real-time monitoring and seamless integration, our device enables proactive maintenance planning, enhances operational efficiency, and provides valuable insights for informed decision-making. Upgrade your industrial operations with precise tracking and analysis capabilities for optimized performance and cost savings.

Pin Definition

1

Power Requirements and Expected Battery Life

Power Requirements

This Sensor has two power options:

  1. Powered by AA batteries (NCD recommends Energizer L91 batteries) 
  2. External power supply (5-12 V DC) Current Requirement 250 mA

Note: The L91 Batteries are non-rechargeable Li-Ion batteries.

While changing the batteries: 

  1. Turn off the sensor 
  2. Only use new L91 batteries
  3. Checkout the polarity marking on the battery holder and batteries 
  4. Replace all six batteries with new L91 batteries. Do not mix old and new batteries 
  5. Batteries should not be replaced in fire-risky areas
  6. Do NOT install rechargeable batteries 

Note: If these Devices are being used with photo eye or any other sensors needing power, use an external power supply. 

Expected Battery Life

SpecificationsMinimumNominalMaximumNotes
Batteries266May be Powered by 2 or 4 AA Batteries
Battery Life 1 TPD10 YearsTPD Transmissions per Day
Battery Life 12 TPD8 YearsTPD Transmissions per Day
Battery Life 24 TPD5 YearTPD Transmissions per Day
Battery Life 96 TPD3 YearTPD Transmissions per Day

Most NCD IoT Sensors are rated for 300,000 to 500,000 transmissions until the batteries become so weak they are unreliable. You could spread these transmissions out over a 10 year period and send 50,000 transmissions per year. This would allow up to 136 transmissions per day, or about 5 transmissions per hour (for a 500K sensor, or 3 per hour for 300K sensor). If you only need the batteries to last 3 years, you could send 166,666 transmissions per year, or about 456 transmissions per day (about 19 transmissions per hour for a 500K sensor). As you can see, battery life is really up to you. By altering advanced settings in the NCD IoT sensor, you have control over longevity. Please note the 500,000 transmission rating is for premium alkaline batteries. NCD ships all sensors with premium Lithium batteries, which include a ultra-wide temperature range that typically lasts in excess of 600,000 transmissions for some sensor types. These batteries weigh less than half of alkalines, and they work in the freezer! A word of caution though, putting a sensor in configuration mode will drain the batteries very quickly. It’s important to configure your sensors and exit configuration mode as soon as possible or use a external power supply during configuration (if supported by the sensor). The table below indicates how many Transmissions Per Hour (TPH) your can expect from different sensors over a lifespan of up to 10 years.

The Truth About Battery Life

Under the best of circumstances, the best non-rechargeable batteries commonly available today are limited to a 10 year non-working shelf life in a room temperature environment. Factors such as actual usage, temperature, and humidity will impact the working life. Be wary of any battery claims in excess of 10 years, as this would only apply to the most exotic and expensive batteries that are not commonly available. Also note that most battery chemistries are not rated for use in extreme temperatures. NCD only uses the best Non-Rechargeable Lithium batteries available today, which are also rated for use in extreme temperatures and have been tested by our customers in light radioactive environments. Lithium batteries offer a 10 year maximum expected shelf life due to limitations of battery technology. NCD will never rate sensor life beyond the rated shelf life of the best batteries available today, which is currently 10 years.

Head to the NCD store if you want to purchase the Machine Uptime Monitoring Sensor.

If you already have the device and would like more information into its basic and advanced operations check out the Quick Start Guide and User Manual.