VIBCONNECT® RF Installation and Operation
Compliance Statement acc. to Sect. 15.19: This device complies with Part 15 of the FCC Rules.Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence.
VIBCONNECT® RF Online Condition Monitoring with Radio Communication Installation and Operation Series: VIB 7.200 VIB 7.220 VIB 7.205-2.9 RF Bridge RF Sensor unit RF sensor Firmware: 1.x Date: November 2011 Prod. no.: LIT 72.200.
The product described in this document, and the content of this manual are protected by intellectual property laws. All rights reserved. The manual may not be copied, reproduced, translated or made accessible to a third party in any form, neither in its entirety nor as an excerpt. No liability may be claimed against the publisher regarding the product described in this manual. The author assumes no liability for accuracy of the manual contents.
3 Foreword Foreword Thank you for purchasing our VIBCONNECT RF online condition monitoring system. VIBCONNECT RF offers maximum flexibility at minimum costs for installation and operation. It caters for the continuous condition monitoring of machines for which wired systems would not be economically viable.
4 Contents Contents Chapter 1: Introduction...................................................... 7 1.1 First steps......................................................................... 7 1.2 Service addresses............................................................. 7 1.3 About this manual........................................................... 8 Chapter 2: Safety................................................................ 9 2.1 Safety symbols .................................................
5 Contents 5.5 Installation of sensors..................................................... 43 5.5.1 Choosing the measuring points............................................ 43 5.5.2 Mounting sensor.................................................................. 44 5.5.3 Installing and connecting sensor line to sensor unit............... 49 5.6 Configuration in OMNITREND (continued)...................... 50 5.6.1 Registering bridge in OMNITREND........................................ 50 5.6.
6 VIBCONNECT RF 11.
7 Introduction Chapter 1: Introduction 1.1 First steps Checking delivery Please check the delivered goods without delay for defects or missing parts. If your delivery is incomplete or you detect defective parts, mark the respective components on the freight dockets and contact the shipping company or local PRÜFTECHNIK sales partner.
8 Introduction 1.3 About this manual This manual forms part of the product delivery and must be kept for the entire service life of the product. It might be necessary to update this document from time to time. If the product is handed on to another user, you must also hand over this manual. Disclaimer The information and data in this manual are provided for information purposes only.
9 Safety Chapter 2: Safety VIBCONNECT RF has been designed according to the harmonized standards and technical specifications listed below. It therefore conforms to the latest state of technology and provides best possible safety. During installation and operation, there are, however, some residual risks that cannot be eliminated by technical measures. Please always comply with the general safety instructions in this chapter, and with the safety instructions in the other chapters of this manual.
10 Safety • The system is installed and operated only by suitably qualified and authorized personnel • All operating personnel have been instructed in the relevant occupational safety and environmental protection issues in relation to the system, and in the use of this manual, with particular reference to the safety instructions • The responsibilities for installation, commissioning and operation have been assigned Compliance with operating manual You must ensure that • This manual has been read and fully
11 Safety Regularly check for the following: • Is there visible damage to the system components? • Are any of the sensor or network cables squeezed or damaged? • If you detect any defects, notify your supervisor and / or repair them. The system must only be operated when in proper working order! • In the event of malfunction of the bridge or the sensor unit, disconnect the affected device from the power supply and secure it against switching on.
12 Safety 2.5 Residual risks and safety measures If installed and operated according to the instructions VIBCONNECT RF is a safe system.
13 Safety machinery. Note Risk of damage to equipment while housing is open! Touching the electronic components on the mother board can lead to electrostatic discharge, which can damage system components. »» If contact with such components cannot be excluded, wear an earthing wristband. Note EMC High-frequency radiation and electrostatic discharge (ESC) near the sensors can lead to incorrect measurements. »» Do not install sensor cables in high-voltage cable ducts. Note VIBCONNECT RF 11.
14 Sicherheit Declaration of Conformity according to EN ISO/IEC 17050-1 PRÜFTECHNIK Condition Monitoring GmbH Oskar-Messter Str. 19 –21, 85737 Ismaning, Germany herewith declares that product VIBCONNECT RF VIB 7.200-XX / VIB 7.205-2.9 / VIB 7.210-XX / VIB 7.220-X Condition monitoring system with radio communication Designation: Product nos.: Description: conforms to the applicable European Directives and standards.
15 Technical data Chapter 3: Technical data VIBCONNECT RF Bridge – VIB 7.220-... Capacity up to 50 sensor units Radio transmission frequency band ISM 868 MHz (Europe) – VIB 7.220-N ISM 915 MHz (USA) – VIB 7.220-F Ethernet Baud rate: 10 / 100 Mbit/s Power supply 100 ... 240 VAC / 50-60 Hz Protection class IP 66 Operating temperature – 25 °C ... +60 °C Relative humidity < 95 %, non-condensing Housing Steel, powder-coated Weight 1.8 kg Dimensions VIBNODE VIBCONNECT RF 11.
16 Technical data VIBCONNECT RF sensor unit – VIB 7.200-... Measuring channels Two synchronized channels. Each channel allows for the simultaneous measurement of vibration and temperature by the VIBCONNECT RF sensor. Radio transmission frequency band ISM 868 MHz (Europe) – VIB 7.200-N..U ISM 915 MHz (USA) – VIB 7.200-F..
17 Technical data VIBCONNECT RF Sensor – VIB 7.205-2,9 Sensor type Vibration acceleration sensor with integrated temperature sensor Transmission factor 3.5 mV / ms-2 (± 10 %) Linearity ± 500 ms-2 (rms) Frequency range 10 Hz ... 10 kHz (± 3 dB) Resonance frequency 29 kHz Temperature measuring range – 40 °C ... +125 °C Accuracy ±3 °C Cable type 3-wire cable, shielded Cable length 2.
18 Technical data Measuring tasks (configurable through OMNITREND PC software) Maximum number of measuring tasks per measuring point 4x vibration, 1x temperature (min. 1x vibration per measuring point) Time signals Vibration acceleration to 10 kHz Vibration velocity to 10 kHz Amplitude spectra Vibration acceleration to 10 kHz Vibration velocity to 1 kHz, 3 kHz or 10 kHz Number of lines: 3200 Envelope spectra Vibration acceleration to 3.
19 System description Chapter 4: System description VIBCONNECT RF is a stationary, radio-based online condition monitoring system designed for easy installation and operation. The system consists of the following components: 1. 2. 3. VIBCONNECT RF bridge VIBCONNECT RF sensor unit VIBCONNECT RF sensor for vibration and temperature 1 2 3 4.
20 System description (characteristic value, FFT spectrum, envelopes) are performed on the bridge. The bridge is equipped with a built-in memory, containing the actual measuring configurations and the measurements that have not yet been transferred to the OMNITREND software. Measurements that have been written to OMNITREND are automatically deleted from the bridge memory. Note The measurement import must be started manually in the OMNITREND software. Ensure that the data is regularly written to OMNITREND.
21 System description 4.2 VIBCONNECT RF sensor unit The sensor unit is the transmitter and receiver unit attached to the machine. Each sensor unit comes with one or two connected sensors for the simultaneous measurement of vibration and temperature. By separating the sensors from the radio unit, it is possible to position the components in the most suitable locations on the machine. For sensors, these are the points with the highest signal level.
22 System description Operating cycle: measuring, sending, idling The sensor unit performs the measuring tasks at preset intervals, sends the data and then returns to idle to save energy. Event-controlled measurement In addition to the time-controlled measurements, the sensor unit can be configured to perform vibration measurements based on events.
23 System description What happens, if ... ... a sensor unit “wakes up” from its idle time? • The sensor unit first checks whether the idle time has been terminated based on the timer settings or due to an event (time-controlled or event controlled operation). It then performs the measurements, using the current measuring configuration, and transfers the data via radio signal to the bridge.
24 System description Topology of radio cell The radio network is of a star formation, and each sensor unit communicates with the bridge through bidirectional communication. The individual sensor units cannot communicate with each other. This ensures that additional sensor units can be added to a cell at any time without affecting the existing components. The failure or switching off of a sensor unit does not in any way affect the rest of the network. VIBCONNECT RF radio cells are of a star formation.
25 System description 4.3 VIBCONNECT RF sensor The sensor simultaneously measures the vibration acceleration and the temperature. It is equipped with a 2.9 m cable and is extremely compact, requiring only minimum space. It can thus be positioned at the best possible measuring point on the machine and connected to the sensor unit that is within the radio range of the bridge. VIBCONNECT RF 11.2011 The sensor is mounted with a M8 threaded bolt to the machine.
26 Installation and commissioning Chapter 5: Installation & commissioning 5.1 Quick guide 5.1.1 Initial installation of system / radio cell In OMNITREND at PC workstation 1. 2. 3. 4. Register device driver Set up measuring point database Print measuring point report Adjust IP address at the bridge On site 5. 6. 7. 8.
27 Installation and commissioning As the system is based on wireless communication, the installation of the components is very simple. All you need to do is installing and connecting the bridge, the sensor unit(s) and the sensors.
28 Installation and commissioning 5.2.2 Setting up measuring point database Online Measuring point type for VIBCONNECT RF *The term “measuring point” refers to the measuring channel of a sensor. • In the OMNITREND Machinery Manager, set up the tree structure for the machine park to be monitored, including a measuring point hierarchy. • Select measuring point type ‘Online’. Note If a sensor is to measure both vibration and temperature, you must set up two separate measuring points* for this sensor.
29 Installation and commissioning 5.2.3 Creating and printing measuring point report During installation, you add the following information to the printed report: • Machine on which the sensor unit is installed • Measuring channel for each measuring point in the OMNITREND database This information is required for the measuring configuration in OMNITREND. The report can be created to include all entries in the database or only a selection of records. VIBCONNECT RF 11.
30 Installation and commissioning 5.3 Installation & commissioning of bridge The bridge is contacted by OMNITREND through the network (Ethernet). The bridge is addressed through the IP address of the bridge. The factory-set address is: 192.168.63.01 If the address range of your network differs from the standard range (e.g. 172. ... or 10. ... ), adjust the IP address of the bridge accordingly before you install the bridge in the machine park. 5.3.
31 Installation and commissioning • Click and enter the new IP address for the bridge. If required, change the address of the Subnet Mask and Gateway, and then click the button. Note Note down the new IP address of the bridge as it might be needed for maintenance or repairs. If you are unsure about the correct addressing procedure within your network, contact the network administrator. • Repeat the above steps for all other bridges.
32 Installation and commissioning 5.3.2 Installation requirements For proper installation of the equipment on site, the operator must ensure that the following requirements are met: Personnel qualification The devices must be installed by a qualified electrician. Location of installation The bridge must be installed at an exposed position to ensure optimum radio reception from all machines in the radio cell.
33 Installation and commissioning Tools and materials • Power drill, drill bit and thread cutter for M7 bolts • M7 bolts and matching washers for fixture of bridge (4 bolts per bridge) • Open-end spanner of suitable size • Open-end spanner (size 22) for M16 cable glands • 3-wire electric cable of appropriate length for power supply line • Ferrules for connection of power supply line • Ring terminal for connection of earth conductor to PE • Industrial Ethernet cable (CAT 5) for data of appropriate length •
34 Installation and commissioning 5.3.4 Connecting bridge • Feed the network cable through the left gland and the power cable through the right gland. • Connect the bridge to the data network and to the power source as shown in the following diagram. CAUTION Risk of injury from electric shock! When connecting the bridge to the power supply without taking the necessary safety precautions, there is a risk of energy from high voltage (220 V).
35 Installation and commissioning 5.3.6 Overview of connections and interfaces Antenna (section) Power supply EIA-TIA 568A VIBCONNECT RF 11.
36 Installation and commissioning Installation & commissioning of sensor unit The operator of the system must ensure that the following conditions are met and all necessary preparations are completed. Location of installation • The sensor unit must be mounted on or near the machine. Choose a suitable position on the machine that is only exposed to low vibration. Alternatively, provide a suitable holder for the sensor unit. • Ensure that the location of installation has good radio reception.
37 Installation and commissioning 5.4.1 Overview of connections and interfaces Battery-powered sensor unit VIB 7.200-FBU or VIB 7.200-NBU 1 8 3 7 2 4 6 5 5. Cable gland for sensor line 6. Cable gland for 24V power supply cable / energy harvester cable 7. Fixing tabs for sensor unit 8. Vibration dampers Terminal strip: sensor / power supply Sensor 2 VIBCONNECT RF 11.
38 Installation and commissioning Terminal strips and LEDs in sensor unit Power supply (24 V version) LEDs in sensor unit: • Green: Data transmission • Yellow: Measurement • Red: Data transmission error Terminal 1 5.4.2 Measuring reception field strength at location of installation • Open the sensor unit housing by loosening the two screws of the cover (size 2.5 Allen screws).
39 Installation and commissioning • Wait for approx. 3 – 4 seconds until the reception / voltage has stabilized. Wait for approx. 3 – 4 seconds until the reception / voltage has stabilized. U > 0.1 V: Reception OK Umax. = 1.25 V • If radio reception at the location of installation is poor, remove the antenna from the housing and mount it in a suitable loca tion. To connect the antenna to the sensor unit, use a SMA cable of appropriate length.
40 Installation and commissioning 5.4.3 Mounting sensor unit CAUTION 4 8 Risk of injury from rotating machine parts! When installing the sensor unit while the machine is running, there is a risk of serious injury caused by exposed, moving machine parts. »» Do not remove any guards on the machine. »» Always adhere to the safety instructions for work on running machinery. • Install the sensor unit at the location with the best possible radio reception. • Drill two mounting holes.
41 Installation and commissioning 5.4.4 Connecting sensor unit Note The sensor cables must only be connected to the sensor unit after the sensors have been installed, so that you have the option to extend or shorten the cables if required (see also, “Installation of sensors“, page 43). • Open the sensor unit and feed the sensor cable through the cable gland provided.
42 Installation and commissioning Sensor unit with external 24 V power supply: • Connect the power supply cable to the second, 4-pin terminal strip (see also “Sensor unit: Overview of connections and interfaces”, page 37). • Tighten the cable glands at the sensor unit and close the housing. 5.4.5 Commissioning sensor unit • Switch on the power supply of the sensor unit (insert battery, switch on 24 V power supply).
43 Installation and commissioning 5.5 Installation of sensors For proper installation of the sensors on site, the operator must ensure that the following requirements are met: Location of installation • The sensors are secured to the machine with the supplied M8 threaded bolt or with a suitable mounting adapter. • Observe the rules for the choice of measuring points for vibration measurements. Permissible ambient conditions Temperature: – 40 °C to +125 °C Relative air humidity: max.
44 Installation and commissioning of contact resonance. This is particularly important for measurements at high frequency. Suitable measuring points on the machine radial, vertical axial axial radial, horizontal 5.5.2 Mounting sensor CAUTION Risk of injury from rotating machine parts! When installing the sensors while the machine is running, there is a risk of serious injury caused by exposed, moving machine parts. »» Do not remove any guards on the machine.
45 Installation and commissioning screwed (M8) VIB 3.480 adhesive VIB 3.418 magnetic VIB 3.423 Mounting sensor with screw adapter Tools and auxiliary equipment • Power drill with two drill bits (3.5 / 6.8 mm) and depth gauge • Spot facer • M8 bottoming tap • Size 19 torque spanner • Compressed air to clean mounting point Installation Select drilling point: • The minimum distance between the drill hole and the protruding edges of the sensor housing is 35 mm.
46 Installation and commissioning • Clean the drill hole and the area around it with compressed air; roughen the surface around the drill hole with sandpaper (grade 220). • Clean the contact faces at the adapter and the machine with solvent. • Allow the contact faces to dry, apply a thin layer of screw locking agent (LOCTITE 243) to improve signal propagation. • Screw the threaded bolt into the sensor and tighten it with a size 4 Allen key.
47 Installation and commissioning Installation Select mounting point: • In order to have sufficient space to apply the adhesive with a wooden spatula, keep a distance of minimum 35 mm between the adapter and the edges of the housing. Level and roughen surface: • Remove all paint from the mounting surface so that the adapter can be glued to bare metal (diameter of area > 30 mm). If necessary, level the mounting area.
48 Installation and commissioning Apply adhesive Press down and turn adapter Mount the adapter: • Press the adapter with minimum force against the mounting area and turn it slightly to distribute the adhesive evenly. • Do not remove adhesive escaping at the side of the adapter. For extra stability, also apply adhesive around the adapter edge. • Allow the adhesive to cure (approx. 24 h at room temperature).
49 Installation and commissioning 5.5.3 Installing and connecting sensor line to sensor unit The sensor cable is permanently attached to the sensor. The other end of the cable must be connected to the sensor unit. • Before installing the cable, mark the cable end with the sensor number to which it belongs. This ensures that there is no confusion when connecting the cables to the sensor unit.
50 Installation and commissioning 5.6 Configuration in OMNITREND (continued) After the system components have been installed and commissioned, continue configuring the system in OMNITREND (see also “Configuration in OMNITREND”, page 27).
51 Installation and commissioning • Click the button. The bridge is now registered in OMNITREND and logged on (no need for password). You do not need a password to register the bridge. 5.6.2 Registering sensor units in OMNITREND • In the main menu, click / . • In the ‘Registration’ window (‘OMNITREND’ tab), check whether ‘VIBCONNECT RF’ is the current OMNITREND version. If this is not the case, change the settings.
52 Installation and commissioning To register the sensor units in OMNITREND, click the button. • In the ‘Configuration’ window, click the button. OMNITREND establishes a connection to the bridge and then lists all sensor units that are within the radio range of the bridge and have sent requests for measuring configurations. Note Each sensor unit is clearly identified by its unique MAC address.
53 Installation and commissioning • In OMNITREND, open the Machinery Manager. • Select one of the previously set up online measuring points (see also “Setting up measuring point database”, page 28). • Call up the ‘Meas. Data’ tab. • In the ‘Meas. Point Type’ section, first select the bridge with the best reception in the ‘Online Device’ field. • In the second field, select the sensor unit that is installed at the respective measuring point (refer to the measuring point report).
54 Installation and commissioning 5.6.4 Creating measuring configuration This chapter explains how to create a measuring configuration for a measuring point in the VIBCONNECT RF system, using the OMNITREND software. A measuring configuration contains information regarding • • • • • the measuring tasks the time intervals at which measurements are to be performed the trigger criteria for event-controlled measurements the measuring point assigned to a sensor unit the associated bridge.
55 Installation and commissioning • For the calculation of the characteristic vibration values, define the respective band analysis in the alarm wizard. Note VIBCONNECT RF calculates the characteristic vibration values from a spectrum, using frequency bands. These bands are preset in the alarm wizard and are then assigned as a subordinate measuring task ‘Bank analysis (Trending Task)’ to the respective spectrum. For more information, please refer to the OMNITREND online help.
56 Installation and commissioning • Activate option ‘Wake up level’, and select the vibration level: 5.6.5 Loading measuring configurations to the bridge After you have set up a measuring configuration for every measuring point in the system, these configurations must be transferred to the respective bridges: (route to device). • In the main menu, click • In the ‘Select Device’ window, select the bridge. • To start the data transfer, click the button.
57 Installation and commissioning 5.7 Installing additional sensor unit after commissioning of the system VIBCONNECT RF can be extended at any time, and sensor units and sensors can be added during operation of the system. Setting up measuring points and printing reports • Set up the required measuring points in the OMNITREND database (see also “Setting up measuring point database”, page 28).
58 Maintenance Chapter 6: Maintenance VIBCONNECT RF is an electronic measuring system that must be handled with care. 6.1 Cleaning If required, clean the housings of the bridges and the sensor units with a damp cloth so that the system component details (serial number, MAC address) remain clearly visible at all times. Replace damaged cables without delay. 6.
59 Maintenance start until the respective battery has been replaced and a new measurement record has been read. • Battery status report: In the main menu, select / / . • Configuration of the bridge: In the configuration window for the bridge, the battery charge status of each assigned sensor unit is displayed (see also “Registering sensor units in OMNITREND”, page 51).
60 Maintenance 6.4 Warranty The warranty period for the VIBCONNECT RF is 1 year. Unauthorized service work on the system shall automatically void all warranty. 6.5 Spare parts and accessories Use only original spare parts and accessories. For details, refer to the VIBCONNECT product catalog (LIT 72.700). The latest catalog edition can be downloaded from the PRÜFTECHNIK website (www.pruftechnik.com). VIBCONNECT RF 11.
61 Troubleshooting Chapter 7: Troubleshooting Symptom: The red LED of the sensor unit is lit, indicating an error in the data transmission (see also “Sensor Unit: Overview of connections and interfaces”, page 37). Possible cause(s): System crash Remedy: • Switch off the power supply to the sensor unit and then switch it on again. • Check the connection to the bridge in OMNITREND or by means of the web browser. Symptom: The bridge cannot be contacted (from OMNITREND or via web browser).
62 Decommissioning and disposal Chapter 8: Decommissioning and disposal Decommissioning Disconnect the bridge and the externally powered sensor units from the power supply. Remove the batteries from the batterypowered sensor units. PRÜFTECHNIK Condition Monitoring WEEE Reg. No.: DE 72273578 Disposal Dispose of the system components and the spent batteries according to the applicable waste disposal regulations.
63 Index Index D Decommissioning Disposal 62 W VIBCONNECT RF 11.
For measurable success in maintenance PRÜFTECHNIK Condition Monitoring Oskar-Messterstr. 19–21 85737 Ismaning, Germany www.pruftechnik.com Phone +49 (0)89 996160 Fax +49 (0)89 99616300 E-mail: info@pruftechnik.com Printed in Germany LIT 72.200.12.2011.DE VIBCONNECT® is a registered trademark of PRÜFTECHNIK AG. Errors and omissions excepted. Subject to technical changes. Reproduction is only permitted with the written consent of PRÜFTECHNIK AG.
PRÜFTECHNIK Condition Monitoring GmbH Oskar-Messter-Str. 19–21 85737 Ismaning, Germany www.pruftechnik.com Phone: +49 89 99616-0 Fax: +49 89 99616-300 E-mail: info@pruftechnik.com www.pruftechnik.
