VC4000

VIBROCONTROL 4000
Register 1.2
Machine monitoring system VIBROCONTROL 4000 Table of contents
1 2
2.1 2.2 2.3 2.4 2.5
2.5.1 2.5.2 2.5.3 2.5.4 2.5.5
System overview ........................................................................... 5 Installation ..................................................................................... 9

General notes on installation.........................................................................10 Installation of module housing.......................................................................12 Insertion of the modules into the module housing.........................................12 Connection of module housing......................................................................14 Connection of monitoring modules................................................................18
Connection of sensors and measuring chains....................................................................... 20 Connection of analog outputs ................................................................................................ 20 Connection of monitoring relay contacts................................................................................ 21 Activation of local control input .............................................................................................. 21 Connection of buffer outputs.................................................................................................. 21
3
3.1
Initial operation ............................................................................ 22

Initial operation with the configuration software VIBROCONFIG CM-401 (Version 3.00) ...............................................................................................23
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6
Minimum requirements to be met by the PC ......................................................................... 23 File extensions ....................................................................................................................... 24 Establishing the interface connection .................................................................................... 24 Installation of software VIBROCONFIG CM-401 ................................................................... 25 Program start ......................................................................................................................... 25 Working with CM-401............................................................................................................. 25
SYSVC4E March 2006 Brel & Kjaer Vibro GmbH Tel. : +49 (0)6151 428-1400
C102 860.002 Leydheckerstrae 10 Fax : +49 (0) 6151 428-1401
Page 1 of 95 D-64293 Darmstadt E-Mail : info@bkvibro.de
VIBROCONTROL 4000
Table of contents
3.2
Initial operation with the configuration software VIBROCONFIG CM-402 (Version 3.00) ...............................................................................................26
3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6
Minimum requirements to be met by the PC ......................................................................... 26 File extension ......................................................................................................................... 27 Establishing the interface connection .................................................................................... 27 Installation of software VIBROCONFIG CM-402 ................................................................... 28 Program start ......................................................................................................................... 28 Working with CM-402............................................................................................................. 28
3.3 3.4 3.5
System calibration.........................................................................................29 Putting the machine into normal operation....................................................30 Parameter cards ...........................................................................................31
4
4.1
4.1.1 4.1.2 4.1.3 4.1.4
Safety concept............................................................................. 53
Passive safety...............................................................................................53
Independent modules ............................................................................................................ 53 Selection of processor and operating system........................................................................ 53 Program structure .................................................................................................................. 54 Double storage of data........................................................................................................... 54
4.2
4.2.1 4.2.2 4.2.3 4.2.4
Active safety = OK monitoring.......................................................................54

Monitoring of the measuring chains ....................................................................................... 54 Self-tests ................................................................................................................................ 55 Monitoring of supply voltage .................................................................................................. 56 Monitoring of the module assignment.................................................................................... 56
4.3
4.3.1 4.3.2 4.3.3 4.3.4 4.3.5
Signalling, displaying and resetting of an OK error .......................................57

Central OK relay..................................................................................................................... 57 OK LEDs of the monitoring modules...................................................................................... 58 OK LED of interface module .................................................................................................. 59 LCD display as a status indication ......................................................................................... 59 Resetting (acknowledging) an alarm or an error message.................................................... 59
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Table of contents
VIBROCONTROL 4000
5
5.1
5.1.1 5.1.2 5.1.3
System behaviour........................................................................ 61
Switch-on behaviour/readyness for operation ...............................................61
Automatic readiness for operation ......................................................................................... 61 Readiness for operation not before acknwoldegement has been made ............................... 62 Recognition of errors.............................................................................................................. 62
5.2 5.3 5.4
System behaviour during configuration:........................................................62 Behaviour of the limit value relays in case of faults.......................................64 Behaviour of the analog outputs in case of malfunctions ..............................66
6
6.1
6.1.1 6.1.2 6.1.3
Components of VIBROCONTROL 4000 ..................................... 68

Module housing RC-400 ...............................................................................68
Slot assignment (see fig. 6-1) ................................................................................................ 70 Changing of slot assignment.................................................................................................. 70 Thermal protection switch for LCD displays .......................................................................... 70
6.2 6.3 6.4 6.5

6.5.1 6.5.2 6.5.3 6.5.4
Power supply unit module PS-410 and PS-420 ............................................71 Interface modules CI-411, CI-421 and CI-431 ..............................................72 Control panel TP-419....................................................................................74 Monitoring modules.......................................................................................75
General .................................................................................................................................. 75 Monitoring modules and their measuring tasks ..................................................................... 76 Configuring of the modules .................................................................................................... 77 Measurement types of the monitoring modules..................................................................... 78
6.6
Multiplexer module MX-410 ..........................................................................78
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VIBROCONTROL 4000
Table of contents
7
7.1 7.2
7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7
General functions of the monitoring modules .............................. 80

Indication of measurement types ..................................................................80 Monitoring of the measurement types...........................................................80
Absolute monitoring of the measurement types .................................................................... 81 Trend monitoring of measurement type 1.............................................................................. 82 Setting of the limit values ....................................................................................................... 84 Display of limit values............................................................................................................. 85 Indication in case of limit value violation (limit value LEDs) .................................................. 85 Functions of the limit values................................................................................................... 86 Limit value relay ..................................................................................................................... 87
7.3 7.4 7.5 7.6
Analog outputs (recorder outputs).................................................................89 Buffer outputs (Diagnosis outputs)................................................................92 Local control input.........................................................................................93 System calibration / reference calibration .....................................................95
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System overview
VIBROCONTROL 4000
System overview
VIBROCONTROL 4000 is, within the system VIBROCAM 4000, the solution for the task of permanent condition monitoring of machines and installations, aiming at an increased operational reliability and a reduction in repair costs.
Monitoring includes:
Recording of the current machine condition by continuous measuring of all relevant condition and operation parameters Recognition of the deviation from the desired condition Alarm in case critical limit values are exceeded Switching off the machine or installation in case of dangerous conditions
Fig.1-1
Example of the use of a VIBROCONTROL-4000 system
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VIBROCONTROL 4000
System overview
The VIBROCONTROL system has a modular design.
Its prinicipal components are the monitoring modules for various measuring tasks and the central CI module (Computer interface) The monitoring modules, working autonomously and having two independent measuring channels each (except for TA-41x), enable the following parameters to be measured: Vibration values from 1 Hz to 10 kHzsuch as vibration, vibration velocity, vibration acceleration Static measuring parameterssuch as displacement, pressure, temperature and other process parameters Quasi-static measuring parameters from 0.1 to 10 Hz, such as shaft excentricity, shaft position with minimum bearing play Parameters which are measured on the basis of counting pulses such as speed, flow rate The central CI module constitutes the communication interface between the monitoring modules and the peripherals - usually a normal PC - and offers the following possibilities: Configuration of the monitoring modules Inquiry of measured values and monitoring conditions (status information) Numerical and graphic evaluation of measuring results and process visualization.
With the programs VIBROCONFIG CM-401, VIBROCONFIG CM-402 and VIBROEXPERT CM-410, the corresponding PC programs are available.
The optimum PROFIBUS interface communication on field bus level.
supports
the
standardized
The measuring concept designed with a focus on versatility allows the use of sensors of almost any sensitivity as long as their signal range keeps within 25 V / 25 mA. The universal applicability of the system VC-4000 is due to the almost free configurability of the measuring and monitoring parameters of the individual modules.
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System overview
VIBROCONTROL 4000
The combined operation together with modules of the multiple-channel data acquisition system VIBRODAU-4000 meets the requirements for machine monitoring and takes the evaluation of measured values on the basis of various criteria into account. VIBROCONTROL-4000 complies with all basic requirements of the following standards: ISO DIN VDI VDI API API 7919 45670 2056 2059 670 678
Moreover, VIBROCONTROL-4000 is subject to a certified quality system in accordance with ISO 9001/EN 29001.
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VIBROCONTROL 4000
System overview
This page has been left for your own notes.
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Installation
VIBROCONTROL 4000
Installation
Note the enclosed Safety Instructions!
The installation of a VIBROCONTROL 4000 system includes the following works:
Installation of the measured value sensors, measuring chains and reference pickups. The individual installation instructions are to be found in register 2 Measuring chains ". The corresponding wiring diagrams are contained in register 5. Installation of the module housing Inserting the modules Connection of module housing Connection of monitoring modules (subsequent chapter 2.2) (subsequent chapter 2.3) (subsequent chapter 2.4) (subsequent chapter 2.5)
In case of a combined operation with VIBRODAU-4000, the installation instructions for the VIBRODAU-4000 system included in register 1.1 of this documentation are to be observed in addition. The combined operation is explained in detail in the System description of VIBROCAM 4000" in register 1 of this documentation.
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VIBROCONTROL 4000
Installation
2.1
General notes on installation

The activities described in the chapters 2.2 to 2.4 apply for the standard module housing RC-400. If instead of this one a special design RC-40x is employed,refer to the detailed description in register 4 of this documentation. The deviations from the standard described in the following must be taken into account.
If the 24 V power supply unit PS-420 is used, the type plate for the power supply unit PS-410 on the back of the module housing has to be covered by the self-adhesive type plate for the power supply unit PS-420! (see figure below) It is delivered in a bag together with the power supply unit.
10 fuses (type 5 x 20) for the power supply unit are also supplied together with the unit in a bag. (10 fuses 5 A time-delay for PS-410 or 10 fuses 12.5 A time-delay for PS-420). Two of these fuses must be inserted into the sockets on the back of the module housing provided for this purpose (F1, F2). The earthing and shielding terminals for the TE and the SE bar are also included with the delivery in a bag. SE and TE bar must not touch the side panel of the module housing. For each module, a set of terminals is supplied together with the delivery in a bag. They are designated as follows AC-510/1 AC-510/2 AC-510/3 for the CI module for the power supply unit PS-4xx for each monitoring module
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Installation
VIBROCONTROL 4000
The terminals are grouped together in function blocks and are provided with connection numbers. The individual blocks are pluggable and may be removed to facilitate connection of the cable cores. They also provide for the possiblity of a provisional installation without module housing and modules.
Use cables with flexible cores only and provide with connector sleeves (e.g. AC-192). The maximum core cross-section of the connecting cables is 1.5 mm2 All cables to be connected, with the exception of the mains cable, must be shielded in order to suppress interferences in the modules. The SE bar is provided to connect the shields. All signal lines must be layed at a distance of at least 0.5 m from the power cables. If crossing points of signal lines and power cables cannot be avoided, they should be at right angles if possible.
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VIBROCONTROL 4000
Installation
2.2
Installation of module housing

The module housing with its 6 units in height and 84 in width is designed for installation into control cabinets, wall or table-top housings which correspond to the 19" system. If the operating authority is responsible for the installation, the following notes must be taken into account:
First check whether the wiring works described in chapter 2.4 must be carried out before installation, which is the case if the back of the module housing is difficult to access after installation. wo oblong holes are provided on each side of the front panel (in the handles) to fix the module housing in the cabinet. Appropriate guide rails must be mounted to support the module housing. If several module housings are accomodated in one cabinet/housing, a distance of at least one height unit (1 HU) must be kept to between them. On the back of the module housing, sufficient room must be left to allow for the bend radius of the connected cables. The temperature in the cabinet/housing must not exceed 50C.
As a basis for calculation for cooling, which might become necessary, the power loss of a fully equipped module housing can be specified with approx. 175 W.
The equipment must be installed in a room which is free from vibrations, corrosive atmosphere and electromagnetic interferences.
2.3
Insertion of the modules into the module housing

The module housing is pre-assembled. Usually, the modules are alrweady inserted, either according to the specifications of the customer (if mentioned as binding in the offer) or, if there are no specifications, as we deem reasonable. Free slots are covered with blank panels. In case individual modules are supplied separately, i.e. not together with the module housing, the following applies:
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Installation
VIBROCONTROL 4000
The power supply unit PS-4x0 (far left if viewed from front) and the interface module CI-4x1 (slot 0) have fixed locations in the module housing. The monitoring modules - in case of combined operation with VIBRODAU 4000 also the multiplexer modules - may be inserted in any order into the slots 1 ... 12. (for combined operation refer to System description of VIBROCAM 4000" in register 1 of this documentation) The optional control panel TP-419 must be mounted in front of the power supply unit (also see chapter 6.1.1). Note:: Cable connection between CI-4x1 and TP-419 CI-4x1 and TP-419 are connected by a short flat cable. When inserting or removing the CI module, proceed as follows: Insertion of CI module: Insert the module into slot 0. Connect the plug of the flat cable on the TP-419. Fix the TP-419. Removing of CI module: Remove the TP-419. Disconnect plug to the CI module. Take out the CI module.
Fix all modules with the two screws provided for this purpose on the front panel. The power supply unit PS-4xx is fixed with a counter-sunk screw M4 x 6 in the module housing (see figure on the left). This connection also establishes the electric contact between power supply unit housing and module housing! The counter-sunk screw is supplied separately in a bag, together with 10 fuses 5 x 20.
Important note!
If using the power supply unit PS-420, the type plate must be covered (see chapter 2.1). Be careful when removing the modules:: Before a module is removed from the module housing, all plug connections at the rear must be disconnected. Note: The modules may be removed under voltage.
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VIBROCONTROL 4000
Installation
2.4
Connection of module housing

All connecting points with the exception of the buffer outputs (BNC sockets) for diagnostic purposes are located on the back panel of the module housing or the modules.Figure 2-1 shows all connections (numbered from 1 ... 10) which must be established before the system can be started. The voltage busses (SE and TE), screw-type terminals and cables pieces (greenish yellow) are included in the delivery.
RC - 400
0011 0012 0013
DC -24V CC 0V (TE) REF A -24V DC 0V (TE) REF B Relais reset Trip multiply Trend inhibit Trip override
0011 0012 0013 0014 0015
SE
6
SE
SE 0014 0015 0016
TE
1
0001
0001 0002 0003
TE TE TE
0017
7
SE
0018 0019 0020
PE
+/L1 -/N
0002 0003 0004 0005
0004 0005
5
PE +/L1 -/N
0016 0017 0018 0028 0029 0030 0031
Signal Ground GND Receive Data RD Transmit Data TD Schirm
0028 0029 0030 0031
0019 0020
Mains Supply
4 2
F1
Achtung, Netzspannung! Vor Ziehen des Netzgertes Netzspannung unterbrechen. Caution, Mains voltages! Disconnect mains voltages before pulling modul.
0026
F2
Attention, Tension secteur! Avant de retirer le bloc d'alimentation. Mettre hors tension.
0032 0033 0034 0035
Signal Ground GND Transmit Data TD Receive Data RD Schirm
0032 0033 0034 0035 0022 0023 0024 black (1) 0006 black (2) 0007 0008 +/L1 -/N
0006 0007 0008
0022
10
SE
0023 0024
Netzteil PS-410 Power Supply PS-410 Netzspannung / Mains AC 115/230V 45-400Hz 190 VA F1, F2 5A trge / slow
+/ L1 -/N PE
MONTAGE3 (030512)
Fig. 2-1
Connections and wiring of module housing. The connections provided with a number are described separately below.
For the following activities, the power supply unit and the CI module must be inserted in the module housing.
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Installation
VIBROCONTROL 4000
1 Connection of the zero potentials

In figure 2-2, which shows an enlarged part from figure 2-1, four channels are shown, which connect the individual zero and earth potentials. The individual connections are: A) Connection between side part and rear side (PE). B) Connection of internal TE potential with TE bus.The connections A and B are always required. C) Connection of SE bus with PE. This connection may only be established if it is guaranted that no shields are connected which are already grounded in another place. Otherwise, differences in potential may lead to the destruction of the shield and the cable caused by circulating currents. D) Connection of the internal TE potential with PE. This connection may only be established if it is guaranteed, that an interference-free PE potential is connected. Otherwise, the TE bus has to be connected to an interference-free, separated functional earthing. PE = Protective earth, SE = shield earth, TE = functional earth (techncal earth) More detailed information is contained in the Earthing recommendation" in register 5 of this documentation.
Fig. 2-2 Connection of the zero potentials of a module housing
2 Interference suppression measure for CI module

Connection of the CI module (connection point 0026) with PE potential.This connection prevents the shield connection of the terminals 0031 and 0035 to being lead through the CI module which could lead to interference. The shield connection is directly connected to PE potential. Important: The shield may only be connected on one side.
3 Mains connection to the power supply unit

As shown in figure 2-3, this connection leads the supplied power via the fuses F1 and F2 to the power supply unit (connections 0006 ... 0008).
Abb. 2-3
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VIBROCONTROL 4000
Installation
4 Mains connection
Possible electric supplies: With power supply unit PS-410: 230 V AC (are admissible 184 V - 264 V) 115 V AC (are admissible 93 V - 140 V) With power supply unit PS-420: 24 V DC (are admissible 19 V - 38 V) Meaning of terminal marking: +/L1: In case of A.C. voltage supply (93 V - 264 V), the phase (L1) is connected here. In case of D.C. voltage supply (19 V - 38 V), the positive pole is connected here. - /N: In case of A.C. voltage supply (93 V - 264 V), the neutral conductor is connected here (N). In cas of D.C. power supply (19 V - 38 V), the negative pole is applied here.
5 Jumper at 115 V AC
The connections 0004 and 0005 must be jumpered in case of a power supply of 115 V AC. In case of 230 V AC or 24 V DC, no jumper is required.
6 Connection of the reference pickups

In a "pure" VIBROCONTROL-4000 system, the inputs are not important. In case of combined operation with VIBRODAU-4000, reference pickups for channel A and B may be connected. (For combined operation, see System description of VIBROCAM 4000" in register 1 of this documentation)
7 Central control input

The control inputs
Relays reset Trip multiply Trend inhibit Trip override
which are valid for all monitoring modules in the module housing, may be activated - indepently of each other - by jumpering with 0V (TE bus). More detailled information on central control functions are to be found in chapter 6.2.
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Installation
VIBROCONTROL 4000
8 Serial interface to the computer (Master interface)

The connection is usually only needed for the configuration of the monitoring modules during the initial operation phase, or for alterations in the configuration. Only in case of combined operation with VIBRODAU 4000 must the computer be permanently connected (on-line operation). In this case, i.e. if various module housings are connected in a network, connection may also be made to the CI module of a preceding module housing.
9 Serial interface to the next CI module

This connection is only required if the module housing constitutes a station in the network.Information on the network operation are contained in the System description of VIBROCAM 4000" in register 1 of this documentation
10 Connection of a central OK relay

All errors and faults recognized in the module housing cause the central OK relay to be released (see chapter 4 Safety concept"). A changeover contact of this relay (connection 0022 ... 0024) signals the fault. The task of evaluation of this message is the responsibility of the operating authority.
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VIBROCONTROL 4000
Installation
2.5
Connection of monitoring modules

All terminals are located on the back of the modules. Assignment of the terminals is identical for all modules. Figure 2-4 shows all connections of a module, which will then be briefly explained. The connecting examples are shown for channel A only, for channel B the same applies. Optional elements are surrounded by a dotted box.
Fig. 2-4
Connection possibilities of a monitoring module. The connections are identical for all modules..
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Installation
VIBROCONTROL 4000
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VIBROCONTROL 4000
Installation
2.5.1
Connection of sensors and measuring chains

The voltage/current signals of the employed sensors and measuring chains must be in accordance with the input conditions of the corresponding modules. For the input conditions, refer to the Technical Data of the module descriptions in register 4 of this documentation under "Input signal". Figure 2 - 4 shows three basic possibilities for the connection of sensors.
Sensors without supply voltage (e.g. vibration velocity pickups of the Brel & Kjr Vibro type series VS-...) Sensors with a supply voltage of -24 V DC supplied by the module (e.g. vibration acceleration sensors of the Brel & Kjr Vibro type series AS-... or displacement sensors of the Brel & Kjr Vibro type series SD-...) Sensors with external supply (purchased products).
Note:
Obligatory wiring diagrams/earthing recommendation/four-wire technique. The obligatory wiring diagrams for the sensors and measuring chains forming part of the delivery are included in register 5 of this documentation. There you will also find a general earthing recommendation with a short comment (chapter 3) on the advantages of the four-wire connection system for measured value sensors with supply voltage in comparison with the three-wire method.
2.5.2
Connection of analog outputs

The two analog outputs are provided, preferably, for the connection of indicating and recording units (e.g. plotters), they may, however, also be used as a signal source for other measuring systems.
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VIBROCONTROL 4000
2.5.3
Connection of monitoring relay contacts

Within the limits set by their capacities, the contacts may be employed for any external control purposes (see Technical Data of the module descriptions in register 4 of this documentation).
Provide for spark suppression!

In case of non-ohmic loads of the contacts, a spark suppressor must be provided as near as possible to the spark generator.
2.5.4
Activation of local control input

Jumpering with the 0 V potential of the TE bus activates the function of the local control input; this function is determined by the configuration. A switch or a potential-free contact may be employed as a jumper.
2.5.5
Connection of buffer outputs

The buffer outputs of channel A and B are mainly provided for diagnostic purposes, e. g. for connection of oscilloscopes or diagnostic units (e.g. VIBROPORT 41). You can choose between the terminals on the back of the module or the BNC sockets on the front of the module.
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VIBROCONTROL 4000
Initial operation
Initial operation
The initial operation procedure of the VIBROCONTROL-4000 system includes only a few activities - thanks to its modern concept- ion. These are:
Establishment of the connection from the VC-4000 system to the computer (PC) Installation of the configuration software VIBROCONFIG CM-401 or CM-402 on the computer Configuration of the modules with CM-401 or CM-402, with the possibility of storing the complete module configuration in files and loading it into the corresponding module whenever it may be necessary. Parameter lists / parameter cards Configuring means entering the module-specific configuration parameters. To do so, parameter lists and parameter cards are provided.
Parameter lists Detailed parameter lists with the description of the individual configuration parameters of a module are included in the module descriptions in register 4 of the present documentation. Parameter cards The parameter cards are abbreviated versions of the parameter lists intended for quick information and as a basis for the activities to be carried out during initial operation. The parameter cards are to be found in chapter 3.5.
For more information on how to carry out the mentioned activities, which is also a question of the employed software (CM-401 or CM-402), please refer to chapters 3.1 or 3.2. Computer connection after initial operation When all configuration data have been loaded into the modules of a module housing, VIBROCONTROL-4000 works on a totally independent basis. If only the monitoring operation is to be run, connection to the computer is no longer necessary. This connection must only be maintained if you wish to utilize any program features of CM-401 or CM-402 during operation of the VIBROCONTROL-4000 (e.g. display of measured values).
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Initial operation
VIBROCONTROL 4000
3.1
Initial operation with the configuration software VIBROCONFIG CM-401 (Version 3.00)
Vibroconfig CM-401 V3.00 is a program which serves mainly for configuring the modules for the machine monitoring system VIBROCONTROL 4000. Configuring means that the operating parameters for the module/ unit are set in accordance with the monitoring task to be fulfilled. These parameters are, e.g., sensor type, measuring range, filter corner frequency etc. In addition, the following possibilities are available: The module assignment may be
displayed stored in a file and, if you wish, commented, the stored file may be printed
The parameter list may be
displayed edited printed stored in the module or in a file, the stored file may be commented with the help of a text editor, the stored file may be printed.
3.1.1
Minimum requirements to be met by the PC

Microprocessor 286 Operating system DOS 3.3 Main memory 512 kB Hard disk 20 MB for data filing Diskette drive 3.5 inches Serial interface RS-232c data only. (COM 1) Parallel interface Centronics(LPT 1) Printer setting: Epson graphics mode
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VIBROCONTROL 4000
Initial operation
3.1.2
File extensions
In the directory CM401 on the program diskette, a subdirectory is to be found under the name DATA, which contains files with the following extensions:
XXXXXXXX.ORG XXXXXXXX.VC4
(XXXXXXXX = freely selectable by user) The XXXXXXXX.ORG files contain the standard settings for the parameters of a module/unit. These files are "write-protected", i.e. the parameters of this file cannot be altered. The XXXXXXXX.VC4 files contain the parameter list or the module assignment for the VIBROCONTROL 4000 modules. These files are generated with the configuration program CM-401 by the user.
3.1.3
Establishing the interface connection

Interface connection from PC to VC-4000
Connect interface cable to PC (COM 1) and module housing (CI-4x1 module on slot 0). The cable may be connected either to the service interface or to the master interface.
Connection to the service interface

This is located on the front panel (underneath the designation area of the CI module. The transmission rate is permanently set to 9600 bauds.
Connection to the master interface (connections 0028 ... 0031)

This interface is located on the back of the CI - 4.. connection. Set baud rate to 9600(Set switch "1" to position "6").
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Initial operation
VIBROCONTROL 4000
3.1.4
Installation of software VIBROCONFIG CM-401

Installation is explained with an example, assuming that the hard disk drive be "C" and the diskette drive "A".
Switch on and boot PC Insert program diskette into diskette drive [ A ] Change to diskette drive by entering a: The PC signals that the diskette drive is activated by displaying A:\
Install program on hard disk drive [ C ]

Enter: cm _inst d a c (d, a and c are separated by blanks) Hard disk drive c (or d, e etc.) Diskette drive a (or b) Language d = German, (or e = English) File name When the installation has been completed, the configuration program with the selected disk drive and the subdirectory appears: C:\CM401.
3.1.5
Program start
Make sure that the PC and the unit are ready for operation. Change to the directory in which CM-401 V3.00 is installed. Program call from the directory CM401 with "cm401" The configuration program will be loaded. Loading time approx. 10 ... 50 sec. The program is called up and the following image is displayed:
Operation with Vibrocontrol without Vibrocontrol
(Displaying and editing of the current configuration) (Displaying and editing of parameter files)
3.1.6
Working with CM-401

After the program has been started, the user is guided through the program. Each screen image is provided with on-line help texts (key F1). For this reason, a description in the present documentation is not necessary.
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VIBROCONTROL 4000
Initial operation
3.2
Initial operation with the configuration software VIBROCONFIG CM-402 (Version 3.00)
Vibroconfig CM-402 V3.00 is a program which serves mainly for configuring the modules for the machine monitoring system VIBROCONTROL 4000. Configuring means that the operating parameters for the module/ unit are set in accordance with the monitoring task to be fulfilled. These parameters are, e.g., sensor type, measuring range, filter corner frequency etc. In addition, the following possibilities are available:
the measured values and limit values may be displayed. the event messages may be displayed. the LCD displays and LEDs may be checked. various control functions may be switched on and off.
The assignment of the modules may be displayed stored in a file and, if you wish, commented, the stored file may be printed
The parameter list may be
displayed edited printed stored in a module or a file, the stored file may be commented with the help of a text editor, the stored file may be printed.
3.2.1
Minimum requirements to be met by the PC

Microprocessor 286 Operating system DOS 3.3 Main memory 512 kB Hard disk 20 MB for data filing Diskette drive 3.5 inches Serial interface RS-232c data only. (COM 1) Parallel interface Centronics (LPT 1) Printer setting: Epson graphics mode
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Initial operation
VIBROCONTROL 4000
3.2.2
File extension
In the directory CM402 on the program diskette, a subdirectory is to be found under the name DATA, which contains files with the following extensions:
XXXXXXXX.ORG XXXXXXXX.VC4
(XXXXXXXX = freely selectable by user) The XXXXXXXX.ORG files contain the standard settings for the parameters of a module/unit. These files are "write-protected", i.e. the parameters of this file cannot be altered. The XXXXXXXX.VC4 files contain the parameter list or the module assignment for the VIBROCONTROL 4000 modules. These files are generated with the configuration program CM-402 by the user.
3.2.3
Establishing the interface connection

Establish interface connection from PC to VC-4000
Connect interface cable to PC (COM 1) and module housing (CI-4x1 module on slot 0). The cable may be connected either to the service interface or to the master interface.
Connection to the service interface

This is located on the front panel (underneath the designation area of the CI module. The transmission rate is permanently set to 9600 bauds.
Connection to the master interface (connections 0028 ... 0031)

This interface is located on the back of the CI - 4.. connection. Set baud rate to 9600 (Set switch "1" to position "6").
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3.2.4
Installation of software VIBROCONFIG CM-402

Installation is explained with an example, assuming that the hard disk drive be "C" and the diskette drive "A".
Switch on and boot PC Insert program diskette into diskette drive [ A ] Change to diskette drive by entering a: The PC signals that the diskette drive is activated by displaying A:\
Install program on hard disk drive [ C ]

Enter: cm _inst d a c (d, a and c are separated by blanks) Hard disk drive c (or d, e etc.) Diskette drive a (or b) Language d = German, (or e = English) File name When the installation has been completed, the configuration program with the selected disk drive and the subdirectory appears: C:\CM402.
3.2.5
Program start
Make sure that the PC and the unit are ready for operation. Change to the directory in which CM-402 V3.00 is installed. Program call from the directory CM402 with "cm402" The configuration program will be loaded. Loading time approx. 10 ... 50 sec. The program is called up and the following image is displayed:
Operation with Vibrocontrol without Vibrocontrol
(Displaying and editing of the current configuration) (Displaying and editing of parameter files)
3.2.6
Working with CM-402

After the program has been started, the user is guided through the program. Each screen image is provided with on-line help texts (key F1). For this reason, a description in the present documentation is not necessary.
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3.3
System calibration
Before delivery, all monitoring modules are subjected to both a system calibration and a reference calibration (see chapter 7.6) at approx. 20 C. If the ambient temperature in operation deviates markedly from 20 C, we recommend to carry out a system calibration when the system is started for the first time, in order to adjust the modules to the different circumstances. The system should then be re-calibrated every 12 months.
Starting the system calibration

System calibration is started with the cofiguration programs VIBROCONFIG CM-40x which are provided with extensive on-line help texts. During calibration, the ambient temperature should be the same as in normal operation.
Duration of the system calibration

The system calibration takes between 20 and 70 minutes, depending on the module. The presumable duration will be displayed after the program start.
Important note!
All measuring and monitoring functions of a module are switched off during system calibration. The current state of the limit value relays will be "frozen".
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3.4
Putting the machine into normal operation

Before the machine/installation to be monitored is put into normal operation, please make sure the following requirements have been met:
All modules of the module housing must be configured completely and in accordance with the application to be fulfilled. Check once more whether all connections are correct! Check whether the contacts of OK and limit value relays are wired correctly. Make sure that NC and NO contact are not mixed up? The mains supply voltage must be available. Check whether alarm signals (LEDs) correspond to the actual, current condition of the machine/installation.
As long as the machine/installation is not yet in normal operation, errors might be displayed which will no longer occur in later operation. Example 1: A TA-41x module can signal an OK error when the machine is started, if a pulse generator is used whose signal voltage alternates between the upper and the lower value of the signal voltage (see module description TA-41x, chapter 1.5). Example 2: A GP-41x module may signal a limit value violation during monitoring of the axial displacement of a shaft, if this adopts, when the machine stops, a position exceeding a configured limit value.
An OK alarm output as a result of the mains voltage being switched on (every time after the voltage returns an OK alarm is output), must be acknowledged and thus cancelled with RESET ALARM. Also refer to chapter 4.3.5.
If possible, carry out a test run in which the desired functions are checked. Keep in mind that the ambient temperature of the VC-4000 modules may not exceed 50 C.
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3.5
Parameter cards
The parameter cards are abbreviated versions of the paramerter lists describing all configuration parameters of the monitoring modules in detail. They are intended for quick information and as a reference during initial operation. The parameter cards of all modules are included following this page and may be taken out for the purpose of entering individual information.
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Monitoring Module VB - 410/411/412 Channel A and B Parameter Settings for Module Position _________
Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Channel A Group G Measuring point description : G01 Measuring point description G02 Measuring point description Group I Sensor selection : I01 Channel is active I02 Sensor type I03 Unit of sensor sensitivity Y a s mV/m mV/mm/s mV/m/s mV/eu [_____________] [_____________] [] N[] [] v[] [] eu [ ] [] mV/mils [ ] [] mV/ips [ ] [] mV/g [ ] [] [_____________] Y [] N[] Y a s mV/m mV/mm/s mV/m/s mV/eu Channel B [______________] [______________] N[] v[] eu [ ] mV/mils [ ] mV/ips [ ] mV/g [ ] [] [______________] Y [] N[] [] N[] [] v[] [] eu [ ] [] m/s [ ] [] mm/s [ ] [] mm [ ] [] [______________] [______________] [] p[] [] pc [ ] [] p(A+B) [ ] [] pp(A+B) [ ] [] [] Medium [ ] [] [] N[] [______________] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ] [] [] [] [] [] []
I04 I06
Value of sensor sensitivity Moving coil linearization
Group J Measurement type : J01 Measurement type 1 is aktive J02 Measurement type 1 J03 Unit of measurement type 1
Y a s g ips mils eu
J04 J05 J06
Unit of eu Full scale measurement type 1 Signal detection of type 1
J07 J10 J14
rms pp Vector p(A-B) pp(A - B) Optimization at sudden signal change Fast Slow Measurement type 2 is aktive Y Zero setting (with s-sensors only) 1 Hz 5 Hz 250 Hz 1 kHz 1 kHz ISO
[] N[] Y [] v[] a [] eu [ ] s [] m/s [ ] g [] mm/s [ ] ips [] mm [ ] mils [] eu [_____________] [_____________] [] p[] r ms [] pc [ ] pp [] p(A+B) [ ] Vector [] pp(A+B) [ ] p(A-B) [] pp(A - B) [] Medium [ ] Fast [] Slow [] N[] Y [_____________] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ] 1 Hz 5 Hz 250 Hz 1 kHz 10 kHz ISO 0...10 V 0...20 mA Y A GP A
Group K Band-pass filter : K01 Lower limit frequency (-1 dB) K02 Upper limit frequency (-1 dB)
Group L Analog outputs : L01 Range of output signal L02 L03 L06
0...10 V 0...20 mA Output of characteristic curve bent Y Allocation of analog output to channel ... A GP A Full scale of value
Output 1 [] 2...10 V [ ] [ ] 4...20 mA [ ] [] N[] [] B[] max(A, B) [ ] [] GP B [ ] [_____________]
Output 2 [] 2...10 V [ ] [] 4...20 mA [ ] [] N[] [] B[] max(A, B) [ ] [] GP B [ ] [______________]

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Monitoring Module VB-410/411/412 Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1 M03 Monitoring LIM 2 M04 Monitoring LIM x M05 Monitoring LIM t M10 Limit value LIM 1 M11 Limit value LIM 2 M12 Limit value LIM x (V DC min.) M13 Limit value LIM x (V DC max.) M14 Limit value LIM t M20 Alarm delay LIM 1 M21 Alarm delay LIM 2 M22 Alarm delay LIM x M24 Alarm delay LIM t M30 Trip multiplier M40 Direction of limit value violation LIM 1 exceeding up (+),exceeding down (-) M41 Direction of limit value violation LIM 2 exceeding up (+),exceeding down (-) Group N Relays : N01 LIM 1 is assigned to relay N02 LIM 2 is assigned to relay N03 LIM x is assigned to relay N04 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED Group O OK Monitoring : O01 OK Monitoring active O03 No monitoring in case of OK error O04 OK Lower limit O05 OK Upper limit Y Y Y Y Y
Channel A [] N[] [] N[] [] N[] [] N[] [] N[] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] -[] -[] Y Y Y Y Y
Channel B [] N[] [] N[] [] N[] [] N[] [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] + [] + [] -[] -[]
+ [] + []
[_____________] [_____________] [_____________] [_____________] Y[] Y[] Y[] Y[] AND [ ] AND [ ] AND [ ] AND [ ] Y[] Y[] Y [] N[] Y [] N[] [_____________] [_____________]
N N N N OR OR OR OR N N
[______________] [______________] [______________] [______________] [] [] [] Parameters [] N10 ... N51 [] are inde[] pendent of [] channels [] [] []
Y [] N[] Y [] N[] [______________] [______________] [] [] [] [] [] [] [] [] []
Group Q Local control input : Q01 OK Monitoring inactive Trip multiplier active Trip override active OK Monitoring inactive and trip override active No monitoring channel A No monitoring channel B No monitoring channel A and B Changing monitoring from channel A to channel B Q10 Power-up (after voltage failure) = system error
NOK TRMULT TROVER NCHKNOK CHKA CHKB CHKAB CHGAB Y[] N
Parameters Q01, Q10 are independent of channels
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Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Group G Measuring point description : G01 Measuring point description G02 Measuring point description Group I Sensor selection : I01 Channel is active I02 Sensor type I03 Unit of sensor sensitivity Y a s mV/m mV/mm/s mV/m/s mV/eu Channel A [_____________] [_____________] [] N[] [] v[] [] eu [ ] [] mV/mils [ ] [] mV/ips [ ] [] mV/g [ ] [] [_____________] [] N[] [] v[] [] eu [ ] [] m/s [ ] [] mm/s [ ] [] mm [ ] [] [_____________] [_____________] [] p[] [] pc [ ] [] p(A+B) [ ] [] pp(A+B) [ ] [] [] Medium [ ] [] [] N[] [_____________] [] N[] [_____________] [_____________] [_____________] [] [] [] [] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ] Output 1 2...10 V [ ] 4...20 mA [ ] N[] B[] max(A, B) [ ] Y a s mV/m mV/mm/s mV/m/s mV/eu Channel B [______________] [______________] [] N[] [] v[] [] eu [ ] [] mV/mils [ ] [] mV/ips [ ] [] mV/g [ ] [] [______________] [] N[ ] [] v[] [] eu [ ] [] m/s [ ] [] mm/s [ ] [] mm [ ] [] [______________] [______________] [] p[] [] pc [ ] [] p(A+B) [ ] [] pp(A+B) [ ] [] [] Medium [ ] [] [] N[] [______________] [] N[] [______________] [______________] [______________] [] [] [] [] [] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ] Output 2 2...10 V [ ] 4...20 mA [ ] N[] B[]
I04
Value of sensor sensitivity Y a s g ips mils eu
Y a s g ips mils eu rms pp Vector p(A-B) pp(A - B) Fast Slow Y Y
J04 J05 J06
J07 J10 J11 J12 J13 J14 J15
rms pp Vector p(A-B) pp(A - B) Optimization at sudden signal change Fast Slow Measurement type 2 is aktive Y Full scale of BCU BCU averaging active Y Time constant for BCU averaging Zero setting (with s-sensors only) BCU scaling factor 1 Hz 5 Hz 250 Hz 1 kHz 1 kHz ISO
1 Hz 5 Hz 250 Hz 1 kHz 1 kHz ISO 0...10 V 0...20 mA Y A max(A, B)
Group L Analog outputs : L01 Range of output signal L02 L03
0...10 V 0...20 mA Output of characteristic curve bent Y Allocation of analog output to channel ... A
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VIBROCONTROL 4000 BCU/GP A [ ] BCU/GP B [ ] [_____________]
Initial operation BCU/GP A [ ] BCU/GP B [ ] [______________]
L06
Full scale of value
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Monitoring Module VB-420/421/422 Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1 M03 Monitoring LIM 2 M04 Monitoring LIM x M05 Monitoring LIM t M10 Limit value LIM 1 M11 Limit value LIM 2 M12 Limit value LIM x (V DC min.) M13 Limit value LIM x (V DC max.) M14 Limit value LIM t M20 Alarm delay LIM 1 M21 Alarm delay LIM 2 M22 Alarm delay LIM x M24 Alarm delay LIM t M30 Trip multiplier M40 Direction of limit value violation LIM 1 exceeding up (+),exceeding down (-) M41 Direction of limit value violation LIM 2 exceeding up (+),exceeding down (-) Group N Relays : N01 LIM 1 is assigned to relay N02 LIM 2 is assigned to relay N03 LIM x is assigned to relay N04 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED Group O OK Monitoring : O01 OK Monitoring active O03 No monitoring in case of OK error O04 OK Lower limit O05 OK Upper limit Y Y Y Y Y
Channel A [] N[] [] N[] [] N[] [] N[] [] N[] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] -[] -[] Y Y Y Y Y
Channel B [] N[] [] N[] [] N[] [] N[] [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] + [] + [] -[] -[]
+ [] + []
[_____________] [_____________] [_____________] [_____________] Y[] Y[] Y[] Y[] AND [ ] AND [ ] AND [ ] AND [ ] Y[] Y[] Y [] N[] Y [] N[] [_____________] [_____________]
Y [] N[] Y [] N[] [______________] [______________] [] [] [] [] [] [] [] [] []
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Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Channel A Group G Measuring point description : G01 Measuring point description G02 Measuring point description Group I Sensor selection : I01 Channel is active I02 Sensor type I03 Unit of sensor sensitivity Y a s mV/m mV/mm/s mV/m/s mV/eu [_____________] [_____________] [] N[] [] v[] [] eu [ ] [] mV/mils [ ] [] mV/ips [ ] [] mV/g [ ] [] [_____________] [] N[] [] v[] [] eu [ ] [] m/s [ ] [] mm/s [ ] [] m [ ] [] [_____________] [_____________] [] p[] [] pc [ ] [] p(A+B) [ ] [] pp(A+B) [ ] [] [] Medium [ ] [] [] N[] [_____________] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ] Y a s mV/m mV/mm/s mV/m/s mV/eu Channel B [______________] [______________] [] N[] [] v[] [] eu [ ] [] mV/mils [ ] [] mV/ips [ ] [] mV/g [ ] [] [______________] [] N[ ] [] v[] [] eu [ ] [] m/s [ ] [] mm/s [ ] [] mm [ ] [] [______________] [______________] [] p[] [] pc [ ] [] p(A+B) [ ] [] pp(A+B) [ ] [] [] Medium [ ] [] [] N[] [______________] [] [] [] [] [] 2 Hz [ ] 10 Hz ISO [ ] 5 kHz [ ] 10 kHz [ ]
I04
Value of sensor sensitivity Y a s g ips mils eu
Y a s g ips mils eu rms pp Vector p(A-B) pp(A - B) Fast Slow Y
J04 J05 J06
J07 J10 J14
rms pp Vector p(A-B) pp(A - B) Optimization at sudden signal change Fast Slow Measurement type 2 is aktive Y ero setting (with s-sensors only) 1 Hz 5 Hz 250 Hz 1 kHz 1 kHz ISO
1 Hz 5 Hz 250 Hz 1 kHz 1 kHz ISO 0..10 V 0..20 mA Y A GP A
Group L Analog outputs : L01 Range of output signal L02 L03 L06
0..10 V 0..20 mA Output of characteristic curve bent Y Allocation of analog output to channel ... A GP A Full scale of value
Output 1 [] 2..10 V [ ] [] 4..20 mA [ ] [] N[] [] B[] max(A, B) [ ] [] GP B [ ] [_____________]
Output 2 [] 2..10 V [ ] [] 4..20 mA [ ] [] N[] [] B[] max(A, B) [ ] [] GP B [ ] [______________]
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Monitoring Module VB-430/431/432 Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1 M03 Monitoring LIM 2 M04 Monitoring LIM x M05 Monitoring LIM t M10 Limit value LIM 1 M11 Limit value LIM 2 M12 Limit value LIM x (BCU max./V DC min.) M13 Limit value LIM x (V DC max.) M14 Limit value LIM t M20 Alarm delay LIM 1 M21 Alarm delay LIM 2 M22 Alarm delay LIM x M24 Alarm delay LIM t M30 Trip multiplier M40 Direction of limit value violation LIM 1 exceeding up (+),exceeding down (-) M41 Direction of limit value violation LIM 2 exceeding up (+),exceeding down (-) Group N Relays : N01 LIM 1 is assigned to relay N02 LIM 2 is assigned to relay N03 LIM x is assigned to relay N04 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED Group O OK Monitoring : O01 O OK Monitoring active O03 No monitoring in case of OK error O04 OK Lower limit O05 OK Upper limit Y Y Y Y Y
Channel A [] N[] [] N[] [] N[] [] N[] [] N[] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] -[] -[] Y Y Y Y
Channel B [] N[] [] N[] [] N[] [] N[] Y [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] + [] + [] -[] -[]
+ [] + []
[_____________] [_____________] [_____________] [_____________] Y[] Y[] Y[] Y[] AND [ ] AND [ ] AND [ ] AND [ ] Y[] Y [] Y [] N[] Y [] N[] [_____________] [_____________]
Y [] N[] Y [] N[] [______________] [______________] [] [] [] [] [] [] [] [] []
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Monitoring Module GP - 410/411/412 Channel A and B Parameter Settings for Module Position _________
Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Channel A Group G Measuring point description : G01 Measuring point description G02 Measuring point description [_____________] [_____________] Channel B [______________] [______________]
Group I Sensor selection : I01 Channel is active Y [] N[] I02 Input signal u [] i[] I05 Sensitivity (V or mA / Unit of [_____________] measurement type ->J03) I50 Linearization of sensor characteristic Y [] N[] I51 Number of desired points of characteristic [_____________] I52 1. point of curve: value of input parameter [_____________] in V or mA I53 1. point of curve: value of meas. parameter [_____________] in the unit of measurement type (J03) I54 2. point of curve: value of meas. parameter [_____________] I55 2. point of curve: value of measurem. type [_____________] I56 3. point of curve: value of input parameter [_____________] I57 3. point of curve: value of meas. type [_____________] I58 4. point of curve: value of input parameter [_____________] I59 4. point of curve: value of meas. type [_____________] I60 5. point of curve: value of input parameter [_____________] I61 5. point of curve: value of meas. type [_____________] I62 6. point of curve: value of input parameter [_____________] I63 6. point of curve: value of meas. type [_____________] I64 7. point of curve: value of input parameter [_____________] I65 7. point of curve: value of meas. type [_____________] I66 8. point of curve: value of input parameter [_____________] I67 8. point of curve: value of meas. type [_____________] I68 9. point of curve: value of input parameter [_____________] I69 9. point of curve: value of meas. type [_____________] I70 10. point of curve: value of input parameter [_____________] I71 10. point of curve: value of meas. type [_____________] I72 11. point of curve: value of input parameter [_____________] I73 11. point of curve: value of meas. type [_____________] I74 12. point of curve: value of input parameter [_____________] I75 12. point of curve: value of meas. type [_____________] I76 13. point of curve: value of input parameter [_____________] I77 13. point of curve: value of meas. type [_____________] I78 14. point of curve: value of input parameter [_____________] I79 14. point of curve: value of meas. type [_____________] I80 15. point of curve: value of input parameter [_____________] I81 15. point of curve: value of meas. type [_____________]
Y [] N[] u [] i[] [______________] Y [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________]
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Initial operation
Monitoring Module GP-410/411/412 I82 16. point of curve: value of input parameter I83 16. point of curve: value of meas. type I84 17. point of curve: value of input parameter I85 17. point of curve: value of meas. type I86 18. point of curve: value of input parameter I87 18. point of curve: value of meas. type I88 19. point of curve: value of input parameter I89 19. point of curve: value of meas. type I90 20. point of curve: value of input parameter I91 20. point of curve: value of meas. type Group J Measurement type : J02 Combination of channels Measurement on shaft cone: Measurement with transition point:
Channel A [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________]
Channel B [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________]
A=A; B=B [ ] A=A+B [ ] A=A-B [ ] A=A; A=B [ ] A=B; A=A [ ] A=A; A=B* [ ] A=B; A=A* [ ] A=MAXU(A;B) [ ] A=MAXU(A;B)* [ ] mm [ ] mils [ ] eu [ ] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________]
A=A; B=B [ ]
Parameter J02 is independent of channel
J03 J04 J05 J06 J08 J09 J13 J14 J15
Unit of measurement type Display text for "eu" units Measuring range, lower limit Measuring range, upper limit Set point [ V ] or [ mA ] Set point of measured value unit Transfer point of measured value unit Zero point defination in measured value unit Step correction in unit of the measured value
mm [ ] mils [ ] eu [ ] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________]
Group K Input filter : K02 Upper limit frequency (-1 dB)
0,5 Hz [ ] 2 Hz [ ]
1 Hz [ ] 10 Hz [ ]
0,5 Hz [ ] 2 Hz [ ]
1 Hz [ ] 10 Hz [ ]
Group L Analog outputs : L01 Range of output signal L02 L03 L05 L06
0...10 V 0...20 mA Output of characteristic curve bent Y Allocation of analog output to channel ... A Lower limit of analog output Upper limit of analog output
[] [] [] []
Output 1 2...10 V [ ] 4...20 mA [ ] N[] B[] max(A,B) [ ] [_____________] [_____________]
0...10 V 0...20 mA Y A
[] [] [] []
Output 2 2...10 V [ ] 4...20 mA [ ] N[] B[] max(A,B) [ ] [______________] [______________]
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Monitoring Module GP-410/411/412 Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1+ M03 Monitoring LIM 1M04 Monitoring LIM 2+ M05 Monitoring LIM 2M06 Monitoring LIM t M10 Limit value LIM 1+ M11 Limit value LIM 1M12 Limit value LIM 2+ M13 Limit value LIM 2M14 Limit value LIM t M20 Alarm delay LIM 1+ M21 Alarm delay LIM 1M22 Alarm delay LIM 2+ M23 Alarm delay LIM 2M24 Alarm delay LIM t M40 Direction of limit value violation LIM 1+ exceeding up (+), exceeding down (-) M41 Direction of limit value violation LIM 1exceeding up (+), exceeding down (-) M42 Direction of limit value violation LIM 2+ exceeding up (+), exceeding down (-) M43 Direction of limit value violation LIM 2exceeding up (+), exceeding down (-) Group N Relays : N01 LIM 1+ is assigned to relay N02 LIM 1- is assigned to relay N03 LIM 2+ is assigned to relay N04 LIM 2- is assigned to relay N05 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED
Channel A
Channel B
Y Y Y Y Y Y
[] N[] [] N[] [] N[] [] N[] [] N[] [] N[] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________]
Y Y Y Y Y Y
[] N[] [] N[] [] N[] [] N[] [] N[] [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________]
+ [] + [] + [] + []
-[] -[] -[] -[]
+ [] + [] + [] + []
-[] -[] -[] -[]
[_____________] [_____________] [_____________] [_____________] [_____________] Y[] Y[] Y[] Y[] AND [ ] AND [ ] AND [ ] AND [ ] Y[] Y[]
[______________] [______________] [______________] [______________] [______________] [] [] [] Parameters [] N10 ... N51 [] are inde [] pendent of [] channels [] [] []
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Monitoring Module GP-410/411/412 Group O OK Monitoring : O01 OK Monitoring active O03 No monitoring in case of OK error O04 OK Lower limit [V] O05 OK Upper limit [V]
Channel A
Channel B
Y [] N[] Y [] N[] [_____________] [_____________]
Y [] N[] Y [] N[] [______________] [______________]
Group Q Local control input : Q01 OK Monitoring inactive Trip override active OK Monitoring inactive and trip override active No monitoring channel A No monitoring channelB No monitoring channel A and B Q10 Power-up (after voltage failure) =system error
NOK TROVER NCHKNOK CHKA CHKB CHKAB Y [] N
[] [] [] [] [] [] []
Parameters Q01, Q10 are inpendent of channels
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Monitoring Module GP - 420/421/422 Channel A and B Parameter Settings for Module Position _________
Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Channel A Group G Measuring point description : G01 Measuring point description G02 Measuring point description [_____________] [_____________] Channel B [______________] [______________]
Group I Sensor selection : I01 Channel is active Y [] N[] I03 Trigger flank positive [ ] negative [ ] I04 minimum trigger level [ V ] [_____________] I05 maximum trigger level [ V ] or [_____________] Unit of sensor sensitivity in mV pro Unit of measurement type (->J03) Group J Measurement type : J02 Measurement type J03 Unit of measurement type
Y [] N[] positive [ ] negative [ ] [______________] [______________]
t pp mm mils Hz eu
J04 J05 J07 J08 J09 J10 J11 J14 J15
Display text for "eu" units Full scale measurement type Max. measuring time in sec. or measuring time at untriggered measurem. Set point [ V ] Set point of mesaured value unit Multiplicator at time/frequency measurem. Divider at time/frequency measurement Zero correction of mesaured value unit Angle correction
[] f[] [] rest [ ] [] mm [ ] [] RPM [ ] [] s[] [] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________]
t pp mm mils Hz eu
[] f[] [] rest [ ] [] mm [ ] [] RPM [ ] [] s[] [] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________]
Group K Input filter : K02 Upper limit frequency (-1 dB)
10 Hz [ ] 75 Hz [ ]
15 Hz [ ] 150 Hz [ ]
10 Hz [ ] 75 Hz [ ]
15 Hz [ ] 150 Hz [ ]
Group L Analog outputs : L01 Range of output signal L02 L03
0...10 V 0...20 mA Output of characteristic curve bent Y Allocation of analog output to channel ... A1 B1 Lower limit of analog output Upper limit of analog output
L05 L06
Output 1 [] 2...10 V [ ] [ ] 4...20 mA [ ] [] N[] [] A2 [ ] [] B2 [ ] max(A1,B1) [ ] [_____________] [_____________]
0...10 V 0...20 mA Y A1 B1
Output 2 [] 2...10 V [ ] [] 4...20 mA [ ] [] N[] [] A2 [ ] [] B2 [ ] max(A1,B1) [ ] [______________] [______________]

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Monitoring Module GP-420/421/422 Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1+ M03 Monitoring LIM 1M04 Monitoring LIM 2+ M05 Monitoring LIM 2M06 Monitoring LIM t M10 Limit value LIM 1+ M11 Limit value LIM 1M12 Limit value LIM 2+ M13 Limit value LIM 2M14 Limit value LIM t M20 Alarm delay LIM 1+ M21 Alarm delay LIM 1M22 Alarm delay LIM 2+ M23 Alarm delay LIM 2M24 Alarm delay LIM t M40 Direction of limit value violation LIM 1+ exceeding up (+), exceeding down (-) M41 Direction of limit value violation LIM 1exceeding up (+), exceeding down (-) M42 Direction of limit value violation LIM 2+ exceeding up (+), exceeding down (-) M43 Direction of limit value violation LIM 2exceeding up (+), exceeding down (-) Group N Relays : N01 LIM 1+ is assigned to relay N02 LIM 1- is assigned to relay N03 LIM 2+ is assigned to relay N04 LIM 2- is assigned to relay N05 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED Group O OK Monitoring : O01 OK Monitoring active O03 No monitoring in case of OK error O04 OK Lower limit [V] O05 OK Upper limit [V] Y Y Y Y Y Y
Channel A [] N[] [] N[] [] N[] [] N[] [] N[] [] N[] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] [_____________] -[] -[] -[] -[] Y Y Y Y Y Y
Channel B [] N[] [] N[] [] N[] [] N[] [] N[] [] N[] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] [______________] -[] -[] -[] -[]
+ [] + [] + [] + []
+ [] + [] + [] + []
[_____________] [_____________] [_____________] [_____________] [_____________] Y[] Y[] Y[] Y[] AND [ ] AND [ ] AND [ ] AND [ ] Y[] Y[] Y [] N[] Y [] N[] [_____________] [_____________]
[______________] [______________] [______________] [______________] [______________] [] [] [] Parameters [] N10 ... N51 [] are inde [] pendent of [] channels [] [] []
Y [] N[] Y [] N[] [______________] [______________] NOK TROVER NCHKNOK CHKA [] [] [] []
Group Q Local control input : Q01 OK Monitoring inactive Trip override active OK Monitoring inactive and trip override active No monitoring channel A
Parameters Q01, Q10 are inpen-
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VIBROCONTROL 4000 No monitoring channelB No monitoring channel A and B Q10 Power-up (after voltage failure) =system error CHKB [ ] CHKAB [ ] N []
Initial operation dent of channels
Y[]
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Monitoring Module TA - 410/411/412 Channel A and B Parameter Settings for Module Position _________
Device : __________________________________________________________________________ Measuring point : ___________________________________________________________________ Module housing : ___________________________________________________________________ Filled in by : __________________________________________________ Date : _______________ Group G Measuring point description : G01 Measuring point description G02 Measuring point description Group I Eingangsbedingungen : I01 Channel A is active I02 Channel B is active I03 Channel A trigger flank I04 Channel B trigger flank I05 Channel A and B impuls generator I07 Channel A minimum trigger level in V I08 Channel B minimum trigger level in V Group J Measurement type : J02 Multiplier J03 Divisor J04 Unit of measurement type J05 J06 J07 J10 J11 J12 Display text for "eu" units Rotational direction recognition "on" Rotational direction Acceleration "on" Acceleration units Display text for "eu" units Y Y positive positive s
[___________] [___________] [] N [] [] N [] [ ] negative [ ] [ ] negative [ ] [] p [] [___________] [___________] [___________] [___________] [] CPM [ ] [] [___________] [] N [] [] B-A [ ] [] N [] [] eu [ ] [___________] [ ] 2...10 V [ ] [ ] 4..20 mA [ ] [] .N [ ] [ ] dRPM [ ] [] [___________] [___________] [] N [] [] N [] [] N [] [] N [] [] N [] [] N [] [___________] [___________] [___________] [___________] [___________]
RPM eu Y A-B Y RPMPM
Group L Analog output : L01 Range of output signal L02 L03 L05 L06 Output of characteristic curve bent Speed / Speed change Lower limit of recorder range Upper limit of recorder range
0...10 V 0...20 mA Y RPM ABS(RPM)
Group M Limit monitoring : M01 Monitoring active M02 Monitoring LIM 1+ M03 Monitoring LIM 1M04 Monitoring LIM 2+ M05 Monitoring LIM 2M06 Monitoring LIM t M10 Limit value LIM 1+ M11 Limit value LIM 1M12 Limit value LIM 2+ M13 Limit value LIM 2M14 Limit value LIM t (admissible speed change)
Y Y Y Y Y Y
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Monitoring Module TA-410/411412 Group M Limit monitoring (continued): M20 Alarm delay LIM 1+ M21 Alarm delay LIM 1M22 Alarm delay LIM 2+ M23 Alarm delay LIM 2M24 Alarm delay LIM t M40 Direction of limit value violation LIM 1+ exceeding up (+), exceeding down (-) M41 Direction of limit value violation LIM 1exceeding up (+), exceeding down (-) M42 Direction of limit value violation LIM 2+ exceeding up (+), exceeding down (-) M43 Direction of limit value violation LIM 2exceeding up (+), exceeding down (-) Group N Relays : N01 LIM 1+ is assigned to relay N02 LIM 1- is assigned to relay N03 LIM 2+ is assigned to relay N03 LIM 2- is assigned to relay N05 LIM t is assigned to relay N10 Relay K1 latching N11 Relay K2 latching N12 Relay K3 latching N13 Relay K4 latching N20 Relay K1 logic N21 Relay K2 logic N22 Relay K3 logic N23 Relay K4 logic N50 Latching of OK-LED N51 Latching of limit value LED Group O OK Monitoring : O01 OK Monitoring for channel A O02 OK Monitoring for channel B O03 No monitoring in case of OK error O04 OK Lower limit for channel A O05 OK Upper limit for channel A O06 OK Lower limit for channel B O07 OK Upper limit for channel B O08 OK-Toleranz bei Drehzahlvergleich Group Q Local control input : Q01 OK Monitoring inactive Trip override active OK Monitoring inactive and trip override active Switch off speed and speed change monitoring Switch off speed monitoring Switch off speed change monitoring Q10 Power-up (after voltage failure) =system error
[___________] [___________] [___________] [___________] [___________] + [] + [] + [] + [] - [] - [] - [] - []
Y Y Y Y AND AND AND AND Y Y
[___________] [___________] [___________] [___________] [___________] [] N [] [] N [] [] N [] [] N [] [] OR [ ] [] OR [ ] [] OR [ ] [] OR [ ] [] N [] [] N []
Y [] N [] Y [] N [] Y [] N [] [___________] [___________] [___________] [___________] [___________]
NOK [ ] TROVER [ ] NCHKNOK [ ] CHK [ ] CHKRPM [ ] CHKTREND [ ] Y [] N []
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Safety concept
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Safety concept
The operation of the monitoring system VC-4000 for the protection of machines and installations, even employed in nuclear power stations, requires a high degree of safety measures to be taken. Therefore, the most important principle for the safety concept of the VC4000 system is: Errors must not lead to uncontrolled system behaviour! In the following chapters, we will describe which measures have been taken in order to
avoid errors and to recognize errors the behaviour of the system in case of errors is described.
in addition,
4.1
4.1.1
Passive safety
Independent modules
Each monitoring module is an autonomous measuring and monitoring system with its own processor and operating system and is completely independent of all other modules in the module housing. Thus, the failure of one module does not affect the other modules in their functions. The only malfunction which would affect all modules in the housing would be a failure of the common power supply unit. However, such an event is signalled by drop-out of the central OK relay (see chapter 4.2.3).
4.1.2
Selection of processor and operating system

Microprocessor and operating system are the core of each monitoring module. They have a determining influence on the reliability of a system. Besides the required high performance, reliability is the most important feature. The selected processor is an HD64180, the operating system a prioritycontrolled real-time system. Both are well established with Brel & Kjr Vibro and are considered free from faults. In our house, they are employed in other areas as well, e. g. in the production of legal-for-trade weighing systems.
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4.1.3
Program structure
Computer programs with a modern structure are divided in individual, independent sections which perform specific tasks. Depending on the importance, certain priorities are allocated to the individual tasks. Within a VC-4000 module, the monitoring task has the highest priority, followed by the measuring task. This means that no other program process, e. g. the communication with the higher-level computer, can impede monitoring and measuring. The internal program flow is monitored by a hardware and a software watchdog.
4.1.4
Double storage of data

All configuration and calibration data required for measuring and monitoring are stored in the EEPROM and are secured against power failure. The entire data record is stored twice in order to exclude the risk of a data loss; each time they are accessed, the records are checked to ensure that they are still identical.
4.2
Active safety = OK monitoring

The OK monitoring constitutes a continuous control of the operating saftety of the VIBROCONTROL-4000 system. It covers four areas, described in the following chapters 4.2.1 to 4.2.4. Each recognized error triggers an OK alarm!! An OK alarm causes the central, monostable OK relay in the power supply unit PS-4x0 to be de-energized (refer to chapter 4.3.1).
4.2.1
Monitoring of the measuring chains

Each monitoring module checks the input signal per measuring channel - or a measurement type (OK variable) derived from it - continuously for settable limit values. The OK variable depends on the module type and on the measurement type. Information on this aspect are to be found in the corresponding module descriptions. Due to the monitoring of the OK variable, the entire measuring chain starting from the sensor to the measuring input of the module is monitored. Cable breakage, short circuits and defects of the sensor are recognized in this way and trigger OK alarms.
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Configuring the monitoring of the measuring chain

Monitoring of the measuring chain may be configured with the configuration parameters of the group O, separately for each measuring channel of a module. The following settings are possible:
Switch-off of OK monitoring (parameters O1) An error in the measuring chain does not trigger an OK alarm. The LED of the corresponding measuring channel always signals OK condition in this case (permanent light). However, all other errors (system errors) do trigger OK alarms! Blocking of limit value monitoring and analog output (parameter O3). In case of an error in the measuring chain, limit value monitoring is blocked and the analog output which is assigned to the measuring channel is set to 0 V / 0 mA.
Limit values of OK monitoring (parameters O4 and O5) Upper and lower limit value which the OK variable may not exceed above or below. Otherwise, OK alarm will be triggered.
4.2.2
Self-tests
All monitoring modules are equipped with an extensive self-testing program which checks the program and memory areas for system errors. Recognized errors trigger an OK alarm. The following tests are carried out:
Continuous EPROM and RAM test. EEPROM test when the configuration and calibration data stored twice therein are accessed, including a check as to their absolute correspondence. Access is made after a change in the configuration, after power failure or after recognized system errors. Permanent checking of the congifuration and calibration data copied from the EEPROM into the RAM (constant check). Dynamic program monitoring which checks continuously whether the different measuring and monitoring programs are run through as often as required.
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4.2.3
Monitoring of supply voltage

A failure of the mains voltage always triggers an OK alarm if the duration of the failure exceeds the buffer time (stored-energy time) of the power-supply unit. This buffer time depends on the current consumption of all modules in the module housing and the connected sensors at the given time and is within the range of 20 ... 350 ms. The description of the power supply unit in register 4 of this documentation contains a graph showing the mains failure buffering under various conditions.
4.2.4
Monitoring of the module assignment

If a monitoring module is removed from the module housing, all relays of the modules are maintained in the conditions in which they were last. If the same or a new module is later inserted again into the same slot or different one, an OK alarm will be triggered and its bistable limit value relays are reset. Following the automatic new initialization of the module, the relays are set in accordance with the current monitoring condition.
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4.3
4.3.1
Signalling, displaying and resetting of an OK error

Central OK relay
The central OK relay in the power supply unit PS-4x0 responds to all OK errors occuring in the module housing. The monostable OK relay is normally energized, i.e. it is energized as long as no alarm has been output and de-energized if one of the OK errors described in chapter 4.2 occurs. It remains in this condition until the error has been eliminated and acknowledged (see chapter 4.3.5).
Exception:
If the parameter Q10 is not set to "Y" in any of the inserted monitoring modules, the OK relay returns automatically to the OK condition as soon as the voltage returns after a power failure. A potential-free changeover contact of the OK relay is lead on the back of the power supply unit on screw-type terminals and signals OK alarm to the peripherals.
Important note: Combination of OK relay and limit value relay. If the application requires a closed-circuit behaviour of the limit value monitoring, i.e. if also a limit value violiation is to be signalled in case an OK error occurs, this may be obtained by a simple external connection of the OK relay with the corresponding limit value relay. Example: Switch-off of a machine in case of an OK alarm even if no limit violation has taken place (see figure 4-1.)
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Fig.: 4-1 Example of a closed-circuit behaviour for the limit values LIM2 (to each of which the relays K2 are assigned) by external connection with the OK relay. The monitored machine is to be shut off if a limit value is exceeded. The relays K1, assigned to LIM1 are, in this case, normally de-energized and signal a pre-warning. Representation of the contacts is in accordance with DIN 40713
4.3.2
OK LEDs of the monitoring modules

OK errors are not only signalled by the central OK relay, which serves to issue a group signal for all OK errors, but they are also indicated indiviually by LEDs on the front panel of each module. An OK error recognized by a monitoring module is indicated by the green OK LED on the front panel of the module.. OK LEDs may adopt the following states:
OK-LED is lighted: OK-LED is flashing:
No OK error has occured Measuring chain defective (cable breakage, short circuit and defects of the sensor)
OK-LED is extinguished: System error - one of the self-tests of the module has recognized an error. After a power failure, the OK LEDs of those modules whose configuration parameter Q10 is set to "Y" remain unlighted. In this case, the power failure is seen as a system error. The same applies for a newly inserted module.
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Configurable "latching" of the LEDs

The OK LEDs may be configured as "latching" or "non-latching" with the help of the configuration parameter N50. "Latching" means that a flashing or extinguished LED remains in this state even after the cause of the alarm has been eliminated, until it is reset by acknowledgement, i. e. lighted again (see chapter 4.3.5).
4.3.3
OK LED of interface module

The green OK LED of the interface module CI-4xx indicates the switching condition of the OK relay. LED lighted = OK relay energized.
Exception:
After switch-on or return of voltage, the LED is lighted for about 4 seconds without the OK relay being energized.
4.3.4
LCD display as a status indication

As far as modules with an LCD display on the front panel are concerned, the last occurred error may be inquired by pressing the STATUS key of the control panel TP-419. E.g., the error message "ER -6" indicates a power failure. The error message may be deleted by using the command RESET (see chapter 4.3.5)
4.3.5
Resetting (acknowledging) an alarm or an error message

All alarms and error messages which remain active even when the cause of the error has been eliminated can only be reset by acknowledgement. This is done by
pressing the RESET ALARM key on the control panel TP-419 or by an external contact which acts on the Reset input of the power supply unit PS-4x0 wirkt.
This applies to:
OK alarms OK LEDs configured as latching limit value relays configured as latching limit value LEDs configured as latching error messages displayed after pressing of the STATUS key of the TP-419 on the LCD display of the modules.
The attempt to acknowledge an alarm/error which has not yet been eliminated does not have any effect.
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5
5.1
System behaviour
Switch-on behaviour/readyness for operation
The behaviour of VC-4000 described in this subsection applies both for normal switch-on and for return of the voltage after a power failure.
After the mains voltage has been switched on, all 4 LEDs of the CI-4xx are lighted. Except for the green "READY" LED which indicates the voltage supply, the LEDs will go out after about 4 seconds. After that, the LCD displays of all modules will be lighted for about 1 second. Subsequently, the automatic initialization of the individual modules will be carried out. In this phase, various tests are carried out and the configuration parameters stored in the EEPROM are taken over, all limit value relays are reset and the analog outputs are set to 0 V / 0 mA.
The duration of this phase depends on the module and can be up to 50 s. When the initialization phase is over, the three following cases must be distinguished:
5.1.1
Automatic readiness for operation

The modules start with the execution of their measuring tasks in accordance with their configuration. The limit value relays are set in accordance with the current monitoring condition. The analog outputs are set in accordance with their configuration and the current display value.
If the CI module recognizes, via the internal communication, that all modules are in the OK condition (all OK LEDs of the modules are lighted), the OK relay in the power supply unit PS-4x0 is energized. As a result, the system C-4000 signals its full readiness for operation.
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5.1.2
Readiness for operation not before acknwoldegement has been made

The system behaviour is different from that described in chapter 5.1.1 in that the OK relay remains de-energized until acknowledgement is made (see chapter 4.3.5). This behaviour is obtained with the help of the configuration parameter Q10 with which every monitoring module is provided. In at least one module Q10 must be set to "Y".
Note!
When configuring the parameter Q10, this will appear with the parameters for channel A and channel B. Make sure that both settings are identical.
5.1.3
Recognition of errors
If one of the monitoring modules signals at least one OK error after the initialization phase, the OK relay remains de-energized and will not be energized again before acknowledgement has been made (see chapter 4.3.5) after all errors have been eliminated. Modules without errors can fulfill their monitoring tasks already before acknowledgement has been made.
5.2
System behaviour during configuration:

The configuration of the individual modules with the configuration program CM-401 or CM-402 consists of 3 phases:
1. Establishment of the connection

The connected PC starts the telegram communication with the CI module via the serial interface RS-232. The CI sends the module assignment to the PC. It is displayed on the screen. System behaviour:
All functions show a normal behaviour. Already configured modules measure and monitor as normal.
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2. Loading configuration data into the PC

After a module has been selected, its current configuration data are loaded into the PC and may be modified. System behaviour:
All functions show a normal behaviour. Already configured modules measure and monitor as normal. The selected module measures and monitors with its current configuration.
3. Storing of configuration data in the module

The configuration data modified in the PC are transmitted to the selected module and stored by it. Subsequently, the module automatically carries out a re-initialization in which the new data are taken over. System behaviour:
All funcitons show a normal behaviour. Already configured modules measure and monitor as normal. Until the initialization is started, the selected module measures and monitors with its current configuration. During the initialization phase, the module does not carry out any measurements. All limit value relays of the module are reset. The analog output is "frozen". The LCD display shows the version number.
After initialization, the module carries out its measuring and monitoring tasks with the new parameters; the analog outputs follow the value displayed in each individual case. In all cases the OK relay remains energized as long as no OK error occurs.
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5.3
Behaviour of the limit value relays in case of faults

... in case of errors of the measuring chain:
The behaviour of the limit value relays depends on the type of the module and its individual configuration. Limit value violations may be signalled if the the indicated value which has been determined in spite of the error and is therefore wrong, exceeds one or several limit values. This may be prevented by setting the configuration parameter O 03 to "Y" (= no limit value violation signalled in case of OK error).
... in case of system errors:

Each module carries out continuous self-tests such as the RAM-/EPROM test etc. (see chapter 4.2.2). Recognized errors are indicated as signal errors (ER-34 = RAM error) on the LCD display of the module after pressing of the STATUS key on the control panel TP-419. All limit value relays remain in their current condition. The same applies in case of a failure of the processor.
... in case of a power failure:

Short power failure (within the load-dependent buffer time of the power supply unit PS-4x0 of 20 ... 350 ms): All limit value relays remain in their current condition. Long power failure (load-dependent buffer time of the power supply unit PS-4x0 of 20 ... 350 ms exceeded): First, all limit value relays remain in their last condition. When the voltage returns, they are reset.After the automatic re-initialization of the modules, the relays are set in accordance with the then current monitoring condition. During re-initialization, the version number of the LCD display is indicated if this is lighted.
... when a module is inserted:

If a monitoring module is removed from the module housing, all relays of the module remain in their last condition. If the module is later inserted into the same slot or a different one, all relays will be reset first. After the automatic re-initialization all relays are set in accordance with the then current monitoring condition.
... if the configuration of a module is changed:

During the duration of the initialization phase, all relays remain in their current condition. Subsequently, they will be set in accordance with the then current monitoring condition.
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5.4
Behaviour of the analog outputs in case of malfunctions

As a general rule, the two analog outputs always refer to the current display value of the measuring channel to which they are assigned by the configuration (parameter group L). The following events are an exception to this rule:
... in case of errors in the measuring chain:

There are two different cases:
The parameter O03 is set to "N": The analog output follows the display value. The parameter O03 is set to "Y": The analog output is reset to 0 V/0 mA. The correct value is indicated only after elimination and acknowledgement of the error (see chapter 4.3.5).
... on power failure, system error or insertion of a module:

The output is set to 0 V/0 mA for the duration of the re-initialization. After that, it follows the display value.
... in case the configuration of a module is changed:

If the parameters of a module are changed, the current output is frozen for the duration of the initialization phase in which this change is effected. After that, it follows the display value.
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Components
Components of VIBROCONTROL 4000

The VC-4000 system consists of the following components which may be combined to form a monitoring system in accordance with the requirements of the application. Module housing: RC-400 Power supply module: PS-410 or PS-420 Interface module: CI-411 CI-421 or CI-431 Control panel: TP-419 Monitoring modules: VB-4xx, TA-41x, GP-41x, GP-42x, GP-43x Blank panels: BF-405 (5 TE), BF-410 (10 TE), BD-419 (19 TE), Configuration software: Vibroconfig CM-401 or CM-402 All components are described in detail in register 4 of this documentation. Chapter 3 Initial operation" contains the instructions for installation of the configuration software and the minimum requirements to be met by the PC (see chapter 6.5) (see chapter 6.4) (see chapter 6.3) (see chapter 6.2) (see chapter 6.1)
6.1
Module housing RC-400

The module housing RC-400 accomodates all modules of the VC-4000 system. It conforms to the international 19" system. It has 6 height units (HU) and 84 width units (TE) and is thus primarily suited for panel or wall mounting. Its printed-circuit distribution board contains all control, data and supply lines which are necessary for operation. It is designed for a maximum equipment, so there is no need for an additional wiring, regardless of number and type of the modules. Special designs RC-400: If module housings are used which deviate from the standard RC-400, please refer to register 4 of this documentation where you will find a detailed description.
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6.1.1
Slot assignment (see fig. 6-1)

Two of the 14 module locations are reserved for the power supply unit PS4xx and the interface module CI-4xx. The power supply unit is located in the far left slot, the interface module in slot 0. The control panel TP-419 is, if required, mounted in front of the power supply unit, thus covering the front of this unit. The slots 1 - 12 may accomodate any monitoring modules, they may, however, also be used for additional interface modules or multiplexer modules of the VIBRODAU-Systems.
Fig.6-1
Slot assignment of the module housing RC-400
6.1.2
Changing of slot assignment

If the slot assignment for the monitoring modules is to be changed after the initial operation has been carried out, a re-initialization is to be performed with the help of the configuration programs CM-401 or CM-402. The configuration data of the individual modules are maintained in this case.
6.1.3
Thermal protection switch for LCD displays

The interior side of the printed-circuit distribuition board contains an electronic circuit which switches off the power supply of the LCD displays as soon as the ambient temperature exceeds 55 C. If this temperature is dropped below, the supply is automatically switched on again and the LCD display is fully operable again.
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6.2
Power supply unit module PS-410 and PS-420

The module housing may be equipped with one of the two power supply units. The only difference between the two modules consists in the input voltage.
PS-410: The input voltage may be set to either 93 ... 140 V AC or 184 ... 264 V AC in the range of 45 ...400 Hz PS-420: Input voltage 19 ...38 V DC
The power supply unit provides all modules of the module housing and the connected measured value sensor with the corresponding voltages.
Further characteristics of the power supply unit:

Central OK relay
All OK errors occuring in the module housing (see chapter 4.2) result in the de-energizing of the monostable OK relay. A potential-free changeover conctact which is connected on the back of the power supply unit on screw-type terminals signals the event to the peripherals.
Reference pickup input

Also on the back of the power supply unit, two inputs (3 screw-type terminals each) are located for connection of reference pickups. The power supply unit itself transmits the incoming signals via the backplane wiring unchanged to the interface module CI-4xx. The CI converts the signals into square-wave pulses with voltage levels of 0 and 5 V. The signals converted in this way are transmitted to the two BNC sockets on the front panel of the CI.
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Central control input

All monitoring modules are provided with a local control input with the help of which one of the various control functions of the corresponding module may be activated. The central control input on the back of the power supply unit acts on all modules in the housing simultaneously. The following functions may be activated:
Relays reset = Resets all limit-value and OK LEDs, limit value relays and OK relays which are configured as latching to the no-alarm condition. Trip multiply = Activates the limit value multiplier of all VB-4xx modules. In the process, the limit values entered for LIM1 and LIM2 (parameters M10 and M11) are multiplied by the factor entered for the parameter M30. This raises the limit values, e. g. to prevent an unwanted alarm in the start-up phase when the point of resonance is exceeded. Trend inhibit = Switches off the trend monitoirng of all modules Trip override = Switches off the limit value monitoring for all modules
6.3
Interface modules CI-411, CI-421 and CI-431

The interface modules CI-411 and CI-431 are used for communication between the monitoring modules of a module housing and the peripherals. They have no measuring function. Which of the two modules is used depends on the type of communication.
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The following table shows the different possibilities: CIModul CI-411 Type of communication Configuring of monitoring modules Communication software CM-401
Use for VIBROCONTROL-4000
Notes The software CM-401 is only used during initial operation or in case of alterations to the configuration The software CM-402 is used during initial operation and during normal operation
CI-421
Configuring of the monitoring modules and enquiry of measured values and monitoring conditions Numerical and graphical evaluation of measured values and process visualization just as with CI-411 with additional PROFIBUS interface
CM-402
VIBROCONTROL-4000
CM-410
CI-431
CM-401 or CM-402
VIBROCONThe software CM-410 is TROL-4000 or only used during VIBRODAU-4000 operation. For configuring or combined of the monitoring operation with modules, the software both CM-401 or CM-402 is required VIBROCONOperation of the TROL-4000 PROFIBUS interface requires none of the specified communication programs
Note on the use of the interface module CI-421: The interface module CI-421 has to be employed if monitoring modules of the system VIBROCONTROL 4000 and multiplexer modules (MX-410) of the multiple-channel data acquisition system VIBRODAU are operated within one module housing (combined operation). The interface module C-421 fulfills the same task as CI-411. In addition, it is provided with a complete measuring and control electronics system which transmits, measures, stores and processes the measuring signals at the inputs of the multiplexers and of the monitoring modules. Through communication with the evaluation software CM-410 installed on the higher-level computer (PC), all acquired data may be evaluated numerically and graphically. The measured values formed in the monitoring modules are then only used for monitoring purposes and will not be transmitted to the higher-level computer. When the system is started for the first time, the monitoring modules must be configured first with the help of the software CM-401 or CM-402. During operation, the software CM-410 is used.
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Configuring of the interface module

A few parameters such as the module housing address (rack address) are sufficient to adapt the interface module to the interface. This is effected when the monitoring modules are configured with the help of the CM-401 or CM-402 software.
6.4
Control panel TP-419

The control panel TP-419 enables all significant display and setting values of each module to be displayed on the LCD display or alarm conditions to be reset (acknowledged) by key actuation. Each key actuation switches on the illumination of the LCD displays of all modules for the duration set in the configuration of the IC-4xx. If no key is pressed, the corresponding measurement type 1 is displayed. The 12 keys of the TP-419 allow the following functions to be carried out:
Display of measurement type 2 Indication of input voltage or input current in case of DC signals or DC portion (e. g. GAP voltage) in case of AC signals Display of all entered limit values Display of current trend reference value Display of STATUS (version number and alarms) LAMP TEST = the LEDs of all modules and all elements of the LCD display are lighted RESET TREND = the trend reference value is set to the current display value of measurement type 1 RESET ALARM = all "latching" alarm conditions are set to the alarmfree condition (see chapter 4.3.5) if the cause of the alarm has been eliminated. After an OK alarm, the central OK relay on the power supply unit is energized again and the OK LEDs are lighted (alarm-free condition).The same function is served by the reset input of the power supply unit PS-4x0.
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6.5
6.5.1
Monitoring modules
General
The monitoring modules VB-4xx, TA-41x and GP-4xx are completely independent measuring and monitoring units. Failure of one monitoring module does not influence the other modules in any way. All monitoring modules (with the exception of TA-41x) are provided with two independent measuring channnels with a complete set of configuration parameters each for individual adaptation to the measuring and monitoring task. The monitoring modules and their configuration parameters are described in detail in register 4 of this documentation. The following chapters will provide you with an overview of the typical measuring tasks and of the features which are commonn to all modules.
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6.5.2
Monitoring modules and their measuring tasks

The following table specifies the individual monitoring modules with their typical measuring and monitoring tasks:
Monitoring module VB-410 VB-411 VB-412
LCD displa 2
Monitoring relays 4 4
Special features with integrator and frequency response linearization with integrator and BCU measuring
Typical measuring signals
Typical measuring task Broad-band measurement of: Absolute housing vibration Rapid movements of the machine housing, especially for assessment of the condition of rotors supported on roller bearings Relative shaft vibration Rapid movements of the rotor shaft in relation to the bearing; indicator for the condition of rotors with plain bearings Absolute shaft vibration Rapid movements of the rotor shaft in case of large steam turbines Speed, changes in speed, sense of rotation as independent measurement types or as a correlation factor of - mainly - the vibrations Axial position axial displacement of rotors on plain bearings to detect wear of the bearings, and changes in load Relative expansion Differential expansion between rotor and stator of steam turbines Absolute housing expansion In case of large thermal expansions of steam turbines Process parameters measurement types such as pressure performance flow rate
Dynamic signals from 1Hz...10 kHz
VB-420 VB-421 VB-422 VB-430 VB-431 VB-432 TA-410 TA-411 TA-412
2 2 1
4 4 4 4 4 4
Pulses from 1Hz...20 kHz
GP-410 GP-411 GP-412
4 4
Static and quasistatic signals
GP-420 GP-421 GP-422
4 4
LowSpeed-frequency- time measurement frequency Eccentricity signals and (triggered peak-peak measurement) pulses of Bending deformation occurring almost 0,01 ... 60 Hz exclusively on steam turbines caused by non-uniform warming Radial shaft position, minimum bearing clearancel (untriggered peak-peak measurement) Radial position of the rotor in the plain bearing as an indicator for the bearing load or for misalignment
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6.5.3
Configuring of the modules

All parameters which a module requires to carry out its individual measuring and monitoring task are stored for each measuring channel in the fail-safe EEPROM of each module before initial operation. This is effected quite easily by means of the configuration programs
Vibroconfig CM-401 or Vibroconfig CM-402
via a normal PC. During configuring, the modules remain the the module housing. The parameters may be altered or corrected at any time without problems, even during operation. To make things clearer, parameters of the same type of a module are grouped together (group I to Q). Identical groups of different modules have the same functions; e. g., the monitoring parameters of all modules are in group M.
Configuration programs
The configuration programs Vibroconfig CM-401 or CM-402 are different in the following aspects:
Vibroconfig CM-401 forms part of the delivery of a VIBROCONTROL4000 system. It may be used to configure, via user dialog on the screen, all modules and compatible units of the VIBROCAM-4000 system. Vibroconfig CM-402 is the extended version of Vibroconfig CM-401. In addition to the functions carried out by CM-401, it is possible to display measured values, limit values and event messages and switch on or off various control functions.
For installation instructions of the configuration programs CM-401- or CM-402 and the minimum requirements to be met by the PC please refer to the chapters 3.1 and 3.2. of the initial operation.
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6.5.4
Measurement types of the monitoring modules

All monitoring modules are provided with several measuring paths for each measuring channel, so it is possible to measure various variables at the same time. All measurement types are determined on the basis of the input signal. The measurement type 1 is, for each module, the characteristic main variable to be measured. Module Measurement type 1 (is always monitored) Vibration displacement or vibration velocity or vibration acceleration as for VB-41x, VB-43x Measurement type 2 (*is monitored) Radial shaft displacement (GAP) * Additional measurement types (always monitored) OK measurement type = D.c. portion of the sensor signal and Trend reference value as for VB-41x, VB-43x
VB-41x, VB-43x
VB-42x
TA-41x
Speed (in addition: sense of rotation if 2 pulse sensors are used)
Radial shaft displacement (GAP) * or BCU measurem. type (Bearing condition) * Change in speed *
GP41x
GP-42x
Axial position Relative expansion Absolute housing expansion Process parameter Speed or frequency or time measurement or triggered peak-peak measurement (eccentricity) or untriggered peak-peak measurement
Amount of the sensor signal
OK measurement type = low-pass filtered sensor signal in case of displacement sensors (s) or Speed in Hz in case of p-sensors and trend reference value OK measurement type = sensor signal and trend reference value OK measurement type = low-pass filtered sensor signal and trend reference value
In case of untriggered peak-peak measurement: Radial shaft position and minimum bearing clearance *
6.6
Multiplexer module MX-410

The multiplexer module MX-410 is, basically, a component of the multiplechannel data acquisition system VIBRODAU-4000 and fulfills, in this system, the function of an automatic measuring point switch. However, in case of combined operation of VIBROCONTROL-4000 and VIBRODAU-4000, both monitoring and multiplexer modules may be accomo-dated in one module housing. In this case, a CI-421 is used as an
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VIBROCONTROL 4000 interface module. For details refer to the System description of VIBROCAM 4000" in register 1 of this documentation.
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General functions of the monitoring modules

This chapter describes functions and characteristis which are identical or at least similar for all monitoring modules.
7.1
Indication of measurement types

All measurement types determined by a module may be indicated or enquired as follows:
In case of modules with LCD displays, the respective measurement types of both measuring channels may be displayed separately by pressing the corresponding key of the control panel TP-419. The configuration program CM-402 enables the measurement types to be displayed on the screen of the connected PC. If the interface module CI-431 is employed, all measurement types may be enquired via the PROFIBUS connection.
7.2
Monitoring of the measurement types

Almost all measurement types of a monitoring module are monitored, for each measured channel separately, with regard to limit values (see table in chapter 7.4.5). The limit values are designated by "LIM". The amount and the functions of the limit values may be set with the help of the configuration parameters of group M and N. Depending on how these parameters are set, one or several of the 4 limit value relays are activated if a limit value is exceeded above or below. Monitoring in case of an OK alaram Since all monitoring modules inserted in the module housing are independent units, they carry out their measuring and monitoring functions correctly even if an OK alarm has been triggered, provided that they are not directly concerned. The same applies to an intact measuring channel of a module if the other channel has recognized an error in the measuring chain.
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7.2.1
Absolute monitoring of the measurement types

In an absolute monitoring, the individual measurement types are monitored with regard to the violation of limit values which are not changed when the display value of the measurement type changes, as opposed to trend monitoring (see below). The limit values LIM 1, LIM 2 for the modules VB-4xx and LIM 1+, LIM 2+, LIM 1- and LIM 2- for all other modules are always assigned to the measurement type 1, with the only exception of GP-42x. The limit value LIM x (for all VB-4xx) refers to measurement type 2.
The numbering of the limit values (e. g. 1+ or 2+) is to be understood as an aid for presetting, i. e. the values entered for LIM2+ must not necessarily be higher than those for LIM1+. Likewise, LIM1- and LIM2- may be configured to trigger alarm signals if exceeded or dropped below.
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7.2.2
Trend monitoring of measurement type 1

In many applications, not only the absolute value of a measurement type, which is monitored by LIM 1, LIM 2 etc. is of importance, but also the value by which it changes, in particular if such a change occurs very suddenly with-in a very short period of time. The change of the measurement type can provide important information on the state of a machine, even if the limit values LIM 1, LIM 2 etc. are not yet exceeded. E. g., the abrupt rise of the vibration characteristic value of a ventilator may suggest that the build-up of material on one of the blades has broken off. How does the trend monitoring work? (see figure 7-1) The trend monitoring checks whether the current display value of the measurement type 1 keeps within a range (trend window) which follows a trend reference value generated by the module.
With LIM t (parameter M14 in all modules), the range of the trend window is defined. M 14 is entered in % of the set full scale. The trend window represents a range of 2 x M 14 around the trend reference value. The trend reference value and thus the trend window follows the display value in the form of an e-function A trend alarm is triggered if the display value leaves the trend window.
That means that LIM t is to be set with M14 in such a way that the trend reference value keeps within the trend window if a slight change occurs.
Special case:
If the sum from thedisplay value + absolute value of M 14 is higher than the upper full scale, the upper trend limit value is set to the upper full scale. If the difference of indicated value - absolute value of M 14 is smaller than the lower full scale, the lower trend limit value will be set to the lower full scale
Formation of the trend reference value

The current display value is lead by its own measuring path via a low-pass element with a time constant of approx. 1 hour. The measured value formed in this way, i. e. the trend reference value follows the display value slowly according to an e function with the abovementioned time constant. In case of very slow changes, display value and trend reference value are nearly identical, in case of abrupt changes of the display value they differ, immediately after the change, by the full amount of the change.
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Fig.: 7-1
Representation of trend reference value and trend window. The upper figure shows the response in case of small, abrupt changes of the display value. The display value keeps within the trend window and does not trigger a trend alarm. The lower figure shows a great, abrupt change of the display value. In this case the display value exceeds the limits of the trend window. A trend alarm is triggered. The trend reference value and thus the trend window follow the change in the form of an e-function with a time constant of ... = aprox. 1 hour.
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Resetting the trend reference value

The following events cause the trend reference value to be reset:
Pressing of the key RESET TREND on the control panel TP-419 to acknowledge a previous trend alarm. Triggering of the function Trip Override (see chapter 7.5) Triggering of the function Trip Multiplier (limit value multiplier)
Each of these events sets the trend reference value to the current display value. After that it continues to follow the current display value, as described.
7.2.3
Setting of the limit values

The value which is entered for a limit value is always referred to the selected measurement type and its unit and, if required, to its signal detection.
Example:
Selected measurement type of a VB-430: Vibration velocity (parameter I 02 =v) Selected unit: Selected signal detection: mm/s (parameter I 03) effective value (parameter J 06 = rms)
If for the limit value LIM 1 "15" is entered and for LIM 2 "20", these are set to 15 mm/s rms / 20 mm/s rms.
As for the setting range of the limit values, the following must be considered:
A limit value must be set to a value which is at least 10 % of full scale. A limit value must be lower than full scale. If it has the same value, its monitoring function is switched off. A limit value alarm is only triggered if the display value exceeds or drops below the limit value, not when the display value is identical with the limit value.
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7.2.4
Display of limit values

All entered limit values of a monitoring module may be displayed on the LCD display by pressing the corresponding pushbuttons of the control panel TP-419. With the help of the configuration software CM-402, the limit values of all modules may be displayed on the screen.
7.2.5
Indication in case of limit value violation (limit value LEDs)

Each limit value of a module is assigned one LED on the front panel for each measuring channel. If a limit value is violated, the corresponding LED starts flashing...
for the duration of the limit value violation,or, in case of LEDs configured as "latching", until an acknowledgement is made (see chapter 4.3.5).
Whether the LEDs of a module are to be latching or not is specified with its parameter N 51.
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7.2.6
7.2.6.1
Functions of the limit values

Exceeding of limit value above or below
All limit values assigned to the measurement type 1 of the corresponding module, i. e. LIM 1, LIM 2, LIM 1+, LIM 2+, LIM 1- and LIM 2-, may be set individually to exceeding above or below with the parameters M 40 ... M 43. This also allows a window function to be realized which monitors whether the display value keeps within an admissible range or whether it leaves this range (see fig. 7-2).
Fig.:7-
Monitoring window for the measurement type 1 of a module. If the display value leaves the range limited by LIM1 (lower limit) and LIM2 (upper limit), a limit value alarm is triggert..
7.2.6.2
Limit value delay

For each limit value of a module, a delay time may be set individually which prevents triggering of an alarm in case of short limit value violations caused by external circumstances or circumstances which have to do with the operation, but not by damage (parameter group M 20 ... M 24).
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7.2.6.3
Suppression of an alarm
There are three possibilies to suppress an alarm:
The central control input on the back of the power supply unit (see chapter 6.2) enables the limit value monitoring to be suppressed for all modules of the module housing by means of the trip override function. The local control input with which every module is provided enables the limit value monitoring to be suppressed for individual modules. You can choose between the "trip override" function and the alarm suppression". In case of a trip override, not only is the alarm suppressed but all red LEDs are switched on and the trend reference value is reset (see chapter 7.2.2). An alarm suppression for the case of an OK error (see 4.2) may be configured for each individual module (parameter O 03).
7.2.6.4
Limit value multiplier

For all VB-4xx modules the limit value multplier is a factor by which the limit values entered for LIM1 and LIM2 are multiplied (parameter M 30). Raising the limit values avoids the undesirable triggering of an alarm when passing resonaces during the acceleration and deceleration phase of a machine. The limit value multiplier is activated by means of the local control input (see chapter 7.5)
7.2.7
Limit value relay

Since the monitoring modules are independent of each other, each module is equipped with four limit value relays. Each relay has a potential-free changeover contact the connections of which are wired on the back of the module to pluggable screwed terminals. The switching capacity of the contacts is described in the chapter Technical data" of each module.
Bistable limit value relays

To provide for a minimum heat generation and a low load of the power supply unit, a bistable relay tye has been selected for the limit value relays. The contact condition of bistable relays does not depend on the current flow. They remain in their last condition even in case of power failure. If the contact condition of a relay corresponds to an alarm message, the relay is activated.
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Closed-circuit arrangement By combination with the monostable OK relay, it is possible to achieve that the limit value relays are normally energized. This is described in detail in chapter 4.3.1.
Assignment of the relays to the limit values

The modern concept of the monitoring modules enables the individual relays to be assigned at will to the different limit values. Thus it is possible to assign one limit value to all relays or one relay to all limit values. For individual combinations, refer to the parameter lists of the module descriptions (parameter group N 01 ... N 05).
AND/OR operation of the limit values

If several limit values of a module are assigned to one relay, an AND or an OR operation can be defined individually for this relay (parameter group N 20 ... N 23).
In case of an AND operation, the relay is only activated if all of the limit values assigned to it are exceeded. In case of an OR operation, the relay is always activated if one of the assigned limit values is exceeded.
Latching function of the relays

If a relay is latching, this means that it remains activated even if the limit value violation does no longer exist. This function may be defined individually for each relay with the parameters N 10 ... N 13. All latching relays may be reset by acknowledgement (see chapter 4.3.5).
Important: Provide for spark suppression!

In case the relay contacts activate/deactivate a non-ohmic load, it is essential to provide a spark suppressor as near as possible to the spark generator!
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7.3
Analog outputs (recorder outputs)

Each monitoring module is equipped with two completely independent analog outputs. Each output converts the digital display value of a measuring channel assigned to it via the configuration into an analog voltage or current signal. The connections are made to pluggable screwed terminals on the module back. The technical data vary from module to module and are specified in the individual module descriptions in register 4 of this documentation. Each analog output is to a large extent variable and may be adjusted with the configuration parameters of the group L. The following possibilies are provided:
Free assignment of measuring channels The assignment to the two measuring channels may be selected at will. So it is possible to assign both analog outputs to the same channel. Selection of the measurement type For each channel, selection between several measurement types can be made in accordance with the module type. Output of highest value The analog outpug may be configured in such a way that it is always switched to the measuring channel with the highest display value for the measurement types 1. (Selection "MAX(A,B)" in the menu of parameter L 03) Selection of output signal The following output signals may be selected for the output range: 0 ... 10 V 2 ... 10 V 0 ... 20 mA 4 ... 20 mA
The upper values (10 V / 20 mA) are never exceeded, even if full scale is exceeded.
Output range independent of measuring range (Parameter L 05, L 06 (L 05 for the lower limit is not applicable with VB-4xx)) Limits of the measuring range of the measurement type to be output, any partial range may be selected as an output range. For this partial range, the entire range of the selected output signal will be available.
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Example:
Measuring range of the measurement type: 0 ... 2 mm Range of the output signal: 0 .. 20 mA Output range: 1 ... 1,5 (mm) In case of this setting, a signal of 0 ... 20 mA will be output for a display range of 1 ... 1,5 mm. In the display range of 0 ... 1 mm, the signal is constantly 0 mA, in the display range of 1,5 ... 2 mm, the signal is constantly 20 mA. This possibilty may be used to enlarge measuring ranges of particular interest or critical ones and to suppress the rest of the range.
Selection of the output characteristic

The guideline VDI-2059 sheet 4, paragraph 4 recommends the use of continuous-line recorders of two different sensitivities for recording of the measuring result in case of certain applications (e.g. vibration measuring). These should represent the lower 50 % of the measuring range on 80 % of the recording range and the upper 50 % of the measuring range on the remaining 20 % of the recording range. Thus, the lower half of the measuring range is enlarged, so slight changes of the display value in this range may be seen better. In order to make full use of this effect also if recorders with continuous linear sensitivity are employed, the analog output may be switched from the linear sensitivity to a dual-range sensitivity, which leads to the same result on the recorder as described above. Figure 7-3 shows the corresponding assignment of the output signal to the display value of the selected measurement type. The selection of the output characteristic is made for all modules with the configuration parameter L 02.
Fig. 7-3
Characteristics of analog output signal. Left: linear, right: with break point according to VDI-2059
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Switch-off of analog output in case of an OK error

In case of an OK error, the analog output might be incorrect. For this reason, it is possible to suppress the analog output in case of an Ok error with the parameter O 03. It is then set to 0 V or 0 mA, depending on the parameter L 01. Important note for the configuration of the analog outputs: The parameters for the two analog outputs (group L) are independent of the channel. When configuring with the help of the software CM-401 or CM-402, the parameters L 01 ... L 06 of the analog output 1 are assigned to channel A and those of the analog output 2 to channel B. However, the actual assignment to the measuring channels is effected with their respective parameter L 03.
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7.4
Buffer outputs (Diagnosis outputs)

For diagnostic purposes, each monitoring module provides one output per measuring channel which enables the input signal to be picked up.
The input signal is transmitted through its own measuring channel and via an operational amplifier ("buffer"), thus the picking-up of the signal remains decoupled even in case of a short-circuit and does not affect the monitoring action (see fig. 7-4). The amplification factor is 1. The output signal (buffer signal) is transmitted to one output on the front panel (BNC socket) and one output on the back of the module (pluggable screwed terminals). A short circuit of one output entails a short circuit of the other output as well. Buffer outputs are short-circuit-proof. The d.c. coupling of the operational amplifier is appropriate for d.c. or a.c. voltage signals. The output range of +12 V to -20 V is designed for the typical applications of the modules. The buffer outputs of the two channels do not affect each other.
Fig. 7-4 Buffer outputs: Principle of the output of the decoupled input signal on the front and on the rear side.
Important note:
The buffer signal is always identical with the input signal. Internal corrections in the module such as frequency lineari-zation (VB-410) or compensation of the signal loss due to a high internal resistance in the sensor do not influence the buffer signal in any way. Such corrections therefore lead to corresponding differences between the value of the buffer signal and the display value.
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7.5
Local control input

Each monitoring module has its own configurable "local control input" with the help of which the monitoring process may be controlled from the outside at any time. The local control input acts on both measuring channels.
Control functions for monitoring

With the help of the configuration parameter Q 01, one of the following functions may be selected: NOK (for all modules) Switching-off the OK monitoring TRMULT Trip Multiplier (for all VB-4xx) For all monitoring modules VB-4xx, a factor by which the limit values entered for LIM1 and LIM2 are multiplied. Raising of the limit values prevents an unwanted triggering of an alarm when the resonances are run through in the acceleration or deceleration phase of a machine. TROVER Trip Override (for all modules) Alarm suppression 1) for channel A and B, switch-on of the red limit value LEDs and resetting of the trend reference value (see chapter 7.2.2). NCHKNOK (for all modules) Switch-off of OK monitoring, trip override is activated. CHKA (for all VB-4xx and GP -4xx) Alarm suppression 1) only for channel A. CHKB (for all VB-4xx and GP -4xx) Alarm suppression 1) only for channel B. CHKAB (for all VB-4xx and GP-4xx) Alarm suppression 1) for channel A and B.
1)
Alarm suppression = The limit value monitoring for the respective measurement type 1 is switched off.
CHGAB (for all VB-4xx) Change-over of monitoring from channel A to channel B
If the local control input is not activated, monitoring is performed only by channel A. If the local control input is activated, monitoring is performed only by channel B.
Regardless of this, both channels measure their respective measurement types.
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CHK (for all TA-41x) Switch-off of speed and speed variation monitoring. CHKRMP (for all TA-41x) Switch-off of speed monitoring. CHKTREND (for all TA-41x) Switch-off of speed variation monitoring.
Activation of the selected function

The selected function for parameter Q 01 does not become effective for the corresponding module before the local control input is activated. This is effected by jumpering the back-panel screwed terminal xx07 with 0 V potential, that is, e. g., with the TE busbar. Figure 7-5 shows the principle of the local control input.
Fig.: 7-5 input.
Principle of activation and configuration of the local control The desired function is selected with parameter Q 01, the function is activated by means of the external switch S.
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7.6
System calibration / reference calibration

Even measuring instruments which have been manufactured and tested in accordance with the most modern manufacturing methods, like the modules of the system VIBROCONTROL-4000, are subjected to slight changes of their components. These depend largely on the ambient temperature and on their age. However, this process is only relevant as far as the components of the various measuring paths of a module are concerned as they determine the measuring accuracy. In order to correct this so-called "drifting", each monitoring module of the system VIBROCONTROL-4000 (except for TA-41x) is equipped with the following two calibration programs: 1. System calibration (may be performed by operating company/authority) (can only be performed by a Brel & Kjr Vibro service team)
2. Reference calibration
System calibration
With the help of an integrated calibration generator, the system calibration checks the measuring deviations of the measuring paths (amplifiers, attenuators, filters, linaerization) of one or several modules of the module housing (An exception are the input amplifiers and all drivers and operational amplifiers concerning the relay and analog outputs.)he measuring deviations which have been detected in the process are stored as correction factors in the module and automatically taken into account in the further measuring operation. A system calibration should be carried out every 12 months. It is started with the help of the configuration programs VIBROCONFIG CM-40x, which are provided with detailed on-line help texts. During the calibration, the ambient temperature should correspond to the temperature in normal operation.
Important !
All measuring and monitoring functions of a module are switched off for the duration of the system calibration. The current condition of the limit value relays is frozen.
Reference calibration
The reference calibration includes a test for the module-internal reference element which provides the standard value for the system calibration. The reference element guarantees a stability within the specified tolerance of at least 5 years. We recommend a reference calibration by a Brel & Kjr Vibro service team every 5 years.
SYSVC4E March 2006
Page 95 of 95

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VIBROCONTROL 4000

System overview ........................................................................... 5 Installation ..................................................................................... 9

Initial operation ............................................................................ 22

3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6

C102 860.002 Leydheckerstrae 10 Fax : +49 (0) 6151 428-1401

Page 1 of 95 D-64293 Darmstadt E-Mail : info@bkvibro.de

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6

3.3 3.4 3.5

Active safety = OK monitoring.......................................................................54

Signalling, displaying and resetting of an OK error .......................................57

5.2 5.3 5.4

Components of VIBROCONTROL 4000 ..................................... 68

6.2 6.3 6.4 6.5

Multiplexer module MX-410 ..........................................................................78

SYSVC4E March 2006

General functions of the monitoring modules .............................. 80

7.3 7.4 7.5 7.6

SYSVC4E March 2006

Example of the use of a VIBROCONTROL-4000 system

SYSVC4E March 2006

The VIBROCONTROL system has a modular design.

The optimum PROFIBUS interface communication on field bus level.

SYSVC4E March 2006

SYSVC4E March 2006

This page has been left for your own notes.

SYSVC4E March 2006

The installation of a VIBROCONTROL 4000 system includes the following works:

SYSVC4E March 2006

General notes on installation

SYSVC4E March 2006

SYSVC4E March 2006

Installation of module housing

Insertion of the modules into the module housing

SYSVC4E March 2006

SYSVC4E March 2006

Connection of module housing

0011 0012 0013

SE 0014 0015 0016

0001 0002 0003

0018 0019 0020

0002 0003 0004 0005

0016 0017 0018 0028 0029 0030 0031

Signal Ground GND Receive Data RD Transmit Data TD Schirm

0028 0029 0030 0031

0032 0033 0034 0035

Signal Ground GND Transmit Data TD Receive Data RD Schirm

0006 0007 0008

SYSVC4E March 2006

1 Connection of the zero potentials

Fig. 2-2 Connection of the zero potentials of a module housing

2 Interference suppression measure for CI module

3 Mains connection to the power supply unit

SYSVC4E March 2006

6 Connection of the reference pickups

7 Central control input

Relays reset Trip multiply Trend inhibit Trip override

SYSVC4E March 2006

8 Serial interface to the computer (Master interface)

9 Serial interface to the next CI module

10 Connection of a central OK relay

SYSVC4E March 2006

Connection of monitoring modules

Y [] N[] Y [] N[] [] [] [] [] [] [] [] [] [] [] []

Y [] N[] Y [] N[] [] [] [] [] [] [] [] [] [] [] []