Epro CON 011 Manuel

MMS Machine Monitoring Systems

Direction for use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Date: 12.12.2006

6‘th Edition

6140-00029

Please note

In correspondence concerning this instrument, please quote type number and serial number as given on

the type plate and software version if applicable.

Bitte beachten

Bei Schriftwechsel über dieses Gerät wird gebeten, die Typennummer und die Gerätenummer wie auf

dem Typenschild aufgedruckt sowie, wenn vorhanden, die Softwareversion anzugeben

Important

As this instrument is an electrical apparatus, it may be operated only by trained personnel. Maintenance

and repairs may also be carried out by qualified personnel.

Wichtig

Da das Gerät ein elektrisches Betriebsmittel ist, darf die Inbetriebnahme und Bedienung nur durch

eingewiesenes Personal erfolgen. Wartung und Reparatur dürfen nur von geschultem, fach−und

sachkundigen Personal durchgeführt werden.

©epro GmbH

Jöbkesweg 3

D48599 Gronau

Germany

Telefon: (+49) 02562.709 0 Fax: (+49) 02562.709255 email: [email protected]

All rights are strictly reserved

Reproduction or divulgation in any form whatsoever is not permitted without written authority from the copyright owner.

Issued by epro GmbH

Printed in Germany

Page 3

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

1GB Direction for use 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Purpose and Application 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Function Principle 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Installation and Comissioning 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Hints for installation and connection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Inherently safe installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Adjustment of measuring chains at the machine 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.4 Mutual influences of two measuring chains 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.5 Recalibration of the converter ( only necessary in special cases ) 9. . . . . . . . . . . . . . .

1.4 Maintenance, Fault finding, Repair 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.1 Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2 Hints for fault finding 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.3 Repair 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Technical Data 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1 Input 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.2 Supply 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.3 Output 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.4 Errors and tolerances 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.5 Environmental conditions 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.6 Explosion protection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2DGebrauchsanleitung 15. . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Zweck und Anwendung 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Funktionsprinzip 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Installation und Inbetriebnahme 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Verkabelungs−und Anschlußhinweise 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 Explosionsgeschützte Installation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Einstellung der Messkette an der Maschine 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4 Gegenseitige Beeinflussung zweier Messketten. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Nachkalibrierung des Konverters (nur in Sonderfällen erforderlich) 19. . . . . . . . . . . . . .

2.4 Wartung, Fehlersuche, Reperatur 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Wartung 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Fehlersuchhinweise 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3 Reparatur 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Technische Daten 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 Eingang 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2 Speisung 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3 Ausgang 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4 Fehler und Toleranzen 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.5 Umgebungsbedingungen 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.6 Explosionsschutz 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

3 Figures / Abbildungen 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 1: Block diagram / Blockschaltbild 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 2: Layout of CON 011 / Bauteileanordnung CON 011 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 3: Characteristical curve / Kennlinie 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 4: Shaft vibration signal, example / Wellenschwingungssignal, Beispiel 27. . . . . . . . . . . .

Fig 5: Connection diagram, example / Anschlußdiagramm, Beispiel 27. . . . . . . . . . . . . . . . . .

Fig 6: Connection diagram for intrinsically safe installation /

Anschlußdiagramm für eigensichere Installation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 7: Cable end prepared for connection to CON 011 /

Kabelende vorbereitet für Anschluss an CON 011 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 8: Dimensions / Abmessungen 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fig 9: Measuring arrangement for calibration / Messaufbau für Kalibrierung 30. . . . . . . . . . . .

Page 5

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

GB DIRECTION FOR USE

1.1 Purpose and Application

The CON 011 Signal Converter in combination with sensors of type PR 6422 ... PR 6426 of epro

Machine Monitoring Systems form eddy current measuring chains to be used for static and

dynamic distance measurements at all kinds of rotating machinery. This means that slow axial

displacements as well as fast radial vibrations of rotating machines can be measured. By using

pulse wheels or key marks sticked on the shaft, the speed of the machine can be measured and

key pulses generated.

Probes and signal converters are adjusted together and are delivered as complete measuring

chains in order to achieve a maximum accuracy. For this reason it is very important that probes

and converters always operate together. The type of the sensor and its serial number are marked

on the type plate of the converter.

The characteristics of the measuring chain are adapted to the material mainly used for

turbomachinery (reference material: 42 Cr Mo 4, according to SAE 4140). The standard

adjustment of the measuring chains is generally related to this material −if necessary, other

materials can be used for the adjustment (refer to operating manual PR 6422...PR 6426). During

installation at the machine only the distance between the head of the sensor and the measuring

target are to be adjusted. Criterion for the adjustment of the sensor is the output signal of the

converter.

The CON 011 Signal Converter is accommodated in a rugged housing, the electronic

components are completely sealed. Connection of the eddy current probe is made with a

LEMOSA connector at the front of the converter. A M20 tapped bush allows the protection of

the sensor cable by means of a cable protection tube set MPT 064/.. . Supply circuits for the eddy

current probe and the measuring electronic are contained in the converter. The nominal supply

voltage for the converter is 24VDC, the nominal range of the output signal −proportional to the

nominal measuring range of the sensor−may be set to either –4...−20 or –2...−18V. With the

converters for the special measuring range (CON 011 / 91x−xxx) the output voltage is firmly

adjusted to the range −4... −20V.

Five eddy current probes are at disposal. The actual type to be used depends on the measuring

range, on the available space for measuring and on the environmental temperature.

1.2 Function Principle

The measuring coil of the eddy current sensors PR 6422...PR 6426 is connected to an oscillator

circuit in the converter via a screened connection cable (see Fig 1).

The oscillator circuit generates a high frequent signal, thus resulting in a high frequent magnetic

field around the tip of the eddy current probe. If this magnetic field meets a metallic target, it

induces high frequent currents and another magnetic field which is inversely induced to the

original one. According the rule of Lenz, the induced currrent damps the oscillator signal.

The damping factor depends on the distance between sensor head and target material. The

smaller the distance to the sensor, the smaller the amplitude of the oscillator.

Page 6

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

The demodulator at the output of the oscillator generates a low−frequent signal from the

amplitude modulated HF– signal. The following units serve the purpose of linearization and

amplification of the signal. The output connectors OUT and ⊥provide a signal proportional to

the actual distance between sensor head and target material.

1.3 Installation and Comissioning

1.3.1 Hints for installation and connection

To ensure the electromagnetic compatibility of the eddy current measuring chain, we

recommend using double screened twisted pair cable for connecting the signal converter to the

measuring amplifier. For direct connections to the converter, cables of type LiYCY – CY

2x2x0,25 mm@should preferably be used. Master connection cable may be any multicore cable

with a corresponding cable structure. We recommend to connect the outer screen of the cable

to protective earth/measuring ground close to the measuring amplifier directly at the cable inlet

of the control cubicle. Moreover, the outer screen of the cable should be connected to protective

earth as often as possible i.e. at every intermediate distribution frame or cable gland.

An extremely high electromagnetic compatibility can be achieved by connecting the cable

screen to protective ground at either side of the cable – provided that no compensating current

goes over the screen. The signal converter CON 011 is provided with a specific cable gland M16

which allows proper connection of the screen to the CON housing, see Fig 5 and Fig 7. In case

of high disturbances it might be useful to connect the screen only to the housing of the CON.

The internal cable screens must be fed through the cable glands of the CON and then precisely

cut off, refer to the wiring scheme Fig 7. In the control cubicle, close to the measuring amplifier,

the screen has to be connected to 0V / common. Connection of the wires is to make according

to Fig 5.

In case that only cables of type LiYCY−CY 2x2x0,25mm@are used, the maximum cable length

is 400m, if longer cables are used an intermediate distributor must be set close to the converter

and cables with a higher cross section used for connection to the measuring amplifier (e.g.

LiYCY−CY n x 2 x 1,5 mm@).

•Measuring cables have to be installed according to general standards for measuring and

control cables and, if possible, in metallic cable channels or tubes. It must be observed that

the measuring cables are arranged orthogonally.

•Close CON housing carefully and observe the correct position of the rubber sealing ring.

•At special applications, where high static discharges(> 6kV) could occur, it must be checked

whether the ground connection via the mounting screws are sufficient. In this case it could

be useful to connect the CON housing to protective earth with an extra cable.

1.3.2 Inherently safe installation

On the following conditions, the sensors PR 6422 ... PR 6426 together with the CON 011 signal

converter may be used for applications in hazardous areas for zone 0, protection class

”Inherently safety” – EEx ia IIC T6 :

Page 7

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

Connection must be made according to Fig 6 e.g. via safety barriers from Stahl of type:

Supply circuit: 9001/00−280/085/101

Measuring circuit: 9001/00−280/020/101

The safety barriers must be installed outside the explosive area in cabinets or control cubicles

with protection classes of at least IP 20 according to DIN 40 050.

In order to achieve compensations of electric potentials, the connectors for protective earth of

the barrier (mounting screw, internally connected to pin 2) must be linked to the corresponding

protective earth connectors within the explosive areas via a compensation line. The mounting

rail for the safety barriers has to be isolated.

The compensation line has to be rated according to VDE 0100 ’ 9 N, table 2 and ’ 21 Nb 1.1 to

1.4, minimum cross section 1,5 mm@Cu. The connection terminals of these safety barriers may

be used for cables with cross sections of up to 2,5 mm@.

The total capacity is calculated from the sum of the capacities at the sensor input (refer to section

1.5. technical data), at the measuring signal output (between Out, ⊥and screen) and at the

supply input (–24 V, ⊥and screen). The capacity of the sensor circuit amounts to 1,2nF (cable

length 10m). Thus, the maximum permitted cable capacity between converter and safety

barriers is for protection class IIC: CLmax = 49 nF and for IIB: CLmax = 616 nF (wire / wire

and wire / screen). The maximum permitted line inductance between converter and safety

barriers is LLmax = 1,6 mH for IIC resp. LLmax = 8 mH for IIB. The following table shows the

resulting cable length l between converter and safety barrier:

Protection class: IIC IIB

•Cable LiYCY−CY 2x2x0,25 and

meas. cable PT 1492/00 with C = 2 x 150nF/km Lmax = 163 m > 1000 m

•Low capacity cables C = 2 x 60nF/km, Lmax = 408 m > 1000 m

e. g. Li2YCY (TP)

In case of extremely long cables between safety barriers and measuring amplifiers, the upper

cut−off frequency might be reduced by the series resistor of the barrier (1510 Ω) and the line

capacity:

3dB at f = 2kHz and CL= 50nF, corresponding to 330m cable length with 150nF/km

1dB at f = 2kHz and CL= 25nF, corresponding to 165m cable length with 150nF/km

!When operating the CON 011 Signal Converter in hazardous areas, the instal-

lation has to be carried that the converter is not exposed to strokes or mecha-

nical shocks and friction of metallic parts at the converter housing is avoided.

Since the housing is installed steadily at the machine and must not be cleaned, there is no

danger of electrostatic charges of the plastic parts.

Page 8

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

1.3.3 Adjustment of measuring chains at the machine

Connect converter supply −24Vdc (+24V to ⊥). Fit connector of sensor to converter input.

Measure output level at pins OUT and ⊥.

Sensor PR 6422...PR 6425:

•Loosen the lock nut from the sensor.

•For mounting and turning the sensor remove the sensor cable to avoid twisting of the cable.

•Turn the sensor in the holder as long as the nominal distance between sensor head and

measuring target is reached and the voltmeter indicates the desired point on the

characteristical curve.

•For measuring shaft vibrations it is sufficient to adjust the sensor to an output value of 12V

resp. 10V ±1V.

•For static measurements a precise adjustment to one output value is required, the sensor

is preferably set to one of the three output levels of the CON 011:

→for symmetrical displacements around the centre point (see Fig 3, Ace) to −12V

(−4...−20V) or –10V (−2... −18V) ±0,05V (recommended procedure)

→for the measuring range minimum (= minimum distance) to –4V (−4...−20V) resp. –2V

(–2...−18V) ±0,05V for single−sided movements to greater distances (Fig 3, Amin)

→for the measuring range maximum (= maximum distance) to –20V (−4...−20V) resp.

–18V (–2...−18V) ±0,05V for single sided movements to smaller distances. (Fig 3,

Amax)

→or to any other value within the measuring range when different distances in both

directions must be measured.

•Fix the sensor by means of the lock nut. The maximum torque is:

PR 6422: 1Nm (0,1 kpm); PR 6423: 15Nm (1,5kpm);

PR 6424 and PR 6425: 100Nm (10kpm).

Sensor PR 6426:

If the distance between mounting flange and measuring target is not correct, it must be adjusted

by shifting the mounting flange (refer to Fig 7 of the operating manual PR 6422...PR 6426). In

order to achieve a precise adjustment, we recommend using a linear guided support e.g. a dove

tail bearing. Special solutions for the customer’s application can be designed and produced at

epro’s on request.

Adjust the distance between sensor and measuring target by shifting the support, until the

con−verter output signal has reached the required point of the characteristical curve.

•−12V (−4...−20V) or –10V (−2...−18V) ±0,05V for symmetrical displacements around the

centre point (see Fig 3, Ace) (recommended procedure)

•the measuring range minimum (= minimum distance) – 4 (−4...−20V) resp. –2V (–2...−18V)

for single sided displacements in direction to greater values (greater distances) (Fig 3, Amin)

Page 9

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

•the measuring range maximum (= maximum distance) −20V (−4...−20V) resp. –18V (–2...

−18V) for single sided displacements in direction to smaller values (smaller distances)

(Fig 3, Amax)

•or any other value within the measuring range if different displacements in both directions

are to be measured (unsymmetrical measuring ranges)

Fix the mounting flange in the correct position and secure screws and nuts to prevent them from

getting loose. The sensor must be mounted vertically to the measuring target.

1.3.4 Mutual influences of two measuring chains

If two eddy current measuring chains are mounted close together, it might happen that they

influence each other and generate invalid measuring results. This could e.g. happen with a shaft

vibration measurement by using two PR 6423 sensors, mounted in an 90°angle at a shaft with

≤100mm diameter, in case of measuring shaft displacements with two sensors in tandem

arrangements, with cone or double cone arrangements of two sensors.

In this case the carrier frequency must be slightly shifted at one of the converters by opening link

J1 (e.g. with side−cutting pliers). After this, the measuring chain must be calibrated anew,

refer to section 1.3.5.

1.3.5 Recalibration of the converter ( only necessary in special cases )

The adjustment is made with a micrometer calibration device, refer to Fig 9.

STOP

Before soldering at the converter, switch off the supply power.

!To change the output voltage range from –2...−18V to –4...−20V, link J2 must

be opened. This action does only change the voltage range without any

influence on linearity or adjustment of the measuring chain.

Opening of link J1 increases the oscillator frequency of the converter by approx. 250 kHz, a new

adjustment of the measuring chain according to the following description is necessary. The

position of the components is shown in Fig 2.

Adjustment sequence for PR 6422...6424 and PR 6426:

Adjustment steps: [...] values are valid for J2 open

1. Desolder resistances R 22 (gain factor, approx. 0...10kΩ) and R 23 (zero point, approx. 10kΩ

...200kΩ) and connect resistance decades to these positions. Set potmeter GAIN to centre

position. Resistance R24 depends on the sensor type:

PR 6422 / 6423 / 6425: 4,02kΩ, PR 6424: 5,62kΩ, PR 6426: 10kΩ.

Page 10

Direction for Use (GB) / Gebrauchsanleitung (D)

Converter CON 011

Direction for use

2. Set distance measuring target −sensor head to minimum gap (PR 6423: 500μm, refer to

operating manual PR 6422...6426, section 1.3.2)

3. Set output level to −2,00V [−4,00V] with potmeter R23.

4. Set distance to half the meas. range (+ minimum gap) (PR 6423: 1500μm)

5. Calculate difference between output voltage and −10,00 V [−12,00V] . Adjust output voltage

with R 22:

→at Uout > −10V [−12V] reduce it by twice the difference,

→at Uout < −10V [−12V] increase it by twice the difference.

Example: Measured value (centre of the range) Adjustment value (with R 22)

Uist > −10V: −10,50V −9,50V

Uist < −10V: −9,00V −11,0V

6. Repeat steps 2...5 till optimum accuracy is reached (1%).

7. Set distance to full range (+ minimum gap) (PR 6423: 2500μm)

→If the output voltage is −18,00V [−20,00V] (max. ±1%), the adjustment is correct, go

on with step 8.

→If the output voltage is < −17,8V [−19,8V] repeat the adjustment with a slightly reduced

minimum gap according to steps 2...6 (PR 6423: e.g. 490μm)

→With output voltages > −18,2V [−20,2V] repeat the adjustment with a slightly increased

minimum gap according to steps 2...6 (PR 6423: e.g. 510μm).

8. If the distances at −2V, −10V and −18V [−4, −12 and −20V] are within the tolerances, check

the linearity at intermediate steps −4 V, −6 V, −8 V.... .

9. Set the distance to the full range, and note the output voltage. The resistance values for R22

and R23, found with the decades, must now be soldered as fixed resistors.

After the resistors have cooled down, set the output voltage with potmeter GAIN to the value

you have just noted.

10. Check the linearity according to step 8.

1.4 Maintenance, Fault finding, Repair

1.4.1 Maintenance

During operation, sensors and converter do not require any maintenance. High sophisticated

materials and a rugged construction ensure undisturbed operation and a long life time, even in

harsh environments.

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