Flowserve IPS Detect Manual

IPS Detect
Document : OIM_FLS_IPS Detect
File :
OIM_FLS_IPS Detect_EN_14
Date / Version : 06.10.2016 / 14
Sterling SIHI GmbH
Lindenstraße 170 - 25524 Itzehoe - Germany
Telefon: [phone] / 771-01 -
Fax [phone] / 771-274
Created 06.10.2016 Kortstock
Verified 06.10.2016 Lott
Released 06.10.2016 Dr. Kösters
Installation & Operating
Instructions
IPS Detect
(vibration sensor and condition monitoring for pumps)

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Content
1 Safety instructions ..................................................................................................... 3
2 Prescribed Operation of IPS Detect .......................................................................... 4
2.1 Product code ......................................................................................................... 5
3 Mounting the IPS Detect ............................................................................................ 6
3.1 Mounting details .................................................................................................... 6
4 Electrical connection ................................................................................................. 7
4.1 Wiring in the housing ............................................................................................. 7
4.2 Electrical connection check ................................................................................... 9
5 Operation IPS Detect ................................................................................................ 10
5.1 Configuration ....................................................................................................... 10
5.1.1 Configuration vibration velocity ........................................................................ 12
5.2 Calibration condition monitoring .......................................................................... 13
5.2.1 Calibration condition monitoring with push button ........................................... 14
5.2.2 Calibration with IPS Vibrosoft software ............................................................ 17
5.3 Monitoring operation ........................................................................................... 19
5.3.1 Vibration velocity .............................................................................................. 19
5.3.2 Condition monitoring ........................................................................................ 19
6 Trouble-shooting ...................................................................................................... 20
7 Maintenance and repair ........................................................................................... 21
7.1 Cleaning .............................................................................................................. 21
7.2 Repair .................................................................................................................. 21
7.3 Exchange ............................................................................................................ 21
7.4 Software history .................................................................................................. 21
8 Technical data .......................................................................................................... 22
9 Certification and approvals ..................................................................................... 24
9.1 CE-mark, Declaration of conformity .................................................................... 24
9.2 EU Type Examination Certificate ........................................................................ 27
9.3 Certification of Conformity ................................................................................... 29
10 Accessories .............................................................................................................. 33
10.1 Cooling element .................................................................................................. 33
10.2 Software .............................................................................................................. 34
10.2.1 IPS Vibrosoft software ................................................................................. 34
10.2.2 EDD for Siemens and Emerson ................................................................... 34
10.2.3 DTM for FDT frame applications .................................................................. 34
10.3 IPS DataUSB ..................................................................................................... 35

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1 Safety instructions
The IPS Detect system has been designed to operate safely and in accordance with the
current regulations and EU standards.
This device must be installed and commissioned by personnel that are suitably qualified to
local and national electrical and/or safety regulations. Importantly, the device must be
installed and operated in accordance with this manual & respective instructions.
Failure to install and operate the IPS Detect module in accordance with the instruction
manual will invalidate any warranty, although your statutory rights will remain unaffected.
Also, it should only be used for applications in which its manufacturer, Flowserve Sterling
SIHI GmbH, prescribes.
Modifications and/or repairs to the device should not be undertaken unless expressly
stated and explained within this manual. Failure to comply with this instruction may cause
serious harm to site personnel and will invalidate any warranty. Should any fault occur
that is not described in this manual, then the manufacturer should be contacted for
guidance and the device taken out of use.
Caution! Explosion hazardous area
Integrated within this manual is a section that covers the use of the device in
Ex-hazardous areas where an explosion could occur. In such Ex-rated
circumstances, it is vital that the respective section of this manual is
observed.
Please note EN / IEC 60079-14 along with other relevant national,
International, and European standards, directives, and regulations.
Mounting and connection within an Ex rated area must be done only by
suitably qualified personnel.

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2 Prescribed Operation of IPS Detect
The IPS Detect module is a remote sensor that is easily attached to the pump.
The sensor is an ideal solution for vibration velocity measurement in accordance with
DIN/ISO 10816, 5199, 9905. The unit also monitors the condition of the pump at
frequencies in excess of those cited within DIN/ISO10816 (sometimes known as noise) in
order to predict long(er) term failure through process upset that can lead to vibration and
consequent failure.
Monitoring of these parameters allows the user to optimise Life Cycle Cost by controlling
the effects caused by bearing failure, imbalance, misalignment, detrimental pipe-work
forces, and cavitation, etc.
Simply put, the sensing module compares actual running values with a pre-defined
threshold in order to notify the user about any alarming conditions. There are two ways to
get this information. Firstly, there is an LED display on the module with a traditional Green,
Yellow, and Red lamp arrangement. Secondly, the 4-20mA signal can be connected to
site-standard control modules.
With the same interface, digital communication can be achieved through an FSK-Modem
(FSK STERLING link) for further information and calibration (HART
®
compatible modems
can be used). A software tool is also available for use with a WINDOWS
®
operated PC.
Features:
Output of vibration velocity (RMS 10Hz 1kHz; 0 20 mm/s ) according to DIN/ISO
10816, 5199, 9905
Condition monitoring up to 5.6 kHz (normal / unacceptable operating mode)
4 ... 20 mA interface
Installation up to 160 °C surface temperature by use of cooling elements
LED display green, yellow and red
Digital communication through FSK* modem (HART
®
compatible) for additional
information or the professional software IPS Vibrosoft
EDD driver for Siemens SIMATIC PDM and Emerson AMS
DTM driver for FDT frame applications
Integrated error memory
Simple mounting on the pump
Requires no experience of vibration analysis technology
II 2G Ex ia IIC T4 Gb
IECEx Ex ia IIC T4 Gb
* FSK Frequency Shift Keying

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2.1 Product code
e.g. IPS Detect 100 C1 P6 H K Ex
Type / Function (software) Pump sensor
100
Design Compact
C1
Housing/casing Polyamid PA6
P6
Output interface 4..20 mA HART
H
Connectivity Terminal block
K
Approval For non hazardous areas
00
Ex-ia
Ex
Name plate
II 2G Ex ia IIC T4 Gb
ATEX Labeling
1 Device group 2 Category
3 Area (gas or dust) 4 Electrical type of protection
5 Explosion group 6 Temperature Class
7 Equipment Protection Level (EPL)
IECEx Ex ia IIC T4 Gb
IECEx Labeling
1 Electrical type of protection 2 Explosion group
3 Temperature Class 4 Equipment Protection Level (EPL)
1 2 4 5 6 7 3
1 2 3 4

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3 Mounting the IPS Detect
3.1 Mounting details
The recommended mounting position for the IPS Detect sensor is shown in the document
FLS_IPS Detect the document on
the IPS Detect CD.
The sensor is mounted with a single M8 x 60mm [VA2] screw at the pump.
Flowserve SIHI volute casing pumps with a bearing bracket are generally prepared with
two standard M8 tapped holes. For other pumps, or if no M8 threaded hole available, an
M8 adaptor can be used which is be bonded to the surface with a suitable metal adhesive
glue. This eliminates the need to drill a fixing hole. The M8 adapter is included in delivery.
The metal adhesive should be suitable for condition of use.
Examples for metal adhesive: Pattex Stabilit Express, Henkel
Best-Quick Mix 801, Best Klebstoffe
SikaFast-5215, Sika
Picture: Mounting at bearing bracket Picture: adaptor piece with metal adhesive

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4 Electrical connection
Please note before connecting the sensor:
- The supply voltage must match the associated voltage as specified on the nameplate.
Warning!
- If the device is to be installed in an explosion hazardous (Ex) rated area, then all
associated national standards, directives, and safety instructions must be adhered to
for the appropriate area. Specifically, the correct type of cable gland must be
employed.
4.1 Wiring in the housing
1. Undo the cover screws in order to remove housing cover and gasket.
Picture: Sensor IPS Detect
2. Strip the ends away from the protective covering of the supply cable as shown
below.
Picture: Supply cable
50 mm
10 mm

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+-
3. Insert the cable through the cable gland so that the ends easily reach the
connection terminals.
Picture: Cable ends
4. Connect the cable to the terminals. To open the terminal clamps use a screwdriver
to press open and then insert the cable ends.
Picture: Connection description Picture: Open the clamp
Caution! Explosion hazardous area
Disconnect the electrical supply before installing the device.
Ensure that the bare cable ends cannot make contact with any other part of
the device other than the terminals.
Ensure that the device is kept free from moisture and foreign bodies.

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5. Pull back the cable in order to remove any excess from within the terminal head.
Subsequently tighten the cable gland.
Picture: Connected cable Picture: Cable inside of the housing
6. Replace the gasket ensuring that it does not cover the LEDs and then tighten with
the two screws.
Picture: Sensor gasket
4.2 Electrical connection check
Perform the following checks after completing electrical installation of the device.
Is the connection in accordance with the description?
Is the cable gland firmly tightened?
Is the fitting of the gasket correct and the LEDs clearly visible?
Are the housing cover screws tightened correctly?
-up once the electrical supply is (re) connected.

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5 Operation IPS Detect
IPS Detect measures the vibration velocity of the pump in accordance with DIN/ISO
10816, 5199 and 9905 for preventive maintenance.
Furthermore, an optional condition-monitoring element can be simply activated in order
to monitor vibration up to 5.6kHz. For this condition monitoring to be possible, however,
the sensor must be calibrated beforehand (see topic 5.2). Subsequently, the sensor
compares actual values of the vibration Third-octave spectrum (up to 5.6 kHz) with pre-
defined alarm thresholds. Consequently, site personnel can be informed if these values
are exceeded.
5.1 Configuration
For most applications, the sensor is sent out already configured without the need to make
any changes. Should the user want to make any changes to the pre-set parameters,
however, then such configuration is possible with an FSK-modem (HART -Modem) with
the IPS Detect EDD and DTM framework software tools or with IPS DataUSB
(SIHIdataUSB) coupled to IPS Vibrosoft software. See also page 30.
Picture: Configuration over IPS DataUSB (SIHIdataUSB) and IPS Vibrosoft Software

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Picture: Configuration over FSK-Modem (HART -Modem) and EDD/DTM via FDT frame application
Caution! Explosion hazardous area
If FSK-Modem is to be installed in an explosion hazardous (Ex) rated area, then all
associated national standards, directives, and safety instructions of the FSK-Modem
must be adhered to for the appropriate area

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5.1.1 Configuration vibration velocity
Measurement of the vibration velocity (RMS) enables the condition of the pump to be
determined. This gives an indication of the Mechanical wear within the pump unit.
Examples for causes of high vibration velocity:
Mechanical wear
Imbalance
Misalignment
Excessive force from the pipe-work
Vibration Velocity Settings:
Parameter standard setting possible setting
Measuring range [mm/s] 0...10 1.) 0...10
2.) 0...20
Warning LED [mm/s] 3,5 0...20
Failure LED [mm/s] 4,5 0...20
Changes to the standard values can be saved and loaded onto the sensor through the use
will be displayed in the configuration software.

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5.2 Calibration condition monitoring
Optionally, the IPS Detect can detect changes in the vibration Third-octave spectrum by
comparing actual values with calibrated threshold values. Therefore, the sensor must be
calibrated to the pump installation. Cavitation, misalignment, imbalance together with
other wrong operation modes can subsequently be easily detected.
The sensor used thresholds (RMS vibration acceleration m/s²) from the Third-octave
reference ) refer to the calibrated values and are described as signal multiplication.
After the calibration the sensor compares the actual values with specified alarm thresholds
and informs if the values are exceeded (see topic 5.3.2).
Note:
During calibration the vibration velocity is monitored in order to check if the pump is
operating in an acceptable condition. Should the vibration velocity exceed the threshold
value, then a warning (yellow LED display see topic 5.1.1) light is displayed. This would
cause the calibration to be cancelled and the system should be checked before
continuing. Upon successful calibration, subsequent mechanical manipulation of the
sensor and/or pump is no longer possible.

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5.2.1 Calibration condition monitoring with push button
5.2.1.1 Starting calibration with the push-button
1. Start the pump and wait until normal operating conditions have been reached.
2. Loosen the screws and remove the housing-cover and gasket. Depress and hold
the button down for approximately 3 seconds until red and yellow LED flash
alternatively.
3. Release the button until green and yellow LED flash alternately.
4. To commence (and confirm) the calibration process; within 1 minute depress the
button once again for approximately 3 seconds until the green, yellow, and red
Caution!
If calibration is not commenced at this point, then the sensor changes to measuring
mode and all calibration data is deleted. Consequently, the condition monitoring
element is deactivated.
5. The calibration must last at least 60 seconds. The calibration cannot be
interrupted within this time. The maximum calibration time is not limited and can be
of indefinite duration, until all normal operation conditions are detected.
It is recommended to calibrate the sensor at least 10 minutes.
If the pump operates with different motor speeds, it is recommended to adjust the
motor speed manually operated and calibrate the sensor for each third-octave-band
at least 5 minutes. During the calibration the speeds of the pump can be operated
one after another. It is also possible to stop the calibration and to start once again.
In this case the calibration data will be complemented.
Third-Octave-
Band [Hz]
lower
speed [RPM]
centre speed
[RPM] for calibration
upper
speed [U/min]
CF 13 600 780 840
CF 16 840 980 1080
CF 20 1080 1200 1320
CF 25 1320 1500 1680
CF 32 1680 1920 2100
CF 40 2100 2400 2640
CF 50 2640 3000 3360
CF 63 3360 3780 4200
CF 80 4200 4800 5280
Example:
Pump is operated in speed from 2000 RPM up to 3600 RPM.
The calibration should be operated in the following speed steps:
2000 U/min minimal speed
2400 U/min
3000 U/min
3600 U/min maximal speed

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6. To stop the calibration process, depress the push button for approximately 3
seconds until the green LED flashes.
7. At the end of calibration, the sensor changes to the condition-monitoring mode. The
calibrated reference values are also saved even if the power supply is
disconnected.
These calibrated values can now be compared with actual readings. Importantly,
the maximum value, which has been measured during the calibration phase, is
saved.
Condition monitoring mode is now activated.
Picture: Push button sensor
Caution! Explosion hazardous area
Ensure that the screwdriver cannot make contact with other parts of the
device other than the terminals.
Ensure that the device is kept free from moisture and foreign bodies.

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5.2.1.2 Deactivating the condition monitoring mode with the push-button
1. Loosen the screws and remove housing-cover and gasket. Depress the push-
2. Release the push-button until the green and yell
3. After approximately 1 minute the sensor will change to measuring mode and any
existing calibration data is deleted.
The condition monitoring is then deactivated.

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5.2.2 Calibration with IPS Vibrosoft software
5.2.2.1 Starting calibration with the IPS Vibrosoft software
1. Start the pump and wait until normal operation conditions are reached.
2. Start up the IPS Vibrosoft software and wait until is displayed.
3. Click the button At the sensor the green, yellow and red LED
flash alternately. The calibration must last at least 60 seconds. The calibration
cannot be interrupted within this time. The maximum calibration time is not limited
and can be of indefinite duration, until all normal operation conditions are detected.
It is recommended to calibrate the sensor at least 10 minutes.
If the pump operates with different motor speeds, it is recommended to adjust the
motor speed manually operated and calibrate the sensor for each third-octave-band
at least 5 minutes. During the calibration the speeds of the pump can be operated
one after another. It is also possible to stop the calibration and to start once again.
In this case the calibration data will be complemented.
Third-Octave-
Band [Hz]
lower
speed [RPM]
centre speed
[RPM] for calibration
upper
speed [U/min]
CF 13 600 780 840
CF 16 840 980 1080
CF 20 1080 1200 1320
CF 25 1320 1500 1680
CF 32 1680 1920 2100
CF 40 2100 2400 2640
CF 50 2640 3000 3360
CF 63 3360 3780 4200
CF 80 4200 4800 5280
Example:
Pump is operated in speed from 2000 RPM up to 3600 RPM.
The calibration should be operated in the following speed steps:
2000 U/min minimal speed
2400 U/min
3000 U/min
3600 U/min maximal speed
4. Click the button .
5. Subsequently, the sensor changes to the condition-monitoring mode. The
calibrated reference values are saved even if the power supply is disconnected.
These calibrated values can now be compared with actual readings. Importantly,
the maximum value, which has been measured during the calibration phase, is
saved. Condition monitoring mode is now activated.

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5.2.2.2 Deactivating the calibration condition monitoring using IPS Vibrosoft
software
1. Click the button .
2. Wait until the green display behind the button is then switched off. The sensor
changes to measuring mode and exist calibration data is deleted. The condition
monitoring is deactivated.

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5.3 Monitoring operation
You can simply check the pump operation by taking a quick glance at the pump and
viewing the LED display.
Online detection is possible with a 4-20mA interface directly connected to conventional
control equipment.
5.3.1 Vibration velocity
LED Display
Normal operation Warning Failure
failure
warning
normal
failure
warning
normal
failure
warning
normal
4-20mA Interface
Measurement range Interface display Calculation
Vibration velocity 0...10 mm/s 10...20 mA v
eff
[mm/s] = i[mA] - 10
Vibration velocity 0...20 mm/s 10...20 mA v
eff
[mm/s] = 2 * i[mA] 20
CM-mode
[CM = Condition Monitoring]
9,10,11 and
12 mA 9 mA (flashing)
CM-TRUE
10 mA normal
11 mA warning
12 mA failure
5.3.2 Condition monitoring
LED Display
Normal operation
( FALSE)
Condition monitoring
(TRUE)
failure
warning
normal
failure (flashing)
warning
normal
4-20mA Interface
Condition monitoring Interface display
FALSE Vibration velocity (see topic. 5.3.1)
TRUE 9 mA

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6 Trouble-shooting
Failure during operation and/or measurement modes are displayed as follows:
-
Green, ye
electronic failure / sensor failure
The user needs to check that the power supply has been adequately connected before the
system was started.
Error Resolution Personnel
LED display no system
check
[running light
LED]
- Power supply [Vcc>=11V]
- Check the polarity of the cable
Operator
No LED display - Check the polarity of the cable
-
No software
Operator
Service
...