SKF IMx-W User manual

User Manual
Copyright 2016 by SKF Group
All rights reserved.
SKF Condition Monitoring Center – Luleå
Aurorum 30, 977 75 Luleå, Sweden
Telephone: [phone], Fax: [phone]
SKF Multilog On-Line
System IMx-W
User Manual Part No. 32146100-EN
Revision T
WARNING! Read this manual before using this product. Failure to follow the
instructions and safety precautions in this manual can result in serious injury, damage
to the product, or incorrect readings. Keep this manual in a safe location for future
reference.

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© SKF 2016
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right to alter any part of this publication without prior notice.
Patents: US 4,768,380 • US 5,633,811 • US 5,679,900 • US 5,845,230 • US 5,852,351 •
US 5,854,553 • US 5,854,994 • US 5,870,699 • US 5,907,491 • US 5,992,237 • US 6,006,164 •
US 6,124,692 • US 6,138,078 • US 6,199,422 • US 6,202,491 • US 6,275,781 • US 6,301,514 •
US 6,437,692 • US 6,489,884 • US 6,513,386 • US 6,633,822 • US 6,789,025 • US 6,792,360 •
US 7,103,511 • US 7,697,492 • WO/2003/048714
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SKF Multilog On-Line System IMx-WTOC - 1
User Manual
Table of Contents
Introduction 1
Important Messages .................................................. 1-1
System Overview........................................................ 1-2
IMx-W, WindCon Unit................................................ 1-3
LED Indicators............................................................. 1-4
Installation 2
Safety and Requirements ......................................... 2-2
Scenario ....................................................................... 2-2
Vibration Sensor Cable.............................................. 2-3
Other Sensor Cables.................................................. 2-3
Supply Cable ............................................................... 2-3
Cable Glands ............................................................... 2-4
Mains Power ............................................................... 2-4
External Mains Out .................................................... 2-6
Communication Cable ............................................... 2-8
Data Communication................................................. 2-8
Ethernet....................................................................... 2-8
Unit Configuration 3
DIP Switches and Jumpers....................................... 3-1
Analogue In 1 to 16 and Analogue
Isolated 15, 16 ........................................................ 3-2
Digital/Tacho .............................................................3-19
Relay Drivers.............................................................3-23
CAN-bus ....................................................................3-25
RS485/Modbus.........................................................3-26
Network Configuration............................................3-27
Network Load ...........................................................3-29
IMx-W Time ..............................................................3-30
Hardware Maintenance 4
Performance over Time............................................ 4-1
Dismantling IMx-W.................................................... 4-1
Assembling IMx-W..................................................... 4-6
Replacing a Burnt Fuse in IMx-W........................... 4-6

TOC - 2 SKF Multilog On-Line System IMx-W
User Manual
Electrical Waste 5
Technical Data 6
Environmental ............................................................ 6-1
Power Supply.............................................................. 6-1
Analogue Inputs ......................................................... 6-1
Digital Inputs............................................................... 6-2
Outputs ........................................................................ 6-2
Analogue Measurement............................................ 6-2
Digital Measurement ................................................. 6-2
Signal Processing....................................................... 6-3
Interface....................................................................... 6-3
Data Processing ......................................................... 6-3
Miscellaneous.............................................................. 6-4
Quality Control............................................................ 6-4
Troubleshooting Guide 7
Problems and Symptoms ......................................... 7-1
Component Check ...................................................... 7-4
Summary 8
Switch Settings........................................................... 8-1
LED Status .................................................................. 8-3
Wire Connections....................................................... 8-3
IMx-W, WindCon Drawings 9
Stainless Steel Cabinet Drawings ........................... 9-1
Painted Steel Cabinet Drawings.............................. 9-4
Connectors and Switches Location......................... 9-7
Limited Warranty A
Index

SKF Multilog On-Line System IMx-W1 - 1
User Manual
1
Introduction
Important Messages
The following messages are important information which require special care in order
to have a safe and reliable IMx-W system.
Important messages, instructions and information in this manual must be
carefully followed. Otherwise, harm might occur to equipment and/or personnel.
In order to fulfill fire enclosure requirements the following must be ensured:
-The cabinet must always be mounted using all four supplied mounting
brackets.
-All unused cable ways must be closed with the supplied blind plugs.
-All cable glands and blind plugs must be made of material with fire protection
V-1 or better.
Important messages related to mains power (see Mains Power section as well):
-In some countries, you have to be certified in order to connect an IMx-W to the
power grid
-Make sure that the power is disconnected before the installation.
-Mains cable must be properly fixed with a cable gland to prevent the cord from
strain, twist or move. See Cable Glands section as well.
-In order to prevent a hazardous event, mains cable Neutral (N) and Line (
∼
)
wires must be secured together with a cable tie (for example, a nylon cable tie
CV-100K) close to the mains power connector.
-For permanently connected IMx-W, an external all pole power switch must be
installed in order to be able to disconnect the IMx-W from the mains power
grid. The switch must be labeled "IMx-W” or similar. On/Off position must be
clearly marked. The switch must be located close to the IMx-W, within
operator's easy reach.

Introduction
System Overview
1 - 2 SKF Multilog On-Line System IMx-W
User Manual
Before the use of external mains output, be sure to read External Mains Out
section carefully.
-All externally provided equipment must be evaluated individually and approved
together with IMx-W unit regarding EMC and safety requirements (CE and
ETL). Always consult SKF CMC Luleå before the usage of the external mains
output.
System Overview
IMx-W, WindCon is a part of the SKF Multilog On-line System product range. IMx-W,
WindCon is designed to be used in the wind power industry. In conjunction with SKF
@ptitude Observer Monitor Service and SKF @ptitude Observer client, the IMx-W,
WindCon forms a complete and flexible on-line turbine condition monitoring system
tool. This enables trending, analyzing and preventing of catastrophic machine failures.
Figure 1 - 1.
System Overview of IMx-W, WindCon On-line System.
The figure above illustrates how IMx-W, WindCon units are linked together in a network
that is connected via LAN to @ptitude Observer Monitor Service. The @ptitude Observer
Monitor Service in turn, can be connected to e.g. LAN network making it possible for
several of @ptitude Observer clients to link to this network.
@ptitude Observer clients can also be installed on the same computer as the @ptitude
Observer Monitor Service login software. Through a general interface known as ODBC
(open database connectivity), it is possible to link the login computer and @ptitude
Observer Monitor Service to an existing database for an existing control or processing
system, if desired. The @ptitude Observer Monitor Service, @ptitude Observer clients
and the database can be separated from each other as long as they are on the same
network where ODBC calls can travel freely.
It is also possible to connect different types of on-line units in the same network, for
example, IMx-W, WindCon together with other MasCon/IMx systems.

Introduction
IMx-W, WindCon Unit
SKF Multilog On-Line System IMx-W1 - 3
User Manual
IMx-W, WindCon Unit
Figure 1 - 2.
IMx-W, WindCon Unit.
IMx-W, WindCon Unit
The IMx-W, WindCon unit is a modern industrial product designed for on-line vibration
monitoring.
•The unit is highly environmentally resilient, and is specially adapted to withstand
machines where damage might develop and/or where periodical monitoring is
difficult to carry out.
•The IMx-W, WindCon unit should be mounted inside a nacelle, onto a vertical
structure (e.g. wall), as far away as possible from vibrating or high voltage objects.
•There are two different types of cabinet for IMx-W, WindCon unit; Painted steel
cabinet and Stainless steel cabinet. The type of cabinet is chosen by the customer
upon purchasing of the unit. Refer to IMx-W, WindCon Drawings for the drawing of
cabinets.
Analogue Channels
•Up to 16 analogue channels can be connected to each IMx-W, WindCon unit.
Digital Channels
•Up to 2 digital sensors can be connected to each IMx-W, WindCon unit.
•The digital inputs can interface with all standard types of digital inputs/sensors,
including trigger level of 5 to 14 V.
Network Configuration
•The IMx-W, WindCon is provided with a default IP address 10.0.0.101 and server
IP address 10.0.0.1.

Introduction
LED Indicators
1 - 4 SKF Multilog On-Line System IMx-W
User Manual
•However, if there is a need to change the IP address within the range of 10.0.0.X, it
can be done by turning the HEX rotary switches on the main board. It will change
the X value from 101 to 199.
•Furthermore, if there is a need to change the entire IP address, use the On-line
Configurator tool which is provided with @ptitude Observer. Refer to Network
Configuration.
•All initiation parameters such as IP address, IMx identification number, etc. are
stored first in a separate configuration file, then transferred to the IMx-W, WindCon
memory through the serial interface. These are retained in the events of power
losses, so that the IMx-W, WindCon can start automatically when the power
returns.
Storage Capacity
Each IMx-W, WindCon unit has 8 MB flash memory used for the following:
•2 MB for firmware, configuration files, etc.
•2 MB for trend value buffer
About 13 000 vibration trend values can be buffered
Speed and process data use half the space of vibration
•4 MB for spectra and time signal buffer
About 250 spectra using 1 600 lines with phase and time signal can be
buffered
If you use more lines, the number of spectrum is reduced.
If you use less lines, the number of spectrum is increased
•When the buffer gets full, the oldest data is thrown away.
LED Indicators
The IMx-W, WindCon card has two rows of LED indicators on the front panel as shown
below:
Figure 1 - 3.
LED Indicators on the Front Panel.
•Yellow LEDs Ch1 to Ch16 represent the sixteen analogue input channels.
•Green LED CON indicates the status of connection to the @ptitude Observer
Monitor Service.
•Green LED SYS indicates the system status.

Introduction
LED Indicators
SKF Multilog On-Line System IMx-W1 - 5
User Manual
•Red LED ALR indicates measurement alarms/warnings.
•Red LED ERR indicates system error(s).
•Green LEDs RS485, RS232 and CAN indicate receive and transmit communication
activity (not in use).
•Yellow LEDs DigIn1 and DigIn2, also known as Tacho1 and Tacho2, indicate the
status of digital inputs.
The following summarizes the behavior of each LED indicator described above, and its
corresponding status.
Table 1-1: Status of LED indicators
LED Indicator
Behaviour
Description
Ch1–Ch16
On
Off
Slow flash
Fast flash
Channel configured & running
Channel not configured
Channel cable fault
Channel warning/alarm
CON
On
Off
Slow flash
Fast flash
Connected
Not connected
Trying to connect
Server forced connection
SYS On
Flash
System configured & running
System start-up
ALR
On
Off
Flash
Warning indicator
No alarm
Alarm indicator
ERR
On/Flash
System fault
RS232
Off
Not in use
RS485
Off
Not in use
CAN
Off
Not in use
DigIn1, DigIn2
On
Off
Flash
Input logic one
Input logic zero
Input toggle
If the boot code does not discover any errors or is manually halted, the main
measurement software will be started. While the main software is reading the
configuration and setting up the system, the SYS LED is flashing and each channel's
LED is lit as it gets defined. When the system configuration is done, the SYS LED will
stop flashing but will stay on. There is a thirty seconds delay to ensure that the sensors
are producing valid results before the system starts measuring.
If an alarm occurs, the LED for the actual channel will start flashing. Slow flash of a
channel LED indicates the channel cable fault where as the fast flash indicates a
warning/alarm. In addition, the red LED ALR (alarm) will also light up. However, this
only works after the IMx-W, WindCon has been configured and collected some data for
measurements, because only then alarms can be checked according to the alarm and
danger levels.

Introduction
LED Indicators
1 - 6 SKF Multilog On-Line System IMx-W
User Manual
RS485, RS232 and CAN LEDs are not in use.
Digital In 1 and Digital In 2 indicate the status of digital inputs. On indicates logical one
(1) and off indicates logical zero (0). Whereas, flash indicates input toggle.

SKF Multilog On-Line System IMx-W2 - 1
User Manual
2
Installation
Figure 2 - 1.
IMx-W, WindCon Front Panel Inside of a Cabinet.
The installation of a IMx-W, WindCon system must be carried out according to the
instructions and advice given in this manual. Any deviation from these directions can be
made only after consulting with the SKF IMx-W, WindCon team or personnel from SKF
Condition Monitoring Center Luleå. Otherwise, the installation will not be approved and
the start-up of the system can not be carried out until the errors are rectified.
Important - Installation errors which require the involvement of SKF Condition
Monitoring Center Luleå personnel in order to rectify the start-up of the system,
might be debited.

Installation
Safety and Requirements
2 - 2 SKF Multilog On-Line System IMx-W
User Manual
Safety and Requirements
It is important to assess and evaluate the current site for safety instructions and
stipulations.
During the installation work, make oneself acquainted with the valid safety stipulations
for the specific turbine. Different types of wind turbines can have different safety
hazards and safety instructions. In all cases, read the instructions carefully and act
accordingly.
If the IMx-W, WindCon vibration sensors are to be mounted with glued pads, the
temperature must be observed. The glue used for these pads, or studs will not solidify
below 16 ºC (60.8 ºF).
Note that, even when ambient temperature is well below 16 ºC (60.8 ºF), installations
can still take place with glue by using the heat of the turbine. In such a case, make sure
the wind turbine has been running until the installation starts. Usually, the gearbox
provides enough heat for several hours after the turbine has been stopped which
guarantees a solid glue connection. However, when in doubt, measure the temperature.
An IMx-W, WindCon unit contains circuit boards that are static sensitive. Therefore, use
appropriate precautions to prevent ElectroStatic Discharge (ESD) when handling circuit
boards.
The following are some of the ways to prevent ESD:
•Use an ESD wrist strap when handling circuit boards
•Use a grounding mat when handling circuit boards
•Use correct packaging materials such as antistatic bags when transferring circuit
boards
Important - IMx-W, WindCon unit contains circuit boards that are static
sensitive. Therefore, use appropriate precautions to prevent ElectroStatic
Discharge (ESD) when handling circuit boards.
Scenario
It is also important to assess and evaluate the current site where the system is to be
installed.
Draw a plan on a piece of paper to demonstrate, how you would like this installation to
look like after it is completed, and then consider if it can be achieved. Among other
things, consider lengths of cables, where electrical power to the IMx-W, WindCon units
can be connected, where the @ptitude Observer Monitor Service should be installed and
positioned and who should analyse the data. Good and thorough planning is the basis
for a successful solution and installation.
Make a detailed layout of the equipment, the network, and distances between
components. Include specifically the IMx-W, WindCon unit, the SQL server computer,
the @ptitude Observer Monitor Service computer and all hubs/routers in the network.

Installation
Vibration Sensor Cable
SKF Multilog On-Line System IMx-W2 - 3
User Manual
Specify each component’s network configuration such as IP addresses and subnet mask.
Application engineers can not help you if you do not have these information up front.
Note that a CAT5/6 twisted pair (TP) Ethernet cable has maximum working distance of
100 m. If longer cable lengths are needed, fibre optic cables may be used along with
needed converters, such as converters for fibre optic to CAT5 Ethernet and vice versa.
When SKF supplies the GPRS router, it makes use of a "lifeline" connection to an SKF
server at IP: 80.126.94.126. This is an integral part of the application solution.
Important - Failure of this communication path will force the GPRS router to
reboot itself constantly and can hamper the success of the application. This is
especially valuable to consider when the GPRS forms a part of the customers
internal IP network (VPN). In such case, SKF must be informed of this before
ordering the GPRS, so that SKF can disable the lifeline functionality of the GPRS
router.
Vibration Sensor Cable
When routing a vibration sensor cable, it is important that the cable is firmly fixed. The
cable must not be allowed to vibrate or oscillate, since this effects the capacitance of the
cable, and thereby the measurement result.
The sensor cable may not be routed or bundled together with supply cables, which
generate strong magnetic fields, such as supplies to generator, yaw and pitch-motor
drives, radiators, electronic frequency converters, etc.
Important - In general, all cables must be routed as far away as possible from the
high voltage electrical cables. If this cannot be done, care should be taken to use
high quality shielded cables.
Other Sensor Cables
To connect IMx-W, WindCon to other sensors, such as speed sensor, displacement
sensor, pressure sensor, data communication RS485, etc, use the following:
•Shielded, twisted pair 2 x 0,5 mm2(FKAR-PG 1 x 2 x 0,50, DUE 4002 or
corresponding), with minimum voltage requirement 300 V and minimum
temperature −40 ºC (
− 40 °F).
Supply Cable
To connect IMx-W, WindCon to 240 VAC or 120 VAC, use the following or better:
•FKLK 3 x 1,5 mm2(16 AWG) or EKLK 3 x 1,5 mm2(16 AWG) or corresponding,
with minimum voltage requirement 300 V and temperature range of −40 to
+70 ºC (
− 40 to +158 °F).
It is required that the IMx-W, WindCon must be connected to protective ground/earth
(PE). Refer to Mains Power for attaching power cable to the mains power or power grid.

Installation
Cable Glands
2 - 4 SKF Multilog On-Line System IMx-W
User Manual
Important - The cross section area of the PE wire must be equal or greater than
the cross section area of the power wires. The PE wire should be color labeled
green/yellow. However, in some countries, other cable requirements may apply.
Important - Mains cable must be properly fixed with a cable gland to prevent the
cord from strain, twist or move. See Cable Glands section as well.
Cable Glands
The shield of IMx-W, WindCon sensor cable should be cut off at the entrance of the
cabinet and be shielded off from the cabinet by an isolating cable gland.
Important - All unused cable ways must by closed with the supplied blind plugs. All
cable glands and blind plugs must be made of material with fire protection V-1 or
better.
Mains Power
In order to attach power cable to the mains power grid, follow the direction below.
•First connect the green-yellow wire to the protective earth (PE) rail.
•Connect another green-yellow wire from PE-rail to mains PE terminal.
•Connect the blue wire to the neutral (N) terminal.
•Connect the brown or black wire to the line (∼) terminal.
Figure 2 - 2.
Mains Power Connection.

Installation
Mains Power
SKF Multilog On-Line System IMx-W2 - 5
User Manual
Refer to the tables in Wire Connections and the drawing of Connectors and Switches
Location for connectors naming and location details.
Power inlet fuses are slow blow 2A (T2A 250 V, 5 x 20 mm) and mounted internally on
the location labeled as F1 and F2. Refer to Connectors and Switches Location.
Refer to Power Supply in Technical Data section for power requirements.
Important - In some countries, you have to be certified in order to connect an IMx-
W to the power grid.
Important - Make sure that the power is disconnected before the installation.
Important - For permanently connected IMx-W an external all pole power switch
must be installed in order to be able to disconnect the IMx-W from the mains
power grid. The switch must be labeled "IMx-W” or similar. On/Off position must be
clearly marked. The switch must be located close to the IMx-W, within operator's
easy reach.
Figure 2 - 3.
Mains Power Terminal (See also the figure below for the cable tie arrangement).

Installation
External Mains Out
2 - 6 SKF Multilog On-Line System IMx-W
User Manual
Figure 2 - 4.
Mains Cable Wires Secured with a Cable Tie.
Important - In order to prevent a hazardous event, mains cable Neutral (N) and
Line (
∼
) wires must be secured together with a cable tie (for example, a nylon cable
tie CV-100K) close to the mains power connector.
External Mains Out
Important - All externally provided equipment must be evaluated individually and
approved together with IMx-W unit regarding EMC and safety requirements (CE
and ETL). Always consult SKF CMC Luleå before the usage of the external mains
output.
In order to attach power cable to the external equipment via the external mains out
connector, follow the direction below.
•First connect the green-yellow wire from the external equipment to the protective
earth (PE) rail.
•Connect another green-yellow wire from PE-rail to external mains out PE terminal.
•Connect the blue wire to the neutral (N) terminal.
•Connect the brown or black wire to the line (∼) terminal.

Installation
External Mains Out
SKF Multilog On-Line System IMx-W2 - 7
User Manual
Figure 2 - 5.
External Mains Out Power Connection.
The maximum allowed external mains output is 0,35 A.
The cable should have the following specification or better:
•FKLK 3 x 0,75 mm2(19 AWG) or EKLK 3 x 0,75 mm2(19 AWG) or corresponding,
with minimum voltage requirement 300 V and temperature range of -40 to +70 ºC
(
− 40 to +158 °F).
Important - In order to prevent a hazardous event, external mains out cable
neutral (N) and line (
∼
) wires must be secured together with a cable tie (for
example, a nylon cable tie CV-100K) close to both the external mains out connector
and the external equipment mains connection.
Important - External mains out must be connected according to the above
information to avoid causing harm to equipment or personnel.
Important - External mains output must be carefully used to secure lightning
protection.

Installation
Communication Cable
2 - 8 SKF Multilog On-Line System IMx-W
User Manual
Communication Cable
For length up to 15 meters, it is recommended to use pre-fabricated FTP Ethernet
twisted pair cable FTP type, CAT5/6.
For longer cable length, it is recommended to use S-FTP (screened shielded twisted
pair) Ethernet cable CAT5/6.
Data Communication
IMx-W, WindCon unit data communications are compliant with the Ethernet standard
10/100 Mbit. IMx-W, WindCon has two Ethernet ports which work like an internal
switch.
Ethernet
The Ethernet TP cable on the IMx-W, WindCon is connected at one of the standard
Ethernet RJ45 connections. Both Ethernet ports have auto detection of crossover or
straight through Ethernet cable connection. Basically, IMx-W, WindCon has a built-in
Ethernet switch. It is possible to connect several IMx-W, WindCon units in a daisy chain,
with up to eight units in a single cable layout. If the system is correctly connected to
another network device, the green LED lights up. The yellow LED flickers when there is
traffic on the network.
Figure 2 - 6.
Ethernet Outlet.

Installation
Ethernet
SKF Multilog On-Line System IMx-W2 - 9
User Manual
Table 2-1: Ethernet Pin/LED.
Ethernet 1–2
Pin/LED
Description
1
2
3
4
5
6
7
8
Yellow LED
Green LED
Transmit data (+)
Transmit data (–)
Receive data (+)
N.C. (Not Connected)
N.C. (Not Connected)
Receive data (–)
N.C. (Not Connected)
N.C. (Not Connected)
Ethernet traffic indicator
Ethernet link indicator
Refer to the tables in Wire Connections and the drawing of Connectors and Switches
Location for connectors naming and location details.