Vibrosystm Pcs-200esb User manual

PCS-200ESB with LIN-304S / LIN-306S_Intsallation_Contents_Rev. 1 O

PCS-200ESB Measuring Chains

with LIN-300 Series Signal Conditioner

Front End Installation Manual

(P/N: 9428-25I2A-311)

Applies to measuring chain model #: LIN-304S-6I-0.3/4.3

LIN-306S-6I-0.3/6.3

This manual divides into the following sections:

Section 1: Overview of the PCS-200ESB Measuring Chain

Section 2: Installation of the PCS-200ESB Universal Proximity Probe

Section 3: Installation of the LIN-300 Series Protection Box

Section 4: Installation of the LIN-300 Series Linearization Modules

2PCS-200ESB with LIN-304S / LIN-306S_Intsallation_Contents_Rev. 1

OPCS-200ESB Measuring Chains with LIN-300 Series Signal Conditioner_TOC

TABLE OF CONTENTS

1. OVERVIEW OF THE PCS-200ESB MEASURING CHAINS

1.1 Safety information................................................................................................................................. 6

1.2 Planning and installation requirements.................................................................................................. 7

1.3 General specifications of measuring chains .......................................................................................... 8

2. INSTALLATION OF THE PCS-200ESB PROXIMITY SENSOR

2.1 Preliminary considerations.................................................................................................................... 9

2.1.1 Supplies needed........................................................................................................................ 11

2.1.2 Tools needed............................................................................................................................. 11

2.2 Step by step installation of the PCS-200SB sensor............................................................................... 11

2.2.1 Choosing the sensors location.................................................................................................. 11

2.2.2 Machining of mounting brackets.............................................................................................. 12

2.2.3 Installating mounting brackets and sensors.............................................................................. 13

2.2.3.1 Sensor installation on an insulated bearing.............................................................. 14

2.2.4 Routing and clamping the integral cable.................................................................................. 15

2.3 General specifications of the PCS-200ESB sensor ............................................................................... 16

3. INSTALLATION OF THE LIN-300 PROTECTION BOXES

3.1 Installation of the 10X6X3 ABS Protection Box .................................................................................. 17

3.1.1 Preliminary considerations....................................................................................................... 17

3.1.2 Installation of the Protection Box............................................................................................. 18

3.1.3 Supplies needed........................................................................................................................ 18

3.1.4 Tools needed............................................................................................................................. 18

3.1.5 Preparing the holes for the liquidtight connectors.................................................................... 19

3.1.6 Fastening the protection box .................................................................................................... 20

3.2 Installation of the 14 x 12 x 8 Metal Protection Box............................................................................. 22

3.2.1 Preliminary considerations....................................................................................................... 22

3.2.2 Installation of the Protection Box............................................................................................. 23

3.2.3 Supplies needed........................................................................................................................ 23

3.2.4 Tools needed............................................................................................................................. 23

3.2.5 Preparing the holes for the liquidtight connectors and grounding assembly............................ 24

3.2.6 Fastening the protection box .................................................................................................... 26

3.2.7 Grounding the protection box................................................................................................... 28

4. INSTALLATION OF LIN-300 SERIES MODULES

4.1 Preliminary considerations.................................................................................................................... 31

4.1.1 Supplies needed........................................................................................................................ 32

4.1.2 Tools needed............................................................................................................................. 32

4.2 Step by step installation ......................................................................................................................... 32

4.2.1 Connection of the SMA triaxial cable carrying signal input .................................................... 32

4.2.2 Connection of modules fed by an external power source......................................................... 33

4.2.2.1 Field-assembly of an M12 connector onto extension cable ..................................... 33

4.2.2.2 Connection of the M12 extension cable (Power Input and Signal Output).............. 34

4.2.3 Connection of modules in a protection box with optional power supply ................................. 35

4.2.3.1 Connection of the power source cable...................................................................... 36

4.2.3.2 Connection of the Signal Output Extension Cable................................................... 37

4.2.4 Verification ............................................................................................................................... 38

4.3 LED functionality................................................................................................................................... 38

4.4 LIN-300 Series Modules - General specifications................................................................................. 39

PCS-200ESB Measuring Chain_Overview_Rev. 2 O

1. OVERVIEW OF THE PCS-200ESB MEASURING CHAINS

WITH LIN-300 SERIES CONDITIONERS

Figure 1 : Typical PCS-200ESB / LIN-300 Series measuring chains installation

LIN-304S OR LIN-306S LINEARIZATION MODULES

INSIDE PROTECTION BOX

PCS-200ESB SENSOR

6PCS-200ESB Measuring Chain_Overview_Rev. 2

The basic measuring chain includes:

LIN-300 modules are usually installed in a protection box, either an ABS housing for a single module, or a

metal cabinet, which can house two modules, and can also house an optional +24VDC power supply.

1.1 Safety information

This manual contains information and warnings that must be observed to keep instruments in a safe condition

and ensure safe operation.

Warning - Danger messages identify conditions or practices that could cause bodily harm, and

result in damage to the measuring chain and other equipment to which it is connected.

Caution messages identify conditions or practices that could result in permanent loss of data.

Qty Description

1 PCS-200ESB Universal Proximity Probe

1 LIN-300 Series Signal Linearization Module, either

a) LIN-304S-6I-0.3/4.3 Linearization Module for a 4mm [157 mils] detection range

b) LIN-306S-6I-0.3/6.3 Linearization Module for a 6mm [236mils] detection range

Option Description

A) 10X6X3 ABS Protection Box

B) 14x12x8 Metal Protection Box without power supply

C) 14x12x8 Metal Protection Box with universal +24VDC power supply

Warning - Danger

•To use the described measuring chains correctly and safely, read and follow all the safety instructions

or warnings given throughout this manual.

•To avoid electric shock, personal injury, or death, carefully read the information under “Safety Infor-

mation” before attempting to install, use, or service the measuring chains.

•In addition, follow all generally accepted safety practices and procedures required when working with

and around electricity.

•For safe operation and to ensure that your system functions at its optimum capability, the installation

and adjustment process should be handled only by VibroSystM trained service specialists.

PCS-200ESB Measuring Chain_Overview_Rev. 2 O

•Although most instruments and accessories are normally used at non-hazardous level voltages,

hazardous conditions may be present in some situations.

•This product in intended for use by qualified operators and maintenance personnel who recognize shock

hazards and are familiar with the safety precautions required to avoid possible injury. Read and follow all

installation, operation, and maintenance information carefully before using the product.

•Install and use the measuring chains only as specified in this manual, or the protection provided by the

measuring chain might be impaired.

•Do not use the measuring chain in wet environments.

•Whenever it is likely that safety protection has been impaired, make the measuring chain inoperative and

secure it against any unintended operation.

•Have the LIN-300 Series modules serviced only by qualified service personnel.

•Safety and electrical symbols that appear in this manual and on the material:

1.2 Planning and installation requirements

Respect the following guidelines when planning your equipment configuration:

•The signal linearization module (and power supply module, if present) must be kept away from sources

of electrically conductive dust, as well as oil, water or moisture.

•Allow sufficient clearance around the LIN-300 protection box for verification and maintenance of enclosed

components..

•Cabling must be kept away from sources of electrical noise, power lines and fluorescent lighting fixtures.

emphasizes important information.

Caution - identify conditions or practices that could result in permanent loss of data.

Warning - Danger - identify conditions or practices that could cause bodily harm, and

result in damage to the measuring chain and other equipment to which it is connected.

Conditions include a risk of electric shock (voltage > 30 VDC or VAC peak might be

present).

Do not apply paint or other coating.

Earth (ground) terminal.

Category 1 protective conductor terminal, including grounding and equipotential

protection.

8PCS-200ESB Measuring Chain_Overview_Rev. 2

1.3 General specifications of measuring chains

Operation

•Sensor PCS-200ESB

•Matching linearization modules LIN-304S-6I-0.3/4.3

LIN-306S-6I-0.3/6.3

•Output 4 to 20 mA linearized signal

Power requirement

•Voltage +24VDC +/- 15%

•Consumption 90 mA (+24VDC)

PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1 O

2. INSTALLATION OF THE PCS-200ESB PROXIMITY SENSOR

2.1 Preliminary considerations

•The PCS-200ESB Universal Proximity Probe

is used in applications such as non-contact

measurement of relative vibration, axial

position, and relative displacement. It is well

suited for the detection and monitoring of shaft

vibration and runout, rotor imbalance and

misalignment, bearing wear, and stator frame

displacement. The 4 to 20 mA output from the

LIN-300 Series module can be sent to any

compatible instrument.

•The surface of the target in front of the PCS-

200ESB sensor must be of conductive/semi-

conductive material.

•The integral cable on the standard PCS-

200ESB is protected on its full length by

flexible stainless steel cable armor .

Figure 2 : PCS-200ESB Sensor

•Due to the calibration process, the length of the integral cable may vary lightly from one sensor to another.

Minimum length is 5.5 m [18 ft.]. Protection boxes for the LIN-300 Series signal conditioners must be

installed within this range.

•The integral cable is terminated by a male SMA connector on standard sensors, or by a male BNC

connector on legacy sensors.

•A mounting bracket will have to be machined

on site. The assembly must be sufficiently rigid

to avoid adding vibrations.

Figure 3 : PCS-200ESB Sensor installed on a bracket

Warning - Danger

•Never install triaxial cables on high voltage components.

10 PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1

High-frequency grounding of the sensor body is

essential to proper operation of the system. The

grounding lug at the end of the integral cable must

also be connected to a grounding pin on the LIN-

300 Series module.

Figure 4 : Legacy PCS-200ESB sensor terminated with BNC connector

Legacy PCS-200ESB sensors terminated by a

BNC connector can be connected to LIN-300

Series modules by using a special BNC to SMA

adapter.

Figure 5 : BNC to SMA adapter

Caution

•Whenever possible, ABS Protection Box for single LIN-300 module should be preferred for PCS-200ESB

measuring chains.

•To avoid crosstalk, special care must be taken while routing the integral cables. Two cables should never

be inserted in the same conduit. Never install integral cables in parallel close to one another. Keep cables

at least one meter apart.

•If the sensor is installed on an insulated bearing, a thin insulating sheet must be placed between the

mounting bracket and the insulated bearing to preserve the integrity of the insulation. Insulated screw

assembly must also be used.

•Handle the sensor with great care.

•Never pull on the triaxial cable or on the connector.

Adequate installation of the ground

wire to the grounded structure is

essential for reliability of results.

Do not apply paint or silicone on

the sensor sensing surface.

5.5 m [18 ft]

INTEGRAL

CABLE

PROBE TIP

DIAMETER

15.87 mm [0.625”]

LENGTH:

142.24 mm [5.6”]

3/4”-16UNF

FLEXIBLE CABLE ARMOR

5 m [16.4 ft] FOR PCS-200ESB

PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1 O

2.1.1 Supplies needed

•PCS-200ESB sensor - including two 3/4”-16 UNF nuts

•mounting bracket (fabricated on site)

•cable straps or cable clamps

•nut thread locker compound (such as LocTite®)

2.1.2 Tools needed

•depth gauges

•wrench or pliers

•machining tools to fabricate and install the mounting brackets

2.2 Step by step installation of the PCS-200SB sensor

The installation of PCS-200ESB normally includes the following steps:

•choosing the sensors location;

•fabrication of mounting brackets;

•installation of mounting brackets and sensors;

•routing and clamping of integral cable.

2.2.1 Choosing the sensors location

The location for the sensors depends on the type of vibrations that have to be measured.

When measuring radial vibrations, two sensors

must be installed at a 90° angle around the shaft.

Figure 6 : Two PCS-200SB sensors installed for radial vibration measurement

12 PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1

The face of the PCS-200ESB sensor must be

installed at mid-range distance from thetarget. The

measuring range of the sensor depends on the

linearization module used.

Figure 7 : Sensor installed at mid-range distance from the target

2.2.2 Machining of mounting brackets

Figure 8 : Various shapes of custom mounting brackets

Factors to be considered when machining the mounting bracket:

•The mounting bracket must be installed at a perfectly stable location;

•The sensor is 3/4” in diameter, with 3/4-16 UNF thread. It can be fitted in a 19 mm (3/4”) unthreaded hole

with the two jam nuts supplied with the sensor;

•The mounting bracket must be rigid to avoid vibrations. The use of aluminium plates with a thickness

between 10 and 13mm (3/8” and 1/2”) is recommended. If needed, use lateral reinforcement to add rigidity.

It is important to make sure that the bracket does not vibrate, as this would alter the

readings from the sensor.

PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1 O

2.2.3 Installating mounting brackets and sensors

1. Install the mounting bracket on the

structure at the chosen location.

2. Adjust the sensor at mid-range

distance from the target, using a

gauge between sensor face and

target. Refer to the specifications of

the LIN-300 Series module used

3. Set the sensor in place by tightening

jam nuts at recommended torque.

When adjustment has been

completed and measurements have

been validated, thread lock

compoundmustbe appliedto prevent

the nuts from loosening.

Figure 9 : Setting the PCS-200ESB sensor in place

Caution

Proceed with gap distance adjustment only after the complete measuring chain, including grounds,

has been installed. Apply power to the measuring chain, and measure signal output. The distance is

correct when the conditioner output reads precisely 12 mA.

Grounding

The principle of operation of the PCS-200ESB sensor requires adequate high-frequency grounding. To

ensure the permanent conductivity of the ground, some precautions must be taken during installation.

•On a grounded metallic structure, avoid the use of paint or sealant inside and around mounting holes

on the mounting bracket. This will ensure electrical contact between the sensor body, the mounting

bracket, and the machine.

•When a direct electrical contact between the mounting bracket and the machine cannot be achieved

(for instance, when the mounting bracket is installed on concrete), a grounding copper wire must be

installed between the metallic mounting bracket and the nearest location of a grounded structure.

•In the presence of insulated bearing, special caution must be used. Refer to the following instructions

for installation of the mounting bracket on an insulated bearing.

25 Nm (218 in.-lb.)

14 PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1

2.2.3.1 Sensor installation on an insulated bearing

When a sensor is installed on an insulated bearing, special care must be taken while mounting the bracket to

preserve the integrity of insulation. Insulation must be added between sensor housing and insulated bearing

surface, but low impedance at high frequency must still be achieved. The most widely recommended

mounting method consists in placing a mica sheet (1.6 mm [0.063”] thick or less) between mounting bracket

and bearing, and using either non-metallic bolts, or metallic bolts insulated from the bearing by phenolic

sleeves and washers .

Figure 10 : Installation on an insulated bearing

Verification:

1. Once the bracket is installed, test with a ohmmeter for an open circuit condition between the mounting

bracket and insulated bearing.

2. Place a temporary cable between the sensor casing and insulated bearing to create a short-circuit path.

3. Complete the measuring chain by connecting the sensor to its LIN-300 Series conditioner and apply

power to the conditioner. Take a measurement of the 4-20 mA output signal .

4. Remove the temporary cable between the sensor casing and insulated bearing.

5. Take a new measurement. The results should be similar to the previous reading, within a +/- 2 mA margin.

6. If the results differ beyond the mentioned margin, the insulating sheet is probably too thick.A thinner sheet

should be used before going through the verification procedure again.

Caution

If the sensor is installed on an insulated bearing, a thin insulation sheet must be placed between

the mounting bracket and the insulated bearing. Insulated screw assembly, such as phenolic

sleeves and washers, must also be used.

Bolt

Mica sheet

PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1 O

2.2.4 Routing and clamping the integral cable

Complete the installation by strapping all conduits and cables

over the whole distance from PCS-200ESB sensors to LIN-300

Series linearization modules.

Figure 11 : Cable secured with cable clamps

Caution

•To prevent damage to the cable, do not force beyond the minimal bending radius (6 cm [2.5”] ).

•Cable clamps must be used to secureall components subjected to vibrations. This step of the installation

is essential to prevent damage from wear by abrasion.

16 PCS-200ESB Universal Proximity Sensor_Installation_Rev. 1

2.3 General specifications of the PCS-200ESB sensor

Operation

•Type of measurement non-contact proximity, capacitive technology

•Linear measuring range varies depending on Linearization Module used

•Frequency response limited by the Linearization Module used

•Accuracy < 2.5 % of reading at mid-range

•Repeatability < 0.3 % of reading at mid-range

•Interchangeability < 2.5 % of reading at mid-range

Environmental

•Temperature range -50° to 200°C [-58°to 392°F]

•Humidity Up to 95%, non-condensing

Connection

•Integral Cable

- Type Triaxial

- Length 5.5 m [18 ft.] minimum

- Connector Male SMA with ground lug (standard),

or male BNC with ground lug (legacy)

- Cable Armor Integral flexible stainless steel metallic conduit,

diam. 5.6 mm [0.220 in.], on 5 m [16.4 ft.] standard

Dimensions

•Probe overall dimensions

- Diameter 19 mm [0.75 in.]

- Length 142.24 mm [5.60 in.]

- Tip 15.84 mm [0.625 in.]

•Thread 3/4-16 UNF

Figure 12 : PCS-200ESB dimensions

130.17 mm /

5.125 in

Ø 15.87 mm

0.625 in.

Probe Tip

3/4"-16 UNF Integral Cable (Minimum Length 5.5 m /

18 ft

)

Including 50 cm / 20 in.Flexible Cable Armor

142.24 mm /

5.600 in

LIN-300 Protection Boxes_Installation - Rev. 0 O

3. INSTALLATION OF THE LIN-300 PROTECTION BOXES

LIN-300 modules may be protected by an ABS enclosure (single module) or a larger steel enclosure with a

mounting plate for two modules and, if desired, a rail-mounted power supply and terminal blocks. The

following details the installation procedure for both types of protection boxes.

3.1 Installation of the 10X6X3 ABS Protection Box

3.1.1 Preliminary considerations

The ABS protection box is a plastic enclosure which can house a single LIN-300 Series conditioner. Outer

dimensions are 254 x 152 x 76 mm (10 x 6 x 3 in.).

All connected cables must be protected by flexible

protective conduits and attached with liquidtight

connectors. Prepare the openings on the protection

box and set the liquidtight connectors in place before

fastening the protection box.

To determine the best location for the protection box,

survey all potential locations with respect to the

following limitations:

•the optimal location at which the protection box can

be installed depends on the length of the triaxial

cables used;

•all cables should be placed inside 19mm (3/4”)

flexible protective conduits or equivalent when

possible;

•sufficient space must be allowed around the

protection box for the installation of the protective

conduits.

Figure 1: Front view of the ABS protection box

When routing cables into the protection box for

connection to the conditioner, the excess length of

cable can be coiled as shown inside the protection

box.

Note: Be carefull when handling the cable. Do not kink

the cable and avoid forming sharp bends.

Figure 2 : Inside view of the ABS protection box

18 LIN-300 Protection Boxes_Installation - Rev. 0

3.1.2 Installation of the Protection Box

3.1.3 Supplies needed

•(2) 3/4” flexible conduit liquid tight connectors

•(4) bolts 1/4-20 x 5/8”

•(4) concrete anchors

•(4) bolts M6 - 1.00 x 16 mm

•(4) spring lockwashers 1/4”

•(4) flat washers 1/4”

•(4) brackets

•(4) spring lockwashers 10-32

•(4) flat washers 10-32

•(4) screws 10-32 x 1/2”

Figure 3 : Protection Box -Installation kit

3.1.4 Tools needed

•Drill bits 5mm (13/64’’) and 8mm (5/16’’)

•Tap drill 1/4’’-20

•Hammer drill

•Drill

•Concrete drill bit 8mm (5/16’’)

•Anchor setting punch

•Ratchet set

•3/4’’ conduit hole saw or knockout punch set for 3/4’’ liquidtight fittings

LIN-300 Protection Boxes_Installation - Rev. 0 O

The installation of the LIN-300 ABS protection box involves two main steps:

1. Preparing the holes for the connectors;

2. Fastening the protection box.

3.1.5 Preparing the holes for the liquidtight connectors

1. To prevent damage, remove the LIN conditioner

before drilling the protection box. Do not misplace

the anti-vibration rubber mounts added to the

mounting brackets.

Before deciding on the location for the holes, make

sure that the liquidtight connectors will not be too

close to the LIN conditioner once it is reinstalled,

and that the cables will not be kinked.

Figure 4 : Suggested location for liquidtight connector holes

2. Drill holes and install the the liquidtight connectors.

Refer to Figure 5 : “Mounting the liquidtight

connectors on ABS protection box”.

Figure 5 : Mounting the liquidtight connectors on ABS protection box

1.19'' [30mm]

SIDE A

CL Hole:1 1/8''[28.5mm]

20 LIN-300 Protection Boxes_Installation - Rev. 0

3.1.6 Fastening the protection box

Choose the location for the protection box.

The protection box can be mounted on a concrete

wall or, whenever possible, directly onto the

structure of the stator or machine casing.

Figure 6 : Mounting holes location

Mounting a protection box on the stator or

machine casing:

1. Drill (refer to Figure 6 : “Mounting holes location”)

and thread into the structure (refer to Figure 7 :

“Fastening the ABS protection box on steel”).

2. Fasten the protection box as shown.

Figure 7 : Fastening the ABS protection box on steel

13.19'' [335mm]

4.00'' [102mm]

PROTECTION BOX

ON STEEL

HOLE: DRILL BIT 5mm (13/64'')

TAP DRILL 1/4-20 or M6-1.00

DEPTH: 19mm (3/4'')

1/4''-20 x 5/8'' BOLT

M6-1.00x16mm BOLT

LOCKWASHER

WASHER

ANTI-VIBRATION MOUNT

SCREW 10/32 x1/2

LOCKWASHER 10/32

WASHER 10/32

BRACKET

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