User Manual for Vibration Monitoring via IRD8800
1. Introduction
This Article serves as the User Manual for Vibration Monitoring via IRD8800
1.1 Introduction to IRD Mechanalysis Limited
IRD Mechanalysis Limited is a provider of Condition Monitoring Solutions to the World since 1962. Also commonly referred to as 'IRD' and 'The Vibration People' - IRD provides Portable Instruments and Online Systems for Vibration, Temperature, Speed, Gap and Turbine Monitoring. IRD also provides associated services like Training, Consulting, Commissioning, Repairs and Calibration. IRD has its Head Office and Manufacturing in Thane, Maharashtra, India
1.2 Introduction to Vibration Monitoring
Vibration Monitoring is the practice of installing Sensors and Systems for continuous monitoring of Vibration levels of Machinery such as Motors, Pumps, Blowers, Compressors, Turbines and more in a Continuous process plant. It is done to ensure that there is advance warning to User in the event of a rising trend in Vibration. It is also done to ensure prevention of Machine Breakdown and Downtime.
Vibration Monitoring can be done via Casing Vibration Monitoring, Relative Shaft Vibration Monitoring or End Winding Vibration Monitoring.
1.3 Introduction to IRD8800
IRD8800 is a Series of Rack Based and API670 Compliant Machinery Protection System (MPS). It has modules that can do Vibration, Temperature, Speed, Gap and Turbine Monitoring. This article focuses on IRD8800 when used for Vibration Monitoring
2. Modules of IRD8800
IRD8800 has a variety of Modules to serve Monitoring varieties like Casing Vibration, Shaft Vibration, End Winding Vibration and more
2.1 Casing Vibration Module M88200
M88200 is the Casing Vibration Module of IRD8800. It is able to accept 2 Vibration Inputs (Accelerometers or velometers) and 1 Phase reference Input (Laser or Non-Contact Eddy Current based Sensor)
2.1.1 Power Input to M88200
M88200 can be factory made for either AC Power Input or DC Power Input. When M88200 is made for AC Power Input - it is named M88200-AC and is able to work on 90-270 V AC, 50/60 Hz, Single Phase Power Input. When M88200 is made for DC Power Input - it is named M88200-DC and is able to work on 24 V DC Power Input.
Standard Practice - We use a Regulated Power Supply (RPS) to convert standard 90-270 V AC, 50/60 Hz, Single Phase power Input of Purchaser to Regulated 24 V DC. We supply M88200-DC as a standard practice to work on this regulated 24 V DC
2.1.2 Sensitivity Options in M88200
M88200 supports 2 Sensitivity Options - mV/g and mV/mm/s. By default we set the card to 100 mV/g and 4 mV/mm/s. However, using the push buttons on Keypad and the menu options on display - the customer can adjust the sensitivity to mV/g or mV/mm/s for each channel. The Customer can also fine tune the Sensitivity between 0.1 and 999.9 mV/g when in mV/g and between 0.001 and 9.999 mV/mm/s when in mV/mm/s
2.1.3 MODBUS Output in M88200
M88200 supports both MODBUS RTU as well as MODBUS TCP Output. The Module acts as a Slave for Modbus communication. Each Module has its own Slave ID (also called Module Address), Baud Rate and Parity. The Slave ID can be set between 001 and 255. The Baud Rate can be set to 4800, 9600, 19200 or 38400 bps. Parity can be set to Odd, Even or None. Our default settings are 001 for Slave ID, 9600 for Baud Rate and None for Parity.
The MODBUS Output is available in RS485 form (2 wire - Receive (Rx) and Transmit (Tx) and a terminal for Ground) at the Backplane of each Module. If the Customer requests for Ethernet TCP Output - then we provide a Serial to Ethernet converter after our Rack where Ethernet TCP is available on an RJ45 Port.
2.1.4 Over Range Condition in M88200
When the Vibration exceeds the set Full Scale in M88200 - it is called an Over Range Condition. The following happens during Over Range:
- The Alphanumeric display flashes Over Range
- Since Over Range is above Alarm, Trip and Full Scale levels - the Alarm and Trip Relays become active after their set delay
- 4-20 mA output is pulled to 4mA
2.2 Shaft Vibration Module M88210
M88210 is the Shaft Vibration Module of IRD8800 Series. It accepts 2 x Non Contact Eddy Current Based Sensors as Input along with 1 x Phase Reference Sensor Input (Laser or Non-Contact Eddy Current Based Sensor)
2.3 Casing Vibration Module M88250
M88250 is the Casing Vibration Module of IRD8800 specifically designed to work with Velometers that provide mV/mm/s output. It accepts 2 x Velometer Inputs and 1 x Phase Reference Input
2.4 End Winding Vibration Module M88280
M88280 is the End Winding Vibration Module of IRD8800 specifically for Generator and/or Exciter End Winding Vibration Monitoring. It accepts 2 x Vibration Sensor Inputs (Charge Output via Charge Amplifier or Fiber Optic)
3. Connection Drawings
3.1 How to Connect IEPE Accelerometer to Casing Vibration Module M88200
IEPE Accelerometer are usually 2 Wire (Signal and Ground) with a Shield. IEPE Accelerometers like IRD521 of Nominal Sensitivity 100 mV/g +/- 10% can be connected to Casing Vibration Module M88200 as shown in the drawing below
3.2 How to Connect Non-Contact Eddy Current based Sensors to Shaft Vibration Module M88210
Non-Contact Eddy Current based Sensors have a Probe, Extension Cable and Driver. Drivers are available in 2 types - 1 that works on -24 V DC Input Power and the other that works on +24 V DC Input Power. The Drawing below shows how such a Non-Contact Eddy Current based Sensor that works on -24 V DC Input Power can be connected to Shaft Vibration Module M88210
It is important to specify the Input Power required to Driver at the time of manufacturing of the Module M88210 (-24 V or +24 V) as the module is manufactured accordingly. If this was not specified at the time of manufacturing and a +24 V DC Driver needs to be connected to a module M88210 factory set for -24 V DC Driver - then at site Jumpers will need to be changed at Module level to ensure compatibility. Please ensure you take telephone or email assistance from IRD Mechanalysis Limited before carrying out such change as it may Void your Warranty if done without information
4. Repair and Calibration of IRD8800 Vibration Monitoring Modules
4.1 Validity of Calibration Certificate
All Vibration Monitoring Modules of IRD8800 are accompanied with a Calibration Certificate that is valid for 1 year from the date of Issuance
4.2 Calibration check pre-dispatch
All Vibration Monitoring Modules of IRD8800 undergo a 5-point Calibration check before dispatch. The Display, 4-20mA and Relay Contacts are checked at 0%, 25%, 50%, 75% and 100% Input
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