Download Riotech Instruments Ltd LLP VTU1X

Riotech Instruments Ltd LLP
VTU1X-Mini Installation Guide
Contents
Introduction..................................................................................................................................................1
Specifications...............................................................................................................................................1
Operational Overview..................................................................................................................................1
Update Rate..................................................................................................................................................1
Standard Equipment.....................................................................................................................................2
Additional Parts Required............................................................................................................................2
Optional Software and Equipment...............................................................................................................2
Tachometer Configuration Options..............................................................................................................2
Board Layout and Wiring Connections........................................................................................................2
0-20mA Output (VTU1X-Mini-A)..............................................................................................................4
Alarm Outputs (VTU1X-Mini-D)................................................................................................................5
Hardware Installation...................................................................................................................................5
Locating VTU1X-Mini Modules.................................................................................................................6
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Introduction
Thank you for choosing Riotech Instruments’ VTU1X condition monitoring system. The VTU1X
condition monitoring system is designed to indicate the condition of reciprocating machines, whether the
machine is a compressor or engine. This document is intended to describe the options available when
installing a system, as well as a guide when wiring and configuring the unit.
Specifications
 Supply Voltage: 10-25 VDC
 Power Requirements: < 150mW
 Number Outputs: 1
 Frequency range: 2 - 30 Hz
 Output Type:
• 0-20mA (0-3mA error codes, 4-20mA process variable)
• 4-20mA (error codes disabled)
 Speed Input:
• Pulse:
◦ Frequency: 2 Hz - 30 kHz (using multi pulse-per-rev)
◦ Input Impedance: 50KΩ
◦ Pulse Voltage: low level < 0.25V, high level > 3V (up to 80V)
◦ Duty Cycle: 30% - 70%
• Voltage: 0-5V or 1-5V
 Communications: USB and RS485 (Modbus optional)
 History Buffer:
• One day (86,400) of 1-second average values
• One month (43,200) of 1-minute average and maximum values
• One 1 year (8,760) of 1-hour average and maximum values
 Maximum Operating Temperature: 150ºF (65ºC)
Operational Overview
The VTU1X condition monitoring system is designed to monitor vibrational energy occurring at the
running speed, or 1X frequency, of reciprocating equipment. The 1X frequency is a strong indicator of
damaging conditions such as looseness, condensate slugs, and other machine anomalies. These
conditions are encoded along with other alarm parameters into a 4-20mA output that can be read by an
analog input of any controlling device, such as a SCADA or PLC.
Update Rate
The VTU1X tracks the speed of the monitored equipment (when a tachometer is used) and calculates the
vibration level based on that speed. It takes a minimum of four rotations to acquire enough data to
generate a stable process variable. Therefore the update rate is ¼ the RPM.
How the monitored equipment is configured will determine if an optional tachometer input is required.
Users have the option of configuring the unit to use a fixed running speed or to use a tachometer input to
continuously track the current running speed.
If the equipment’s running speed varies by more than ±10% from a configured fixed running speed, then
it is necessary that a tachometer be used with the system. A tachometer input can be generated using a
proximity switch, optical sensor, or TTL pulse from a PLC. A voltage input (0-5V or 1-5V) is also
accepted.
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Standard Equipment
The VTU1X-Mini condition monitoring system comes standard with:
 One explosion proof enclosure with monitoring computer mounted inside
 Speed indication. Unless the system operates within a fairly tight speed range of +/-15%, it will be
necessary to input the running speed of the equipment into the VTU1X-Mini. The VTU1X-Mini can
read speed by the following methods.
• Pulse input: Any device that can output either one pulse or multiple pulses per turn (such as an
inductive sensor).
• Voltage input: 0-5V or 1-5V which also allows the VTU1X-Mini to read from a 4-20mA output
with a 250Ω resistor placed across its terminals.
Additional Parts Required
Pipe fittings and strain relievers:
The explosion proof enclosure comes pre-drilled with one ½" NPT tapped hole. Because of the various
implementation options, it cannot be known ahead of time all the parts that would be needed to maintain
a NEMA 4X environment. RTI will supply, for an additional charge, a collection of parts that should
allow users to implement most configurations.
Optional Software and Equipment
Configuration and historical trends software, laptop and USB cable: If installation information is
supplied, Riotech Instruments will pre-configure and test units before leaving our facility. If users wish
to configure the unit themselves, they will need to purchase the optional configuration software kit that
comes with software and USB cable for connecting the VTU1X-Mini to a computer or laptop.
Historical trends may also be downloaded from the VTU1X-Mini and viewed on the PC with the
purchase of an optional software module.
Tachometer Configuration Options
The VTU1X-Mini speed monitoring system can be configured using optional software as:
 Preset fixed running speed where no tachometer sensor is needed.
 Pulse tachometer input:
• Single pulse-per-rev: Tachometer pulse supplied by either a sensor or controller with TTL level output.
• Multi pulse-per-rev (PPR): PPR range = 1 - 300 (Configure PPR when using an inductive sensor
on a flywheel).
 Voltage tachometer input:
• 0-5V
• 1-5V (when using a 4-20 mA output tachometer with a 250Ω resistor placed across its terminals)
• Corresponding speed range is 0-2000 RPM.
Settings may be changed in the field or after installation, as long as power is supplied to the board.
Settings are changed using Riotech Instruments’ optional VTU1X configuration software with a PC and
supplied USB cable. Most commercially available tachometer sensors will work or can be purchased
from Riotech.
Board Layout and Wiring Connections
When the enclosure is opened, the user will see the electronics used to operate the system. The USB
connection (on the back side of the board) allows the user to configure the unit and/or download history
data as long as the unit is powered. Various jumpers on the VTU1X-Mini-A and VTU1X-Mini-D boards
control different options, such as tachometer type, 4-20 loop power source, and alarm default states.
The tachometer selection for the VTU1X-Mini-D is slightly different from that of the Mini-A, as is
described below.
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VTU1X-Mini-A
VTU1X-Mini-D
Terminals (front)
Terminals (front)
Jumpers (back)
Jumpers (front)
Description of Terminals
 Power supply:
• P+: Power supply positive voltage (12-24 V).
• PG: Power supply ground.
 B- / A+: RS-485 connection.
 Mini-A terminals:
• Tachometer: for use with a tachometer which has a pulse, voltage, or current output. Jumper JP1
must be set to the correct position (PT for pulse tach, VT for voltage tach). When set to VT, the input
accepts a voltage from 0-5V or 1-5V, so if a tachometer with a 4-20 mA current output is used, a
250Ω resistor may be placed across its terminals to produce a 1-5V voltage output.
◦ TG: Tachometer ground.
◦ TS: Tachometer signal in.
• 4-20 Output:
◦ OS: 4-20mA output signal to PLC 4-20mA input module.
◦ O+: 4-20mA supply voltage from power supply module. When a jumper is placed across
420_PWR_ENABL, the current loop will be powered by the VTU1X Mini-A's power supply.
When the jumper is removed, the loop is powered by the O+ terminal.
 Mini-D terminals:
• Tachometer: for use with a tachometer which has a pulse, voltage, or current output.
◦ T+: Tachometer supply out, used to power three-wire tachometers.
◦ TG: Tachometer ground.
◦ TS: Pulse tachometer signal in.
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◦
•
I2: Auxiliary input for use with a tachometer which has a voltage or current output rather
than a pulse output. When using this option, the input accepts a voltage from 0-5V or 1-5V,
so if a tachometer with a 4-20 mA current output is used, a 250Ω resistor may be placed
across its terminals to produce a 1-5V voltage output.
◦ Only one tachometer source may be used, either pulse or voltage.
Alarm Outputs:
◦ H: High (warning) alarm output.
◦ HH: High High (shutdown) alarm output.
◦ Alarms may be configured as NO or NC outputs by changing the HIGH and H_HIGH
jumper settings on the board.
NOTE: Ground terminals are common, but all shields should be connected to chassis/earth ground.
0-20mA Output (VTU1X-Mini-A)
The VTU1X Mini-A outputs a 0-20mA current level that indicates both system and equipment
condition.
 < 4mA indicates different fault conditions of the system. (See table below)
 4-20mA indicates the synchronous vibration energy of the monitored machine.
0-20mA wiring options:
 The VTU1X is the power source for the current output.
 Outputs can be wired directly to a current input module of a PLC or other monitoring device.
 For monitoring devices with voltage inputs, a 250Ω precision resistor can be placed across the input
terminals at the PLC. This will give a range of 0-5 Volts.
 For long cable runs the 0-20mA outputs can source current up to the voltage level of the power
positive terminal (Power +)
4-20mA output options:
 The 4-20mA range of the 0-20mA output indicates the amount of motion occurring within a narrow
frequency band centered about the 1 times running speed of the equipment.
 This narrow range of energy indicates both looseness as well as knocking caused by extreme
looseness or condensate slugs.
 Operators and analysts become familiar with specific units of measure when evaluating the condition
of reciprocating equipment. A common unit of measure of “looseness” or motion is mils.
4-20mA output units of measure selection:
 Displacement (mils p-p)
 Velocity (in/s pk)
 Acceleration (Gs pk)
 Raw signal voltage (mV pk)
Choosing 4-20mA output units:
If the VTU1X-Mini-A is to be used in a fixed speed application, there is little difference in the choice for
correlating output amount to units. A 10% change in vibrational energy will correspond to a 10%
change in units change in whatever units are selected.
If the VTU1X-Mini-A is to be used in a variable speed application, then it is the user’s choice as to which
units would allow the easiest evaluation of the machine’s condition across its operating range of speeds.
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4-20mA output value stability:
Output value stability is greatest when the output amount is correlated to “Gs”, because of the amplifying effect
of the mathematical calculations on the inherent system noise when converting to other units. Choosing output
units other than “Gs” could affect the number of false positives for alarms, depending upon the tolerance or
headroom given to alarm levels from normal operating conditions.
0-20mA output table: The following is the lookup table for the different output units and their ranges.
Output (mA)
1.0
1.5
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
mV pk
Gs pk
in/s pk
mil p-p
Machine powered off
Tach too high (N/A if fixed tach value is used)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
0.000
0.125
0.250
0.375
0.500
0.625
0.750
0.875
1.000
1.125
1.250
1.375
1.500
1.625
1.750
1.875
2.000
0.00
1.25
2.50
3.75
5.00
6.25
7.50
8.75
10.00
11.25
12.50
13.75
15.00
16.25
17.50
18.75
20.00
4-20mA Error Codes: Output levels below 4 mA indicate an error condition as noted above. The error
codes may be disabled using the optional configuration software, giving a true 4-20mA output.
Alarm Outputs (VTU1X-Mini-D)
 Shutdown Alarm:
• Output goes high (or low, depending on jumper setting) when vibration level exceeds configured
shutdown alarm level.
 Warning Alarm (optional):
• Output pulses when vibration level exceeds configured warning alarm level.
• 1 pulse per second: Warning level reached.
• 2 pulses per second: 25% between warning and shutdown.
• 3 pulses per second: 50% between warning and shutdown.
• 4 pulses per second: 75% between warning and shutdown.
• Solid on: Shutdown level reached.
Hardware Installation
In most instances the VTU1X-Mini will be in a hazardous location. Because of this, Riotech Instruments
supplies an explosion proof enclosure with one ½" NPT hole. Attached to the bottom of the enclosure is a
1¾"×4" hexagonal mounting bracket. Both short sides of the bracket have ¼" slots for mounting bolts.
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VTU1X-Mini enclosure
Locating VTU1X-Mini Modules
Generally, when mounting sensors, while not critical, it is better when mounting:
• On the compressor frame, mount it high and toward the free end.
• On a internal combustion driver, mount it near the middle and as inline as possible with the crankshaft.
• When driven by an electric drive, mount on the compressor near the dive end and as high as possible.
Drive end VTU1X-Mini should go here.
Locate free end VTU1X-Minis here.
If monitoring each cylinder, locate the Minis
near the top of the cylinder on Ariel compressor
frames and the bottom of the cylinders on
Superior frames. No Mini is needed on frame
when monitoring each cylinder.
RioTech Instruments Ltd LLP
27326 Robinson Rd, Suite 225
Conroe, TX 77385
281-292-9051
[email protected]
V1 – 2014-10-27
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