Angel

The value of any monitoring system is not in the equipment – it is in the data. The data from a portable data collection system starts to lose value immediately after it is collected because it is already out of date. To ensure full value from a portable monitoring system the engineer must be absolutely certain that all of the failure mechanism durations on the monitored machines are shorter than the data collection interval. If the data is old or if the analysis is wrong then there is no value in the monitoring system. If the data is new and the analysis is accurate you have full value continually.

Accurate analysis of vibration data requires a great deal of experience and knowledge in both the understanding of how vibration works and a solid grounding in maintenance engineering. It is vitally important that the vibration analyst is dedicated only to this type of work but is trained in all aspects of analysis techniques. In the real world of maintenance and operations it is not always feasible to allocate one man or sometimes more to one particular system – this is where Angel comes in.

At set intervals, the Angel portion of the system transmits all data to our offices (the default is every

midnight) via the Internet. At the start of work the next day our engineers examine the data in Guardian. The allocated engineer for your system then examines the log file for alarm events and carries out a full analysis of the data which has gone into alarm. If any corrective action is required the PreDiCon engineer calls his contact in your organisation either by phone, e-mail or fax depending on your preference. Every week you receive a summary of the condition of all of your monitored equipment.

The data under analysis is always less than one day old and you can be sure that trained and experienced engineers carry out the analysis. Your system will give you full value for all of its operational life.

FEATURESMimic Based Visual InterfaceSupports Vibration and Process MeasurementsFull Trending, Spectral Displays and ArchivingNetwork and Transducer Diagnostic FacilitiesHigh Speed “Live” Spectrum AnalysisVirtually Infinite Expansion Capability

PreDiCon LtdSuite 8, 330 Lytham Rd.

Blackpool FY4 1DWUnited Kingdom

Tel +44 1253 400554Fax +44 1253 400553

e-mail: info@predicon.neturl: www.predicon.net

The Guardian SystemGuardian is a fully featured monitoring software package for rotating or reciprocating machinery and other types of plant. It can handle both dynamic measurements, typically vibration, and process measurements such as temperatures and pressures. The software operates with the ICONET industrial network to provide a highly flexible distributed data acquisition system.

The Guardian application includes all the common functions for plant monitoring, including alarming, trending, analysis and data archiving.

The visual interface is entirely mimic driven giving clear indication of plant status at a glance. A simple hierarchy and intuitive controls combine to set new standards in ease-of-use. Mimics and the internal database are easily modified allowing a straightforward upgrade path from a handful of points to hundreds.

“If it’s Simple, Operators will Use it”The Guardian application has been designed to monitor plant with the minimum amount of operator involvement and intervention. Overall plant status can be seen by simply glancing at the front screen mimic. Any excursions above pre-set alarm limits are reported immediately, and these are acknowledged and cleared as required. All system activity is automatically recorded in a log so that a complete history of plant operation is maintained. Operators can even enter their own notes and observations.

The “traffic light” display at the foot of the screen shows the status of all measurement points. If a point goes into alert or alarm, that

portion of the mimic changes colour accordingly, thus giving clear and unambiguous reporting of machine problems.

Faults Pinpointed and Clarified

A mouse click brings up a measurement screen that provides further details of the highlighted problem. Here, it is possible to tell whether a problem is, for example, shaft or bearing related. It pinpoints the precise area of the machine needing to be looked at.

If several alerts or alarms have occurred simultaneously, these can be reviewed in turn.

Trends and LevelsOnce a problem has been identified on a machine, the next question is inevitably “How long can

we leave it running?” This is where trending comes in. The rate of deterioration can be assessed, and comparisons made with previous occurrences on this, and other machines. Flexible comparison and overlay facilities are available.

Further AnalysisAdditional analysis tools are available to determine the exact cause of a problem. Full time and spectral analysis displays can be called up with the ability to overlay and compare with other historical data.

It is also possible to go “live” to any point on the system and see time/spectral updates in real time. This is especially useful where machine parameters are changing, such as speed and load.

System ConfigurationConfiguration of measurement points has been made easy with a single screen entry for each point. This is “what you see is what you get” in its simplest sense. For larger systems, a database editing facility is available enabling a short-hand method of entering hundreds of points.Scan rates and data storage criteria are fully programmable to optimise system performance.

Data ArchivingThe Guardian software is designed to carry out its monitoring tasks for months and years with a minimum of system maintenance. Large amounts of data can be recorded over extended periods, and so straightforward data reduction methods are needed. Guardian provides highly flexible data archiving methods to ensure that the system operates efficiently and without overloading the host computer’s storage facilities.Archiving can be programmed to occur automatically at pre-set intervals. In this case, no operator intervention is required, and the system will sift out the important data for safe-keeping while removing uneventful information.

Global AccessThe combination of Guardian and ICONET hardware enables the full power of the internet to be utilised. Remote access via telephone and internet is possible enabling data to be examined from virtually anywhere. The system even allows the possibility to go “live” to a single measurement point from anywhere in the world!

Security and System DiagnosticsGuardian incorporates a two-level security system to ensure that system parameters can only be changed by authorised personnel.The quality of data monitored by the system is only as good as the measurement devices that are connected to it. Guardian has automatic diagnostic facilities for checking the integrity of acquisition

nodes and even the transducers connected. Failing accelerometers and open circuits or shorts on their connecting cables can be identified.

for Local … Plant Wide ... Global …Condition Monitoring Applications

Imagine a flexible network system that can be used to gather vital information on your machinery. One which can be incorporated into your existing Ethernet networks in the plant and which can be accessed locally or remotely. Imagine this can be set up by anyone who knows how to set up an Ethernet system and imagine it is so affordable that it can fit into your budget with ease.

You are now thinking of ICONET on Ethernet.But don’t let your imagination stop there. Think what you could do if you could access data directly from your measurement points anywhere in the world via the Internet. Now you can realise how ICONET on Ethernet captures the power of the global communications revolution and enables you to call up real time measurement data on-line, absolutely anywhere.

You are now thinking: LOCAL ... PLANT-WIDE ... GLOBAL ...

System DescriptionWide Choice of Inputs

ICONET on Ethernet sets out to interface to just about any sensor type that is encountered in the field of machinery monitoring, Typical transducers for vibration measurement are accelerometers and eddy current probes, and these are two of the types that can be used for so-called “dynamic” measurements. Often, process measurements such as temperatures and pressures need to be monitored. These so-called “static” parameters can also be accommodated.

There are three types of node in the ICONET on Ethernet series, called Type 1, Type 2 and

Type 3. The types of signal input that each can accommodate are summarised below:

Type 1 Sixteen multiplexed analogue inputs Sixteen ICP supplies for accelerometer

interfacing Optional AC/DC coupling Accelerometer bias voltage check Bearing condition measurement

Type 2 Sixteen analogue inputs, multiplexed in

pairs for simultaneous acquisition (X-Y, orbit etc)

Standard interface to eddy current probes

Type 3 Twenty multiplexed process

measurement inputs Modules available to interface to

thermocouples, RTD’s, pressure sensors (bridge type), 4-20mA etc

The full features of each node type are summarised on page 4.

Speed and Trigger Channels

Each node type is fitted with the same trigger/tacho interface. This comprises four digital inputs that can be set as isolated or non-isolated. Any trigger input can be tagged to any of the analogue input channels allowing maximum triggering flexibility. A trigger input can be used for any of three purposes, namely:1. tacho input for measuring machine speed

(also incorporating a divide-by-N Counter for taking inputs from gear teeth or similar);

2. once-per-rev sensing for time synchronous averaging;

3. input to digital phase-lock function for order analysis.

Full pre-trigger and post-trigger sampling facilities are provided.

Gated Measurements

Two of the trigger input channels can be used to gate measurements from the analogue input channels. Only when a pre-determined logic level is present on a digital input will data acquisition take place. This feature can

be used, for example, to acquire data only from machines that are running.

Event Triggers for Synchronised Measurements

Two of the trigger input channels can be used as event triggers. These are used to synchronise measurement sequences between nodes on the occurrence of an external event. In addition, the ITA-1 incorporates a high-drive synchronising output. This can be connected to the event inputs of a number of other nodes (as in a master-slave concept) enabling synchronised data gathering between nodes on a system. This operates independently of the Ethernet network. Bearing Condition Measurement

The Type 1 node incorporates an on-board hardware demodulator for the detection of bearing defect signals. These are passed over the network to be presented either as an overall value of bearing condition or as a spectrum highlighting actual bearing defect frequencies. In this way, bearing problems are differentiated from shaft related problems.

Watchdog Function

A watchdog function is incorporated that monitors the operation of the nodes. If, for example, the supply voltage drops, the watchdog will automatically reset the node when power is restored. No user intervention is needed in the event of a power interruption.

An RS232 serial port is available for diagnostic purposes.

Acquisition Modes

To optimise system performance in time critical applications, three acquisition modes are supported.

Mode 1: Data on Demand – the node is instructed to acquire data, store it, and await a download instruction from the host computer.

Mode 2: Data Ready Flag – the node is instructed to acquire data, and then sends a Data Ready flag to the host computer indicating that acquisition is complete and new data is available.

Mode 3: Data Broadcast – the node sends data to the host computer as soon as acquisition is complete without waiting for a command.

The above modes can be modified in the application. For example, the mode could be switched from Mode 1 to Mode 3 when live data is required.

Fast Node ControlIn order to obtain maximum data throughput, channel configurations (and the sequence in which they are called) are downloaded to the node and stored in flash memory. The node is then instructed to execute a stored sequence of measurements, (and keeps rotating through if required). A large number of configurations and sequences can be stored in the node so that, if the order or configuration of measurements needs to be changed, this can be done with a short command instead of having to download a new set of instructions.

Standard Ethernet

ICONET on Ethernet uses the latest Ethernet technology ensuring compatibility with existing Ethernet systems. Communication is possible within the system’s own environment, across switches and routers, and across the Internet. Standard off-the-shelf hubs and PC adapters can be used throughout. Each node has a unique MAC address. Physical connection is 10Base-T using the standard RJ45 plug and socket arrangement.

For optimum performance, Icon recommends a dedicated local Ethernet network is used to connect the nodes to the PC as shown in the typical installation diagram. The ICONET part of the network can then be linked into 100Base-T Ethernet networks through standard switches or can be linked to the PC running, for example, Icon’s GUARDIAN or other compatible software directly. Several PC’s running GUARDIAN can be connected to the local network and remote PC’s running GUARDIAN can interface with the system also through a switch from the plant’s Ethernet highway. For larger Ethernet applications, routers can allow global access to the system. In effect, three levels of access are possible: Local, Plant Wide and Global. Both UDP/IP and TCP/IP protocols are supported.

Wireless Operation and Internet

Being fully Ethernet compatible, ICONET on Ethernet can be connected in to standard wireless LAN’s (including the IEEE 802.11 standard). In addition, nodes can communicate live over the Internet anywhere in the world.

Low System Cost

ICONET is purely a data capture system. It does not attempt to analyse data in the field at each node – the power of the modern PC is used to do this at a fraction of the cost. This keeps the hardware cost to a minimum.

Installation costs are also low. The small number of points per node minimises sensor wiring costs while the network wiring uses low cost CAT5 Ethernet cables and standard Ethernet components. It may even be possible to use existing Ethernet network cabling at effectively no cost.

Enclosures

ICONET is available in a number of enclosure types. The standard is powder-coated mild steel, but stainless steel and high-impact plastic are available at small additional cost.

Nodes can be fitted with power supplies for mains input at any voltage, or can be configured for a number of standard factory dc voltages. Power consumption is very low, thus putting negligible load on existing power systems.

Specifications - Guardian

Human Machine Interface

Mimic driven interface

Main and sub mimic levels

Trend plots

Trace plots (time, spectrum and orbit)

Point and click operation

Pop-up alert and alarm notification

Graphic colour change on alert or alarm

Traffic light indication of point status count

Interfacing Features

Interfaces to ITA-1and ITA-2 nodes

Up to 4,194,304 sensors possible

Multiple reading types from sensors possible (eg. accel, velocity and g from accelerometers)

Virtually unlimited sub mimic levels

Operates under Windows NT or 2000

Uses standard Ethernet interface

System Features

Periodic network checking

Network check on demand

Bias voltage check for accelerometers at user definable intervals

System log and network log

Log search facilities

Log print, serial output and shared file options

On-line help and user accessible HTML help

Measurements with ITA-1

ICP devices (eg. accelerometers)

DC voltages

AC coupled signals

Tacho speed inputs from 1/rev or gear

Measurements with ITA-2

X-Y signal pairs (eg. orbits)

DC or AC inputs in 0 to –24V range from standard eddy current (proximity) probes

Tacho speed inputs from 1/rev or gear

Results

Scalar measurements

Overall and derived measurements

Spectrum graphs for acceleration, velocity, displacement and gbrg

Spectral Bands

Orbits

Phase measurements

Trigger synchronised readings (sync, pre and post available)

Orders spectral display using phase lock loop

Gates available to check data integrity

Alerts and Alarms

Main and sub mimic colour change

Pop up alert/alarm box

Acknowledge function

Clear function (only if condition clears)

Log entries automatically generated

Traffic light indication of total alerts/alarms

External Outputs

External relay activation

Point Selection

From mimic hierarchy

From Explorer function

From pop-up alert/alarm box

Review of trends – Live modeLive trend graphsTime scale zoom in/out

Multiple trend view of historical data (up to 5)

Access to live trace (eg. spectrum)

Review of Trends – Browse Mode

Specifications - Guardian

Cursor on trend(s)

Timescale zoom in/out with cursor centred

Multiple trend view (up to 5 trends)

Point highlight for overlay

Multiple trend overlay (up to 5 of same type)

Access to trace overlays

Point delete function

Hardcopy print-out

Analysis of Results – Spectra

Current spectrum view

Acquire / hold facility

Real-time mode for instant analysis

Single, dual, harmonic and sideband cursors

Spectral overlay up to 5 spectra, selected from trend screen

Zoom

Hardcopy print-out

Optional grids

Auto peak detect

Line or bar display

Choice of Hz, CPM, RPM

Analysis of Results – Orbits

Current orbit view

Acquire / hold facility

Real-time mode for instant analysis

Angle / magnitude cursor

True and measurement angle

Overlay up to 5 orbits, selected from trend screen

Zoom

Hardcopy print-out

Optional grids

Auto peak detect

System Set-Up

Security key protected (2 levels)

Full control over measurement parameters

Adjustment of alert and alarm levels

High, low, in-window and out-of-window alert and alarms (spectrum and spectral bands)

Furthest from a datum alert and alarms available

Selectable storage frequency depending on normal / alert / alarm status

Averaging of results selectable

Tell user after X consecutive fails option

Selectable signal gain

Band set-up and naming – up to 10 bands

Trigger set-up for phase lock loop, trigger and pre and post trigger

Match any trigger channel to any input or inputs

Selectable sifting strategy – highest, lowest, furthest from or typical

Up to 12 machine relay alarms settable

Email recipients for alert and alarm settable by machine

Settable gates to check data integrity

Override logging to capture sample data on all points

Database Management

Automatic database sifting, backup and file export at selectable intervals

Associated Applications

Ability to run Iscope1 real time spectrum analyser utility

Ability to run Iscope2 real time X-Y (orbit) utility

Specifications - Guardian

Specifications subject to change without notice

TYPE 1 NODE

AnalogueSixteen Multiplexed Analogue InputsICP Power for Accelerometers on All ChannelsAC/DC Input Coupling OptionsFull Anti-AliasingProgrammable HP FiltersOn-board Hardware IntegratorProgrammable Gain in Range 1 to 1000On-board Bearing Demodulation Function

TriggersFour Digital Trigger Inputs5-24Vdc Range, Isolated or Non-IsolatedAveraging, Pre and Post-Trigger FunctionsTrigger, Tacho and Order Analysis

FunctionsEvent and Gate Trigger Options

Processing16-bit ADCSample Rate to 51.2kHzWatchdog Function10Base-T Ethernet InterfaceUDP/IP and TCP/IP Protocol Support

TYPE 2 NODE

AnalogEight Synchronous Pairs or SixteenSingle Input ConfigurationsInput Range Compatible with Standard

Eddy Current ProbesProgrammable DC/AC Coupling for

Optimised DC Gap and Vibration Measurement

Full Anti-AliasingProgrammable HP FiltersProgrammable Gain in Range 1 to 1000Fault Protected InputsChannel-to-Channel Common Mode

Difference to 40V

TriggersAs Type 1 Node

ProcessingDual 16-bit ADC’sSample Rate to 51.2kHzWatchdog Function10Base-T Ethernet InterfaceUDP/IP and TCP/IP Protocol Support

TYPE 3 NODE

AnalogTwenty Static Analog InputsConfigurable Module Types, including

Thermocouple, RTD, 3-Wire Bridge, 4-20mA

On-Board Excitation Supply172dB Input Sensitivity RangeProgrammable Gain in Range 1 to 100

Automatic DC Offset RemovalTwo Isolated Relay OutputsRS232/RS485 Communications Channel

TriggersAs Type 1 Node

Processing22-bit ADCAutomatic Removal of 50/60Hz Mains-

Borne InterfaceWatchdog Function10Base-T Ethernet InterfaceUDP/IP and TCP/IP Protocol Support