IQS450 204-450-000-001-A1-B21-H05-I0 Signal Conditioner

The IQS450 204-450-000-001-A1-B21-H05-I0 is a high-performance, high-reliability non-contact proximity measuring system designed and manufactured by Vibro-Meter SA. Based on the proven eddy current principle, this system is optimized for monitoring relative vibration and axial displacement of rotating machinery in demanding industrial environments. The system core consists of a TQ 402/TQ 412 series proximity transducer paired with an IQS 450 signal conditioner, forming a calibrated, component-interchangeable complete measurement chain.

This system is particularly suitable for condition monitoring and protection of large rotating equipment such as steam turbines, gas turbines, hydraulic turbines, alternators, turbo-compressors, and pumps. Its design complies with stringent international standards and carries certifications for use in potentially explosive atmospheres (ATEX and CSA), ensuring safety and reliability in hazardous area applications. The system provides voltage or current output with short-circuit protection, features wide frequency response, excellent temperature compensation, and is an ideal choice for industrial predictive maintenance and machinery protection applications.

Core Features:

• Non-contact measurement: Based on the eddy current principle, enabling precise displacement measurement without physical contact with the target, resulting in no wear and long service life.

• High Safety Certifications: ATEX and CSA certified for use in potentially explosive gas atmospheres such as Zone 1 and 2 (depending on configuration).

• Exceptional Performance: Wide frequency response (DC to 20 kHz), high sensitivity, excellent linearity, and temperature stability.

• Flexible Configuration: Transducer (standard or reverse mount), sensitivity, measuring range, cable length, and protection level can be selected according to application needs.

• Rugged Construction: Transducer features stainless steel housing and Torlon tip; cables offer various protection options; suitable for harsh conditions like high temperature and vibration.

• System Integrity: Transducer and conditioner are factory-paired and calibrated, ensuring plug-and-play accuracy and component interchangeability.

2. System Working Principle

This proximity measuring system operates based on the eddy current effect. The high-frequency oscillator circuit inside the IQS 450 signal conditioner generates a high-frequency signal, which is fed via the coaxial cable to the coil in the tip of the TQ 402/412 transducer. This coil produces a high-frequency electromagnetic field around it.

When this electromagnetic field approaches a conductive metal target (e.g., a machine shaft), eddy currents are induced on the target surface. These eddy currents generate a secondary magnetic field opposing the transducer coil's field, thereby absorbing energy and causing a change in the effective impedance of the transducer coil. This impedance change is closely related to the distance (gap) between the transducer tip and the target surface.

The modulation/demodulation circuitry inside the IQS 450 precisely detects the change in coil impedance and converts it into a DC voltage (Option B21) or current (Option B22) signal linearly proportional to the gap. This output signal can be directly connected to monitoring systems (e.g., PLC, DCS, or dedicated vibration monitors) for real-time display, recording, alarm, and trip protection.

The system's temperature compensation circuitry ensures output signal stability over a wide temperature range. All components are factory paired and calibrated, guaranteeing excellent interchangeability and measurement accuracy.

3. Typical Application Fields

The IQS450 204-450-000-001-A1-B21-H05-I0 system is widely used for monitoring critical rotating machinery in the following industrial sectors:

1. Power Generation: Shaft vibration and axial position monitoring for steam turbines, gas turbines, and alternators; swing and gap monitoring for hydraulic turbines.

2. Oil & Gas: Vibration monitoring for turbo-compressors, centrifugal compressors, pumps, and fans, applicable in hazardous areas like offshore platforms and refineries.

3. Industrial Manufacturing: Machinery protection for large motors, gearboxes, blowers, and centrifuges.

4. Marine Propulsion: Vibration monitoring for main propulsion turbines and gearboxes.

5. Research & Development: Precise displacement and vibration measurement on rotating machinery test beds.

Measurement Objectives:

• Radial Vibration Measurement: Monitoring shaft vibration relative to the bearing housing to diagnose unbalance, misalignment, rubs, etc.

• Axial Position Measurement: Monitoring thrust bearing wear, rotor thermal expansion, or axial float.

• Keyphasor Measurement: Providing a speed reference signal and phase information for dynamic balancing and analysis.

4. Installation and Commissioning Guide Summary

Correct installation is crucial for ensuring system performance. Below is a summary of core steps based on the installation manual:

1. Mechanical Installation Preparation:

• Target Area Preparation: The target shaft surface should be smooth, clean, with uniform conductive material, avoiding scratches, rust spots, or magnetic spots (sources of electrical runout).

• Transducer Mounting Constraints: Must strictly adhere to the mounting constraints outlined in the manual (Section 2.2), including:

• Free space around the transducer head (Figure 2-1).

• Minimum distance between transducer and mounting support (Figure 2-2).

• Minimum distance between two transducers (Figure 2-3).

• Minimum distance between transducer and shaft shoulder, shaft end (Figures 2-4, 2-5, 2-6).

• Minimum shaft diameter requirements (Figures 2-7, 2-8) to avoid curve distortion and increased noise.

• Mounting Method Selection:

• Inside Casing Mounting: Using a bracket mounted directly on a stationary part inside the machine (Figures 2-9 to 2-12).

• Through Casing Mounting: Using PA 15x probe mounting adapters (Figures 2-13 to 2-15), allowing adjustment and replacement from outside.

• Cable Feedthrough: If the transducer is mounted inside the casing, use an SG 10x cable feedthrough (Figures 2-16, 2-17) for sealed penetration.

2. Mechanical Adjustment of Initial Gap (Machine Stopped):

• Use a feeler gauge to measure and adjust the physical gap between the transducer tip and the target.

• For Vibration Measurement: It is recommended to set the initial gap near the middle of the linear measuring range (e.g., for TQ 402 B21: around 1.15 mm) to allow for bi-directional movement.

• For Axial Position Measurement: Set the initial gap at one end of the measuring range (near or far) based on the anticipated direction of one-way movement.

• Recommended minimum safety gap (to prevent contact): For transducers with 8 mV/μm sensitivity, a minimum of 0.2 mm is suggested.

3. Cable Installation:

• Never shorten or lengthen the transducer integral cable or extension cable. Only use standard lengths specified by Vibro-Meter, meeting the minimum "Total System Length (TSL)" requirement (e.g., 4.4 m minimum for a 5 m system).

• Respect Minimum Bending Radius: Coaxial cable ≥ 20 mm, stainless steel protection tube ≥ 50 mm.

• Fixing and Routing: Secure cables at regular intervals (100-200 mm) using cable clamps both inside and outside the machine to prevent interference signals from vibration (Figure 3-1). Use heat-shrinkable sleeves on connectors to prevent loosening.

• EMI Protection: Signal cables should be routed in separate conduits, away from power cables and communication lines. Conduits should be well-grounded. Use grounded metal protection tubes for additional shielding if necessary.

4. Electrical Connection and Final Adjustment:

• Wiring: Connect strictly according to the electrical wiring diagrams in Figures 6-1 to 6-3. Ensure the shield is grounded at a single point (typically at the conditioner or barrier end).

• In Explosive Atmospheres: Must use certified explosion-proof (Ex) version components (transducer, conditioner, cables, junction box, barrier, etc.) and strictly adhere to the limits specified in the corresponding "EC Type Examination Certificate" (e.g., cable lengths, inductance/capacitance parameters).

• Electrical Adjustment (Optional Fine-tuning): After mechanical coarse adjustment, power can be applied for fine electrical adjustment.

• For B21 (Voltage Output): Use the "3-wire" technique (Figure 4-7). Power the IQS 450 (-24VDC), connect a voltmeter to the output. Vary the gap using feeler gauges, record output voltage, plot gap-voltage curve to verify linear range and sensitivity.

• If using conductive feeler gauges, they must be removed from the gap before reading the output, otherwise the measurement is false.

• Gap Setting Verification: Finally, confirm that the system's DC output voltage (corresponding to the static gap) is within the expected range (e.g., around -9V when set in the middle).

5. Accessory Installation:

• Junction Box (JB 118): Used to protect the connection point between the transducer integral cable and the extension cable (IP 65). Mount on a vibration-free surface (Figure 4-1).

• Industrial Housing (ABA 15x): Used to mount and protect the IQS 450 signal conditioner, suitable for explosive atmospheres (IP 66). Features an insulating base plate to prevent ground loops (Figure 4-2).

• Barrier/Isolator: In explosive atmosphere applications, the front-end IQS 450 (hazardous area) must be connected to the safe area equipment via a GSV 14x (for voltage output, 3-wire) or a GSI 124 (for current output, 2-wire). GSI 124 with current output mode enables stable transmission over longer distances (up to 1000 m).

5. Maintenance and Care

• Regular Inspection: Periodically check transducer mounting for tightness, inspect cables and protection tubes for damage, wear, or excessive bending, and ensure connectors are secure.

• Cleaning: Keep the transducer tip and target area clean, free from oil, dirt, or dust accumulation.

• Calibration Check: During major overhauls or if measurement data is questionable, it is recommended to check the system output characteristics against the performance curves using a calibration target under standard conditions.

• Replacement: Due to component interchangeability, when replacing a transducer or conditioner, using an identical model typically restores performance consistent with the original system without on-site recalibration.

• Repair: Any repair work should be performed by qualified personnel. If a product needs to be returned to Vibro-Meter for repair, please complete the provided Failure Report Form.