IQS450 204-450-000-001-A1-B21-H10-I0 Signal Conditioner

The IQS450 204-450-000-001-A1-B21-H10-I0 is a high-precision, high-reliability non-contact eddy current displacement measuring system introduced by Vibro-Meter SA. This system is specifically designed for continuous online monitoring and protection of critical parameters such as shaft vibration, axial displacement, eccentricity, and speed (Keyphasor) in rotating machinery operating in harsh industrial environments. As a key sensing component for industrial predictive maintenance and machine health management, its measurements are directly related to equipment safety and production continuity.

Based on the classic eddy current principle, the system core consists of a TQ 402 or TQ 412 series non-contact transducer paired with an IQS 450 signal conditioner, factory-calibrated as a unit to ensure exceptional measurement accuracy and component interchangeability. The "H10" code in the model number indicates a system configuration with a 10-meter total cable length. This is suitable for applications where the transducer mounting point is far from the monitoring cabinet or junction box, providing layout flexibility for monitoring large units such as power station steam turbines and large compressor trains.

Its design strictly adheres to international machinery protection standards (e.g., API 670) and offers multiple configuration options for different environmental requirements. The system outputs a voltage signal linearly proportional to the measured gap, featuring wide frequency response, low temperature drift, and strong anti-interference capability. It is an ideal choice for safeguarding the safe and stable operation of critical assets like turbomachinery, power generation equipment, and large pumps and fans.

Core Value & Features:

• Reliable Fault Prediction: Precisely measures relative shaft vibration and positional changes, providing diagnostic basis for early faults like unbalance, misalignment, rubs, and bearing wear.

• Adaptability to Harsh Environments: The transducer can operate stably in high-temperature environments from -40°C to +180°C. The overall system is ruggedly designed, resistant to oil, dirt, and corrosion.

• Long-Distance Signal Fidelity: The 10-meter system length (H10) configuration, combined with high-quality coaxial cables and optimized signal conditioning, ensures signal integrity over long transmission distances.

• Simplified Engineering & Maintenance: Components are fully interchangeable without requiring field recalibration, significantly reducing spare parts inventory and repair downtime.

• Flexible System Integration: Standard voltage output can be directly connected to DCS, PLC, or dedicated vibration monitoring systems, meeting various automation control and protection needs.

2. Brief System Working Principle

The system operates based on the eddy current effect in electromagnetic induction. The high-frequency oscillator inside the IQS 450 signal conditioner applies a constant high-frequency current through the coaxial cable to the coil in the tip of the TQ 402/412 transducer, generating a high-frequency alternating magnetic field around the coil.

When this field approaches a conductive metal target (e.g., a rotating shaft surface), eddy currents are induced in the target surface layer. These eddy currents generate a new magnetic field opposing the original one, thereby weakening the transducer coil's field and causing a change in the coil's effective impedance. This impedance change is a function of the distance (gap) between the transducer tip and the target surface.

The precision circuitry inside the IQS 450 detects and demodulates this impedance change, converting it into a DC voltage signal (Option B21) highly linear to the gap. The output voltage becomes more negative as the gap increases (e.g., -2V represents a small gap, -18V a large gap). This voltage signal contains a static DC component (average gap) and a dynamic AC component (vibration) of the target position, and can be directly acquired, analyzed, and processed by backend monitoring equipment.

The system features temperature compensation, effectively suppressing changes in transducer coil resistance and cable characteristics caused by ambient temperature variations, thus ensuring long-term measurement stability.

3. Typical Application Scenarios

This system with a 10-meter cable length is particularly suitable for medium to large rotating equipment with dispersed monitoring points and long wiring distances:

1. Power Generation Industry:

• Steam/Gas Turbines: Monitoring shaft vibration (X/Y direction), axial position, and eccentricity of HP/IP/LP casings and bearings.

• Generators: Monitoring bearing vibration. (For shaft voltage monitoring with grounding brushes, special application is required.)

• Hydraulic Turbines: Monitoring swing and blade clearance.

2. Oil, Gas & Petrochemical:

• Centrifugal/Axial Compressors: Monitoring vibration and axial position of various stage bearings to prevent surge and wear.

• Large Pump Trains: Monitoring vibration status of transfer pumps, feedwater pumps.

• Gas Turbine Driven Equipment: Applications in pipeline compressor stations, LNG plants.

3. Heavy Industry & Manufacturing:

• High-Speed Motors, Gearboxes: Condition monitoring and fault diagnosis.

• Steel Industry: Vibration monitoring for large fans, dedusting fans.

• Paper Industry: Roller bearing monitoring.

4. Marine Propulsion: Vibration monitoring for main propulsion turbine sets and reduction gearboxes.

4. Key Points for Installation, Configuration & Commissioning (for H10 System)

1. Installation Planning Phase:

• Cable Routing Planning: Plan a reasonable path for the 10-meter cable in advance to avoid excessive redundant coiling. Allow sufficient slack for equipment thermal expansion and vibration, but secure it neatly.

• Electromagnetic Interference (EMI) Protection: Long cables are more susceptible to acting as antennas picking up interference. Ensure signal cables are routed in separate cable trays/conduits from strong interference sources like power cables and VFD feeder cables, with a minimum parallel spacing >30 cm. Using grounded metal conduits or cable trays is recommended for additional shielding.

• Connector Protection: Use heat-shrink sleeves to seal and prevent loosening of connectors between the transducer and extension cable, and between the extension cable and conditioner, especially in environments with vibration or potential condensation.

2. Transducer Mechanical Installation:

• Strictly Adhere to Installation Constraints: Carefully read and follow all diagrams and tables in Section 2.2 of the Installation Manual (e.g., free space, spacing, shaft diameter requirements). This is fundamental to achieving the system's nominal performance.

• Initial Gap Setting: Set the gap mechanically using feeler gauges with the machine stationary.
  * For Vibration Measurement: It is recommended to set the initial gap near the middle of the linear range (~1.15 mm), corresponding to an output of ~ -9.6V, allowing sufficient margin for bi-directional vibration.
  * For Axial Position Monitoring: Set near one end of the linear range (near or far) based on the expected direction of movement.

• Target Area Preparation: The target shaft surface should be smooth, clean, and of uniform material. Avoid local scratches, corrosion, or coatings, which can cause "electrical runout" and interfere with the vibration signal.

3. Cable Fixing:

• Anti-Vibration Fixing: Inside and outside the machine, cables must be securely fixed to rigid structures using cable clamps or ties at intervals of 100-200 mm. This is crucial for a 10-meter cable to prevent false signals from cable vibration.

• Minimum Bending Radius: Ensure smooth bends with a radius of no less than 20 mm along the entire cable route.

4. Electrical Connection & Power-Up Check:

• Power & Grounding: Provide a stable -24VDC power supply to the IQS 450. Ensure the system shield is grounded at a single point on the monitoring system side to avoid ground loops introducing noise.

• Power-Up Verification: After connection, power up. With the target stationary, measure the output voltage of the IQS 450. This voltage should be between -1.6V and -17.6V and roughly correspond to the mechanically set initial gap (can be estimated using the calibration curve for VCL 140 steel). If the voltage is near the negative supply rail or zero, check connections, power supply, and transducer condition.

5. Optional Electrical Fine-Tuning:
After mechanical installation and basic verification, fine calibration can be performed to obtain the best characteristic curve for that specific installation:

• Use non-conductive feeler gauges (e.g., phenolic) or a standard calibration target to change the gap to several known values around the initial gap.

• Record the corresponding IQS 450 output voltage for each gap.

• Plot the "gap vs. voltage" curve to verify the system sensitivity and linearity for this actual installation.

5. Supporting Accessories & Selection Guide (Based on Attached Documents)

• Extension Cable (EA 402): Used when the transducer's integral cable length is insufficient. The 10-meter total length for this system may already be achieved by a long integral cable or a combination of integral + extension cables.

• Probe Mounting Adapter (PA 151/152/153): Used to mount the transducer outside the machine casing, allowing gap adjustment from outside for easier maintenance.

• Cable Feedthrough (SG 102): Used to maintain casing seal (IP 68 protection rating) when the transducer cable passes through a machine pressure hull or explosion-proof enclosure.

• Junction Box (JB 118): Used to protect the connection point between the transducer cable and extension cable in harsh environments.

• Industrial Housing (ABA 15x): Used for field mounting and protecting the IQS 450 signal conditioner, providing IP 66 protection.

• Mounting Adapter (MA 130): Used for easy mounting of the IQS 450 signal conditioner on a standard DIN rail.

• Safety Barrier/Isolator (GSV 14x / GSI 124): When the entire system or part of it needs to be installed in a potentially explosive atmosphere (hazardous area), corresponding certified explosion-proof version components (A2/A3) must be selected, and certified safety barriers (e.g., GSV 14x for voltage output, GSI 124 for current output) must be installed between the safe and hazardous areas to limit energy in the hazardous area. This A1 model is standard and not suitable for hazardous areas.

6. Important Notes & Maintenance Recommendations

• Never Modify Cables: Absolutely do not cut or splice transducer or extension cables on site. This destroys system calibration and impedance matching, leading to severe performance degradation or failure.

• Connector Handling: Hand-tighten connectors only. Over-tightening can damage threads and internal pins.

• Regular Inspection: During routine inspections, check if the transducer is loose, if cable sheathing shows wear, cuts, or high-temperature aging, and if connectors are tight.

• Troubleshooting: If system output is abnormal (e.g., no output, saturated output, excessive noise), first check power supply, cable connections, and grounding, then check for contamination on the transducer surface or changes in the target surface condition.

• Storage & Transport: Store transducers in a dry environment. During transport, it is recommended to fit a protective plastic cap over the transducer tip to avoid impact.