IQS450 204-450-000-001-A1-B22-H10-I0 Signal Conditioner

The IQS450 204-450-000-001-A1-B22-H10-I0 is a high-performance, long-distance non-contact displacement and vibration measuring system designed by Vibro-Meter for demanding industrial environments. This system combines the widely adopted 2-wire 4-20mA current output technology (Ordering Option B22) from the industrial process control field with a 10-meter total system cable length (Ordering Option H10) suitable for long-distance wiring. It provides a complete solution with stable signal transmission, exceptional anti-interference capability, and flexible installation layout for condition monitoring and protection of large rotating machinery.

Based on the proven eddy current induction principle, the system achieves precise measurement of radial vibration, axial displacement, eccentricity, and Keyphasor® of rotating machinery shafts through the precise matching and factory calibration of the TQ 402/412 series proximity transducer and the IQS 450 signal conditioner. The core advantage of the B22 current output mode lies in its strong resistance to electromagnetic interference (EMI) and insensitivity to line resistance variations. This enables signal transmission without distortion and with high fidelity over cable lengths of several hundred meters, making it particularly suitable for monitoring applications in large plants, distributed machine sets, and complex electromagnetic environments. The total cable length of 10 meters provides ample margin for routing from the sensor to junction boxes or cabinets, facilitating flexible measurement point placement on large equipment such as power station steam turbines, pipeline compressors, and large pump sets.

As a standard industrial environment (A1) version, the system offers rugged mechanical construction and broad environmental adaptability. At the same time, users can select explosion-proof certified versions (A2 or A3) suitable for use in potentially explosive atmospheres (Zone 1/2 or Zone 2) according to their actual application scenarios, paired with corresponding intrinsic safety barriers to meet the highest safety regulation requirements.

Core Value & Differentiating Advantages:

• Exceptional Long-Distance Signal Fidelity: The golden combination of "B22 Current Output + H10 Cable Length" is optimized to overcome signal attenuation and interference in long-distance transmission, ensuring the authenticity and reliability of monitoring data.

• Unparalleled Anti-Interference Capability: Current signals have inherent immunity to induced noise, performing particularly robustly in complex industrial sites with strong interference sources like VFDs, high-power motors, and switchgear.

• Simplified System Architecture & Wiring: The 2-wire design allows power supply and signal transmission to share a single wire pair, significantly reducing cable usage, wiring complexity, and potential connection failure points.

• Seamless Integration with Industrial Control Systems: The standard 4-20mA signal can be directly connected to the analog input cards of DCS, PLC, or Safety Instrumented Systems (SIS), enabling plug-and-play system integration.

• Comprehensive Remote Monitoring Capability: The 10-meter cable offers great freedom in selecting measurement points. Combined with the long-distance transmission characteristics of the current signal, it easily facilitates centralized monitoring across areas and floors.

• Maintenance-Friendly & Cost-Effective: System components are fully interchangeable, reducing spare parts inventory and maintenance costs. Long cables reduce intermediate connection points, enhancing overall system reliability.

2. System Working Principle & In-depth Advantages of B22-H10 Configuration

The system operates based on the electromagnetic eddy current effect. The high-frequency signal generated by the IQS 450 conditioner excites the probe coil, producing an alternating magnetic field. When the field approaches a metal target, eddy currents induced on the surface absorb magnetic energy, changing the coil's equivalent impedance. The conditioner's internal precision circuitry detects this impedance change in real-time.

In B22 mode, this change is linearly converted into a 2-wire DC current signal. Its technical essence lies in:

1. "Live Zero" & High Resolution: Mapping the 0.15-2.15mm mechanical range to a 15.5-20.5mA current range, rather than the traditional 4-20mA full range. This is equivalent to expanding the measurement within a 5mA "window," giving the system a resolution as high as 2.5 μA/μm, making it extremely sensitive to micron-level vibration anomalies.

2. Robust Current Loop: The magnitude of the current signal remains constant in the transmission loop, unaffected by voltage drops caused by line resistance, and exhibits strong suppression of electromagnetic induction noise.

3. Built-in Diagnostics: An output current below 4mA (e.g., wire break) or above 20.5mA (e.g., saturation) can be identified by the host system as a hardware fault, facilitating predictive maintenance.

The combination of H10 (10-meter) cable length with B22 current output addresses the core pain points of long-distance monitoring:

• Overcomes Voltage Drop & Signal Attenuation: Long cable resistance causes severe attenuation of voltage signals, but current signals are completely free from this concern.

• Suppresses Distributed Capacitance Effects: The distributed capacitance of long cables can degrade high-frequency response. The system's design and cable length matching calibration ensure the nominal 20kHz frequency response is maintained even at 10 meters.

• Simplifies Engineering Design & Inventory: The 10-meter option is a standard long length that can meet the wiring needs of most large machine sets, eliminating the need for custom cables and reducing engineering variables and spare part types.

3. Typical Application Scenarios & Selection Guide

Ideal Application Fields for H10-B22 Configuration:

• Large Units in Power Generation: Vibration monitoring of bearing pedestals in supercritical and ultra-supercritical steam turbine generator sets, generator air gap monitoring (requires special application), monitoring of large circulating water pumps in power stations.

• Oil & Gas Pipeline Transportation: Large centrifugal compressors driven by gas turbines in pipeline compressor stations, with dispersed measurement points requiring long-distance signal transmission to the station control room.

• Large Chemical & Petrochemical Plants: Key high-speed compressors, expanders, and exhaust gas turbines in catalytic cracking and ethylene plants, with complex environmental EMI.

• Metallurgy & Heavy Machinery: Blast furnace blowers, main drive systems for rolling mills, where equipment is large and monitoring points are far from the control room.

• Marine Propulsion Systems: Monitoring of main turbine sets and gearboxes, where signals need transmission from the engine room to the centralized control room.

Key Points for Selection Decision:

1. Prioritize B22 Current Output when:

• Signal transmission distance exceeds 15 meters.

• Significant electromagnetic interference sources are present on-site.

• Direct connection to DCS/PLC systems using 4-20mA input is required.

• Requirements for long-term signal stability and reliability are extremely high.

2. Choose H10 (10-meter) Cable Length when:

• Preliminary estimation of the wiring path (including inside machine, through-wall, cable tray to junction box) is between 5-10 meters.

• Ample installation margin is desired to avoid insufficient cable length.

• Standardized configuration is preferred to reduce customization needs.

4. Installation, Commissioning & System Integration Key Points

1. System Architecture Diagram:
For long-distance applications in non-hazardous areas (A1), the typical architecture is:
[Target Shaft] ← (Gap) → [TQ 402/412 Transducer] → [10m Integral Cable] → [IQS 450 Conditioner (B22 Mode)]
[IQS 450] ←→ (2-core shielded cable, e.g., K 209) → [Control Room Terminal Block/Safety Barrier] → [DCS/PLC AI Card (250Ω)]

2. Core Installation Steps:

• Mechanical Installation & Gap Setting: Strictly follow the manual's geometrical constraints. Set the initial mechanical gap using feeler gauges. For vibration monitoring, setting it at 1.15mm (linear midpoint), corresponding to a current output of ~18.0mA, is recommended.

• Key Points for Long Cable Installation:

• Fixing & Anti-Vibration: Use cable clamps or ties to securely fix the cable along the routing path every 100-200mm, especially in vibration areas, to prevent false vibration signals from cable whipping.

• Shielding & Grounding: Fully shielded cable must be used. The shield must be grounded at a single point on the control system cabinet side. Absolutely avoid grounding at both the transducer end and cabinet end to prevent "ground loops."

• Separate Routing: Signal cables must be routed in separate cable trays/conduits from power cables and VFD output cables, with a minimum parallel spacing of at least 30cm.

• Electrical Connection:

• Connect the IQS 450's "-24V" and "COM" terminals to the current loop formed by the safety barrier or power supply.

• The IQS 450's "OUTPUT" terminal is the signal output, connected to the positive side of the loop.

3. Commissioning & Verification:

• Loop Integrity Test: Use a multimeter to measure the total resistance of the entire current loop, ensuring the working voltage across the IQS 450 terminals is within its required range for the given supply voltage.

• Static Calibration Verification: With the machine stationary, connect a precision milliammeter in series in the loop. The measured value should be between 15.5-20.5mA and roughly match the current value estimated based on the initial mechanical gap.

• Dynamic Function Test: After startup, observe if the gap and vibration values displayed on the monitoring system are within a reasonable range. Cross-verification can be performed using a handheld vibrometer on the bearing pedestal.

4. Use with Safety Barrier (GSI 124) (for Explosion-Proof or Ultra-Long Distance):
When used in explosive atmospheres or for extremely long transmission distances (approaching the theoretical limit of 1000 meters), the GSI 124 is an essential core accessory. It plays three roles:

• Intrinsic Safety Power Source: Provides energy-limited power to the IQS 450 in the hazardous area.

• Signal Isolator & Converter: Reads the 4-20mA current signal from the hazardous area and outputs an isolated voltage signal (e.g., -1.6 to -17.6V) on the safe area side.

• System Safety Barrier: Ensures that under any fault condition, the energy transferred to the hazardous area is insufficient to ignite an explosive mixture.

5. Maintenance, Troubleshooting & Lifecycle Management

• Preventive Maintenance: Regularly inspect transducer tightness, check cable sheathing for damage or signs of high-temperature burning, and clean oil/grease from the transducer tip.

• Troubleshooting Guide:

• No Current Output: Check power supply polarity/voltage, open circuit in the loop, fuses, and for broken transducer cable.

• Output Fixed at High End (>20.5mA) or Low End (<15.5mA): Check if the transducer is bent, touching the target, or too far away; check for thick insulating coating on the target surface; confirm target material.

• High Signal Fluctuation/Noise: Check shield grounding (single point); check for strong interference sources near signal lines; check for loose or damp connections.

• Lifecycle Management: System components are interchangeable. It is advisable to stock key spare parts (e.g., transducer). Offline calibration checks can be performed during major overhauls.