IQS450 204-450-000-001-A1-B23-H05-I0 Signal Conditioner

The IQS450 204-450-000-001-A1-B23-H05-I0 is a professional-grade non-contact eddy current displacement measuring system meticulously engineered by Vibro-Meter for large-displacement measurement applications. The core features of this system lie in its optimized combination of a voltage output configuration with a 4-mm large linear measuring range (Ordering Option B23) and a standard 5-meter cable length (Ordering Option H05). It provides an ideal solution for industrial applications requiring monitoring of significant mechanical displacement, providing ample safety clearance, or dealing with less-than-ideal target surface conditions.

The system strictly adheres to the eddy current measurement principle, achieving precise measurement of rotating machinery parameters such as axial position, relative vibration, and eccentricity through the accurate matching and factory calibration of the highly reliable TQ 402/412 series proximity transducer and the IQS 450 signal conditioner. The 4 mV/μm sensitivity voltage output provided by the B23 option expands the system's linear measuring range to 0.3-4.3 mm while maintaining sufficient signal resolution. This more than doubles the measurement margin compared to standard 2-mm range systems. This design is particularly suitable for applications such as units with large axial float (e.g., certain pumps, fans), thrust bearing wear monitoring, and scenarios requiring larger installation safety margins.

The 5-meter cable length (H05), as one of the most commonly used configurations in industrial settings, strikes a perfect balance between signal fidelity and installation flexibility. Designed for standard industrial environments (A1), the system also offers optional explosion-proof certified versions (A2, A3) suitable for potentially explosive atmospheres to meet safety regulation requirements in fields like refining, chemicals, and natural gas.

Core Value Proposition:

• Extended Measuring Range: The 4-mm linear range (B23) provides a wider window for displacement monitoring, suitable for large-displacement applications and situations requiring extra installation safety factors.

• Robust Voltage Signal: -1.6V to -17.6V DC voltage output, compatible with the vast majority of vibration monitoring instruments and data acquisition systems, facilitating system integration.

• Optimized Performance Matching: The 5-meter cable length (H05) ensures optimal frequency response and signal-to-noise ratio over typical transmission distances, avoiding parasitic effects introduced by longer cables.

• Excellent Installation Tolerance: The larger linear range reduces the precision requirements for initial gap setting, simplifying the installation and commissioning process.

• Comprehensive Mechanical Protection: System components are ruggedly designed; the transducer can operate continuously in environments up to 180°C, adapting to harsh conditions.

• Cost-Effective Solution: Provides a ready-made product with superior performance, high reliability, and no need for customization for standard large-displacement monitoring needs.

2. System Working Principle & B23 Output Characteristics

The system operates based on the eddy current effect. The high-frequency signal generated by the IQS 450 conditioner drives the transducer coil, producing an alternating magnetic field. When a metal target enters this field, induced eddy currents cause a change in the coil's impedance, which is a function of the air gap.

For the B23 voltage output mode, the IQS 450 linearly converts the transducer's impedance change into a negative voltage signal referenced to ground. Its core characteristics include:

1. Wide-Range Linear Output: Within the 0.3 mm to 4.3 mm air gap range, the output maintains a high degree of linearity with a slope (sensitivity) of 4 mV/μm. This means the system provides a stable, predictable voltage response across the full 4mm displacement range.

2. Extended Dynamic Range: The larger linear range allows the target to move within a greater displacement range without the output signal saturating or entering a non-linear region. This is crucial for monitoring machines with large axial float (e.g., certain vertical pumps) or applications requiring a larger initial gap during installation.

3. Three-Wire Connection: Typically requires three wires: power negative (-24V), common ground (COM), and signal output (OUTPUT). This connection method is simple, direct, and easy to troubleshoot.

4. Direct Voltage Interface: The -1.6V to -17.6V output voltage range can be directly connected to most data acquisition cards, PLC analog input modules, or dedicated vibration monitors without requiring additional signal converters.

Comparative Advantages vs. B21 (8 mV/μm, 2mm range):

• Larger Safety Margin: For the same mechanical displacement, the B23 system uses only a portion of its range, providing a larger buffer space for unexpected over-travel and reducing the risk of transducer-target collision.

• More Forgiving Installation Requirements: The larger linear range reduces the stringent precision requirements for initial gap setting, making installation and commissioning faster.

• Suitable for Rough or Uneven Targets: When the target surface finish is poor or slight eccentricity exists, the larger measuring range can better "accommodate" these mechanical errors while still ensuring an effective measurement interval.

3. Typical Application Scenarios & Advantages of H05 Cable Length

Ideal Application Fields for B23 (4mm range) Configuration:

• Rotating Machinery with Large Axial Displacement: Axial position monitoring for certain multi-stage centrifugal pumps, large fans, and hydraulic turbine runners where the working displacement range may exceed 2mm.

• Thrust Bearing Wear Monitoring: Monitoring the slow change in rotor axial position throughout the entire process from new bearing to complete wear-out; the 4mm range can cover a longer wear cycle.

• Units with Significant Thermal Expansion: Machines where the axial expansion of the rotor relative to the casing from cold to hot state is substantial.

• Installation Space Limitations or Poor Target Surface Condition: When structural constraints prevent installing the transducer very close to the target, or when the target surface has allowable grooves/scratches, requiring a larger initial gap to avoid mechanical interference.

• Universal Test Benches for Education or R&D: Need flexibility to adapt to experimental setups with different displacement amplitudes.

Advantages of 5-meter Total Length (H05) Configuration:
5 meters is a proven "sweet spot" length because it:

1. Provides Excellent Signal Integrity: At this length, signal attenuation and phase delay introduced by the cable are minimal, allowing the system to fully realize its DC-20kHz wide frequency response performance.

2. Satisfies Most Field Layouts: For routing from a transducer inside a casing to an external junction box or nearby cabinet, 5 meters is usually sufficient and facilitates neat cable coiling and fixing.

3. Optimizes Cost and Performance: Avoids the extra cost, weight, and more complex installation requirements of longer cables while ensuring signal quality.

4. Installation, Wiring, Commissioning & System Integration

1. System Wiring Diagram (Typical Non-Explosive Application):

[Target Shaft] <-- Gap --> [TQ Transducer] ==(5m Integral Cable)==> [IQS 450 Conditioner]
                                                                    | (-24VDC)
                                                                    | (COM)
                                                                    | (OUTPUT) --> [Monitoring System AI Channel]

The power supply (-24VDC) and signal output (OUTPUT) share COM as the reference ground.

2. Core Installation & Commissioning Steps:

• Mechanical Installation: Strictly adhere to installation constraints. Due to the wide range, the initial gap can be set in the middle to near end of the linear range (e.g., approximately 2.3mm, corresponding to an output of ~ -9.6V) to provide ample margin for bi-directional displacement (like vibration) or primary one-way displacement.

• Cable Installation: Secure the cable at 100-200mm intervals, observing the minimum bending radius. Using heat-shrink sleeves on connectors for moisture and loosening protection is recommended.

• Electrical Connection:

• Connect the -24VDC power supply to the IQS 450's "-24V" and "COM" terminals.

• Connect the "OUTPUT" and "COM" terminals to the analog input channel of the monitoring equipment (input impedance ≥10kΩ).

• Single-point shield grounding, typically at the monitoring system end.

• Power-Up Verification & Calibration:

1. Power on and measure the static output voltage.

2. This voltage should be between -1.6V and -17.6V and roughly correspond to the mechanically set gap (can be estimated using the VCL 140 calibration curve: Voltage ≈ -3.84 * Gap(mm) - 0.45 V).

3. (Optional Fine-tuning) Use non-conductive feeler gauges to change the gap to several known values, record the output voltage, and plot the actual "gap vs. voltage" curve for the installation to verify linearity and sensitivity.

3. Integration with Monitoring Systems:

• Direct Connection: The output voltage signal can be directly connected to vibration cards, PLC AI modules (configured with correct range), or data acquisition systems.

• Range Setting: In the monitoring software, the channel range must be set to the corresponding mechanical range (0.3-4.3mm) and electrical signal range (-1.6 to -17.6V or converted engineering units).

• Alarm Setting: Based on machinery protection requirements, set Alert and Danger thresholds in the monitoring system, typically based on displacement peak-to-peak values or static position values.

5. Troubleshooting & Maintenance Recommendations

• No Output Change or Output Locked at a Value: Check power supply, cable connections, and for transducer damage. Confirm the target is conductive metal and within the valid measuring range.

• Excessive Output Noise: Check shield grounding (single point); check if signal lines are routed separately from power lines; check for secure connections.

• Abnormal Sensitivity (Output change inconsistent): Check for significant difference between target material and calibration material; check if the transducer tip is contaminated; confirm the system configuration (B23) is correct.

• Regular Maintenance: Periodically check transducer tightness and cable condition. Clean the transducer tip. Functional testing of the system can be performed during machine overhauls.