IQS450 204-450-000-001-A1-B23-H10-I0 Signal Conditioner

The IQS450 204-450-000-001-A1-B23-H10-I0 is a professional-grade industrial monitoring solution from Vibro-Meter designed for large-displacement, long-distance measurement scenarios. This system integrates two core advantages: a 4-mm wide linear measuring range (Ordering Option B23) and a 10-meter cable length (Ordering Option H10). It offers the optimal balance of performance and reliability for complex industrial applications requiring monitoring of significant mechanical displacement where sensor installation points are far from control cabinets.

Based on high-precision eddy current measurement technology, the system consists of a TQ 402/412 series proximity transducer and an IQS 450 signal conditioner, factory-calibrated to ensure excellent linearity and 4 mV/μm sensitivity across the entire wide measuring range of 0.3-4.3 mm. The B23 option's voltage output mode provides a standard -1.6V to -17.6V signal that can be directly connected to most industrial control systems and vibration monitoring instruments. The 10-meter total cable length provides ample wiring flexibility for monitoring point layout on large equipment (such as power station steam turbines, chemical centrifugal compressors, marine propulsion systems), allowing sensors to be installed at locations distant from junction boxes or interface cabinets while maintaining signal integrity.

This configuration is designed for standard industrial environments (A1), featuring a robust structure that withstands harsh conditions. The transducer can operate stably in extreme temperatures from -40°C to +180°C, with full-system temperature compensation ensuring long-term measurement stability. Its design complies with international machinery protection standards such as API 670, and explosion-proof certified versions suitable for use in potentially explosive hazardous areas can be selected as needed.

Core Value Proposition:

• Broad Displacement Monitoring Capability: The 4-mm linear range (B23) is ideal for large-displacement applications, providing ample margin for monitoring high-amplitude parameters like axial float, thermal expansion, and thrust bearing wear.

• Exceptional Long-Distance Signal Fidelity: The 10-meter cable (H10) combined with an optimized voltage output circuit ensures high signal-to-noise ratio and wide frequency response up to 20kHz over long-distance transmission.

• Powerful Environmental Adaptability: The system operates reliably from -40°C low temperatures to +180°C high temperatures, and from humid to dusty conditions.

• Simplified System Integration: Standard voltage output is compatible with most data acquisition systems, reducing signal conversion steps, system complexity, and potential failure points.

• Optimized Installation Flexibility: Long cables reduce the need for intermediate connections, and the wide measurement range lowers installation precision requirements, significantly shortening on-site commissioning time.

• Lifecycle Cost Advantage: Components are fully interchangeable, reducing spare parts variety; robust design lowers maintenance frequency, offering excellent return on investment.

2. System Working Principle & Engineering Advantages of the B23-H10 Configuration

The system operates based on the eddy current induction principle. The IQS 450 conditioner generates a 1-2 MHz high-frequency oscillating signal to drive the transducer coil, producing an alternating magnetic field. The eddy current effect in the metal target absorbs magnetic energy, altering the coil's quality factor (Q) and effective inductance. The conditioner's patented demodulation circuit precisely measures this change and linearly converts it into a voltage signal.

Engineering Advantages of the B23 (4mm Range, 4mV/μm) Mode:

1. Extended Dynamic Range & Safety Factor: Expanding the linear range to 4.3mm means that when monitoring mechanical displacement of the same amplitude, the system operates at only 25%-50% of its range, providing a large safety buffer for unforeseen over-travel (e.g., instantaneous shock, installation settlement), significantly enhancing system robustness.

2. Reduced Installation Sensitivity & Commissioning Difficulty: The wide range relaxes the precision requirements for initial gap setting. Even with installation deviations of several millimeters, the system can still operate within the linear region, greatly simplifying field commissioning, especially in maintenance spaces with limited access or where precise measurement is impossible.

3. Adaptation to Target Surface Defects: For shafts with minor scratches, rust spots, or slight out-of-roundness, the larger measuring range can "average out" the impact of these local defects on gap measurement, yielding a more stable and reliable average gap value (for position monitoring).

Synergistic Effect of H10 (10-meter Cable) & Voltage Output:

• Dedicated Long-Line Compensation Design: The IQS 450's internal circuitry is optimized to compensate for the typical resistance, capacitance, and inductance of the 10-meter standard cable, ensuring frequency response and linearity equivalent to calibration at the cable end.

• Applicability of Voltage Signals: For transmission distances within 10 meters, voltage signals over high-quality shielded cables can provide excellent signal-to-noise ratio. It avoids the need for additional safety barriers or isolators required for current loops (in non-hazardous areas), simplifying system architecture and cost.

• Facilitates Diagnostics & Monitoring: Using a high-impedance multimeter or oscilloscope allows easy voltage measurement at any point in the loop, facilitating fault finding and online health checks.

3. Typical Application Scenarios & Selection Decision Tree

Typical Application Fields for B23-H10 Configuration:

• Large Hydroelectric Generator Sets: Runout monitoring of hydro turbine main shafts, where displacement amplitude often reaches several millimeters, and sensors are far from monitoring cabinets.

• Marine Main Propulsion Systems: Monitoring axial position and vibration of gearbox input/output shafts; engine room environment is harsh with long wiring distances.

• Large Fans/Dust Collection Fans in Steel Industry: Monitoring bearing housing vibration; displacement is large, installation foundation may be unstable, requiring wide-range fault tolerance.

• Reciprocating Compressors in Chemical Plants: Piston rod drop monitoring (for rod packing leak预警), requiring monitoring of significant static position changes.

• Multi-functional Test Rigs in Universities & Research Institutes: Need one transducer to adapt to various experimental projects with different displacement amplitudes, reducing sensor changeover needs.

Selection Decision Logic:
Question 1: Is the expected maximum displacement greater than 2mm, or is a very large installation safety margin required?

• Yes → Choose B23 (4mm range).

• No → Consider B21 (2mm range, higher resolution).

Question 2: Is the estimated wiring distance from the transducer installation point to the nearest junction box/interface cabinet greater than 5 meters?

• Yes → Choose H10 (10-meter length).

• No (3-5 meters) → H05 (5 meters) may be more economical.

• No (<3 meters) → Choose a shorter standard length.

Question 3: Are there strong electromagnetic interference sources on-site, or is the transmission distance greater than 20 meters?

• Yes → Even if the range requirement fits B23, prioritize evaluating the B22 current output model for its noise immunity and long-line transmission advantages.

• No → B23 voltage output is a good choice for simplified systems.

4. Complete Guide to Installation, Commissioning & System Integration

1. System Layout Planning:

• Cable Route Design: Plan the 10-meter cable path from the transducer to the IQS 450 conditioner. Avoid running parallel to VFD output cables or high-current power cables (minimum spacing 30cm). If unavoidable, use galvanized steel conduits for separate shielding.

• Conditioner Location: Install the IQS 450 in a location with low vibration, temperature below 85°C, dry, and easy to wire, such as a field enclosure or control cabinet near the equipment.

• Grounding Strategy: Implement single-point grounding for the entire system. Best practice is to ground the cable shield uniformly at either the IQS 450 end or the control system end to avoid ground loops introducing noise.

2. Installation Execution Steps:

• Mechanical Installation: Use a micrometer or laser alignment tool to ensure the transducer is perpendicular to the target surface. Set the initial mechanical gap using feeler gauges. For B23, it is strongly recommended to set the gap between 1.5-2.5 mm, corresponding to an output voltage of approximately -6.2V to -10.0V, positioned in the middle of the linear range with ample room for bi-directional displacement.

• Cable Fixing: Use nylon cable ties or stainless steel clamps to secure the cable along its route every 150-200mm. In vibration areas, reduce spacing to 100mm. Use insulating grommets when passing through metal plates to prevent abrasion.

• Electrical Connection:

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

2. Connect the "OUTPUT" and "COM" terminals to the differential analog input channel of the monitoring system.

3. Ensure all connections are secure. For outdoor or damp environments, seal connectors with waterproof sealant or heat-shrink tubing.

3. Power-Up, Commissioning & Verification Procedure:

1. Static Zero Verification: Power on with the machine stationary. Measure the output voltage V_initial. It should be between -1.6V and -17.6V and roughly correspond to the set mechanical gap Gap_initial according to the relationship: V_initial ≈ -4.0 * Gap_initial (units: mV/μm) plus an offset of approximately -0.4V (see calibration curve for specifics).

2. Dynamic Function Test: With the machine running, observe the gap and vibration values displayed on the monitoring system. Cross-verify trend consistency using a portable vibrometer on the bearing housing.

3. System Linearity Verification (Optional, recommended for critical applications): After shutdown, use a set of precise non-conductive shims (e.g., Mylar shims) to add several known thicknesses (e.g., 0.5mm, 1.0mm) to the initial gap, record the corresponding output voltages, calculate the actual sensitivity, and compare it to the nominal 4 mV/μm value.

4. Integration with Host Systems:

• DCS/PLC Integration: Create an analog input point in the DCS, scaling it to -1.6V ~ -17.6V corresponding to 0.3mm ~ 4.3mm. Also create secondary calculation points for vibration velocity/displacement.

• Dedicated Vibration Monitoring System Integration: Configure the channel within the monitoring framework, select input type as "Eddy Probe", enter sensitivity "4.0 mV/μm", and set mechanical/electrical zero.

• Alarm & Protection Settings: Based on the machine manufacturer's guidelines, set Alert and Danger thresholds for radial vibration (typically peak-to-peak). For axial position, set positive and negative displacement limits.

5. Predictive Maintenance & Troubleshooting

• Daily Inspection Checklist:

• Check if transducer locknut is loose.

• Inspect cable armor for damage or corrosion.

• Ensure connectors are clean, dry, and tight.

• Check IQS 450 housing temperature for anomalies.