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Brüel & Kjær Vibro VIBROCONTROL 1500 Operating Instructions Manual

2-channel monitoring device for bearing vibrations, rolling-element bearing condition and temperature with diagnostic remote monitoring
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B & K s.r.o.
Palisády 20, 811 06 Bratislava
Slovak Republic
02/ 544 307 01
bk@bruel.sk, www.bruel.sk
VIBROCONTROL 1500
2-channel Monitoring Device for
Bearing Vibrations, Rolling-element Bearing
Condition and Temperature
with Diagnostic Remote Monitoring

Operating Instructions

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Summary of Contents for Brüel & Kjær Vibro VIBROCONTROL 1500

  • Page 1: Operating Instructions

    B & K s.r.o. Palisády 20, 811 06 Bratislava Slovak Republic 02/ 544 307 01 bk@bruel.sk, www.bruel.sk VIBROCONTROL 1500 2-channel Monitoring Device for Bearing Vibrations, Rolling-element Bearing Condition and Temperature with Diagnostic Remote Monitoring Operating Instructions...
  • Page 2 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise without prior written permission from Brüel & Kjær Vibro GmbH. The right to make changes at any time without notice is reserved.

  • Page 3: Table Of Contents

    General ......................9 Relay functions ....................9 Technical Data ................11 Installation .................. 16 With the installation of the VIBROCONTROL 1500 the following are to be observed: ...................... 16 Mounting in an AC-211x protective housing ..........17 4.2.1 Delivery specifications VIBROCONTROL 1500 unit in a protective housing AC-211x ... 18 Connections ................
  • Page 4 Switching the instrument ON ............27 Single-channel operation ................27 Two-channel (acceleration-temperature) operation: ........27 Hardware / Firmware version ................ 28 Operating the VIBROCONTROL 1500 ........29 Commissioning the instrument..............29 Base display ....................29 Bargraph with limit value display ..............30 Measuring the temperatures .................

  • Page 5: Safety Advice

    VIBROCONTROL 1500 Safety advice This operating instruction contains information and advice which must be observed during the installation and operation of the VIBROCONTROL 1500. Please read these operating instructions carefully before installing and taking a VIBROCONTROL 1500 into operation! Please read the general safety advice and grounding recommendations...

  • Page 6: Overview

    VIBROCONTROL 1500 Overview Overview The VIBROCONTROL 1500 is a 2-channel, microprocessor-controlled measurement data acquisition, monitoring and diagnosis instrument. Constant-current powered (CCS) acceleration sensors are used for the vibration measurements. In addition to the measurement of casing vibrations in the frequency ranges from 1/3/10 Hz to 1,000 Hz, a rolling-element bearing condition variable is also calculated for the assessment of rolling-element bearing condition.

  • Page 7: Possible Measurement And Monitoring Tasks

    All setting up tasks are carried out directly at the instrument by entry or selection of parameter values. Setting up is also possible using the VIBROCONTROL 1500 Control-Center-Software. The connections for the power supply, measurement sensors, analogue and contact outputs as well as the CAN-Bus interface are made through plug-in terminal blocks.

  • Page 8: Measuring Range Limits

    VIBROCONTROL 1500 Overview 2.2.2 Measuring range limits The measuring range can, according to the application, be adapted to the machine or monitored plant by a wide range. In the table below the measuring range limits (min. max.) are given dependent upon the characteristic variable = effective (RMS) value of vibration velocity.

  • Page 9: General

    Two values, which are adjustable over the entire measuring range, are available for signaling a violation of the alarm limit settings. A limit value violation is displayed at the VIBROCONTROL 1500 by means of LEDs and the output of the violation respectively through potential-free relay contacts.
  • Page 10 VIBROCONTROL 1500 Overview LIM 2 relay If the current measured value violates the set limit value for the RMS value of vibration velocity L2v for longer than the period of the adjusted response lag time T2, the LIM2 relay is activated (closed).

  • Page 11: Technical Data

    Technical Data VIBROCONTROL 1500 Technical Data Power supply 18 to 36 VDC Current consumption 6 W + 0.25 W Protection class IP 20 Housing Metal Housing dimensions Appr. 90 x 115 x 75 mm (B x H x D) Weight...
  • Page 12 5 mA ± 5% Transmission factor 100 mV/g and OFF selectable in menu. When selecting OFF in channel B, the VIBROCONTROL 1500 operates as a 1- channel instrument and the missing sensor is then not interpreted as a fault! Transmission factor Multiplication factor = 0.5 to 1.99;...
  • Page 13 Technical Data VIBROCONTROL 1500 Latching function of the relays: = self-latching LIM 2 = self-latching Upon violation of LIM 2 the relay is activated and remains in this condition until a RESET is carried out. LIM 1 = not self-latching...
  • Page 14 MENU for at least 3 seconds effects a reset of the instrument. External reset Reset of the relays is possible by bridging terminals 25 and 26 through the VIBROCONTROL 1500 Control-Center- Software Accuracy: Bearing vibration at 80 Hz: ±2% ± 1digit measurement within the filter ranges 1/3/10…...
  • Page 15 (CCS type), transmission factor 100 mV/g Temperature type PT-100, 3-wire or PT-100 integrated in Acceleration sensor max. cable length between VIBROCONTROL 1500 and 130 m Sensor AS-062/T1 For monitoring the casing 600 m vibration only Standards conformity: 2006/95/EU Low-voltage...

  • Page 16: Installation

    Installation and connections must be carried out only by technically qualified personnel. • The VIBROCONTROL 1500 is prepared for installation on a DIN rail. • A minimum space of 5 cm above and below the instrument must be maintained to guarantee sufficient air circulation.

  • Page 17: Mounting In An Ac-211X Protective Housing

    Connect all upper Phoenix plugs at the VIBROCONTROL 1500 unit. • Mount the VIBROCONTROL 1500 unit onto the DIN rail. • Mount all lower Phoenix plugs at the VIBROCONTROL 1500 unit. Use a screwdriver to do this carefully. Fig.2: VIBROCONTROL 1500 unit mounted on a DIN trail 1.

  • Page 18: Delivery Specifications Vibrocontrol 1500 Unit In A Protective Housing Ac-211X

    The trim levels of the protective housing AC-211x with mounted Vibrocontrol unit. Fig.3: One VIBROCONTROL 1500 in protective housing. (Order code: VIBROCONTROL 1500/01/DC) Fig.4: One VIBROCONTROL 1500 unit with power supply in. (Order code: VIBROCONTROL 1500/01/AC) - 18 - VC1500EN / C103845.002 / V 09 / 14.04.2015...
  • Page 19 VIBROCONTROL 1500 Fig.5: Two VIBROCONTROL 1500 units in protective housing. (Order code: VIBROCONTROL 1500/02/DC) Fig.6: Two VIBROCONTROL 1500 units with power supply in protectiv housing. (Order code: VIBROCONTROL 1500/02/AC) VC1500EN / C103845.002 / V 09 / 14.04.2015 - 19 -...

  • Page 20: Connections

    VIBROCONTROL 1500 Connections Connections Upper terminal strip 1st row 2nd row Lower terminal strip Fig. 7: VIBROCONTROL 1500 connection terminals - 20 - VC1500EN / C103845.002 / V 09 / 14.04.2015...

  • Page 21: Connection Terminal Layout - Upper Terminal Strip, 1St Row

    Connections VIBROCONTROL 1500 Connection terminal layout - upper terminal strip, 1st row Channel A – Sensor connections (acceleration sensor – CCS) Shield 0 VA Positive signal input SIG+ SIG- Negative signal input POWER Sensor power Not used Not used Channel B – Sensor connections (acceleration sensor – CCS)

  • Page 22: Connection Terminal Layout - Upper Terminal Strip, 2Nd Row

    VIBROCONTROL 1500 Connections Connection terminal layout - upper terminal strip, 2nd row PT-100 A PT-100 positive power PT-100 signal input PT-100 negative power Shield PT100 B PT-100 positive power PT-100 signal input PT-100 negative power Shield Connection terminal layout -...
  • Page 23 Connections VIBROCONTROL 1500 Limit 2 relay LIM 2-1 LIM 2-2 LIM 2-3 Limit 1 relay LIM 1-1 LIM 1-2 LIM 1-3 OK relay OK 1 OK 2 OK 3 The connections of the relays are done through three-pole Phoenix plugs. There is a danger of incorrectly connecting...

  • Page 24: Connection Terminal Layout - Power Supply Ac-4111

    0 V power supply for VIBROCONTROL 1500 Refere chapter 10.1. for more details. Sensor connection and sensor monitoring VIBROCONTROL 1500 is prepared for connection of two acceleration sensors with constant-current power requirement (CCS type) and an output sensitivity of 100 mV/g.

  • Page 25: Connection Of Sensors

    Connections VIBROCONTROL 1500 Connection of sensors VIBROCONTROL 1500 is prepared for connection of a max. of two acceleration sensors with constant-current power (CCS type) as well as two PT-100 sensors with three-conductor cable As an example the connections for the sensor AS-062/T1 are shown below. For further details about this sensor please consult the technical description.
  • Page 26 L1temp, resp. L2temp if these have been activated in the setup. Because of this the connection of sensors should only be carried out with the VIBROCONTROL 1500 switched off. - 26 -...

  • Page 27: Switching The Instrument On

    Switching the instrument ON Single-channel operation After the VIBROCONTROL 1500 is switched on by applying the supply voltage, a test of the attached sensors, an internal test of the instrument and an initialization of the selected instrument settings takes place. This initial procedure lasts for approx.

  • Page 28: Hardware / Firmware Version

    After the instrument switched on, and during the display of the type description and version number, it is possible to determine the complete hardware and firmware description of the VIBROCONTROL 1500 instrument by simultaneously pushing the  and  pushbuttons.

  • Page 29: Operating The Vibrocontrol 1500

    Fig. 11: Display at the instrument after switching on Base display After initialization of the instrument the base display appears on the front panel of the VIBROCONTROL 1500: The current measured effective (RMS) value of vibration velocity in mm/s (or in/s) from both sensors.

  • Page 30: Bargraph With Limit Value Display

    PT-100 elements for channel A (A:) and channel B (B:) at the installation locations are displayed. The temperature in the VIBROCONTROL 1500 instrument is shown at I:. The display N/A in the lower line signifies that no temperature signal is available (e.g.

  • Page 31: Limit Value Violation - Display

    Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 Limit value violation - Display If the pushbutton  is again pushed the instrument displays information about the last limit value violation by the measured value which has taken place. If the measured value has not violated the limit values L1v, L2v, L1temp, L2temp, L1BC, L2BC the following information is displayed.

  • Page 32: Measuring The Rolling-Element Bearing Condition

    VIBROCONTROL 1500 performs quasi continuous a DFT analysis in the frequency range 500 to 5,000 cycles per second and forms from the 20 largest frequency lines of this frequency range the geometrical sum (∑f the RMS of vibration acceleration [m/s ² eff.] and displays this as the current value Im.
  • Page 33 VIBROCONTROL 1500 monitors the BC value with the help of two adjustable limit values designated as L1BC and L2BC. Beyond that it stores...
  • Page 34 VIBROCONTROL 1500 Operating the VIBROCONTROL 1500 The instantaneous RMS value of acceleration Im and the average RMS value of acceleration Avg. Fig.20: Result of the bearing condition analysis before the establishment of the reference variable Ref. After the determination of the magnitude of the bearing condition reference Ref (at the earliest after a running time of min.

  • Page 35: Switching Off The Automatic Reference Value Determination

    Switching off the automatic reference value determination Using the parameter setting Autoref = <auto> can be set on the VIBROCONTROL 1500, if the reference value is to be updated automatically as soon as the BC-value - the ratio of Avg-Value and the Reference value - falls below the value of 0.9.

  • Page 36: General Advice For Bearing Condition Analysis

    500 Hz to 5,000 Hz. At the display of the VIBROCONTROL 1500 instrument the three largest amplitude values of these with the corresponding frequencies are displayed. Using the VIBROCONTROL 1500 Control-Center-Software all 20 values can be displayed. However the DFT analysis supplies a much higher resolution than the simplified display on the instrument permits.

  • Page 37: Trend Display And Prognosis

    Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 Trend display and prognosis The VIBROCONTROL 1500 instrument stores the measured data. Similarly to a bearing condition measurement, here a measured value is stored only when recognition of the machine's running condition has determined that the machine is not stationary.
  • Page 38 VIBROCONTROL 1500 Operating the VIBROCONTROL 1500 In addition a probability statement for the reliability of the prognosis is displayed: N/A (calculation not possible), LOW (low probability), HIGH (high probability). Fig.26: Predicted time period until the LIM 2 value is violated.
  • Page 39 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 The course of the data reduction for a trend representation. Fig. 28: Structure of the trend representation (AVG = average value) The instrument contains 3 internal memory areas with values for the trend measurement. In each memory area 30 averaged measurement values are stored: –...

  • Page 40: Rolling-Element Bearing Condition And Temperature - Trend

    This trend can be displayed only by the PC software VIBROCONTROL 1500 Control-Center-software. The trend 10 x 8 hours is only present in the VIBROCONTROL 1500 instrument, and is in principle differently formed than all other trends. Therefore it is not possible to find any connection between this and other trends.

  • Page 41: Frequency Analysis

    Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 7.10 Frequency Analysis VIBROCONTROL 1500 is in the position to perform a frequency analysis of the bearing vibrations. The following display is selected in the menu and confirmed by pushing ENTER. Fig. 30: Menu – Frequency analysis In the display the selection of the channel which is to be evaluated appears.

  • Page 42: Post-Mortem Display After A Lim2 Violation

    VIBROCONTROL 1500 Operating the VIBROCONTROL 1500 7.11 Post-mortem display after a LIM2 violation The instrument permits examination of the recorded measured data from both sensors in the time period of 994 seconds before the LIM 2 violation and up to 29 seconds after the LIM 2 violation.

  • Page 43: Setting/Editing Measurement Channel Functions - Channel

    7.12 Setting/Editing measurement channel functions - Channel In this menu the parameters of the VIBROCONTROL 1500 instrument can be edited separately for channel A and channel B. The settings for both limit values, the relay response lag times, measuring ranges, input filters frequencies and the values for recognition of the machine running status for rolling-element bearing condition and trend measurements are carried out in this menu.

  • Page 44: Channel Setup - (Monitor)

    VIBROCONTROL 1500 Operating the VIBROCONTROL 1500 7.12.1 Channel setup - (MONITOR) Using the buttons  and  MONITOR is selected and confirmed with the button ENTER. A password entry is then required. The password for measurement channel- specific settings is 1500 and be changed with the master password. The individual password numbers are entered one at a time using the buttons ...
  • Page 45 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 With L1BC, L2BC, L1temp and L2temp no relay response lag time for the limit value violation is preselectable. Signaling of these events takes place immediately after violation of the set limit values. Fig. 41: Limit settings With further paging through the menu points using the buttons ...
  • Page 46 As long as the actual measured value is lower than the set threshold value, no value is stored in the trend memory because the VIBROCONTROL 1500 assumes that the machine is stationary. Also no rolling-element bearing condition measurement takes place.
  • Page 47 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 Deleting the trend data In a case where the trend values are to be deleted push the button ENTER at the query display below and change No to Yes. The actual deletion takes place after confirmation of the new settings is made (see further below).
  • Page 48 Trim factor to the actual transmission factor of the sensor to be used. The calibration of the VIBROCONTROL 1500 to the sensor that will be used then takes place with the help of the Trim factor, which can be set within the range of 0.50 to 1.99.
  • Page 49 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 The Trim value is calculated according to the following formula: Trim = Sens /Sens nominal real Sens nominal value of the transmission factor 100 mV/g. nominal Sens actual value of the transmission factor xxx mV/g of the sensor...

  • Page 50: Setting Up/Editing The Basic Functions - Device Setup

    Fig. 52: Setting the transmission speed and CAN-Bus address In this menu an individual CAN-Bus address (device ID) can also be entered for each VIBROCONTROL 1500. Here it must be noted that this address for each CAN-Bus connection (i.e. each VIBROCONTROL 1500 instrument) can be assigned only once.
  • Page 51 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 Selecting the units With the help of the buttons the units can be changed from metric (mm/s, °C) to Imperial (in/s, °F). Fig. 53: Changing the units Setting the automatic reference value determination With the help of the buttons can be switched between automatic AutoRef = <auto>...

  • Page 52: Changing The Password

    VIBROCONTROL 1500 Operating the VIBROCONTROL 1500 Changing the password By further use of the buttons the menu option “Change password” can be reached. Here it is possible to replace the instrument password “1500“ with any other password (excluding “0000“). In order to accomplish this change, it is necessary to enter the special master password “7327”...
  • Page 53 Operating the VIBROCONTROL 1500 VIBROCONTROL 1500 After entering the new password, exit the entry window by pushing ESC. A query appears asking whether the new password should be saved. Using the buttons select either "NO" or "YES" and confirm your selection by pushing ENTER.

  • Page 54: Error Messages

    VIBROCONTROL 1500 Error messages Error messages Internal fault in the input amplifier of channel A. Internal fault in the input amplifier of channel B. Not assigned Not assigned Not assigned Not assigned Internal error – supply voltage of the analogue part out of range.

  • Page 55: Function Checks And Self-Diagnosis

    Function checks and self-diagnosis VIBROCONTROL 1500 Function checks and self-diagnosis VIBROCONTROL 1500 has the following internal self- diagnoses: Watchdog – • The Watchdog counter is reset every 200ms by the interrupt routine, which computes the RMS value of the vibration velocity. If the Watchdog is not reset (by the occurrence of an error), the Watchdog counter overflows and an instrument RESET follows.

  • Page 56: Accessories

    Fig. 60: AC-4111 power supply The AC-4111 power supply is a 230 VAC / 24 VDC power supply with 10 W output power. This unit can provide power for one VIBROCONTROL 1500 instrument and it is intended for mounting on a DIN rail.

  • Page 57: Ac-4601 Power Supply

    The AC-4601 power supply is a 230 VAC / 24 VDC power supply with 600 W output power. Up to 8 VIBROCONTROL 1500 instruments can be provided with power by the unit and it is intended for mounting on a DIN rail.

  • Page 58: Usb/Can Interfaceconverter Ac-4201

    VIBROCONTROL 1500 Accessories 10.3 USB/CAN interfaceconverter AC-4201 The converter serves the connection and regulation of up to 40 VIBROCONTROL 1500 units to a PC. Fig. 62: Example of use AC-4201 - 58 - VC1500EN / C103845.002 / V 09 / 14.04.2015...

  • Page 59: User Dialogue - Overview

    User dialogue - Overview VIBROCONTROL 1500 User dialogue - Overview Fig. 63: Structure of the menu-controlled user-dialogue VC1500EN / C103845.002 / V 09 / 14.04.2015 - 59 -...

  • Page 60: Calibration

    VIBROCONTROL 1500 Calibration Calibration We recommend that the VIBROCONTROL 1500 be calibrated every 5 years. This will ensure that the correct functionality of the system is checked, and that the certification according to the quality standard is maintained. Disposal The equipment is to be disposed of through the local valuable material acceptance location.

  • Page 61: Ce Decleration And C-Tick

    CE Decleration and C-Tick VIBROCONTROL 1500 CE Decleration and C-Tick We declare the conformity with the EMV requirement of australian Government authority (AMCA) accordance with C-Tick. VC1500EN / C103845.002 / V 09 / 14.04.2015 - 61 -...

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