VIBROCONTROL 1500
2-channel Monitoring Device for Bearing
Vibrations, Rolling-element Bearing
Condition and Temperature
with Diagnostic Remote Monitoring
Operating Instructions
VIBROCONTROL 1500 CONTENT
Table of Contents
VIBROCONTROL 1500
1 Safety advice................................................................................ 5
2 Overview ...................................................................................... 6
2.1 Display and operating elements......................................................................6
2.2 Possible measurement and monitoring tasks .................................................7
2.2.1 Display values ...........................................................................................................................7
2.2.2 Measuring range limits ..............................................................................................................8
2.2.3 Display value and bandwidth .....................................................................................................8
2.2.4 Signal detection .........................................................................................................................8
2.3 General ...........................................................................................................9
2.4 Relay functions ...............................................................................................9
3 Technical Data ........................................................................... 11
4 Installation .................................................................................. 16
4.1 With the installation of the VIBROCONTROL 1500 the following are to be
observed: ......................................................................................................16
4.1.1 Directions for the installation of the VC-1500 on a top-hat rail ................................................17
4.2 Mounting in an AC-211x protective housing .................................................17
4.2.1 Delivery specifications VIBROCONTROL 1500 unit in a protective housing AC-211x ...........19
5 Connections ............................................................................... 21
5.1 Connection terminal layout - upper terminal strip, 1st row ............................22
5.2 Connection terminal layout - upper terminal strip, 2nd row...........................23
5.3 Connection terminal layout - lower terminal strip .........................................23
5.4 Connection terminal layout - power supply AC-4111 ....................................25
5.5 Sensor connection and sensor monitoring....................................................25
5.6 Connection of sensors ..................................................................................26
6 Switching the instrument ON ...................................................... 28
6.1 Single-channel operation ..............................................................................28
6.2 Two-channel (acceleration-temperature) operation: .....................................28
6.3 Hardware / Firmware version ........................................................................29
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VIBROCONTROL 1500 CONTENT
7 Operating the VIBROCONTROL 1500 ....................................... 30
7.1 Commissioning the instrument......................................................................30
7.2 Base display .................................................................................................30
7.3 Bargraph with limit value display...................................................................31
7.4 Measuring the temperatures .........................................................................31
7.5 Limit value violation - Display........................................................................32
7.6 Menu-guided instrument dialogue.................................................................32
7.7 Measuring the rolling-element bearing condition ..........................................33
7.7.1 Switching off the automatic reference value determination.....................................................36
7.7.2 General advice for bearing condition analysis.........................................................................37
7.8 Trend display and prognosis.........................................................................38
7.9 Rolling-element bearing condition and temperature - Trend.........................41
7.10 Frequency Analysis.......................................................................................42
7.11 Post-mortem display after a LIM2 violation ...................................................43
7.12 Setting/Editing measurement channel functions - Channel ..........................44
7.12.1 Channel setup - (MONITOR) ..................................................................................................45
7.13 Setting up/Editing the basic functions - Device Setup ..................................51
8 Error messages .......................................................................... 55
9 Function checks and self-diagnosis............................................ 56
10 Accessories................................................................................ 57
10.1 Power supply AC-4111 .................................................................................57
10.2 AC-4601 power supply..................................................................................58
10.3 USB/CAN interfaceconverter AC-4201 .........................................................59
11 User dialogue - Overview ........................................................... 60
12 Maintenance............................................................................... 61
12.1 Calibration.....................................................................................................61
12.2 Cleaning........................................................................................................61
13 Disposal ..................................................................................... 61
14 CE Decleration ........................................................................... 62
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VIBROCONTROL 1500 Safety advice
1 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 before
the installation and commissioning!
The safety advice and grounding recommendations are separately included
with the operating instructions!
Intended application
VIBROCONTROL 1500 is intended exclusively for measurement, display and
monitoring of bearing vibrations, rolling-element bearing condition and
temperature in the applications of machine protection and condition-
dependent machine maintenance. Operation is only permitted up to 2000
meters above sea level!
Any application beyond these is considered as invalid for the system.
Reliability
VIBROCONTROL 1500 is equipment which is reliable in service and
corresponds to the state of the art technology. Every instrument leaves our
works in an error-free and safe condition.
Any person who is responsible for carrying out the installation and operation
of the instrument must have read and understood these operating
instructions and especially the safety advice in advance of the installation
and operation.
With inappropriate handling or non-observance of the operating instructions
the working reliability is not guaranteed.
Warning Note!
In the operating instructions reference is made to possible risks and
dangers with the installation and start-up. These references are provided
with the following terms:
Caution
A caution draws attention to the fact that in case of neglect of the
safety advice the possibility of material damage and personal injury
exists.
Commissioning tasks
Commissioning tasks may only be carried out by authorised and trained
technical personnel. The required authorisation is exclusively granted by Brüel
& Kjær Vibro.
Attached safety instructions for installation, commissioning and
disposal must be observed!
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VIBROCONTROL 1500 Safety advice
2 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
10 Hz to 1,000 Hz, a rolling-element bearing condition variable is also
calculated for the assessment of rolling-element bearing condition.
For the measurement and monitoring of temperatures, of type PT-100
temperature sensors may also be applied in addition to the vibration sensors.
For operation of the instrument a power supply of 20 to 32 VDC is necessary.
The power consumption of the instrument amounts to approx. 6 W .
2.1 Display and operating elements
Front view
Fig.1: VIBROCONTROL 1500 front view
Buttons and displays
Buttons for switching to individual displays, making a selection within the
,
menus and entering values
ESC Button for return to previous display
ENTER
Button for confirmation of entry and calling up menus.
MENU
OK Green LED for display of the OK-status
L1 Amber LED for display of L1 status
L2 Red LED for display of the L2 status
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VIBROCONTROL 1500 Overview
The standard equipment contains:
o Two (2) relays with potential-free switch-over contacts for signaling event
messages. The relays are assigned to the set limit values.
o One (1) OK relay with potential-free switch-over contacts for monitoring
of the power supply, the functions of the microprocessor system and the
connected sensors.
o Two (2) analogue outputs proportional to the casing vibration.
o CAN-Bus interface for data transmission between the VIBROCONTROL
1500 and a super-ordinate computer.
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.
2.2 Possible measurement and monitoring tasks
2.2.1 Display values
Corresponding to the national and international prescription for evaluation of
machine vibrations, the effective (RMS) value of vibration velocity is used for
display and monitoring.
Display value Abbreviation Unit
Vibration velocity v mm/s in/s
There is also the possibility to display and monitor the value of rolling- element
bearing condition; unit of rolling-element bearing condition: BC (Bearing
Condition)
Rolling-element bearing BC value BC
condition dimensionless
Measurement and monitoring of temperature is possible by connecting
PT-100 sensors.
Temperature T °C °F
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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.
Sensor : Vibration acceleration sensor
Variable : Effective value (RMS)
Display and monitor value Measurement range Unit
Min Max
Vibration velocity 0 ... 10 0 ... 200 mm/s
0 ... 0.5 0 ... 10 in/s
For the selected measuring range, signals of 4 - 20 mA per sensor
proportional to the characteristic variable are available at the analogue
outputs.
2.2.3 Display value and bandwidth
Acquisition of the measured data is done by vibration acceleration sensors.
Display and monitor value Bandwidth of the
characteristic value
formation
Vibration velocity 10 Hz ... 1,000 Hz
Rolling-element bearing condition 500 ... 5,000 Hz DFT
2.2.4 Signal detection
The output voltage of the measurement sensors is proportional to the
measured magnitude of the time signal (vibration acceleration).
The following signal detection step is carried out by the VIBROCONTROL
1500:
Calculation of the effective (RMS) value of vibration velocity from an
integration of the vibration acceleration signal.
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VIBROCONTROL 1500 Overview
2.3 General
Independently adjustable limit values are assigned to each measuring
channel for the casing vibrations, the rolling-element bearing condition and
the temperatures. The setting of the respective limit values is done in the unit
of the measurement channel.
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.
In order to prevent false alarms due to spurious, very short-term limit value
violations, a relay response lag time can be activated for each limit value of
the vibration.
The entry of the relay response lag time always take place in seconds units.
If a measured value exceeding the assigned limit value is sustained for
longer than the given response lag time, the appropriate event message is
activated.
If the current measured value falls below the limit value during the response
lag time, the event message "limit value violated" is deactivated and upon a
renewed limit value violation the response lag time count begins again.
2.4 Relay functions
VIBROCONTROL 1500 is equipped with a total of three (3) relays.
The status of these relays is signaled at the front panel by LED control
lamps. The relays are shared by both channels.
Note:
Short the reset contacts only for a short notice.
Caution
Voltages of a dangerous level may exist at the relay contacts at any
time!
LIM 1 relay
If the current measured value exceeds the set limit value for the RMS value
of vibration velocity L1v for longer than the period of the adjusted response
lag time T1, the LIM1 relay is activated (closed).
The same is valid - however without consideration of a response lag time -
during a violation of the limit value of the bearing condition L1BC and a
violation of the limit value of temperature L1temp (with the deployment of a
vibration sensor with PT-100 sensor or temperature sensor PT-100).
The LIM 1 relay is not self-latching and is immediately deactivated
(opened) if all L1v, L1BC or L1temp limit value is no longer violated.
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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).
The same is valid - however without consideration of a response lag time -
during a violation of the limit value of the bearing condition L2BC and a
violation of the limit value of temperature L2temp (with the deployment of a
vibration sensor with PT-100 sensor or temperature sensor PT-100).
The LIM 2 relay is self-latching. To reset this condition a reset of the relay
or an instrument reset must be carried out.
OK relay
Monitoring of the power supply, the functions of the microprocessor system
and the connected sensors is done by an OK-monitoring function. The display
of an existing OK fault is by means of an LED; the output of this signal is
by means of a set of potential-free switch-over contacts.
With an error-free operation the green LED at the instrument front panel
lights up (signaling operational readiness) and the contacts of the OK relay
are closed.
In case of a fault the LED is extinguished and the OK relay will be
deactivated.
This OK relay is active during error-free operation (closed, terminals 33 and
34 are connected). W hen a fault occurs these relay contacts open. This relay
is self-latching. To reactivate this, a reset of the relay or the instrument is
necessary.
Instrument Reset
Simultaneously pushing both of the buttons and ENTER/MENU for a
period of at least 3 seconds effects a reset and a restart of the instrument.
Reset of the self-latching relay
A reset of the active (closed) condition of the self-latching relays OK and
LIM2 is possible at the RESET input by connecting terminals 25 (RST REL2)
and 26 (GND). This reset simultaneously also deletes all error messages.
Note:
Short the reset contacts only for a short notice.
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VIBROCONTROL 1500 Technical Data
3 Technical Data
Power supply 20 to 32 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 700 g
Internal resistance 100 k Ω + 10%
Instrument type 2-channel, switchable to 1-channel version
Measurement variable Vibration velocity mm/s or in/s
Measurement ranges 10; 20; 40; 50; 100; 200 mm/s or 0.5, 1; 2;
2.5; 5; 10 in/s
Signal detection Effective value (RMS)
Frequency ranges 10 Hz to 1kHz
Filter slope Acc. to ISO 2373
60 dB/decade with high pass 10 Hz
40 dB/decade with low pass 1 kHz
Limit values Adjustable with push buttons in menu
Alert alarm LIM 1 (arbitrary in selected measuring
range)
Danger alarm LIM 2 (arbitrary in selected measuring
range)
Cable connections:
Lower terminal row Divided terminal rows with terminal blocks,
plugged into the terminal sockets, max. 2.5
mm².
Upper terminal row Divided terminal rows with terminal blocks,
plugged into the terminal sockets,
2
0.14 mm – 1.5 mm².
2 2
Power supply and 1 mm – 2,5 mm
distribution terminal
2 2
Cable glands of the M12: 3.0 mm – 6.5 mm
Protective housing 2 2
M16: 5.0 mm – 10.0 mm
AC-211x
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VIBROCONTROL 1500 Technical Data
Sensor:
Sensor supply 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; value
correction value adjustable in menu. For measurement
using acceleration sensors (CCS type)
whose transmission factor deviates from
the standard factor of 100 mV/g.
Analogue output 4…20 mA, for the RMS value of vibration
velocity of channel A and channel B,
proportional to the set measuring range.
Max. load at the analogue output < 500 Ω .
Limit value outputs: Potential-free contacts
Alert alarm Potential-free contacts LIM 1,
Display: amber LED
Danger alarm Potential-free contacts LIM 2,
Display: red LED
Contact loading: 5A/24 VDC,
Upon violation of the limit value in channel
A or B, the corresponding relays LIM1 or
LIM 2 are activated.
OK monitoring Function test of the instrument and
connected sensors
Range of OK monitoring 6V + 0.5V ...18V + 0.5 V
Display Green LED, instrument OK and
operationally ready
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VIBROCONTROL 1500 Technical Data
