2 INSTALLATION DIRECTIONS MasCon48
Contents
1. MasCon 48 On line system for continuous monitoring Part No 32086800 Revision A User Manual Copyright 2007 by SKF Reliability Systems All rights reserved Aurorum 30 977 75 Lulea Sweden Telephone 46 0 920 75850 Fax 46 0 920 13440 MANUAL MasCon48 NAIDEN TEKNIK AB CONTENTS CONTENTS oiicesisivinsiascavhares aeneusieis oust avhencavearsscaseaacchv eens eserdersieamareeronaienneees I ESYSTEM DESCRIPTION cniin cctesscesies cocscacashenceshdacuandocieetebesearcel acters rasas 1 1 2 INSTALLATION DIRECTIONS MASCON48 cccssssccsssssrcccsscscecssseeees 2 1 2A INSTALLATION irois a AE a EA 2 2 2 1 1 Sensor installation Accelerometer type PCB 327 601 ccccccccseereees 2 2 2 1 2 Sensor installation Displacement sensor inductive non contact 2 3 2 1 3 Sensor installation Pulse transmitter inductive non contact 23 21 4 MOSCOM mountin S sasse lisa race eee E EEA EAT EER 2 3 2 2 CABLES as tases aaa E E ita eat ala ce ola pret la ac i te veer ote 2 4 221 Cable POUT rerea o EEA TE EAE Ea 2 4 2 2 2 Sensor cable vibration s s Be vctyhest beak wash as olbie oxs o das ReabaeNtagtue aa ateds X3 2 2 3 Sensor cable Others i aa eee eet esa a oe Nee at ee hed Le 2 95 2 2 4 Supply cable oononennnnnnnenannasensseeseesnesresresstesressesseesressesseessessesseesseent 23 22I JUNCUON BOK ases eere vastus catia ee a bape E E A E eaees 2 5 22 0 Cable fns ana ea a E EA N 2 5 2 2 7 Comm2. iit DIP2 PTT ay mii DIP1 Allin Closed state ON mia Figure 2 12 Module card vibration signals Installation directions MasCon48 2 13 MANUAL MasCon48 NAIDEN TEKNIK AB A module card for vibration signals FFT can be mounted in module position 1 chan 1 8 module position 2 chan 9 16 module position 3 chan 17 24 and module position 4 chan 25 32 Using DIP1 current supply JCP 4 mA can be engaged or disengaged specifically for each channel ON current supply Using DIP2 the user can select Single Ended or Differential ON Differential 2 6 4 2 Module card ANA default DIP1 00000000 DIP2 11111111 3107 0009 Short jumper RM 2 54 15 All in open state OFF 1 ico CORO H wt 1 4 6 ae ere ra zam I sf DIP2 J2 U9 16 DCDC 1 8 1 DIP1 Component side 1 amel Ino Coe el Re f 4 6 aED All in open state ON 3107 0012 Short jumper RM 5 08 Figure 2 13 Module card analogue signals A module card for analogue process signals can be mounted in any module space 1 chan 1 8 2 chan 9 16 3 chan 17 24 and module space 4 chan 25 32 Using DIP1 the current shunt 4 20 mA can be engaged or disengaged
3. sseesseeseseeresreseeressestestesrstesteseeresseseerrssesresresenee 3 1 4 TROUBLESHOOTING GUIDE eeseesessossescsssesesocscescsecesesosscesesocsoeseseossssossossesee 4 1 4 POSSIBLE FAULT TYPES Awa cdot eines ale as E ES 4 1 4 1 1 Sensor signal disappears or is abnormally changed single channels 4 1 4 1 2 A sensor repeatedly generates a false alarm or varies abnormally 4 2 4 1 3 Speed signal unobtainable faulty for a certain Machine 00600006 4 2 4 1 4 Analogue input gives faulty no SiQnl ccccccecseceteeete tees eeeeeeesteetseees 4 2 4 1 5 Load input gives faulty no input SiQndl ccccccecccceseete eee eeeteeeteeeenseees 4 3 Contents MANUAL MasCon48 NAIDEN TEKNIK AB 4 1 6 MasCon s alarm relay does not activate despite warning alarm 4 3 4 1 7 Logging completely ceases to function cccccccecseceteceteeetseeeeeenseenteeees 4 3 4 1 8 Logging ceases to work from a certain MasCon unit cccccccceceeees 4 3 4 2 CHECK OF SENSOR AND SENSOR CABLING FOR VIBRATION CHANNELG 4 4 4 3 CHECK OF SENSOR AND SENSOR CABLING FOR ANALOGUE CHANNELS 4 6 44 CHECK OF SPEED INPUT cuerercnnnnn enna ai i 4 7 4 5 CHECK OF RELAY SIGNAL enai sata e aa AE 4 7 4 60 LOGGING PROBLEEM S sgsir ieena eaa a EA AR AR a 4 8 5 TECHNICAL DATA MASCON48 ssssssccossesecessssccessesecesssescsnscsecesnsesesseeecs 5 1 Contents ii MANUAL MasCon48 NAIDEN TEKNIK AB 1 SYSTEM DESCRIPTION
4. MasCon units are linked in a network that is connected via a modem to a logging computer ProCon The logging computer in turn can be connected to e g a LAN network Several ProCon clients may be linked in this network Through a general interface ODBC it is possible to link the logging computer to an existing database for an existing control or processing system Each MasCon unit features 5 relay outputs to be used to handle alarms warnings and system errors There are 32 general inputs for vibration signals or analogue inputs and 16 digital inputs for example for speed measurement See Figure 1 1 It is possible to link 16 relay outputs to the logging computer by equipping it with a relay card When the logging computer is used to handle Alarms and Warnings it is possible to control single machines that are linked to the MasCon unit MasCon Communication 16 Digital inputs 32 General inputs pulse FFT analysis DPE Optoisolated DC measurements etc Max 24 Volt ICP 0 5 V alt 0 10 V 4 20 mA System error 1 Figure 1 1 MasCon System description 1 1 MANUAL MasCon48 NAIDEN TEKNIK AB 16 Relay outputs Figure 1 2 MasCon units in a network System description 1 2 MANUAL MasCon48 NAIDEN TEKNIK AB 2 INSTALLATION DIRECTIONS MasCon48 Cuaman MasCon 48 a PF oa woos sucr CETTE aa oe amira m Figure 2 1 MasCon48 Guidance in installation and
5. 47 440 Hz Sensor inputs Pluggable pairs of terminal blocks for easy installation and service 32 general channels equipped in groups of 8 channels with or without ICP measurement 16 digital speed channels optional 2 or 16 channels opto insulated Sensor inputs can be configured for all types of signals and sensors available on the market Signal processing Powerful Pentium processor Sensor noise compensation Automatic gain control Adjustable LP filter with optional switching frequency Automatic overload detection Digital HP filter for DPE Digital Peak Envelope A D converter 16 bit Windowing Internal memory 64 Mbytes Data memory 32 Mbytes Data collection and analysis features Simultaneous 32 channel FFT analysis Frequency bands 10 20 50 100 200 500 1k 2k 5k 10k 40kHz Resolution 400 1600 3200 6400 lines Runup rundown RPM tracking Amplitude Phase Overall Time signal measurement Trigger controlled measurement Technical data MasCon48 5 1 MANUAL MasCon48 NAIDEN TEKNIK AB Orbit Polar plot DPE Digital Peak Envelope Trend analysis Air gap measurement Statistics Alarm Diagnostics Expert system Electronic sensor and cable check Communication TCP IP Ethernet 10 100Mbit Network Remote control via modem Relay outputs 5 relay outputs for e g alarm and warning lamps tripping of machines etc Quality control Naiden Teknik is ISO
6. See Table 4 1 for normal voltage values with and without a connected sensor respectively Sensor type Normal operating bias Open circuit voltage voltage pe pe Standard type 327 e 8 12V Table 4 1 Normal voltage values 3 Is the voltage within the normal working range NO Continue to item 5 YES The cabling to the sensor is probably OK and the sensor electronics have normal input impedance If the sensor signal is still not perceived to be normal one should try changing the sensor 4 Does the fault remain after changing the sensor NO Sensor fault The sensor is defective and must be replaced YES The fault may be in the analogue input section of the MasCon unit Contact Naiden Teknik for service further information 5 Is the voltage close to zero typical lt 0 5 V NO Continue to item 10 YES There is probably a short circuit in the cable or the sensor is defective First verify that the voltage rises to normal open circuit voltage when one of the sensor cable poles is disconnected from the terminal block of the MasCon unit 6 Did the voltage rise to normal open circuit voltage YES Continue to item 9 NO The sensor is not receiving power continue below 7 Is ita Velomitor or Proximitor sensor NO Go to item 8 Troubleshooting guide 4 4 MANUAL MasCon48 NAIDEN TEKNIK AB YES These are powered by an external 24V power pack Therefore check the output voltage from this unit po
7. 9001 certified CE Technical data MasCon48 5 2
8. connection of systems for condition monitoring using MasCon IMPORTANT In cases where Naiden Teknik AB does not have direct responsibility for the assembly and connection of a MasCon system Naiden Teknik AB expects that installation of a MasCon system is carried out in accordance with the instructions and advice given in this manual Any departure from these directions may be made only in consultation with personnel from Naiden Teknik In other cases the installation will not be approved and start up of the system will not be carried out until the errors are rectified Installation errors that Naiden personnel are required to rectify when the system is to be started up will be debited Therefore please contact Ndiden at the slightest doubt during installation of your MasCon system Installation directions MasCon48 2 1 MANUAL MasCon48 NAIDEN TEKNIK AB 2 1 INSTALLATION 2 1 1 Sensor installation Accelerometer type PCB 327 601 The basic pre condition for a successful measurement result is that the sensor is correctly located with regard to vibration factors l Select a location for the sensor where it will not be exposed to mechanical impact and unnecessary radiant heat If the sensor nevertheless is given an exposed location some form of protective cover must be mounted over the sensor Prepare the surface where the sensor is to be fitted Paint rust or other coatings must be removed in order that the senso
9. short as possible since long cables impair frequency properties and expose the system to external interference long cable gt 50 m When routing a sensor cable it is important that the cable is firmly fixed The cable may never be allowed to vibrate or oscillate since this affects the capacitance of the cable and thereby the measurement result The sensor cable may not be routed or bundled together with supply cables which generate strong magnetic fields such as supplies to motor drives radiators electronic frequency converters ovens etc It is permissible to reduce the amount of cable by using multiple conductors In order to facilitate servicing and maintenance it is advantageous to mount junction boxes close to each measurement point This is a requirement in cases where sensors with fixed cables are used An example of the above is shown in Figure 2 2 Approx 50m 1 2 0 5 Junction box MasCon No 1 3 2 0 5 Sensor MasCon No 2 Log computer Ethernet Switch Figure 2 2 Cable routing to MasCon Installation directions MasCon48 2 4 MANUAL MasCon48 NAIDEN TEKNIK AB 2 2 2 Sensor cable vibration A shielded twisted pair cable is used for the vibration sensor Remember also to select a cable that is suited to the environment in which it is to be located temperature water oil Recommendations Twisted pair cable Area 0 5 mm Shielded common copper braid
10. software Amplification and Zero level and determine the conversion to the user s unit Further Cable check must be off N If this still does not produce the correct actual value then the input card is probably damaged Contact Naiden Teknik The cable or the sensor is probably damaged Test the cabling by disconnecting at the sensor end and connecting e g a 1 5V battery Does the input now measure the voltage The cabling is probably damaged Continue to item 6 The sensor is probably not functioning correctly However first check that the channel is correctly configured as regards the terminating resistor In the list of terminal blocks it can be determined whether the channel in question has a terminating resistor for current circuit Check that this corresponds in reality and that it corresponds to the sensor s mode of operation Cabling is probably damaged However first try disconnecting one of the poles on the cable from the MasCon terminal block If the voltage is then OK then the fault is in the MasCon unit input stage otherwise the cabling is damaged and needs repair Does the fault remain after replacing the sensor Sensor fault The sensor is defective and must be replaced The fault can be in the analogue input part of the MasCon unit Contact Naiden Teknik Troubleshooting guide 4 6 MANUAL MasCon48 NAIDEN TEKNIK AB 4 4 CHECK OF SPEED INPUT 1 3 NO YES Determine the
11. the distance between the sensor and measurement object to half the measurement range see sensor data sheet Example A sensor with measurement range 0 10 mm and output signal 4 20 mA is adjusted approximately with a feeler gauge to 5 mm An exact adjustment is then performed to 12 mA 2 1 3 Sensor installation Pulse transmitter inductive non contact A pulse transmitter linked to MasCon is used to measure rotational speed e g of a shaft In order for the inductive sensor to register pulses there must be one or more distinct projections on the shaft Each time a projection passes the sensor a measurement pulse is generated The measurement projection can be an existing spline or bolt M6 M8 The distance between sensor and projection is adjusted to 2 4 mm When configuring ProCon the number of pulses indicated per revolution is specified number of projections 2 1 4 MasCon mounting The MasCon unit is mounted at a location where it is not exposed to unnecessary radiant heat or strong magnetic fields Ambient temperature 10 to 40 C normally 20 to 50 C momentarily The unit should be mounted near the measurement object so that the sensor cable is as short as possible Itis important also that MasCon is mounted at a height that permits easy viewing of the display Installation directions MasCon48 2 3 MANUAL MasCon48 NAIDEN TEKNIK AB 2 2 CABLES 2 2 1 Cable routing The cable should be as
12. voltage to the sensor at 24 V DC B C External supply Installation directions MasCon48 2 16 MANUAL MasCon48 NAIDEN TEKNIK AB 3 MASCON UNIT 3 1 Description of the MasCon unit MasCon is a modern industrial computer designed for continuous vibration monitoring MasCon is highly environmentally resilient IP 66 and is specially adapted for machines where damage develops rapidly and where periodical monitoring is difficult to carry out Up to 32 vibration sensors can be connected to each MasCon unit MasCon can also be connected to digital sensors or other units via one of the 16 digital inputs 5 relay outputs Initiating MasCon is simple to carry out This is done via an initiating program for example using a portable computer All initiation parameters are saved in a separate memory with independent current supply in MasCon These then are retained in the event of a loss of voltage so that MasCon can start automatically when voltage returns To avoid problems with the power supply when starting up if several large electrical machines are started simultaneously then powerful surges often occur on the mains supply the start up routine is delayed by about one minute from the moment when voltage is switched on Communication with the MasCon units complies with Ethernet standard 3 2 Usage of the MasCon unit MasCon is divided into modules In its basic version MasCon is supplied with an input module for vibration sensor and
13. Multicore conductors gives flexible cable The outer sheath must withstand the environment heat cold humidity chemicals It is also permissible to use coaxial cable but this is more troublesome to handle during installation Example LiYCY 1x2x0 5 Twisted pair DUE 4001 1x2x0 5 Twisted pair 2 2 3 Sensor cable Others To connect other sensors to MasCon such as e g speed sensor displacement sensor pressure sensor data communication RS 485 etc use Shielded twisted pair 2 2 0 5 FKAR PG 2 2 0 50 DUE 4002 or corresponding 2 2 4 Supply cable To connect MasCon to 220 V use FKLK 3 1 5 or EKLK 3 1 5 or corresponding 2 2 5 Junction box E 14 395 02 or similar 2 2 6 Cable fittings Metallic EMC type cable fittings are used for all cable lead throughs except the communication cable Installation directions MasCon48 2 5 MANUAL MasCon48 NAIDEN TEKNIK AB 2 2 Communication cable For lengths up to 15 metres it is recommended to use prefabricated Ethernet cable of FTP type For longer cable lengths use S FTP Ethernet cable 2 3 CONNECTING UP 2 3 1 General MasCon48 is built to a modular concept that means that each unit can be equipped uniquely with regard to the type and number of channels The equipment consists of different types of input boards which are mounted on the motherboard under the protective cover see chapter 2 6 Connections are made to the groups of pluggable terminal block
14. e error misconception DNnBWNR Note that the guarantee becomes void if MasCon units are damaged through incorrect intervention in the hardware or a patently incorrect connection in contravention of directions given 4 1 POSSIBLE FAULT TYPES 4 1 1 Sensor signal disappears or is abnormally changed single channels a Break in sensor cable b Short circuit in sensor cable c Sensor fault d Hardware fault MasCon input stage gt Carry out sensor cable test as in item 2 Troubleshooting guide 4 1 MANUAL MasCon48 NAIDEN TEKNIK AB 4 1 2 A sensor repeatedly generates a false alarm or varies abnormally a Break in sensor cable contact b Incorrectly mounted sensor c Hardware fault MasCon input stage gt First carry out sensor cable test as in item 2 Check also the sensor mounting If this is without result contact Naiden Teknik 4 1 3 Speed signal unobtainable faulty for a certain machine a Cable fault short circuit break to speed sensor b Faulty speed sensor or faulty installation c Speed signal too weak impedance too high for MasCon d Faulty MasCon speed input e Incorrect settingin hardware gt Test speed input as in item 4 4 1 4 Analogue input gives faulty no signal a Cable fault short circuit break to sensor b Faulty sensor c Faulty earthing d Faulty MasCon input e Incorrect setting in hardware gt First carry out control of sensor and cabling as in item 3 Troublesh
15. g consists of One or more MasCon units One Ethernet 10 100Mbit network card An Ethernet switch if several MasCon units are to be used A telephone modem only for remote control A logging computer Regarding installation and configurer go to the ProCon Installation manual 2 5 START UP Conditions check that Installation carried out as in Chapter 2 1 Cable routed as in Chapter 2 2 1 Cables connected as in Chapter 2 2 Hardware settings carried out as in Chapter 2 6 Logging computer connected and prepared as in Chapter 2 4 2 Start the system Power on MasCon Attach Ethernet switch Start logging computer Start Logging c procon exe loggning exe Start ProCon c procon exe procon exe Configure Configure the system with the aid of the ProCon manual Synchronise measurement point settings ProCon 2 6 SETTINGS 2 6 1 General Before the MasCon system is started up there are a number of hardware settings that need to be checked This is the unit number of the MasCon unit which is set with the help of a DIP switch located in the upper right corner of the motherboard and Installation directions MasCon48 2 11 MANUAL MasCon48 NAIDEN TEKNIK AB settings for Digital inputs 1 and 2 which are carried out with the help of straps on the motherboard In order to access the switches in MasCon the protective cover must be removed NB Before removing the protective cover the MasCon mu
16. he sensor otherwise the fault is in MasCon YES There is a break in the cable or the sensor is damaged Continue below 11 Go out to the sensor disconnect the contact from the sensor and short circuit YES NO the pins in the sensor contact Then re measure the voltage on the MasCon terminal block Did the voltage sink to close to zero lt 0 5 V There is an internal break in the sensor or the contact is oxidised First try cleaning the contact before replacing the sensor There is a break in the cable Repair the cabling Troubleshooting guide 4 5 MANUAL MasCon48 NAIDEN TEKNIK AB 4 3 Check of sensor and sensor cabling for ANALOGUE channels l NO YES NO YES 6 7 NO YES Determine the unit number and channel number of the channel in question through the measurement point information in the software or through the list of terminal blocks Measure the DC voltage between the sensor cable poles on the MasCon terminal block using a digital voltmeter Does the terminal block have the expected voltage level see sensor sensitivity and the current actual value of the measured object Continue to item 5 The sensor and cabling are probably OK If the actual value is still not perceived to be normal then the fault is probably in the channel settings or there is a hardware fault in the MasCon unit Continue below Check through the current settings for the channel in question in the
17. ing to connect signals from other equipment use the input board with an insulation amplifier Installation directions MasCon48 27 MANUAL MasCon48 NAIDEN TEKNIK AB 2 3 3 Alarm channels Figure 2 5 List of terminal blocks group D The MasCon unit gives a common alarm via internal relay contacts see Figure 2 5 the contacts may be loaded to a maximum of 48 V 1A If higher loads are required then further relays must be fitted Relay functions for alarms are connected as in Figure 2 6 MasCon SYSTEM ERROR D5 D6 WARNING D3 D4 ALARM TRIP D1 D2 Figure 2 6 Relay functions for alarms Configuration of alarm conditions and alarm limits is done in ProCon see separate manual Installation directions MasCon48 2 8 MANUAL MasCon48 NAIDEN TEKNIK AB 2 3 4 Speed channels C1 C16 Figure 2 7 List of terminal blocks group C MasCon48 contains up to 16 digital inputs to be used for speed measurements etc Two digital inputs are located on the motherboard channel and 2 and 14 inputs are located on an optional digital board see Figure 2 7 All 16 digital inputs can also be used for alarm level control as well as parameter gating Using straps the MasCon unit is configured for external or internal power supply of sensor Channel 1 and 2 are configured on the motherboard and channel 3 16 on the input board see chapter 2 6 3 1 and chapter 2 6 4 4 The internal power supply is set to 24 V DC When using ce
18. not store data but is limited to generating alarms at set vibration levels via relay outputs see Chapter 2 3 3 and showing current levels on the integral display It is more common that MasCon units are connected via a network compliant with Ethernet standard with a logging computer where data can be stored and analysed See Figure 2 8 A logging computer is a PC which is equipped with a network card On the logging computer there are programs which regularly log out from MasCon And store data Logging as well as programs for analysis and monitoring ProCon In a system including several MasCon units they are linked together in the same network Network Figure 2 8 System of several MasCon units Communications Ethernet 10 100Mbit Cable type FTP or S FTP Max cable length 100 metres For greater distances a repeater must be attached Logging computer Pentium II 350 MHz 64 Mb RAM minimum Installation directions MasCon48 2 10 MANUAL MasCon48 NAIDEN TEKNIK AB Windows 95 98 ME NT4 2000 or XP 1 free serial port if remote control is used Since the logging computer is always connected to MasCon it should not be used for other purposes Recommended location is a space prohibited to unauthorised personnel To facilitate service and to help in vibration analysis the logging computer is located near a telephone remote control 2 4 2 Logging computer installation configuration Complete on line monitorin
19. number of the alarming channel either through the software measurement point setting or though the list of terminal blocks 2 Disconnect the relay connection from the MasCon unit in question take care if the relay output is used to trip the machines Measure the resistance between the alarm relay poles 3 Has the relay been activated resistance close to zero YES The fault is in the cabling or output connections from MasCon NO Check in the software configuration measurement point settings whether the channel in question is allowed to activate the alarm relay If this is not the case then changes the setting Contact Naiden Teknik if the channel is permitted to activate the relay but does not do so Troubleshooting guide 4 7 MANUAL MasCon48 NAIDEN TEKNIK AB 4 6 LOGGING PROBLEMS l Check first whether the logging PC is functioning as it should Try re starting the computer if there is any doubt as to the status of the logging software Check also that the Ethernet network is functioning and that the logging computer can write to the server disk Troubleshooting guide 4 8 MANUAL MasCon48 NAIDEN TEKNIK AB 5 TECHNICAL DATA MASCON48 General 48 channel measurement data retriever for continuous condition monitoring process diagnostics which can be linked in a network Encapsulation Metal cover painted or acid proof Dimensions BxHxL 500x500x220 mm Enclosure rating IP 66 Power supply 85 264 VAC
20. ooting guide 4 2 MANUAL MasCon48 NAIDEN TEKNIK AB 4 1 5 Load input gives faulty no input signal a Cable fault short circuit break to sensor b Faulty sensor signal c Faulty earthing d Faulty MasCon load input e Incorrect setting in software gt The load input acts as an analogue input Therefore first carry out cabling input test as in item 3 Contact Naiden Teknik if this gives no result 4 1 6 MasCon s alarm relay does not activate despite warning alarm a Cabling fault from MasCon to alarm panel b Configuration error in software c Hardware fault in MasCon unit gt Follow the control schedule as in item 5 4 1 7 Logging completely ceases to function a Logging PC non functional b Logging software incorrectly set c Ethernet switch non functional d Cable break in Ethernet network gt First carry out checks as in item 6 4 1 8 Logging ceases to work from a certain MasCon unit a Loss of voltage MasCon unit b Hardware fault power supply or processor module MasCon unit c Break in RS485 bus Troubleshooting guide 4 3 MANUAL MasCon48 NAIDEN TEKNIK AB 4 2 Check of sensor and sensor cabling for vibration channels 1 Determine the unit number and channel number of the channel in question through the measurement point information in the software or through the list of terminal blocks 2 Measure the DC voltage between the sensor wire on the MasCon terminal block using a digital voltmeter
21. r shall make good contact with the surface In order that the area of contact shall be as large as possible the surface must be flat Drill a hole perpendicular to the surface with a 5 mm bit depth c 10 mm Thread the hole with an M6 threading tap Carefully test screw the sensor in place to ensure that good contact is made If the sensor does not fit flat on the surface and thereby makes bad contact with it Drill a new hole Unscrew the sensor and apply some form of threadlock on the contact surface and mounting screw e g LOCTITE 242 Tighten the sensor with a torque wrench It is important that the sensor is tightened to the correct torque to avoid the occurrence of false vibrations Tightening too hard besides damaging the thread causes stress that causes vibrations The correct tightening torque is 3 7 Nm Installation directions MasCon48 2 2 MANUAL MasCon48 NAIDEN TEKNIK AB 2 1 2 Sensor installation Displacement sensor inductive non contact NB A displacement sensor always measures the distance between the sensor and the measurement object This means that an inadequate reference unstable sensor mounting gives a displacement indication that is not based on the measurement object An unstable reference can be due to Too weak mounting Too long mounting sensitive to temperature gradients Lack of a stable fundament for sensor mounting We recommend use of Naiden s sensor mounting 1419 Adjust
22. rtain sensors with negative pulse output the connection to terminal may need to be reversed To our standard speed sensor 1416 internal power supply is to be used 2 3 5 Data communication MasCon unit communications are compliant with Ethernet standard 10 100Mbit Connecting up of the MasCon48 unit is done with a shielded modular jack The modular jack includes a mount box and a crimpable modular connector where the 8 poles are coloured according to the standard The external communication cable of type S FTP is connected to the connector as the mounting directions provides The modular jack is placed on the right wall inside the coating The modular jack is connected to the right side of the CPU card by a 0 5 metre long patch cable of type FTP The CPU card is the card on the top inside the MasCon unit Installationsanvisning MasCon48 2 9 MANUAL MasCon48 NAIDEN TEKNIK AB If the MasCon48 unit is connected directly to a log computer without an Ethernet switch or hub an adapter that crossover the Ethernet cable is to be used By connecting a crossovered FTP cable between the right side of the CPU card and the log computer the MasCon unit can be connected up without using a modular jack The CPU card is the card on the top inside the MasCon unit 2 4 ON LINE MONITORING 2 4 1 General A MasCon unit is an industrial computer which can function independently without connecting other computers As an independent unit MasCon can
23. s see Figure 2 3 which are located furthest down on the motherboard as Group A General inputs 16 mounted 8 at a time Group B General inputs 16 mounted 8 at a time Group C Digital inputs pulse speed etc Group D Alarm relays Group E Power supply 24 V DC Non standard Note All cableshields is to be connected to the cable fittings of the MasCon unit and isolated in the other end Figure 2 3 List of terminal blocks MasCon 2 3 2 General channels 1 16 A1 A32 and 17 32 B1 B32 There are 16 general inputs for connecting e g vibration signals analogue measuring signals displacement pressure temperature see Figure 2 4 By vibration channels is meant that frequency analysis FFT DPE etc is carried out on these inputs The inputs have an integral generator to supply current to the accelerometers appr 4 Installation directions MasCon48 2 6 MANUAL MasCon48 NAIDEN TEKNIK AB mA If a sensor that does not require any current is to be connected then the configuration of the input board must be changed through the DIP switch setting see Chapter 2 6 Figure 2 4 List of terminal blocks group A and B If current signals 4 20 mA are to be connected resistance 220 ohm must be connected to the input board This is done using the DIP switch on the analogue cards and with an external resistance of 250 ohm on the vibrationcards see Chapter 2 6 When wish
24. specifically for each channel ON current shunt Using DIP2 the user can select Single Ended or Differential ON Differential Installation directions MasCon48 2 14 MANUAL MasCon48 NAIDEN TEKNIK AB 2 6 4 3 Module card ANA ISO default B1 00000000 Allin open state OFF EET T N c amp c S1 iiini Figure 2 14Module card analogue insulated signals A module card for galvanic insulated analogue process signals can be mounted in module space 1 2 3 or 4 chan 1 32 Using B1 the current shunt 4 20 mA can be engaged or disengaged specifically for each channel ON current shunt 2 6 4 4 Module card DIG default D E 3109 0010 Pin Strip 3 pin J3 16 3109 0009 Pin Strip 2 pin J17 30 D E 3109 0011 Short Jumper J17 30 Figure 2 15 Module card pulse input speed Installation directions MasCon48 2 15 MANUAL MasCon48 NAIDEN TEKNIK AB A module card for pulse input speed can be mounted in module space 5 chan 2 10 Channel 1 2 are configured on the motherboard as in Chapter 2 6 3 1 Using short circuit straps as in Figure 2 15 the sensor supply can be engaged or disengaged specifically for each channel D E Internal supply MasCon supplies
25. st be without voltage Then loosen 4 screws one in each corner Carefully remove the cover and detach 2 ribbon cable connectors in the upper left corner and any ribbon cable in the upper right corner 2 6 2 Settings Motherboard UNIT_NR J14 J23 115 J22 S CPU Card feqay 3 i ss i eee Ee te aa CF P EL T P RPM RPM 1 KA oO i JE s 5 __ADCad S fu CREI CRZ pe WETT ELLS L RPM Module Card VIB2 MODUL 1 MODUL 2 BOL MODUL a MODUL_5 Figure 2 9 Location DIP switches MasCon unit 2 6 3 Unit number default Nr 1 Switch U85 is used to determine which identity no the unit will have Settings are binary i e 1000 No 1 0100 No 2 1100 No 3 1 ON 2 6 3 1 Pulse input speed default Internal power supply On the motherboard there are 2 pulse inputs Digital 1 2 For further pulse inputs refer to Module card DIG The pulse inputs are configured with the aid of straps located at the upper right corner of the motherboard as in Figure 2 10 and Figure 2 11 Installation directions MasCon48 2 12 MANUAL MasCon48 NAIDEN TEKNIK AB INTERNAL Figure 2 10Configuration of pulse inputs for internal power supply i e MasCon supplies the sensor with 24V DC EXTERNAL Figure 2 11 Configuration of pulse inputs for external supply 2 6 4 Settings Module board 2 6 4 1 Module board VIB default DIP1 11111111 DIP2 00000000 Allin open state OFF
26. two inputs for pulse sensors MasCon can be supplemented with modules for Additional vibration inputs Analogue process signals Additional digital inputs On the front panel of the computer unit there are LED diodes for the following messages System Lit up if an internal error has occurred and automatically causes MasCon to re start 5 15 15 V_ Lit up if internal power feed is OK Relay 1 4 Lit up if each relay is activated MasCon unit 3 1 MANUAL MasCon48 NAIDEN TEKNIK AB 4 Troubleshooting guide This document is intended as an aid when the MasCon system is not functioning correctly The document is designed for instrumentation engineers and others with sufficient knowledge of electrical troubleshooting in electronic systems with a 230V power supply and of the risks that this can mean in case of incorrect procedure Naiden Teknik strives to provide information that is as accurate as possible Naiden Teknik however cannot be held responsible for any injury or damage to persons or material that can occur in the interpretation of or due to actions taken on the basis of information in this document Proximitor and Velomitor are registered trademarks of the Bentley Nevada Corporation Troubleshooting is aimed to determine which of the following categories the fault belongs to Sensor fault Cabling fault Hardware fault in MasCon unit PC fault Configuration error in software Usag
27. unication cable a oaoeanenneaneneeneseenesoesreseesseeeressresesreeresseesseese 2 6 DS CONNECTING UP t e a a aie a E aa encteaee neues 2 6 Dil General ronie Ea TE A N N S 2 6 2 3 2 General channels 1 16 A1 A32 and 17 32 BI B32 cccccccccccccsseecetsees 2 6 2 33 Alarm channels asenin a haat tea E a noun tran a a 2 8 2 3 4 Speed channels GT C16 i sscdias sevelsaciercatmavaeyasvelaaawtuctswonsaaln tie 2 9 2 3 5 Data COMMUNICATION 00 ececccceccceceeseceesceceeseeceeseeseeseeseeseecnteeeeneeeeeseeeenaeees 2 9 24 ON LINE MONITORING 230 ices ast 2ic Wisetactals Minadchincedoss a R EA 2 10 2AT General hac lcs Wi shale ta ta Bes Ss cra hae ead an eaten is el ersten ES 2 10 2 4 2 Logging computer installation configuration ccccceeeeet eet eetees 2 11 Dio ey AR TUR are aar e ESE eA SENE RE AEE atest taanataqguartucssesumievaecdscah ates 2 11 2 6 SETTING Sai aea EAE EEN E E R E E 2 11 ZO Generalin a A E alee aa at a Decale aeNaae 2 11 2 6 2 Settings Motherboard yest sec ek as ac disek ites eStore ek a 2 12 2 6 3 Unit number default Nii 1 cccccccecccccscceesceesceesceceseeeseceseeeeseeenseeneeenes 2 12 2 6 4 Settings Module DOG vost chen ccs cpiastendapannssndsee ee aad eR 2 13 3I MASCON UNIT we ciscccsisscassncssidschweedessansgsckenaygcausaue idessatequcessvendas adseactesergdaneaiecainn 3 1 3 1 DESCRIPTION OF THE MASCON UNIT i caacasssteplacdynsteandcapbandansdrasiquas basen uaeanies 3 1 3 2 USAGE OF THE MASCON UNIT
28. unit number and speed input of the channel in question either through the software measurement point setting or through the list of terminal blocks Measure the signal on the MasCon terminal block using an oscilloscope or similar However check whether the sensor resists connecting one pole to protective earth as is customary in oscilloscope measurements Is there an expected speed signal on the MasCon terminal block The cabling is damaged or the sensor is not sending the correct output signal Check that the installation of the sensor is correct is the machine rotating and if this produces no result check the cabling The entire chain from cable to input can be tested by linking a signal generator with a suitable frequency and amplitude at the sensor end Note however that MasCon normally supplies power to a sensor shown in equipment list which is why a coupling capacitor must then be connected in series to avoid ruining the signal generator The signal can be too weak or at too high impedance for the MasCon speed input to be triggered Sufficient voltage ripple peak to peak is shown in the electrical specifications If the signal level is sufficient then the MasCon input is defective or the software is incorrectly configured Check the settings in the program as regards the unit number and input number of the speed measurement point Contact Naiden Teknik for consultation 4 5 CHECK OF RELAY SIGNAL 1 Determine the unit
29. wer pack the fault is probable in the voltage unit or in the cabling to the MasCon terminal block However if this turns out to be OK then the MasCon input is damaged Contact Naiden Teknik for further information 8 Sensor of standard type type 327 These are powered internally from the MasCon unit If the MasCon unit does not supply open circuit voltage with input open then the MasCon input is probably damaged or the input is not configured to supply a power feed to the sensor Contact Naiden Teknik 9 The fault is in the sensor cable or the sensor Go out to the sensor position and YES NO disconnect the cable at this end Reconnect the cable on the MasCon terminal block and again measure the voltage over these two poles Does the short circuit remain The sensor cable or contact has a short circuit Repair the cabling The sensor is defective Replace the sensor 10 Is the voltage close to the open circuit voltage NO If the voltage appears to be neither within the normal working range close to zero nor close to open circuit voltage then the fault is an unusual one First check that the measurement was correctly carried out then contact Naiden Teknik Remaining faults can be due to a damaged sensor or a damaged MasCon input First disconnect one pole of the sensor cable and measure the open circuit voltage to verify whether the open circuit voltage is normal If it is normal then the fault is probably in t
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