VIBGUARD® compact

Monitoring solution for small to medium production-critical machinery

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Condition Monitoring increases productivity

PRUFTECHNIK Condition Monitoring solutions

 Reduce planned and unplanned downtime
 Save spare part costs and increase efficiency
 Are integral part of your plant’s production process

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Online Condition Monitoring Systems

Online Condition Monitoring solutions for plants with:

 Components that have Short Mean Time between Failures (MTbF)
 High criticality for the production process
 High initial costs and high spare part costs

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Online Condition Monitoring Systems - example

PRUFTECHNIK Online Condition Monitoring Systems pay off:

 A bearing defect caused a production loss of several days in a steel plant
 Online CMS now monitor the critical components of the hot rolling mill
 Proactive, corrective actions can be carried out and shutdowns can be scheduled

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Typical applications of VIBGUARD® compact

Industrial Extruders
Complex Fans
Drives Vacuum
Pumps

Multiphase
Pumps
Condition Monitoring

Detecting failures early

Turbo Com-
pressors Reducing costs

Big Reci- Centrifuges

Pumps procating Hot
machines Rolling
Mills

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Operation

VIBGUARD® compact - operation

 Offers parallel and synchronous data acquisition on up to 6 analog channels. Protects

even the most complex and high dynamic plants against unplanned shutdowns. High
performance diagnostic tasks are carried out autonomously to ensure maximum
productivity.
 6 parallel and synchronous, analog inputs. Configurable: each channel can be
configured to measure voltage or ICP-type accelerometers
 Sampling rate: 130 kHz
 Continuous measurement of overall values, saved every second, up to 6 overall
values per channel (channel 1 - 4) and up to 3 overall values per channel
(channel 5 - 6)
 Intelligent data reduction on board
 Synchronous measurement of 2 signal measurements (channel 1 - 4) and 1 signal
measurement (channel 5 – 6) for frequency selective trending
 In addition, time and event-triggered diagnostic measurements are possible. An
optional event recording function allows transient events to be recorded.
 Configuration, storage and visualization on the powerful software platform
OMNITREND® Center

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VIBGUARD® compact – application examples

VIBGUARD® Compact – Monitoring of Extruders

 Extruders are highly production-critical
 Complex drive with variable, high loads
 Low speed: Challenge for online CMS

Extruder in plastics production

Accelerometer
Channel Measurement Location Description Sensor Sensor Cable
RPM sensor / Keyphasor
AI1 Extruder Vibration Motor VIB 6.172 VIB 309007-L
AI2 Extruder Vibration Gearbox VIB 6.172 VIB 309007-L
AI3 Extruder Vibration Screw 1 AX VIB 6.172 VIB 309007-L
AI4 Extruder Vibration Screw 2 AX VIB 6.172 VIB 309007-L
AI5 Extruder Vibration Screw 1 RH VIB 6.172 VIB 309007-L
AI6 Extruder Vibration Screw 2 RH VIB 6.172 VIB 309007-L
VIB 5.992-
TP1 1201 - RPM1 15m with cnnctr.
STD
1301 - Digital IN1 – mltpl. wires
DI1 binary
Measurement Release scrnd.
NO1/NC 1401 - Digital OUT1 – Alarm mltpl. wires
binary
1 Vibration scrnd.
mltpl. wires
SYS OK 1402 - System OK binary
Legend: scrnd.
VIB 6.172 ICP Accelerometer for standard application, M8, MIL, 0.1 Modbus1 optional: Extruder Motor load Modbus-TCP
Hz to 10 kHz +/- 3dB, 100 mV/g Modbus2 optional: Extruder Material-Pressure Modbus-TCP
VIB 309007-L Sensor cable, 2 wires, shielded, 1x MIL connector optional: Extruder Material-
Modbus3 Modbus-TCP
Temperature

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VIBGUARD® compact – application examples

VIBGUARD® Compact – Monitoring of

Process Fans
 Critical fan in cement production
 Highly loaded fan in harsh environment
 No redundant plants

Process fan in the cement industry

Accelerometer
RPM sensor / Keyphasor

Channel Measurement Location Description Sensor Sensor Cable

AI1 Motor Vibration NDE VIB 6.172 VIB 309007-L
AI2 Motor Vibration DE VIB 6.172 VIB 309007-L
AI3 Fan Vibration DE VIB 6.172 VIB 309007-L
AI4 Fan Vibration NDE VIB 6.172 VIB 309007-L
AI5 Fan Vibration Axial VIB 6.172 VIB 309007-L
AI6 Reserve VIB 6.172 VIB 309007-L
TP1 1201 - RPM1 VIB 5.992-STD 15m with cnnctr.
1301 - Digital IN1 – Measurement
DI1 binary mltpl. wires scrnd.
Release
mltpl. wires scrnd.
NO1/NC1 1401 - Digital OUT1 – Alarm Vibration binary
mltpl. wires scrnd.
SYS OK 1402 - System OK binary
Legend:
VIB 6.172 ICP Accelerometer for standard application, M8, MIL, 0.1 Modbus1 optional: blade angle Modbus-TCP
Modbus2 optional: Pressure of medium Modbus-TCP
Hz to 10 kHz +/- 3dB, 100 mV/g
Modbus3 optional: Motor current Modbus-TCP
VIB 309007-L Sensor cable, 2 wires, shielded, 1x MIL connector

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PC software configuration

Quick measurement configuration with OMNITREND® Center

VIBGUARD® compact can reliably monitor simple standard vibration parameters, but also complex diagnostic signals.
Measurement sequences, threshold values and trigger conditions can be easily configured:
 Characteristic Group saves vibration parameters and operating parameters once every second
 Trending Group records vibration signals with characteristic band values on all channels synchronously and at the same
time
 Diagnostic Group is started on the basis of a time cycle or is event-dependent and provides extended diagnostic signals

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PC Software Condition Monitoring

OMNITREND® Center monitors the trend of the machine‘s condition

General deterioration of condition and damage due to wear primarily develop over longer periods of time and can only be
detected if you consider the vibration behavior and operating conditions together.

 VIBGUARD® compact records vibration parameters and diagnostic signals depending on the operating conditions to
allow even the smallest changes in the machine's condition to be detected at an early stage
 OMNITREND® Center traces the development of vibration parameters and more complex diagnostic features, selects
changes in the machine's condition and indications of damage

Pre-Damage
RPM visible depending on the load

Trending spectrum

Torque
Alarm

Narrow band trend

Parameters a eff/op/pp

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PC Software Vibration Diagnosis

OMNITREND® Center accurately detects the development of damage

Damage to bearings, gear teeth and other rotating machine components generally results in excitation of specific
damage frequencies or typical frequency patterns.
 VIBGUARD® compact reliably monitors damage frequencies even for transient RPM and load ratios using
order tracking spectra
 OMNITREND® Center analyzes within the time and frequency range and compares the damage frequencies
against the machine kinematics

Roller bearing damage

Outer ring damage

Time signal analysis Frequency analysis

Alarm

Alarm

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PC Software Operating Behavior

OMNITREND® Center analyzes the machine's operating behavior

With variable-speed machines the vibration behavior is generally heavily dependent on the speed, while resonances in
certain speed ranges are frequently the cause of unacceptably high machine vibrations.
• VIBGUARD® compact specifically monitors the rotational frequency of vibration excitations including their phase
position thereby allowing vibration conditions to be assessed even when the operating conditions are changing
 OMNITREND® Center analyzes, for example, the resonance behavior in the waterfall spectrum and Nyquist plot
which in this case allows the plant operator to hide critical speed ranges

Resonance at 1119 RPM

with unacceptably high vibrations

Waterfall spectrum Nyquist plot

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Standard Network Integration

Option: Remote Monitoring

Server PC Automation dep. Maintenance dep.
Access via VPN
OMNITREND® OMNITREND® OMNITREND®
Service Provider Center Center Center
Server Client Client
OMNITREND®
Workspace
Center File Structure
Client
VPN
Access Server Client Client
Router PC PC PC

Server
Client
PC
@ Ethernet LAN TCP/IP

Provider VIBGUARD® VIBGUARD®

compact compact

Internet
Intranet

Plant Plant

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Cloud integration

Cloud Site 2
Cloud solution Maintenance dep.
OMNITREND®
OMNITREND® Center
Site 1 Center Client
Maintenance dep. Server / Client
Server
Workspace PC
OMNITREND® File Structure
Center Provider Client
Client
PC

Client Provider
PC Ethernet LAN TCP/IP

VIBGUARD®
Ethernet LAN TCP/IP
Service compact
Service Provider
OMNITREND®
VIBGUARD® Center
compact Client
Plant

Client
Provider PC
Plant

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 System diagram

VIBGUARD® compact – System diagram

Analog IN: Shunts * Communication:

1101 Analog Input 1 AI1
Ethernet TCP/IP (100 MBit)
1102 Analog Input 2 AI2 LAN
Modbus TCP
1103 Analog Input 3 AI3
1104 Analog Input 4 AI4
RS 232 Service Port
1105 Analog Input 5 AI5
1106 Analog Input 6 AI6

6x ICP or U
* 0/4-20 mA (Shunts) DAQ
Data Processing
Data Storage Digital Outputs:
Communication DO1 1401 Digital OUT 1

VIBGUARD® SYSOK 1404 System OK

compact
VIB 7.900-xxx
Tacho-Pulse Input:
1201 RPM / Pulse TP1 Power Supply:
Power Supply 100 – 240VAC , 50 / 60Hz
24VDC
Digital Input: 24VDC 24 ± 6VDC, 1A
1301 Digital IN 1 DI1

* Shunts 100 Ohm 0.1% TK25

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Cabinet options

VIBGUARD® compact – version in a powder-coated, stainless steel

cabinet
 Cabinet protection: IP65
 Dimensions: 300 x 200 x 130 mm / 11.8 x 7.87 x 11.8 inch

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Cabinet options

VIBGUARD® compact – system module

 VIBGUARD® compact mounted on a standard DIN rail

 Including power supply provided by PRUFTECHNIK

165

52
138
210

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Specifications

VIBGUARD® compact – specs

Inputs/Outputs
Analog Inputs 6 x synchronous channels
Signal type 6 x U / ICP, configurable via software
Sensors Voltage input / ICP-type sensors
Tacho-Pulse Input switching threshold configurable (default 2.5 V)
Digital Input Optocoupler: -3 V to +30 V, switching threshold 6.5 to 8.5 V
Digital Output Relay: 30 VDC / 30 VAC / 2 A
System-OK Output Relay: 30 VDC / 30 VAC / 2 A
Ethernet Data rate: 100 Mbit, half duplex
Serial RS232, 115200 baud, service port
Services Modbus TCP
Status LEDs 6x Analog-IN, 1x Tacho-IN, 1x System, 1x Event, 2x Ethernet, 1x Digital-IN, 1x System-OK,
1x Digital-OUT
Measurements
Dynamics 110 dB @ 24 bit
Sampling Rate 131 kHz / 50 kHz Bandwith
FFT/ Resolution 6400 (Standard), 102400 (Analysis)
General
Operating Temperature -20°C to +70°C (system module)
-20°C to +60°C (system module in cabinet)
Power Supply 24+/-6 VDC / 0.25 A
Data Storage Flash: 2 GB, RAM: 256 MB
Cabinet Material Aluminum
Weight approx. 0.7 kg (system module)
approx. 3.5 kg (system module in cabinet)
IP rating IP 20 (system module)
IP 65 (system module in cabinet)

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Condition Monitoring increases productivity

"The VIBGUARD® compact monitoring concept meets our highest requirements

for an online condition monitoring system. Our highly dynamic machines can be
diagnosed more safely and also more efficiently. The system allows operators
and maintenance personnel to put forward science-based recommendations.“
Frank Gottschalk, Technische Diagnostik Vattenfall Europe Mining AG Schwarze Pumpe

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Thank you for your attention

QUALITY MEANS TO US:

TO MAKE A DIFFERENCE EVERY DAY.

www.pruftechnik.com

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