Guardian is a fully featured monitoring software package for rotating or reciprocat-ing machinery and other types of plant. It can handle both dynamic measurements, typically vibration, and process measure-ments such as temperatures and pressures. The software operates with the ICONET industrial network to provide a highly flexi-ble distributed data acquisition system.

The Guardian application includes all the common functions for plant monitoring, including alarming, trending, analysis and data archiving.

The visual interface is entirely mimic driven giving clear indication of plant status at a glance. A simple hierarchy and intuitive controls combine to set new stan-dards in ease-of-use. Mimics and the inter-nal database are easily modified allowing a straightforward upgrade path from a hand-ful of points to hundreds.

If its Simple, Operators will Use it The Guardian application has been de-signed to monitor plant with the minimum

amount of operator involvement and inter-vention. Overall plant status can be seen by simply glancing at the front screen mimic. Any excursions above pre-set alarm limits are reported immediately, and these are ac-knowledged and cleared as required. All system activity is automatically recorded in a log so that a complete history of plant op-eration is maintained. Operators can even enter their own notes and observations.

The traffic light display at the foot of the screen shows the status of all measurement points. If a point goes into alert or alarm, that portion of the mimic changes colour accordingly, thus giving clear and unambi-guous reporting of machine problems.

Faults Pinpointed and Clari-fied A mouse click brings up a measurement screen that provides further details of the highlighted problem. Here, it is possible to tell whether a problem is, for example, shaft or bearing related. It pinpoints the precise area of the machine needing to be looked at.

If several alerts or alarms have occurred simultaneously, these can be reviewed in turn.

Trends and Levels Once a problem has been identified on a machine, the next question is inevitably How long can we leave it running? This is where trending comes in. The rate of deterioration can be assessed, and compari-

(Continued on page 2)

Inside:

Guardian 1

Angel 3

Iconet 4

System Specifications 7

Training 9

Guardian

Special points of inter-est:

Guardian monitors all machines at low cost

Iconet controls how the nodes talk to each other

Angel ensures that all data is transmitted back to our office for prompt, timely monitoring and analysis

PDC Systems

PreDiCon Systems GuardianAngel

(Continued from page 1)

sons made with previous occurrences on this, and other machines. Flexible comparison and overlay fa-cilities are available.

System Configuration

Configuration of measurement points has been made easy with a single screen entry for each point. This is what you see is what you get in its simplest sense. For larger systems, a database editing facility is available enabling a short-hand method of entering hundreds of points.

Scan rates and data storage criteria are fully programmable to optimise system perform-ance.

Data Archiving

The Guardian software is designed to carry out its monitoring tasks for months and years with a minimum of system mainte-nance. Large amounts of data can be re-corded over extended periods, and so straightforward data reduction methods are needed. Guardian provides highly flexible data archiving methods to ensure that the system operates efficiently and without overloading the host computers storage facilities.

Archiving can be programmed to occur automatically at pre-set intervals. In this case, no operator intervention is required, and the system will sift out the important data for safe-keeping while removing un-eventful information.

Global Access

The combination of Guardian and ICONET hardware enables the full power of the internet to be utilised. Remote access via telephone and internet is possible enabling data to be examined from virtually any-where. The system even allows the possi-bility to go live to a single measurement point from anywhere in the world!

Security&System Diagnostics

Guardian incorporates a two-level security system to ensure that system parameters can only be changed by authorised person-nel.

Page 2

Guardian is designed to carry out its monitoring tasks for months and years

GuardianAngel

Further Analysis

Additional analysis tools are available to determine the exact cause of a problem. Full time and spectral analy-sis displays can be called up with the ability to overlay and compare with other historical data.

Angel Over Guardian

Data Transmitted Over The Internet

The value of any monitoring system is not in the equipment it is in the data. The data from a portable data collection system starts to lose value immediately after it is collected because it is already out of date. To ensure full value from a portable monitoring system the engi-neer must be absolutely certain that all of the failure mechanism durations on the monitored machines are shorter than the data collection interval. If the data is old or if the analysis is wrong then there is no value in the monitoring system. If the data is new and the analysis is accurate you have full value continually

The value of any monitoring system is not in the equipment it is in the data. The data from a portable data collection system starts to lose value immediately after it is collected because it is already out of date. To ensure full value from a portable monitoring system the engi-neer must be absolutely certain that all of the failure mechanism durations on the monitored machines are shorter than the data collection interval. If the data is old or if the analysis is wrong then there is no value in the monitoring system. If the data is new and the analysis is accurate you have full value continually

At set intervals, the Angel portion of the system transmits all data to our offices (the default is every midnight) via the Internet. At the start of work the next day our engineers examine the data in Guardian. The allocated engineer for your system then examines the log file for alarm events and carries out a full analysis of the data which has gone into alarm. If any corrective action is required the PreDiCon engineer calls his contact in your organisation either by phone, e-mail or fax depending on

your preference. Every week you re-ceive a summary of the condition of all of your monitored equipment. The data under analysis is always less than one day old and you can be sure that trained and experienced engineers carry out the analysis. Your system will give you full value for all of its opera-tional life.

PDC Systems has implemented PdM solutions for many industries encompassing many PdM vendor solutions. We have installed and operated systems of all sizes with PDC Systems installed systems win-ning joint first and first runner up in the last inde-pendent PdM awards. All PdM services are per-formed by engineers with experience in implement-ing multiple vendor and technology solutions. PDC Systems is not tied to any particular vendor and can give completely independent advice. Outside of the vendors themselves we have setup more off-line vibration, on-line vibration and ther-mographic systems from many different vendors in a variety of applications than anyone we know.

Complex vibration analysis is carried out by our engineers

A data collection node as used by Angel over Guardian

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If the data is new and the analysis is accurate you have full value continually

GuardianAngel

System Architecture

urement data on-line, absolutely anywhere.

You are now think-ing:

LOCAL ...

PLANT-WIDE ...

GLOBAL ...

The quality of data monitored by the system is only as good as the measurement devices that are connected to it. Guardian has automatic diagnostic facili-ties for checking the integrity of acquisition nodes and even the transducers connected. Failing accelerometers and open cir-cuits or shorts on their con-necting cables can be identified.

Imagine a flexible network sys-tem that can be used to gather vital information on your ma-chinery. One which can be in-corporated into your existing Ethernet networks in the plant and which can be accessed lo-cally or remotely. Imagine this

can be set up by anyone who knows how to set up an Ethernet system and imagine it is so affordable that it can fit into your budget with ease.

You are now thinking of ICONET on Ethernet.

But dont let your imagination stop there. Think what you could do if you could access data directly from your meas-urement points anywhere in the world via the Internet. Now you can realise how ICONET on Ethernet captures the power of the global communi-cations revolution and enables you to call up real time meas-

Sixteen multiplexed ana-logue inputs

Sixteen ICP supplies for accelerometer interfacing

Optional AC/DC coupling Accelerometer bias voltage

check Bearing condition meas-

urement Type 2 Sixteen analogue inputs,

multiplexed in pairs for

(Continued on page 5)

System Description

Wide Choice of Inputs

ICONET on Ethernet sets out to interface to just about any sen-sor type that is encountered in the field of machinery monitor-ing, Typical transducers for vibration measurement are accelerometers and eddy cur-rent probes, and these are two of the types that can be used for so-called dynamic meas-

urements. Often, process measurements such as tem-peratures and pressures need to be monitored. These so-called static parameters can also be accommodated.

There are three types of node in the ICONET on Ethernet se-ries, called Type 1, Type 2 and Type 3. The types of signal input that each can accommo-date are summarised below: Type 1

View the Condition of your Ma-chinery Clearly and Precisely

GUARDIAN System Monitors Connah's Quay Cooling Tower Fans

Page 4

Imagine a flexible network system that can be used to gather vital information on your machinery.

GuardianAngel

Acquisition Modes

Bearing Measurement

example, to acquire data only from machines that are running.

Event Triggers for Syn-chronised Measurements

Two of the trigger input chan-nels can be used as event trig-gers. These are used to syn-chronise measurement se-quences between nodes on the occurrence of an external event. In addition, the ITA-1 incorporates a high-drive syn-chronising output. This can be connected to the event inputs of a number of other nodes (as in a master-slave concept) ena-bling synchronised data gather-ing between nodes on a system. This operates independently of the Ethernet network.

(Continued from page 4) simultaneous acquisition (X-Y, orbit etc)

Standard interface to eddy current probes

Type 3 Twenty multiplexed proc-

ess measurement inputs Modules available to inter-

face to thermocouples, RTDs, pressure sensors (bridge type), 4-20mA etc

Speed and Trigger Chan-nels

Each node type is fitted with the same trigger/tacho inter-face. This comprises four digi-tal inputs that can be set as isolated or non-isolated. Any trigger input can be tagged to any of the analogue input chan-nels allowing maximum trigger-ing flexibility. A trigger input

can be used for any of three purposes, namely: 1. tacho input for measuring

machine speed (also incor-porating a divide-by-N Counter for taking inputs from gear teeth or similar);

2. once-per-rev sensing for time synchronous averag-ing;

3. input to digital phase-lock function for order analysis.

Full pre-trigger and post-trigger sampling facilities are provided.

Gated Measurements

Two of the trigger input chan-nels can be used to gate meas-urements from the analogue input channels. Only when a pre-determined logic level is present on a digital input will data acquisition take place. This feature can be used, for

Bearing Condition Meas-urement

The Type 1 node incorporates an on-board hardware demodu-lator for the detection of bear-ing defect signals. These are passed over the network to be presented either as an overall value of bearing condition or as a spectrum highlighting actual bearing defect frequencies. In this way, bearing problems are differentiated from shaft related problems.

Watchdog Function

A watchdog function is incorpo-rated that monitors the opera-tion of the nodes. If, for exam-ple, the supply voltage drops, the watchdog will automatically reset the node when power is restored. No user intervention is needed in the event of a power interruption. An RS232 serial port is available for diagnostic purposes.

The above modes can be modi-fied in the application. For ex-ample, the mode could be switched from Mode 1 to Mode 3 when live data is required.

Acquisition Modes

To optimise system perform-ance in time critical applica-tions, three acquisition modes are supported.

Mode 1: Data on Demand the node is instructed to acquire data, store it, and await a download instruction from the host computer.

Mode 2: Data Ready Flag the node is instructed to acquire

data, and then sends a Data Ready flag to the host com-puter indicating that acquisition is complete and new data is available.

Mode 3: Data Broadcast the node sends data to the host computer as soon as acquisition is complete without waiting for a command.

Scrollable regions for elongated systems

A flexible network system

Page 5

Modules available to interface to thermocouples, RTDs, pressure sensors (bridge type), 4-20mA etc

GuardianAngel

Fast Node Control

Low Cost

Hardware & Fitting

the typical installation diagram. The ICONET part of the net-work can then be linked into 100Base-T Ethernet networks through standard switches or can be linked to the PC run-ning, for example, Icons GUARDIAN or other compatible software directly. Several PCs running GUARDIAN can be con-nected to the local network and remote PCs running GUARD-IAN can interface with the sys-tem also through a switch from the plants Ethernet highway. For larger Ethernet applications, routers can allow global access to the system. In effect, three levels of access are possible: Local, Plant Wide and Global. Both UDP/IP and TCP/IP proto-cols are supported.

Fast Node Control

In order to obtain maximum data throughput, channel con-figurations (and the sequence in which they are called) are downloaded to the node and stored in flash memory. The node is then instructed to exe-cute a stored sequence of measurements, (and keeps ro-tating through if required). A large number of configurations and sequences can be stored in the node so that, if the order or configuration of measure-ments needs to be changed, this can be done with a short com-mand instead of having to download a new set of instruc-tions.

Standard Ethernet

ICONET on Ethernet uses the latest Ethernet technology en-suring compatibility with exist-ing Ethernet systems. Commu-nication is possible within the systems own environment, across switches and routers, and across the Internet. Stan-dard off-the-shelf hubs and PC adapters can be used through-out. Each node has a unique MAC address. Physical connec-tion is 10Base-T using the stan-dard RJ45 plug and socket ar-rangement. For optimum per-formance, Icon recommends a dedicated local Ethernet net-work is used to connect the nodes to the PC as shown in

Enclosures

ICONET is available in a number of enclosure types. The stan-dard is powder-coated mild steel, but stainless steel and high-impact plastic are available at small additional cost.

Nodes can be fitted with power supplies for mains input at any voltage, or can be configured for a number of standard fac-tory dc voltages. Power con-sumption is very low, thus put-ting negligible load on existing power systems.

Wireless Operation and Internet

Being fully Ethernet compatible, ICONET on Ethernet can be con-nected in to standard wireless LANs (including the IEEE 802.11 standard). In addition, nodes can communicate live over the Internet anywhere in the world.

Low System Cost

ICONET is purely a data capture system. It does not attempt to analyse data in the field at each node the power of the mod-ern PC is used to do this at a fraction of the cost. This keeps the hardware cost to a mini-mum.

Installation costs are also low. The small number of points per node minimises sensor wiring

costs while the network wiring uses low cost CAT5 Ethernet cables and standard Ethernet components. It may even be possible to use existing Ethernet network cabling at effectively no cost.

Excellent construction with simplicity keeps costs down

Page 6

Standard off-the-shelf hubs and PC adapters can be used throughout.

GuardianAngel

Human Machine Interface

Mimic driven interface

Main and sub mimic levels

Trend plots

Trace plots (time, spectrum and orbit)

Point and click operation

Pop-up alert and alarm notification

Graphic colour change on alert or alarm

Traffic light indication of point status count

Interfacing Features

Interfaces to ITA-1and ITA-2 nodes

Up to 4,194,304 sensors possible

Multiple reading types from sensors possible (eg. accel, velocity and g from accelerometers)

Virtually unlimited sub mimic levels

Operates under Windows NT or 2000

Uses standard Ethernet interface

System Features

Periodic network checking

Network check on demand

Bias voltage check for accelerometers at user definable intervals

System log and network log

Log search facilities

Log print, serial output and shared file options

On-line help and user accessible HTML help

Measurements with ITA-1

ICP devices (eg. accelerometers)

DC voltages

AC coupled signals

Tacho speed inputs from 1/rev or gear

Measurements with ITA-2

X-Y signal pairs (eg. orbits)

DC or AC inputs in 0 to 24V range from standard eddy current (proximity) probes

Tacho speed inputs from 1/rev or gear

Results

Scalar measurements

Overall and derived measurements

Spectrum graphs for acceleration, velocity, displacement and gbrg

Spectral Bands

Orbits

Phase measurements

Trigger synchronised readings (sync, pre and post available)

Orders spectral display using phase lock loop

Gates available to check data integrity

Alerts and Alarms

Main and sub mimic colour change

Pop up alert/alarm box

Acknowledge function

Clear function (only if condition clears)

Log entries automatically generated

Traffic light indication of total alerts/alarms

External Outputs

External relay activation

Point Selection

From mimic hierarchy

From Explorer function

From pop-up alert/alarm box

Review of trends Live mode

Live trend graphs

Time scale zoom in/out

Multiple trend view of historical data (up to 5)

Access to live trace (eg. spectrum)

Review of Trends Browse Mode

Cursor on trend(s)

Timescale zoom in/out with cursor centred

Multiple trend view (up to 5 trends)

Point highlight for overlay

Multiple trend overlay (up to 5 of same type)

Access to trace overlays

Point delete function

Hardcopy print-out

Analysis of Results Spectra

Current spectrum view

Acquire / hold facility

Real-time mode for instant analysis

Single, dual, harmonic and sideband cursors

Spectral overlay up to 5 spectra, selected from trend screen

Zoom

Hardcopy print-out

Optional grids

Auto peak detect

Line or bar display

Choice of Hz, CPM, RPM

Analysis of Results Orbits

Current orbit view

Acquire / hold facility

Real-time mode for instant analysis (Continued on page 8)

Specifications

(Continued from page 7) Angle / magnitude cursor

True and measurement angle

Overlay up to 5 orbits, selected from trend screen Zoom

Hardcopy print-out

Optional grids

Auto peak detect

System Set-Up

Security key protected (2 levels)

Full control over measurement parameters

Adjustment of alert and alarm levels

High, low, in-window and out-of-window alert and alarms (spectrum and spec-tral bands)

Furthest from a datum alert and alarms available

Selectable storage frequency depending on normal / alert / alarm status

Averaging of results selectable

Tell user after X consecutive fails option

Selectable signal gain

Band set-up and naming up to 10 bands

Trigger set-up for phase lock loop, trigger and pre and post trigger

Match any trigger channel to any input or inputs

Selectable sifting strategy highest, lowest, furthest from or typical

Up to 12 machine relay alarms settable

Email recipients for alert and alarm settable by machine

Settable gates to check data integrity

Override logging to capture sample data on all points

Database Management

Automatic database sifting, backup and file export at selectable intervals

Associated Applications

Ability to run Iscope1 real time spectrum analyser utility Ability to run Iscope2 real time X-Y (orbit) utility

TYPE 1 N OD E

Analogue Sixteen M ult iplexed Ana logue Inputs ICP Power fo r Acce lerom ete rs on A ll C hannels AC/DC Inpu t C oup ling O ptions Fu ll An ti-A liasing Program m able HP Fi lters O n-board H ardware Integ ra tor Program m able Ga in in Range 1 to 1000 O n-board Bearing Dem odula tion Func tion

Triggers Four D ig ita l T rigger Inputs 5 -24Vdc Range, Isola ted o r Non-Isolated Averag ing , Pre and Post-T rigger Functions T rigger, T acho and O rder Ana lys is Func tions Even t and G ate T rigger Op tions

Process ing 16-b it AD C Sam ple Ra te to 51.2kHz W atchdog Func tion 10Base-T E the rne t In te rface U DP/IP and TCP/IP Protocol Support

T YPE 2 NODE

An alog E ight Synchronous Pairs or Sixteen S ingle Input Configurations

Input Range Compatible w ith S tandard Edd y Current P robes

P rogram mable DC/AC Coupling for Optim ised DC Gap and Vibration M easurement

F ull Anti-A liasing P rogram mable HP Filters P rogram mable Gain in Range 1 to 1000 F ault Protected Inputs

Channel-to-Channel Common M ode D ifference to 40V

T riggers As Type 1 Node

Pro cessing Dual 16-bit ADCs Sam ple Rate to 51.2kHz W atchdog F unction 10Base-T Ethernet Interface UDP/IP and TCP/IP Protocol Support

T YPE 3 N O DE

An a log T we nty S tatic Ana lo g Inp uts C onfigurab le M od ule T ype s, inc lu ding

T h erm oco up le , RT D, 3-W ire B rid ge , 4 -20 m A

O n-Boa rd E xcita tion Sup ply 17 2d B Inp ut Se nsitiv it y Ra n ge

P ro gra m m ab le G ain in Ra n ge 1 to 10 0 Auto m a tic DC O ffs et Rem ova l T wo Iso la ted R e la y O u tpu ts R S23 2/R S48 5 Co m m un ica tio ns C ha nn el

T rig g ers As T yp e 1 N od e

Pro c es sin g 22 -bit AD C Auto m a tic Re m o val o f 50/6 0 Hz M a in s-

Borne In terfa ce W atc hd og F un ctio n 10 Ba se-T E therne t Inte rfac e U DP/IP an d T C P/IP P rotoc ol Su p por t

PdM Training PDC Systems. has devel-oped a modular approach to training PdM technology us-ers, aimed at developing an effective PdM program. We focus not only on the tech-nology and how to interpret data, but we also provide help in program set up and tracking your PdM goals.

Courses can be tailor made to suit your individual re-quirements and are held either at our comprehensive training facility or at your plant.

Training courses start from as little as $200 per student.

Modules I. PdM Management 1 day

a. Maintenance strategies b. Project management c. Choosing the right technologies d. Integration into maintenance e. Procedures f. Reporting

II. Basic Vibration Analysis 2 day a. Frequency -v- time domain b. How the FFT works c. Examples of basic defects d. Transducers e. Accelerometer mounting f. Measurement parameters

III. Advanced Vibration Analysis 2 day a. Resonance b. Dynamic range c. Frequency calculations d. Effects of windowing e. Amplitude demodulation f. Phase g. Fault analysis h. Single plane balancing i. ODS

IV. Two Channel Analysis 1 day a. File capture of vibration data b. Variable speed machines c. Triggering d. Measurement parameters e. Capture and display options f. Two-channel functions g. Impact testing

V. Industrial Thermography 2 days a. Infra red theory b. Qualitative thermography c. Radiometric thermography d. Fault analysis e. PdM integration

VI. Passive Ultra Sound in PdM 1 day a. Ultra sound theory b. Detecting leaks c. Electrical applications d. Mechanical applications e. Integration into spectrum analyzers

VII. Potential Failure Analysis 1 day a. Identifying potential failures b. Determination of applicable technologies c. Definition of suitable measurement parameters

Vibration analysis can be very difficult to analyze. Why not get the experts to carry out all of the work for you and present you with a simple set of results and recommenda-tions after every visit? Our engineers are the best in the business and we will ensure that the reports give you good, practical advice.

After each visit for off-line or every day for on-line remote, you will receive a verbal report immediately if anything is dangerously close to failure followed up by a formal email, fax or written report.

On-line remote monitoring systems will provide a same day verbal and e-mail report and a full condition analysis every month.

PDC Systems 23-25 Windermere Road

Blackpool FY4 2BX United Kingdom

Phone: +44 (0)1253 400541 Fax: +44 (0)1253 400552

Email: info@predicon.net

Condition Monitoring Engineers

Were on the web. http://www.predicon.net

PDC Systems

Classroom or on site training

Specialized training courses

IIX. PdM on Rolling Element Bearings 1 day

a. Bearing construction b. Elastohydrodynamic lubrication c. stages of bearing failure d. Failure modes e. Fault frequency generation f. Vibration examples of common defects g. Tribology

IX. PdM on AC & DC Motor 1 day a. AC motor construction b. Failure modes c. Generation of electrical frequencies d. Vibration examples of common defects e. Motor current analysis f. DC motor construction g. Failure modes h. DC drives i. Vibration examples of common defects j. Thermography

X. PdM on Pumps 1 day a. Centrifugal pumps - theory of opera-

tion b. Centrifugal pump construction c. Positive displacement pumps construc-

tion d. Failure modes e. Vibration examples of common defects f. Performance analysis

XI. PdM on Fans 1 day a. Theory of operation b. Failure modes c. Vibration examples of common defects d. Performance analysis e. Adjusting bedplate resonance

XII. PdM on Large Stamping Presses 2 day a. Press construction b. Failure modes c. Specific monitoring problems d. Sensors & installation e. Defining vibration measurements f. Using advanced vibration techniques