: FALCON Technical data sheet

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3 FALCON Technical data sheet Document Reference Name : TDS3143 September 2013 A : FALCON Technical data sheet support@acoemgroup.com Copyright dB-Metravib SAS This document is the property of 01dB-Metravib SAS. Any dissemination, copying or publicising of this document, in whole or in part, is prohibited without the owner s written authorisation

4 TABLE OF CONTENTS USE AND APPLICATIONS... 5 Main applications... 5 Smart Balancer... 5 Smart Data Collector... 6 Remote access... 6 Packages 7 Balancer package... 7 Machine Auto Controller package... 7 Basic Data Collector package... 7 Smart Data Collector package... 7 Expert Data Collector package... 7 Modularity 8 Functions and options... 8 Temporary licence... 8 General Specifications... 9 Display... 9 Keyboard... 9 Digital architecture... 9 Battery... 9 Analogue inputs... 9 Analogue outputs... 9 Built-in pyrometer with laser-sighting Built-in Stroboscope Built-in camera Identification of measurement point Mechanical/Environment FALCON Intrinsically safe version: WLS Triaxial wireless accelerometer Signal processing Vibration overall level Rotation speed Other parameters Time wave Spectral Analysis Vector measurement (phased spectrum) Collector mode Automatic diagnosis Balancing option Balancing Specifications Digital recorder option FALCON hardware package... 17

5 5 USE AND APPLICATIONS MAIN APPLICATIONS Relying on ACOEM's 25 years of experience (formerly 01dB-Metravib, Stell Diagnostic, 01dB-Stell and then 01dB Acoustics & Vibration) in developing portable instruments for condition monitoring, FALCON includes all the technology to address any set of machines: Suitable for industrial environment, o Shock-proof, o IP65 protection o Dangerous area: ATEX, IECEX (option pending) Wireless communication with sensor and information system 4 channels + trigger input Large colour touchscreen with high contrast Built-in sensors: pyrometer, stroboscope, image FALCON is available for all industrial applications where ONEPROD-based condition monitoring is deployed: Wind power Oil & Gas Steel industry Mining Chemistry Petro-chemistry Energy Cement works Paper industry Food industry Textile industry Car industry Defence Aeronautics Education/Research Other industries FALCON offers all the functions needed to monitor and analyse your machines: SMART BALANCER This function allows correcting unbalance on your machines. It is possible to balance rotors of any size, from the simplest to the most complex one (1 to 4-plane balancing). Using multichannel acquisition, parallel measurements on all sensors are possible, resulting in a faster, safer and more accurate procedure. FALCON Balancer includes all tools to guide the operator and control the results during the entire balancing process: Easy to use with the guided mode Graphic display of measurements and weight positions Automatic setup of tachometer Trial weight estimation Control of the data at each step with recommendation to improve result quality Rotation speed control Tools to split or merge weights Result assessment according to ISO and ISO 1940 Get a detailed report documented with histograms, pictures and spectra.

6 6 SMART DATA COLLECTOR FALCON Data Collector with NEST PC software platform offers the most efficient solution at each step of the implementation of condition monitoring at your plant. Installation: o NEST installation on client workstation: automatic at the first connection to the server. FALCON is plug-and-play. o Ease to use: fast training, no need to be an expert. Possibility to train several persons with the "Remote Display & Control" function o Each user can have a customised access to functions and databases Database initialisation: o Automatic setup: create a machine in few clicks without any vibration knowledge. o Fast duplication with copy/paste or export/import functions o Creating routes: From a map view to optimize data collection regarding the location of machines. Reorder points based on the actual measurement order to improve the effectiveness of future collections Data collection: o Documented routes to guide the operator: Map view of the machines to easily localise them Machine picture to show positions of measurements points Sensor picture to show its mounting o Bar code reader for automatic machine or point identification o Wireless triaxial sensor to improve speed, safety and comfort o Built-in sensors: Pyrometer for temperature measurement Stroboscope for rotation speed o Fast measurement: multichannel acquisition and parallel processing o Single-hand measurements (left or right) o Immediate built-in diagnosis with recommendations o Display measurements: live or stored data o Input of operating condition class o Easy to gather observations during collection: Choose inspection notes in a predefined list Enter a free comment (even with Chinese characters!) Record an audio comment Inspection picture with the built-in camera. Data analysis: o Locally with FALCON o With NEST: access to the status and results of the automatic diagnosis o Manually with the powerful XPR analysis software. Off route mode: o A machine is not in a route or you want to perform additional analysis: go directly in off-route mode and locally create new machines just by simple copy and paste. o Data can be downloaded on PC database and associated to new or existing machines REMOTE ACCESS FALCON can be configured to communicate with your network through its Ethernet or Wi-Fi interface and can be used as a Remote Desktop. You can then use the applications of your computer directly from FALCON, such as NEST software, CMMS or consult any technical document.

7 PACKAGES Several packages are available depending on your own request. BALANCER PACKAGE The FALCON BALANCER package is a fully stand-alone portable device embedding a lot of functions improving the productivity and reliability of balancing, making FALCON the best balancing tool of the market. This package exists in 2- channel and in 4-channel version. MACHINE AUTO CONTROLLER PACKAGE The FALCON Machine Auto controller package is especially adapted to all industrialists who want to perform on-site automatic diagnosis on a set of machines in a very simple way and with minimum investment. BASIC DATA COLLECTOR PACKAGE The BASIC data collector package is especially adapted to all industrialists who want to start condition monitoring on a set of machines and discover the world of vibration analysis step by step. SMART DATA COLLECTOR PACKAGE The SMART data collection package is especially adapted to all industrialists who want to improve the reliability of their facilities in a very productive and easy way. With FALCON SMART data collector, the expert is in the box! EXPERT DATA COLLECTOR PACKAGE The EXPERT data collector package is especially adapted to all users who have good knowledge of vibration analysis and can provide reliable diagnosis and maintenance recommendation on their own. The EXPERT data collector package will provide them with the most productive tool of the market, thus helping them to drastically save time.

8 8 MODULARITY FUNCTIONS AND OPTIONS You can adapt the above functions, as well as options, to easily meet all your needs. Options: Number of channels: 1, 2 or 4 Long-time wave Camera and bar code reader Wired or wireless accelerometer All packages are fully upgradeable. It is thus very easy to switch from one to another without changing the FALCON instrument. TEMPORARY LICENCE Get the function just for the time you need it.

9 GENERAL SPECIFICATIONS DISPLAY KEYBOARD Graphic colour touchscreen Resolution: 800x480 pixels Dimension: 154x92 mm (D7 ) Adjustable brightness Can be used outdoors Icon functions On touchscreen: 10 contextual function keys Functions are organised for singlehand measurement (left or right) Direct access to general functions: Home, Help, Setup, Screen copy, Picture, Bar code reader, Text note, Audio comment, Pyrometer, Stroboscope Full keyboard for text input. Several keyboard available: qwerty, azerty, Chinese DIGITAL ARCHITECTURE BATTERY Acquisition o Synchronous on 4 channels + trigger input o 24-bits conversion o Sampling frequency for each channel: khz on 1 channel o Antialiasing filter Wireless interface with a triaxial accelerometer Digital Signal Processors Real time processing : 40 khz on 4 channels Memory: 3.5 GBytes for storage of measurements Communication: o USB 2 type B device (direct connection with PC) o USB 2 type A host (for USB memory stick) o Ethernet o Wi-Fi Auto test and calibration function High density Li-Ion type Rechargeable without removing Battery lifetime: 10 hours under intense use Programmable automatic standby mode and switch-off ANALOGUE INPUTS Up to 4 programmable signal inputs (depending on instrument option): Frequency range: 0-40 khz on 4 channels, 80 khz on 1 channel Overload indicator in % with memorisation IEPE interface with real time integrity control, range 8V (power supply: 4 ma constant current 23 VDC) Dynamic signal measurements (acceleration, vibration velocity, absolute displacement, relative displacement, electrical current, etc.) o o +/- 10 VAC 0, -24 V for proximity probes (a -24Vdc power supply is available on each channel) Input impedance AC/DC: 100 kω Accuracy: +/- 1% Sensors without electronics with optional charge amplifier DC input: from -24 VDC to +24 VDC for measurements of position and process parameters AC coupling: 0.3 Hz Compatible with triaxial sensor Trigger input: Range : +/- 10 V, 0 to +24 V, 0 to 24 V Adjustable triggering parameters Automatic setup function For rotation speed measurement, synchronous analysis, balancing, order analysis. Input impedance: 100 kω + 5 Vdc power supply for tacho probe -24 Vdc power supply for proximity probes Microphone input for audio inspection notes ANALOGUE OUTPUTS 1 headphone output to listen sensor signal, recorded signal or audio inspection notes 1 stroboscope output: TTL For each channel and trigger input: -24 Vdc power supply for proximity probe

10 10 BUILT-IN PYROMETER WITH LASER-SIGHTING Contactless temperature measurement: Range: 0 to 200 C Accuracy: +/- 3 C for ambient temperature ranging from 18 C to 28 C. Resolution: 0.5 C Repeatability: +/- 1 C Field of view: 50% ( target 4 50 cm) Time response: 1 s Fixed emissivity: 95% BUILT-IN STROBOSCOPE Rotation speed measurement: Range: 30 to RPM Adjustment: o ½, x2 o Fast o Fine Flash duration : adjustable from 0.5 to 15 Can be used independently or to adjust rotation speed in a route or from a spectrum display BUILT-IN CAMERA FALCON INTRINSICALLY SAFE VERSION: ATEX certification (pending) IECEX certification (pending) EX II 3 G, EEx ic IIC T4 option and supplies with certified accessories. WLS TRIAXIAL WIRELESS ACCELEROMETER Battery lifetime: 8 hours 3 20 khz bandwidth Full scale: 80 g Frequency 3db: 10 khz (Z), 3 khz (XY) Dimension: Ø40 x H115 mm Mounting: M6 threaded hole Operating temperature: -20 to +80 C Protection: IP65 ATEX/IECEX certification (pending) Distance FALCON-WLS: up to 10 m in industrial environment Several systems FALCON-WLS can work together in the same area Mounting accessories: cementing studs, magnet for flat surface, orientation indexed magnet, bipolar magnet for curved surfaces WLS sensor can be used for all asynchronous measurement up to 20 khz Resolution: 640 x 480 Autofocus Distance : 20 cm to Flash mode IDENTIFICATION OF MEASUREMENT POINT Built-in bar code reader Reading distance: from 20 cm to 50 cm according to code dimension Bar code format: QRcode Learning mode to avoid codes manual input MECHANICAL/ENVIRONMENT Protection: IP65. Case with shock protection rubber Shock protection: 1.2 m drop Standard compliance: o Safety: IEC o EMC: directive CE Dimensions: 200 x 265 x 65 mm Weight: 1.8 kg including battery and rubber protection Operating temperature: -10 C to 55 C Humidity: 95% no condensation

11 11 SIGNAL PROCESSING VIBRATION OVERALL LEVEL Filters: o High-pass filters: 2, 10, 3,000 Hz, o Low-pass filters: 300, 1,000, 2,000, 3,000, 20,000, 40,000 Hz o 10-1,000 Hz vibration velocity in accordance with ISO 2954, ISO10816, VDI 2056 standards for rotating machinery o Hz for reciprocating machines (VDI 2063 standard) Detection: RMS, true or equivalent peak, true or equivalent peak-to-peak Rolling element detection: defect factor scale from 0 to 12 for standard rotation speed* Measurement of Kurtosis (Shock detection for low speed rolling element bearing)* o High-pass filter: 50 Hz to 20 khz, 1 Hz step o Low-pass filter: 500 Hz to 20 khz, 1 Hz step (LPF > 2 x HPF) Programmable measurement time: 1 to 99 s Alarms: 4 alarm types, up to 4 alarm levels, comparison to previous measurement Display: instantaneous measurement, measured value, alarm limits, previous measurement Display of measurement and alarm levels as bar-graphs Integration: none, single or double integration for measurement of acceleration, velocity or displacement Overall level value in engineering unit and db ROTATION SPEED External trigger input with direct access to trigger level setup. Automatic setup mode. Range: 12 to 288,000 RPM (0.2 to 4,800 Hz) With built-in stroboscope DC input Keyboard input OTHER PARAMETERS Integrated pyrometer with laser-sighting for contactless temperature measurement Any other parameters (user-defined parameter and unit) with DC input and keyboard input Machine operating condition TIME WAVE Number of samples: 256, 512, 1,024, 2,048, 4,096, 8,192, 16,384, 32,768, 65,536. Extended number of samples with long time wave option: up to 80 s split over the number of channels or 4,096K samples. Demodulation of time waveform (band-pass filtered) Sampling frequency (Hz): 204.8K, 102.4K, 51.2K, 25.6K, 12.8K, 5.12K, 2.56 K, 1.28K, 512, 256, 128 Integration: none, single or double integration for measurement of acceleration, velocity or displacement Synchronous analysis: o Triggering on signal or trigger input. Trigger delay programmable from samples to +20 seconds o Programmable trigger level on positive or negative slope o Averaging: from 1 to 4,096 with linear or exponential mode Time analysis on all types of signal: vibration, force, pressure, current (user-defined parameter and unit) Orbit display with 2 channel measurement SPECTRAL ANALYSIS Number of lines: 100, 200, 400, 800, 1,600, 3,200, 6,400, 12,800 (6,400 maxi with 2 channels) Envelope: spectrum of demodulated time waveform filtered by a programmable band-pass filter (any central frequency, band width = 1/2 to 1/128 of analysis range). Max number of lines: 6,400

12 12 Zoom factor: 2, 4, 8, 16, 32, 64, 128. Frequency ranges (Hz): 80k, 40k, 20k, 10k, 5k, 2k, 1k, 500, 200, 100, 50 Averaging: from 1 to 4,096 with linear, exponential or peak hold mode Overlap rate: 0, 50, 75% Real time: up to 40 khz Weighting window: Rectangular, Hanning, Flat-top Synchronous analysis: triggering on signal or trigger input. Trigger delay programmable from -8,192 samples to +20 seconds Programmable trigger level on positive or negative slope Display: Lin/Log, automatic scaling, engineering unit/db, RMS/Peak/Peak-Peak amplitude for each type of parameter, Hz, RPM Display of instantaneous spectrum and averaging during measurement Spectral analysis on all types of signal: vibration, force, pressure, current (user-defined parameter and unit) VECTOR MEASUREMENT (PHASED SPECTRUM) Number of lines: 100, 200, 400, 800, 1,600, 3,200, 6,400 Frequency ranges (Hz): 40k, 20k, 10k, 5k, 2k, 1k, 500, 200, 100, 50 Synchronous averaging: from 1 to 4,096 Display: Lin/Log, automatic scaling, engineering unit/db, RMS/Peak/Peak-Peak amplitude for each type of parameter, Hz, RPM Display of instantaneous spectrum and averaging during measurement

13 13 COLLECTOR MODE Measurement organisation: o Tree structure: Location, Machine, Point, Measurement o Identification: 22 characters/level (20 for measurement) o Simultaneous measurement on 1 to 4 channels o Observations during collection: Choose inspection notes in a predefined list Enter a free comment (even Chinese!) Record audio comment Inspection picture with the built-in camera Review function to analyse measurement data directly on the instrument Single-hand operating (left or right) for measurement Fast browsing through Plant, Machine or Point in a route with list or map browser modes Automatic identification of point or machine using QR Code tags Load/Download route: o Directly from NEST software by USB, Ethernet or Wi-Fi o By intermediates files Copy machine to Off-route mode One shot measurement: synchronous on all channels and parallel processing: exclusive technique to reduce the acquisition time and to optimize data collection Off-Route Mode: o Specific route to carry out measurements not programmed from the PC. o Tree structure: Machine / Point / Measurement o Copy / Paste machine from any route o Measurement can be down loaded in NEST to new machines or existing ones Input of operating condition class Built-in diagnosis (see below) The collector mode is available with 2 levels of functions: Collector Advanced Collector Premium Overall OK OK Time wave (nb of samples) 8 K 64 K Spectrum (nb of lines) Envelope OK OK Zoom No OK Vector OK OK Long time wave No Option

14 14 AUTOMATIC DIAGNOSIS Associated with the automatic setup of NEST PC software, the built-in Automatic Diagnostic of FALCON gives access to condition monitoring to everyone. One just needs to be able to describe the machine and do the measurements. NEST will do the setup and FALCON will issue the diagnosis. Machine and components types o Electric motors (synchronous, asynchronous, DC) o Pump o Fan o Compressors (Centrifuge, Lobed) o Gearbox with up to 4 stages o Bevel gearbox o Roller o Shaft Main analysed defects: o Unbalance o Misalignment o Bearing and lubrication o Mounting, clearance, friction o Gear defects o Cavitation Result: o Overall advice and recommendation o For each defect: location, severity, confidence and recommendation

15 15 BALANCING OPTION This function is used to correct the most usual anomaly, i.e. unbalance, without having to dismantle the machine. It is possible to balance rotors of any size, from the simplest (1-plane balancing) to the most complex one (for 3 or 4-plane balancing, 4-channel option required). Each balancing is memorised with all the information relative to the balancing operation, i.e., configuration, measured values, coefficients, trim measurements, spectrum, pictures and comments. For any stored balancing, it is very easy to perform a new balancing operation, following the one run procedure. Using 2 or 4-channel option, parallel measurements are possible, resulting in a faster, safer and more accurate procedure. BALANCING SPECIFICATIONS Balancing using acceleration, velocity or displacement Measurement and compensation of Run Out if balancing with proximity probes Trial weight value and position estimation Rotation speed indication in Hz or RPM Direct access to the tachometer signal and setup with an automatic adjustment function Measurement with programmable averaging to reduce external disturbances Display instantaneous value during averaging Automatic control of vibration and rotation speed dispersion to check reliability of measurements Measurement display in tabular mode and graphic polar mode Storage in a 2-level tree structure: folder/balancing Easy balancing duplication with copy-paste function. One-run balancing with stored influence coefficients Computation of balancing weights for any run (free run or with trial weights) Trial and balancing weights display in tabular mode and graphic polar mode. 3D mode for 2-plane balancing. Function to split weight on two define angles Function to merge additional weight with previously installed weights Visualisation of grade of balancing quality (standards ISO 1940, VDI 2060, NFE ) Display of ISO limits Balancing report unloaded to PC in Word format. Report is based on a fully user-configurable model. It includes: o Balancing configuration o Balancing summary with graphical histogram o Picture of sensor mounting o Comment o Detailed results o Spectra at the beginning and at the end of the balancing User-defined angle unit to help towards installing weights Friendly mimic menu-driven program allowing to stop and resume balancing as wanted and to repeat any single operation without running the whole procedure again Imperial or metric units Measurement: o Rotation speed: 12 to 288,000 RPM (0.2 to 4,800 Hz) o Amplitude range: with a 100 mv/g accelerometer: acceleration: 80 g. Measurement is also possible for vibration velocity and displacement with a 8 mv/m (200 mv/mil) proximity probe: 1.5 mm (60 mils) o Amplitude: display in engineering units or db o Phase: display with 4 digits from 0 to 360 (or any other user-defined unit). Accuracy +0.5

16 16 DIGITAL RECORDER OPTION This option increases the time wave acquisition capacity to ranges of signals reaching up to 4,096 K samples or 80 s to be split over the number of used channels.

17 17 FALCON HARDWARE PACKAGE FALCON is supplied with following accessories: Carrying case A built-in rechargeable battery pack A mains power supply unit: 110/220 V 50/60 Hz 1 voltage input cable USB cables Quick start manual Full user manual in the internal memory WLS sensor kit or ASH sensor kit (see below) WLS sensor kit: Triaxial Wireless Sensor with built-in rechargeable battery pack A mains power supply unit: 110/220 V 50/60 Hz USB cable Optional mounting accessories: o M6 mounting cementing studs o Magnet for flat surfaces with orientation index o Flat cementing pads with orientation index o Magnet for flat surfaces with orientation index o Flat cementing pads with orientation index o Bipolar magnet for curved surface ASH sensor kit: ASH201-A spiral cable magnet contact point set of 10 cementing studs Balancing kit: 2 x ASH201-A kit Optical triggering device for phase measurement with laser sighting Magnetic holder for Optical triggering device

18 ACOEM Smart monitoring, diagnosis & solutions ACOEM offers comprehensive products and services comprising smart monitoring, diagnosis and solutions, drawing upon its unique expertise in the field of vibrations and acoustics. ACOEM contributes to the improvement of: quality of life and risk prevention in urban and industrial environments productivity and the reliability of industrial processes the design of robust and high-performance products with low noise levels protection of sites, vehicles and people in hostile environments. With its 01dB, METRAVIB and ONEPROD brands, ACOEM works with decision-makers in industry, defence and the environment throughout the world. For more information, visit our website at chemin des Ormeaux LIMONEST FRANCE Tel.: +33 (0) Asia Tel. +66 (2) Fax +66 (2) South America Tel (11) Fax +55 (11)