PDC Systems

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

amount of operator involvement and intervention. 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 acknowledged and cleared as required. All
system activity is automatically recorded in
a log so that a complete history of plant operation 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 unambiguous reporting of machine problems.

Faults Pinpointed and Clarified

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 standards in ease-of-use. Mimics and the internal database are easily modified allowing a
straightforward upgrade path from a handful of points to hundreds.

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.

GuardianAngel

Inside:

Guardian

Angel

Iconet

System Specifications

Training

If several alerts or alarms have occurred

simultaneously, these can be reviewed in
turn.

Special points of interest:

If its Simple, Operators will

Use it
The Guardian application has been designed to monitor plant with the minimum

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)

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

GuardianAngel

Page 2

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

(Continued from page 1)

sons made with previous occurrences on this, and

other machines. Flexible comparison and overlay facilities are available.

System Configuration

Global Access

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.

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 anywhere. The system even allows the possibility to go live to a single measurement
point from anywhere in the world!

Scan rates and data storage criteria are fully

programmable to optimise system performance.

Security&System Diagnostics

Data Archiving
The Guardian software is designed to carry
out its monitoring tasks for months and
years with a minimum of system maintenance. Large amounts of data can be recorded 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 uneventful information.

Guardian incorporates a two-level security

system to ensure that system parameters
can only be changed by authorised personnel.

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

GuardianAngel

Page 3

Angel Over Guardian

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 engineer 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 engineer 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

Data Transmitted Over The Internet

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 receive 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 operational 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 winning joint first and first runner up in the last independent PdM awards. All PdM services are performed by engineers with experience in implementing 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 thermographic systems from many different vendors in
a variety of applications than anyone we know.

A data collection node as

used by Angel over Guardian

If the data is new

and the analysis is
accurate you have
full value
continually

Complex vibration analysis is carried out by our engineers

GuardianAngel

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 facilities for checking the integrity of
acquisition nodes and even the
transducers connected. Failing
accelerometers and open circuits or shorts on their connecting cables can be identified.
Imagine a flexible network system that can be used to gather
vital information on your machinery. One which can be incorporated into your existing
Ethernet networks in the plant
and which can be accessed locally or remotely. Imagine this

Page 4

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
ICONET on Ethernet.

of

But dont let your imagination

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

urement data on-line, absolutely

anywhere.

You are now thinking:

LOCAL ...
PLANT-WIDE ...
GLOBAL ...

GUARDIAN System Monitors

Connah's Quay Cooling Tower
Fans

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

System Description
Wide Choice of Inputs
ICONET on Ethernet sets out to
interface to just about any sensor type that is encountered in
the field of machinery monitoring, Typical transducers for
vibration measurement are
accelerometers and eddy current probes, and these are two
of the types that can be used
for so-called dynamic meas-

urements.
Often, process
measurements such as temperatures and pressures need
to be monitored. These socalled static parameters can
also be accommodated.
There are three types of node
in the ICONET on Ethernet series, called Type 1, Type 2 and
Type 3. The types of signal
input that each can accommodate are summarised below:
Type 1

Sixteen multiplexed analogue inputs

Sixteen ICP supplies for

accelerometer interfacing

Optional AC/DC coupling

Accelerometer bias voltage

check
Bearing condition measurement
Type 2

Sixteen analogue inputs,

multiplexed in pairs for
(Continued on page 5)

View the Condition of your Machinery Clearly and Precisely

GuardianAngel

(Continued from page 4)

simultaneous acquisition
(X-Y, orbit etc)
Standard interface to eddy
current probes

Type 3

Twenty multiplexed process measurement inputs

Modules available to interface to thermocouples,

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

Speed and Trigger Channels

Each node type is fitted with
the same trigger/tacho interface. This comprises four digital inputs that can be set as
isolated or non-isolated. Any
trigger input can be tagged to
any of the analogue input channels allowing maximum triggering flexibility. A trigger input

can be used for any of three

purposes, namely:
1. tacho input for measuring
machine speed (also incorporating a divide-by-N
Counter for taking inputs
from gear teeth or similar);
2. once-per-rev sensing for
time synchronous averaging;
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 channels can be used to gate measurements 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

Page 5

example, to acquire data only

from machines that are running.

Event Triggers for Synchronised Measurements

Two of the trigger input channels can be used as event triggers. These are used to synchronise measurement sequences between nodes on the
occurrence of an external
event. In addition, the ITA-1
incorporates a high-drive synchronising output. This can be
connected to the event inputs
of a number of other nodes (as
in a master-slave concept) enabling synchronised data gathering between nodes on a system.
This operates independently of
the Ethernet network.

A flexible network system

Bearing Measurement
Bearing Condition Measurement
The Type 1 node incorporates
an on-board hardware demodulator for the detection of bearing 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

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

A watchdog function is incorporated that monitors the operation of the nodes. If, for example, 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.

Acquisition Modes
Acquisition Modes
To optimise system performance in time critical applications, 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 computer 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.

The above modes can be modified in the application. For example, the mode could be
switched from Mode 1 to Mode
3 when live data is required.

Scrollable regions for elongated

systems

GuardianAngel

Page 6

Fast Node Control

Fast Node Control
In order to obtain maximum
data throughput, channel configurations (and the sequence in
which they are called) are
downloaded to the node and
stored in flash memory. The
node is then instructed to execute a stored sequence of
measurements, (and keeps rotating through if required). A
large number of configurations
and sequences can be stored in
the node so that, if the order
or configuration of measurements needs to be changed, this
can be done with a short command instead of having to
download a new set of instructions.

Standard Ethernet
ICONET on Ethernet uses the
latest Ethernet technology ensuring compatibility with existing Ethernet systems. Communication is possible within the
systems own environment,
across switches and routers,
and across the Internet. Standard off-the-shelf hubs and PC
adapters can be used throughout. Each node has a unique
MAC address. Physical connection is 10Base-T using the standard RJ45 plug and socket arrangement. For optimum performance, Icon recommends a
dedicated local Ethernet network is used to connect the
nodes to the PC as shown in

the typical installation diagram.

The ICONET part of the network can then be linked into
100Base-T Ethernet networks
through standard switches or
can be linked to the PC running, for example, Icons
GUARDIAN or other compatible
software directly. Several PCs
running GUARDIAN can be connected to the local network and
remote PCs running GUARDIAN can interface with the system 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 protocols are supported.

Standard off-theshelf hubs and PC

adapters can be
used throughout.

Hardware & Fitting

Enclosures
ICONET is available in a number
of enclosure types. The standard 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 factory dc voltages. Power consumption is very low, thus putting negligible load on existing
power systems.

Wireless Operation and

Internet
Being fully Ethernet compatible,
ICONET on Ethernet can be connected 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 Cost
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 modern PC is used to do this at a
fraction of the cost. This keeps
the hardware cost to a minimum.
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

Specifications
Alerts and Alarms
Human Machine Interface

Main and sub mimic colour change

Mimic driven interface

Pop up alert/alarm box

Main and sub mimic levels

Acknowledge function

Trend plots

Clear function (only if condition clears)

Trace plots (time, spectrum and orbit)

Log entries automatically generated

Point and click operation

Traffic light indication of total alerts/alarms

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

External Outputs
External relay activation
Point Selection
From mimic hierarchy
From Explorer function
From pop-up alert/alarm box

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

Review of trends Live mode

Virtually unlimited sub mimic levels

Live trend graphs

Operates under Windows NT or 2000

Uses standard Ethernet interface

Time scale zoom in/out

Multiple trend view of historical data (up to 5)

System Features

Access to live trace (eg. spectrum)

Periodic network checking

Review of Trends Browse Mode

Network check on demand

Cursor on trend(s)

Bias voltage check for accelerometers at user definable intervals

Timescale zoom in/out with cursor centred

System log and network log

Multiple trend view (up to 5 trends)

Log search facilities

Point highlight for overlay

Log print, serial output and shared file options

Multiple trend overlay (up to 5 of same type)

On-line help and user accessible HTML help

Access to trace overlays

Measurements with ITA-1

Point delete function

ICP devices (eg. accelerometers)

Hardcopy print-out

DC voltages
AC coupled signals
Tacho speed inputs from 1/rev or gear

Analysis of Results Spectra

Current spectrum view
Acquire / hold facility

Measurements with ITA-2

Real-time mode for instant analysis

X-Y signal pairs (eg. orbits)

Single, dual, harmonic and sideband cursors

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

probes

Spectral overlay up to 5 spectra, selected from trend screen

Tacho speed inputs from 1/rev or gear

Hardcopy print-out

Results

Optional grids

Scalar measurements
Overall and derived measurements
Spectrum graphs for acceleration, velocity, displacement and gbrg

Zoom

Auto peak detect

Line or bar display
Choice of Hz, CPM, RPM

Spectral Bands

Analysis of Results Orbits

Orbits

Current orbit view

Phase measurements

Acquire / hold facility

Trigger synchronised readings (sync, pre and post available)

Real-time mode for instant analysis

Orders spectral display using phase lock loop

Gates available to check data integrity

(Continued on page 8)

(Continued from page 7)

Angle / magnitude cursor

T YPE 2 N O DE

Adjustment of alert and alarm levels

An alog
E ight S ynchronous Pairs or Sixteen
S ingle Input C onfigurations
Input Range C om patible w ith S tandard
E dd y C urrent P robes
P rogram m able DC /A C Coupling for
O ptim ised D C G ap and Vibration
M easurem ent
F ull Anti-A liasing
P rogram m able HP Filters
P rogram m able G ain in R ange 1 to 1000
F ault Protected Inputs
C hannel-to-C hannel C om m on M ode
D ifference to 40V

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

T riggers
A s Type 1 N ode

Furthest from a datum alert and alarms available

P ro cessing
D ual 16-bit A DC s
S am ple Rate to 51.2kH z
W atchdog F unction
10Base-T Ethernet Interface
U D P/IP and TC P/IP Protocol Support

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

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 3 N O DE
A n a log
T w e nt y S tatic A na lo g Inp uts
C onfigur ab le M od ule T ype s, inc lu ding
T h erm oco up le , R T D , 3-W ire B rid ge ,
4 -20 m A
O n- B oa rd E xcita tion S up ply
17 2d B Inp ut S e nsitivit y R a n ge
P ro gra m m ab le G ain in R a n ge 1 to 10 0
A uto m a tic D C O ffs et R em ova l
T w o Iso la ted R e la y O u tpu ts
R S 23 2/R S 48 5 C o m m un ica tio ns C ha nn el

TYPE 1 N OD E
A n a lo g u e
S ixte en M ultiple xe d A na log u e Inp uts
IC P P o w e r fo r A c ce lerom e te rs on A ll
C ha nn els
A C /D C In pu t C ou p ling O ption s
F u ll A n ti-A liasin g
P rog ra m m a ble H P Filters
O n-b oa rd H ard w are Integ ra tor
P rog ra m m a ble G a in in R a n ge 1 to 1 000
O n-b oa rd B e a rin g D em od ula tio n F u nc tio n
T rig g e rs
F o ur D ig ita l T rigg er In p uts
5 -2 4V d c R an g e, Is ola ted o r N o n-Isolate d
A v erag ing , P re a nd P o st-T rigg er F u nction s
T rigg er, T ach o an d O rde r A na lys is
F u nc tion s
E v en t a nd G ate T rigg e r O p tio ns
P ro c ess in g
1 6-b it A D C
S a m ple R a te to 5 1.2k H z
W atch do g F u nc tion
1 0B a se -T E the rn e t In te rfac e
U D P /IP an d T C P /IP P rotoc ol S up po rt

T r ig g er s
A s T yp e 1 N od e
P ro c es sin g
22 -bit A D C
A uto m a tic R e m o val o f 50/6 0 H z M a in sB or ne In terfa ce
W atc hd og F un ctio n
10 B a se-T E ther ne t Inte rfac e
U D P /IP an d T C P /IP P r otoc ol S u p por t

PDC Systems

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 recommendations after every visit? Our engineers are the best in the
business and we will ensure that the reports give you good,
practical advice.

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

PdM Training

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.

Modules
I.

PDC Systems. has developed a modular approach to

training PdM technology users, aimed at developing an
effective PdM program. We II.
focus not only on the technology and how to interpret
data, but we also provide
help in program set up and
tracking your PdM goals.
Courses can be tailor made III.
to suit your individual requirements and are held
either at our comprehensive
training facility or at your
plant.
Training courses start from
as little as $200 per student.
IV.

V.
Classroom or on site training

VI.

VII.

PdM Management
1 day
a.
Maintenance strategies
b.
Project management
c.
Choosing the right technologies
d.
Integration into maintenance
e.
Procedures
f.
Reporting
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
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
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
Industrial Thermography
2 days
a.
Infra red theory
b.
Qualitative thermography
c.
Radiometric thermography
d.
Fault analysis
e.
PdM integration
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
Potential Failure Analysis
1 day
a.
Identifying potential failures
b.
Determination of applicable technologies
c.
Definition of suitable measurement parameters

Specialized training courses

IIX.

IX.

X.

PdM on Rolling Element Bearings 1 day

a.
b.
c.
d.
e.
f.
g.

PdM on AC & DC Motor

1 day

PdM on Pumps

1 day

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
a.

b.
c.
d.
e.
f.

XI.

XII.

Bearing construction
Elastohydrodynamic lubrication
stages of bearing failure
Failure modes
Fault frequency generation
Vibration examples of common defects
Tribology
AC motor construction
Failure modes
Generation of electrical frequencies
Vibration examples of common defects
Motor current analysis
DC motor construction
Failure modes
DC drives
Vibration examples of common defects
Thermography

Centrifugal pumps - theory of operation

Centrifugal pump construction
Positive displacement pumps construction
Failure modes
Vibration examples of common defects
Performance analysis

PdM on Fans

a.
b.
c.
d.
e.

1 day

Theory of operation
Failure modes
Vibration examples of common defects
Performance analysis
Adjusting bedplate resonance

PdM on Large Stamping Presses 2 day

a.
b.
c.
d.
e.
f.

Press construction
Failure modes
Specific monitoring problems
Sensors & installation
Defining vibration measurements
Using advanced vibration techniques