|
1 Applications
The PCH 1216 and PCH 1218 devices are maintenance free and mounted in an IP 67 enclosure
(IP68 with matching connector) and can be used to monitor structural vibration parameters and
(sudden) heavy shock detection in machines rotating at low RPM, mainly wind turbines.
The PCH 1216 and PCH 1218 devices are also suitable for structural vibration monitoring and
shock detection of bridges, towers and other structures, which need to be protected against the
potential disastrous result of a catastrophic event like unusual very energetic vibration or sudden
shock (impulse).
The internal sensors of the PCH 1216 and PCH 1218 vibration and shock monitors keep
continuously track of the structural vibration level of a machine at the point where the device is
mounted in the structure.
The early warnings produced by the PCH 1216 and PCH 1218 devices allow protective action(s)
while the fault is still under development, resulting in a considerable reduction of structural damage
to the wind turbine (or any other monitored rotating machine).
The vibration parameters calculated are general vibration parameters, i.e. the true RMS, Peak or
Peak-to-Peak value of the vibration signal in m/s2, mm/s, µm, or in percent of full scale.
A PCH 1216 or PCH 1218 device can be (optionally) supplied with a special CHB 1131 USB
Service Cable or ruggedized CHB 1134 Service Adaptor, either of which can be used to transfer the
vibration level and status information directly to a PC. The PC-program used for this is called
“CHT 1044 PCH Vibration Studio – Control software for PCH Engineering vibration monitors”,
which will be abbreviated to “PCH Vibration Studio software” in the rest of this user manual.
By default a PCH 1216 or PCH 1218 device is provided with a M12 8-pin connector.
As an option a PCH1216 or PCH 1218 can also be supplied with an M12 12-pin connector, which
opens up for additional options like RS485 ModBus communication between the device and a PLC
or PC, two string SSD relay function and/or additional 3rd analogue output (for PCH 1216 only).
In applications that require that the outputs are divided over two cables it is possible to obtain a
PCH 1216 or PCH 1218 with two connectors on the same enclosure (housing): an 8-pin connector
and a 5-pin connector.
The enclosure of the PCH 1216 and PCH 1218 devices are made from DIN 1.4404 (AISI 316L)
stainless steel, which makes it possible to use them for applications at high sea or near the sea
shore. Also applications in the food and drugs industry are within the field of applications of such
devices.
The above mentioned Safety Shock Detection (SSD) is tested and certified by Germanische Lloyd
according to GL2010: Guideline for the Certification of Wind Turbines, Edition 2010.
Page 7
2 Customer Specification Agreement
Prior to delivery all parameters are pre-set to a default value by the manufacturer PCH Engineering.
Those wind turbine manufacturers that cannot use the default parameter set-up can enter a signed
“Customer Specification Agreement” with the manufacturer PCH Engineering, which will allow the
customer to get a PCH 1216 or PCH 1218 device delivered with a very specific parameter setup.
The customer specification agreement will describe the total setup configuration of the vibration
monitor. The specification sheet defines: hardware configuration, firmware configuration,
parameter set-up and labelling. Units configured according to this particular set of setup parameters
will get a private item number like CHF 836xxx (PCH 1216) or CHF 838yyy (PCH 1218), where
xxx and yyy are 3-digit numbers. This CHF number will be mentioned on a label that is fixed on the
top of the enclosure of the PCH 1216 or PCH 1218 device. In case the device has an embedded
RS485 ModBus and/or CANopen FieldBus the CHF-number will be followed by R0, R1, R2 or R3
to indicate whether or not a 120 Ω termination resistor is mounted in the device. The same label
also indicates the type number, the customer company name, as well as special markings like CE
marking. A small separate label mentions the serial number.
When a customer has agreed to – and signed – the Customer Specification Agreements, a factory
release project is initiated to ensure that completely identical PCH 1216 or PCH 1218 devices be
delivered to the customer for his/her serial production.
Inside the monitor memory a so-called “Factory Authorisation Code” (FAC) is stored. The FAC
can be read with the PCH Vibration Studio software. The same FAC embedded in the monitor is
also printed in the Customer Specification Agreement. If the customer chooses to change one or
more set-up parameter(s) after the PCH 1216 or PCH 1218 has left the factory, the FAC is erased in
order to indicate that the PCH 1216 or PCH 1218 no longer complies with the (signed) Customer
Specification Agreement.
Only the manufacturer PCH Engineering A/S can re-write the FAC, or can send a new FAC-set-upfile that will store a new FAC in the device that complies to a (new?) signed Customer
Specification Agreement.
The SSD function is a factory installed function that cannot be disabled by the user. In case the
device is ordered with the SSD enabled, a blue/white GL/SSD label is fixed to the box.
In the final production stage a semi-automated test system verifies around 50 different
measurements, calibrations and inspections. For each device a 100% test is carried out and finally a
complete test report is stored with reference to the serial number.
! Note:
Please note that depending on customer requirements one or more features in a PCH
1216 or PCH 1218 device might not have been mounted or enabled and will therefore
not be accessible for parameter setup and upload of result data.
Page 8
3 Introduction
3.1 General wind turbine monitoring Picture 1-1: Type PCH 1216 and PCH 1218 structural vibration monitors with SSD |
Measuring and monitoring the vibration level of wind turbines is a proven method of implementing
safety measures concerning the structural behaviour of the tower, edgewise vibrations of the rotor
blades, as well as torsional stress on the input shaft of the gearbox, thus enabling corrective action
before the stress creates damage.
By monitoring structural vibrations, you can detect the changes in stress levels fast enough to
prevent sudden very costly breakdowns.
3.2 PCH 1216 and PCH 1218 structural vibration monitors
A PCH 1216 or PCH 1218 device is a self-contained vibration monitor in a sealed stainless steel
enclosure. To function, only a +24 VDC power supply and the desired output connections are
required.
The PCH1216/1218 device is designed for low frequency vibration monitoring applications by
means of 3 (redundant) internal vibration sensors. The built-in vibration sensors (accelerometers)
are configured in 3 perpendicular directions: 1A, 2B and 3C. For wind turbines typically only 2
directions are used: 1A & 2B (= horizontal plane) or 1A & 3C (= vertical plane).
A PCH 1216 or PCH 1218 device is delivered including all the necessary test functions for all
sensors and electronic circuits, as well as an internal watchdog for continuously self-monitoring of
its functions. The design of the PCH 1216 and PCH 1218 is based on a digital platform allowing
multiple customer solutions, and – if required – easy and rapid change of configuration and settings
by PC, also in the field.
Before delivering a PCH1216/1218 device is typically pre-configured by the manufacturer
according to a set-up (.MSE) file agreed upon between the customer and the manufacturer. See
section 2 of this User Manual.
Page 9
Modification of the pre-defined set-up is possible by a person authorised by the wind turbine owner
using the PCH Vibration Studio software.
!
Warning:
If the authorised parameter setup that was installed during the final production stage
carried out by the manufacturer is changed/compromised in any way, the stored CHF
836xxx or CHF 838yyy device version number will be erased in the internal memory of
the device. Any PCH1216 or PCH 1218 that has been returned to the manufacturer for
repair and no longer has a valid CHF 836xxx or CHF 838yyy number in its memory will
automatically be subject to a limited liability from the side of the manufacturer with
regard to damages imposed on the wind turbine, its parts and/or surroundings, if caused
by or traceable to an erroneous set-up of a PCH1216 and/or PCH 1218 device.
The PCH Vibration Studio software provides user-friendly set-up menus and testing facilities. This
software can display measurements, including the status of alarms and system failures. Different
set-ups can be saved to a data file, and new set-ups can be uploaded to a PCH1216 or PCH 1218
device at any time. Only one, or at the most a few, monitor hardware version(s) are needed on stock
with this easy loadable set-up facility. The same monitor can in short time be reconfigured to the
meet specifications for many different machines and thus provide a streamlined stock & purchase
handling.
The measured vibration level is compared with user-programmable Alert and Danger threshold
levels, and when these limits are exceeded relays may be selected to initiate actions accordingly,
e.g. shut down of turbine or machine.
Because one or more PCH1216 devices usually are an integral part of a process control system, the
measured analogue DC signal outputs can be used as a process input parameter. The vibration
levels can also be read via an optional RS485 ModBus connection (for PCH 1216 or PCH 1218) or
via a CANopen FieldBus interface (for PCH 1218 only).
For more specific technical data concerning a PCH1216 or PCH 1218 device, please refer to the
Product Data sheets: CHF1145 (PCH 1216) and CHF 1146 (PCH 1218) or to the Technical Data in
chapter 12 of this User Manual.
3.3 Features
A PCH1216 or PCH 1218 device is a semi redundant low frequency shock sensor operating
according to the Germanische Lloyd GL2010 guide lines and the ISO 13849-1 machine directive
standard. The sensor is placed in the nacelle to monitor shocks and low-frequency nacelle
oscillations and is connected directly to the wind turbine control system.
Features:
- 3-directional shock sensor
- Low frequency structural monitoring according to GL2010 Guide Lines
- Design according to EN ISO 13849-1 for safety related parts
- Redundant accelerometer sensors and SSD safety relay
- Two analogue outputs for vibration data (PCH 1216 only)
- CANopen protocol (PCH 1218 only)
- RAW time waveform signal output via analogue DC output (PCH 1216 only) or via CANopen
(PCH 1218 only)
Page 10
Principals of the PCH 1216 and PCH 1218 devices
The PCH1216 and PCH 1218 devices include a PCH Safety Shock Detection function (SSD),
which is a 3-directional vector sum shock detector with user defined alarm levels. The devices are
equipped with a redundant sensor and safety relay and have excellent functional safety parameters
like a high diagnostic coverage and MTTFd time.
In addition to the fixed shock detection filter the user can configure 4 additional narrow filter bands
including various detectors such as RMS, Peak and Peak-to-Peak.
Narrow filter bands are used for protecting the wind turbine against oscillations, which might
become dangerous if the measured vibration frequency gets close to the tower resonance frequency
during normal operation.
For a PCH 1218 (only) these non-shock related scalar values are continuously transmitted to the
controller using the CANopen protocol on a fieldbus. The CANopen protocol also opens the way
for an additional feature like raw time waveform data that can be transmitted to the controller for
tower feedback loops, etc.
For a PCH 1216 (only) these non-shock related scalar values are transmitted to the controller by
using the two (or optional three) available analogue outputs (0-20 or 4-20 mA plus 0-5 or 0-10
Volt). As an additional option the analogue outputs can also be used to transmit raw time waveform
data, which can be used for tower feedback loops, etc.
Diagram of PCH 1216 and PCH 1218 principals
Fail safe
The control system will constantly receive an OK signal from the sensor if no system error is
detected. Any faults will immediately be transmitted to the controller through the redundant safety
relay, which also serves as the SSD alarm relay.
Detector
Output Control
PCH 1216 - PCH 1218 Family
Analog Output A
Analog Output B
SubBus
Modbus Protocol
(optional)
CANopen Protocol
DC Power
Control Unit
4-20mA/0-20mA/0-10V/0-5V
4-20mA/0-20mA/0-10V/0-5V
Selftest
SSD test
24V +/- 10%
RS-485
CANbus
SSD1 Relay
Analog Output C
(optional) 4-20mA/0-20mA/0-10V/0-5V
Filter
Sensor
Redundant Sensor
SSD2 Relay
(optional)
AC Output
Page 11
RS485 Modbus RTU (option)
As an option a PCH 1216 or PCH 1218 device can be integrated into a sensor network that is
directly connected to the wind turbine control system. Using RS485 Modbus RTU communication
online setup is possible while the device is fully operational, i.e. the SSD function and the data
collection of scalar measurement result values are still active.
CANopen
A PCH 1218 device (only) can be integrated in a sensor network that is an integral part of the wind
turbine control system using the CANopen FieldBus protocol. Using this protocol it is possible to
transfer the vibration level of all four general conditioning bands, as well as the dedicated SSD
band, alarm limits plus raw time waveform signals in 10 ms intervals to the controller.
The CANopen protocol is designed according to the international standards 2.0A and CANopen
CIA301. Both PDO and SDO commands are supported.
Status indicator
The sensor has a high level of diagnostic coverage through the use of a built in watchdog function.
The watchdog continuously checks all vital functions in a PCH1216 or PCH 1218 device, but not
the redundant SSD relay. When the sensor is operating normally a status indicator at the surface of
the steel enclosure will appear green.
As soon as a system failure or SSD alarm is detected the redundant safety relay will break the OK
signal chain and the status indicator at the surface of the steel enclosure will appear red. Such an
alarm event will also be transmitted through the CANopen FieldBus connection.
Self-test
To verify the integrity of the sensor, a self-test can be activated:
- digitally from the controller through the CANopen FieldBus connection (PCH 1218 only)
- using the PCH Vibration Studio software (with RS485, LAN (with optional CHB 1120
EtherBridge) or CHB 1131/1134 Service Cable/Adaptor connection)
- by connecting the Self-Test pin in the 8-pin or 12-pin connector to GND (for PCH 1216 only)
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
By carrying out a Self-Test the complete integrity of the signal chain will be tested, except the
redundant safety relay. The wind turbine controlsystem will receive pre-set user-defined scalar
values to verify that the signal chain is functioning correctly without interference with the safety
chain.
SSD test (test of safety functions) and reset of SSD danger alarms
To verify the integrity of the safety function a SSD test can be activated by connecting SSD-test pin
to ground (GND), OR through the CANopen FieldBus connection.
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
By carrying out a SSD Self-Test the complete signal chain for the safety function will be tested
including the redundant safety relay(s) and possible active latched SSD danger alarms will be reset.
Page 12
Electrical protection
The CANopen FieldBus connection, if implemented, is galvanic isolated in such a way that
different shielding designs and rough weather such as thunderstorms will not affect a PCH 1216 or
PCH 1218 device.
Any analogue- and relay outputs, if implemented, are also protected in such a way that different
shielding designs and rough weather such as thunderstorms will not affect a PCH 1216 or PCH
1218 device.
User software for parameter setup
By means of a CHB 1131/1134 Service Cable/Adaptor a PCH 1216 or PCH 1218 device can be
connected to the Windows® based PCH Vibration Studio software for parameter setup alterations.
The software is provided free of cost and can also be used for data logging and trending.
Please note that any parameter set-up is done off-line unless RS485 ModBus RTU is used.
Please note that any authorisation of the factory installed parameter set-up will become invalid.
Housing
The PCH 1216 and PCH 1218 devices are built into a rugged DIN 1.4404 (AISI 316L) rated
stainless steel housing with only one – or optional two – connector(s) to interface to the PLC
Controller and – if matching connectors are used – has an IP67/IP68 ingress protection rating.
The enclosure has no buttons or display, only one multi-colour LED indicator. Therefore the PCH
1216 and PCH 1218 devices are insensitive to damage(s) or alarm(s) triggered by personnel moving
around in the wind turbine.
Installing the sensor is easily done with two bolts through the main casing. A key pin at the base of
the sensor ensures that the sensor always will be mounted in the correct direction thus preventing
phase faults in connection with phase sensitive data outputs.
3.4 Ambient temperatures
3.4.1 Operating temperature range
The operating temperature is the ambient temperature in the immediate vicinity of a PCH 1216 or
PCH 1218 device.
The operating temperature range for both devices is specified as being in the interval: -40°C to
+60°C.
3.4.2 Storage temperature range
The storage temperature is the temperature at which the PCH 1216 or PCH 1218 device might be
kept shelved without being operated during warehouse storage prior to becoming attached to a wind
turbine or during other periods of time where the wind turbine is not in operation.
The storage temperature range for both devices is specified as being in the interval: -40°C to +85°C.
Page 13
4 Connections
The PCH 1216 and PCH 1218 Structural Vibration Monitors come in six (6) main versions:
- PCH 1216 basic version with a M12 male 8-pin connector
- PCH 1218 basic version with a M12 male 8-pin connector
- PCH 1216 version with a M12 male 12-pin connector for additional functions
- PCH 1218 version with a M12 male 12-pin connector for additional functions
- PCH 1216 version with a M12 male 5-pin and male 8-pin connector for additional functions
- PCH 1218 version with a M12 male 5-pin and male 8-pin connector for additional functions
4.1 PCH 1216
PCH 1216 | PCH 1218 |
| M12 / | 8-pin | 5-pin | 8-pin |
| Pin | Colour | Function | Function | Function | 1 | White/WH | +24 VDC supply voltage | SSD2A relay | +24 VDC supply voltage | 2 | Brown/BN | SSD1A relay | SSD2B relay | SSD1A relay | 3 | Green/GN | SSD1B relay | SSD1B relay |
| 4 | Yellow/YE | SSD-Test | SSD-Test |
| 5 | Grey/GY | 4-20 mA analogue output 1 | CANopen-Low |
| 6 | Pink/PK | 4-20 mA analogue output 2 | CANopen-GND |
| 7 | Blue/BU | Power/Signal Ground (GND) | Power/Signal Ground (GND) |
| 8 | Red/RD | Self-test | CANopen-High |
|
!
Note:
By selecting a matching cable connector, which is properly attached to the cable, it is
possible to obtain a high level of ingress protection: IP/67IP68.
Page 14
4.2 PCH 1218
PCH 1216 | PCH 1218 |
| M12 / | 12-pin | 12-pin |
| Pin | Colour | Function | Function | 1 | Brown/BN | +24 VDC supply voltage | +24 VDC supply voltage | 2 | Blue/BU | SSD1A relay | SSD1A relay | 3 | White/WH | SSD1B relay | SSD1B relay | 4 | Green/GN | SSD-Test | SSD-Test | 5 | Pink/PK | RS485 + | RS485 + | 6 | Yellow/YE | 4-20 mA analogue output 2 | CANopen-GND | 7 | Black/BK | 4-20 mA analogue output 1 | CANopen-Low | 8 | Grey/GY | Self-test | CANopen-High | 9 | Red/RD | RS485 – | RS485 – | 10 | Violet/VT | SSD2A relay | SSD2A relay | 11 | Grey-Pink/GYPK | SSD2B relay | SSD2B relay | 12 | Red-Blue/RDBU | Power/Signal Ground (GND) | Power/Signal Ground (GND) |
!
Note:
A possible optional 3rd Analogue Output will be positioned at pin #11 in a 12-pin connector.
It will then no longer be possible to have the two string SSD function
!
Note:
By selecting a matching cable connector, which is properly attached to the cable, it is
possible to obtain a high level of ingress protection: IP67/IP68.
4.3 Power input (pin #1)
At pin #1 the +24 VDC main power is applied to a PCH 1216 or PCH 1218. Any DC voltage
between 10,5 and 30,0 VDC will be sufficient to operate the device.
The corresponding power ground (GND) is available at:
- pin #7 for a PCH 1216 or PCH 1218 device with an 8-pin connector
- pin #12 for a PCH 1216 or PCH 1218 device with a 12-pin connector
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
4.4 SSD1 (pin #2+3) and SSD2 (pin #10+11) relay outputs
SSD1:
The SSD relay function consists of two (2) relays forming a “one string SSD relay function”:
- the actual SSD relay
- a second redundant SSD relay with the same specifications. The redundancy considerably
increases the functional safety parameters of the SSD function.
Two string SSD Relay Function
Page 15
For both a PCH 1216 or PCH 1218 an activation of the SSD Danger alarm will force the SSD relay
outputs at pin #2 (SSD1A) and pin #3 (SSD1B) to become active.
This relay is in “make” mode during standby, i.e. pin #2 and pin #3 are short-circuited.
When activated upon a SSD Danger alarm these relays will be in “break” mode, i.e. the connection
between the pins will become open.
The change from “make” to “break” mode can easily be detected by a PLC in the safety control
system of a wind turbine thus clearing the way for protective measures to avoid further increase of
damage(s).
An SSD alarm event is saved in non-volatile memory and will therefore be persistent (= latched,
sticky) across power off/on. This means that the monitor will not be reset or in any other way lose
the alarm status or SSD parameter settings in connection with an (un-)intentional power down. Also
a loss of communication will NOT result in a reset of a triggered SSD Danger alarm.
SSD2 (optional):
Some applications require the use of a “two string SSD relay function” with an additional set of
relay outputs. Such a set of additional SSD relay outputs is optional and defined as SSD2A and
SSD2B. The electronic layout and safety behaviour of SSD2 is 100 % equivalent to that of SSD1.
There are two possibilities different ways the additional relay outputs can leave the device:
- SSD2A at pin #10 and SSD2B at pin #11 of a 12-pin connector
- SSD2A at pin #1 and SSD2B at pin #2 of an additional 5-pin connector on the enclosure
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
8-pin M12
One string SSD Relay Function
Two string SSD Relay Function
12-pin M12
OR
Two string separate SSD Relay Function
5-pin M12
8-pin M12
8-pin M12
OR
12-pin M12
OR
8-pin M12
5-pin M12
Page 16
4.5 SSD-test and re-set of SSD alarm (pin #4)
To test the integrity of the SSD measuring chain and also to reset an activated SSD alarm, please connect pin
#4 for a short time (i.e. for 2 seconds or more), e.g. by means of an external push button to the digital signal
ground (GND) available at:
- pin #7 for a PCH 1216 or PCH 1218device with an 8-pin connector
- pin #12 for a PCH 1216 PCH 1218 device with a 12-pin connector
Alternatively let a TTL signal on pin #4 that normally is at high level become low during a short pulse (i.e.
for 2 seconds or more). The monitor will start the SSD test procedure during the negative flank of the pulse.
!
Note:
In principal – according to the GL2010 guide lines – the SSD test is to be carried out by
a technician that is personally present in the wind turbine (nacelle). However, if the
wind turbine is densely surveyed by means of cameras (and microphones) that are
positioned both inside and outside the wind turbine thus giving a technician in a remote
control room a full overview of the wind turbine’s operational condition, it is allowed to
initiate the SSD test from this remote control room. See the GL2010 certification guide
lines, chapter 2.2.2.5 on the subject of camera surveillance.
The SSD test will test the SSD function for all six (2x3) internal accelerometer transducers, as well as the
behaviour of the SSD Danger relays.
After the SSD test any possible active SSD alarm will be reset and the SSD Danger alarm relays will be reset as well into their default “make” position. The only way to reset the SSD function after an active SSD
alarm is by performing a SSD test.
The duration of the SSD test procedure depends on the actual vibration level imposed on the internal
accelerometer transducers during testing. The test time is 15 seconds and the settling time is an additional 20
seconds
An SSD reset will not have any effect on any other alarms that might be active.
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
4.6 Analogue DC signal Outputs (pin #5+6 or #6+7)
The PCH 1216 device (only) has default two 4-20 mA current loop analogue DC outputs signals
that each can be made direct proportional to the input vibration level measured by the selected
Detector.
If the colours of the core cables comply to what is suggested in section 4.1 and 4.2 the analogue
output signals will be available at:
- PCH 1216 with 8-pin connector : Analogue output 1 – Pin #5
- PCH 1216 with 8-pin connector : Analogue output 2 – Pin #6
- PCH 1216 with 12-pin connector : Analogue output 1 – Pin #6
- PCH 1216 with 12-pin connector : Analogue output 2 – Pin #7
- PCH 1216 with 12-pin connector : Analogue output 3 – Pin #11
!
Note:
A third analogue output that is implemented in a PCH 1216 with a 12-pin connector is optional
(only). Please contact the manufacturer for availability.
Page 17
The corresponding signal ground (GND) is available at:
- pin #7 for a PCH1216 with an 8-pin connector
- pin #12 for a PCH1216 with a 12-pin connector
See sections 4.1 and 4.2 for the layout of the connectors that are relevant for your PCH 1216 or
PCH 1218 device.
Although the analogue DC outputs in general are intended to be used as 4-20 mA current loop DC
signal output, there are actually four different ways to configure the analogue signal outputs:
- 4-20 mA current loop analogue DC output signal (DEFAULT)
- 0-20 mA current loop analogue DC output signal
- 0-10 Volt analogue DC output voltage
- 0-5 Volt analogue DC output voltage
For example:
An output current of 4 mA at the dc output represents a minimum value of 0, e.g. 0 mm/s, while 20
mA at the output represents full scale, e.g. 10 m/s2.
Any value between 0 m/s2 and 10 m/s2will then be positioned directly linear between 4 mA and 20
mA at the analogue output.
Example 1: the vibration level is a known 6 m/s2. The analogue output should show:
I
|
