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PRIOR TO UNPACK the product READ this INSTRUCTION HANDBOOK !
Added drawings
Assembly
--.
INSTRUCTION HANDBOOK
N. : 5002::EN Hull No: CMA CGM 4125..4128
Type
GENERAL
Geislinger GmbH Hallwanger Landesstrasse 3 A-5300 Hallwang/Salzburg AUSTRIA Phone FAX Email Internet +43 662 66999-0 +43 662 66999-40 info@geislinger.com www.geislinger.com
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GENERAL
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GENERAL
TABLE OF CONTENTS
1. GENERAL
1.1. Description 1.2. Components 1.2.1. Digital Sensors 1.2.2. Junction box 1.2.3. System Unit
5
5 5 6 6 6
2. INSTALLATION
2.1. Sensors 2.2. Junction box 2.3. Cabling 2.4. System Unit 2.5. Alarm outputs / connection to remote control systems 2.5.1. Relay outputs 2.5.2. Analog output 2.5.3. Testing the outputs
7
7 9 10 10 11 11 11 12
3. OPERATION
3.1. Description of display and buttons 3.1.1. Display description 3.1.2. Buttons 3.1.3. Light Emitting Diodes 3.2. Menu Handling 3.3. Standard monitoring functions 3.3.1. Free end total 3.3.2. Free end filtered 3.3.3. Damper twist 3.4. Alarm indication 3.5. Torsional vibration measurements 3.5.1. Requirements 3.5.2. Steps for recording measurements with a PC
13
13 13 14 15 15 17 17 17 17 17 19 19 20
4. TROUBLESHOOTING
4.1. Nothing to see on the display 4.2. System lamp is shining 4.3. No values are shown though the engine is running 4.4. Wrong speed is indicated
23
23 23 23 23
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GENERAL
4.5. Alarms occur 4.6. How to check the power supply of GMS 4.7. How to check the Junction box 4.8. How to check the sensors 4.9. How to test the alarm outputs 4.10. How to find out type and works-no. of GMS installed 4.11. Reset of the GMS
23 24 24 24 25 25 25
5. TECHNICAL DATA
5.1. Dimensions and weights 5.2. Assembly opening for System Unit 5.3. Type sign 5.4. Serial communication line RS232
26
26 26 27 27
6. MISCELLANEOUS
6.1. What are torsional vibrations 6.2. Some torsional vibration terms 6.3. Description of Signal processing 6.4. General range of applications for the GMS 6.4.1. Monitoring of free end 6.4.2. Damper monitoring 6.4.3. Coupling monitoring
28
28 28 28 31 31 31 32
33 34
34
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GENERAL
1. GENERAL
1.1. Description
The Geislinger Monitoring GMS Mark4 (4th generation) is an instrument designed to continuously monitor the torsional vibration amplitudes. The system gives an alarm signal when safety limits are reached or exceeded. Additional the GMS indicates engine speed and operating hours. Measurements of torsional vibration amplitudes and output of analyzed results to a PC can also be done.
1.2. Components
The GMS consists of three main components: Digital Sensors Outer and Inner Junction box System Unit
Fig.1 General Arrangement of Components
outer part
Junction box
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GENERAL
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INSTALLATION
2. INSTALLATION
For detailed information see also the appropriate assembly drawing and cable plan which are included in this Instruction manual.
2.1. Sensors
The sensors are equipped only with short cables to avoid disturbances of the signal. Therefore the Junction box has to be placed close to the sensors (max. distance = 1.7m). Ensure that the welding flanges are installed correctly in the damper-housing. For permissible tolerances of deviation see assembly drawing (sheet1). Use undamaged sensors only (visual check of the sensor head). Installation of the sensor: Lead the sensor through the inlet thread into the sensor holder. Ensure that the sensor is equipped with a counter nut. Use the Outer sensor 2 (orange cable) for the outer part, the Inner sensor 1 (black cable) for the inner part (see: Fig.1 General Arrangement of Components) Screw the sensor into the thread of the angle bracket. Check whether the sensor is positioned correctly in axial direction. The whole front face of the sensor must be placed over the groove (axial vibrations of crankshaft).
Fig. 2 Sensor position
min7mm
Sensor position
permissible area
min7mm
Adjust the correct sensor gap (see Fig.3). Secure the sensor with the counter nut. Fasten the sensor cable with cable ties using the provided holes in the angle bracket.
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INSTALLATION
Thread M12 x 1 Tip: Screw in sensor to surface, and turn 2 revolutions back
sensor head
Mounting of the cable gland (see Fig. 3): It must seal the sensor cable oil tight and secure the protective tube from being pulled out. Insert the body(A) of the cable gland firmly into the inlet thread of the sensor holder. Put a washer(C) + sealing ring(B) + washer(C) over the sensor cable and push them over the whole cable length to the body(A) of the cable gland at the sensor side. ATTENTION: Use only sealings from this delivery with an inner diameter fitting to the outer diameter of the sensor cable. Put gland bolt(D) of the cable gland over the sensor cable towards the sensor side. Screw and tighten the gland bolt(D) into the body(A). Pull the protective tube over the sensor cable. Pull protective tube into the tension-relief(E) and tighten the screws. This stops the protective tube from being pulled out.
Fig. 4 Assembly of cable gland
protective tube
sensor cable
A B C D E
body of cable gland sealing ring washer gland bolt screws of tension relief
Function check of sensors: Ensure that the Junction box is connected with the GMS System Unit and the system is switched on. The red light diode inside the Junction box must be ON. Turn the crankshaft
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INSTALLATION
slowly and watch the green light diode inside the junction box. An other possibility is to measure the voltage inside the Junction box. Sensor position State of green LED State of green LED new pcb 'td 142' old pcb 'td 119'
(since 2005) (before 2005)
Over ground
OFF
ON
(LED shines)
Over a groove
ON
(LED shines)
OFF
no voltage
When you measure with an oscilloscope or scopemeter while the engine is running you must receive a signal with the following shape:
Fig. 5 Sensor signal
Volt time
type NPN
sensor 1
sensor 2
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INSTALLATION
Pay attention to correct allocation of the sensors related to damper inner part and damper outer part:
Fig. 7 sensor allocation
Damper OUTER part SYSTEM UNIT Sensor 1 Inner sensor (black cable)
connect to
2.3. Cabling
All cables are supplied by the customer. This includes also the cable between System Unit and Junction box. The cables used must be approved by the classification society. Between System Unit and Junction box Geislinger recommends a cable with a common copper screen, 6 conductors in pairs, each conductor minimum 0.5 mm cross-section.
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INSTALLATION
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INSTALLATION
The maximum value of the analog indication is the same as the maximum indication value of the bar graph of the corresponding monitoring function. Example: The maximum value for indication of Free end total in the bar graph is 15 mrad. Therefore 20 mAmp. at the analog output are corresponding to 15 mrad vibratory angle. Note that the permissible vibratory for analog output angle may be varying over the speed corresponds to 4 mAmp range. Therefore the analog output should only be used for indication purposes and not for alarm detection.
minimum reading
The ALARMTEST menu is located in the main menu. The number of the service code = 1010. Enter the first digit by pressing the UP or DOWN button. Confirm your selection with the SELECT button. The cursor jumps automatically to the next digit. After entering of all four digits the service menu appears. If a wrong code was entered, the cursor jumps back to the first digit.
Fig. 10 Servicecode
Activating the test function opens the relay for 20 seconds. Then the relay is close for another 20 seconds. After this the relay returns to the conditon it was before the test started.
Attention: If an alarm output is connected to an automatic slow down of the engine, testing the output will activate the slow down.
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OPERATION
3. OPERATION
The System Unit is starting up automatically when electrical power is supplied. The System Unit does not have a Power ON/OFF switch. During startup all LEDs are shining once and all relay outputs are activated once. When the engine is running, the readings are taken from the sensors and processed simultaneously. The computed values of the monitoring functions are shown both as numbers and graphically in a bar graph on the display.
LEDs
push buttons
engine speed
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OPERATION
bar graph
maximum value for bar indication WARNING HIGH limit ALARM limit
3.1.2. Buttons
Fig.15 Buttons
UP / DOWN During normal operation this button changes the contrast of the LCDdisplay. Pressing the button in menu mode moves the cursor one entry up or down. If in menu mode not all applications fit onto the screen at once. (eg. menu Alarmcurves, Signalcurve or Fourier), the buttons switch between the applications. SELECT Pressing the SELECT button during normal operation calls the Menu of the GMS. In Menu mode this button is to confirm a selected function. CANCEL In Menu mode this button is to leave the current menu and to move one menu level higher. If you are already in the Main menu, the Menu disappears.
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OPERATION
SERIAL
CONTRAST In this menu the contrast (brightness) of the LCD-display can also be adjusted. FOURIER Shows the amplitude of the different orders for each application after a FFT (Fast Fourier Transformation) analysis.
Fig. 17 fourier graphic
Pressing SELECT in the FOURIER menu shows the numbers of the analyzed values. By pressing SELECT again, the menu switches back to graphic mode.
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OPERATION
SIGNALCURVE Shows the torsional vibration signal for each programmed application for one revolution.
Fig. 18 waveform graphic
MEASURE This menu defines what kind of data are transmitted via the serial communication line RS232 to a Personal computer. These settings are necessary for recording measurements with a PC only. See 3.5.2, Steps for recording measurements with a PC for further details. SERIAL Sets the parameters for the serial communication line RS232 (baud rate, protocol, communication format). These settings are necessary for recording measurements with a PC and downloading a new setup. See 3.5.2, Steps for recording measurements with a PC for further details. SERVICE ALARMTEST for details. Contains special functions, only for service engineers. Allows testing the outputs of the GMS, see chapter 2.5.3, Testing the outputs
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OPERATION
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OPERATION
30
40
50
60
70
80
90
100
110
120
speed [rpm]
The WARNING LOW curve is normally only defined for monitoring of damper- or coupling-twist. If a value is over a warning or alarm limit the following happens: You can see a message at the right side of the display at which monitoring function the warning respectively alarm occured.
Fig. 20 alarms on display
For monitoring function (application) no. 3 both WARNING limit and ALARM LIMIT are exceeded.
The corresponding LED is shining. If this warning/alarm is combined to a relay, the corresponding relay output is opened. For standard values see chapter 2.5 ,Alarm outputs / connection to remote control systems. The GMS can for special applications be programmed in a way that warnings or alarms from certain monitoring functions are not connected to the relay output. Exceedings of the WARNING levels can occur sometimes due to abnormal engine handling, but should not be the normal condition. Exceeding of ALARM levels must be strictly avoided.
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OPERATION
Geislinger strongly recommends to record the data with a PC. This method ensures datarecording at every speed and allows recording the FFT values which allows enhanced analysis of the data.
Standard values for speed increase 2-stroke engine 4-stroke engine 3 rpm / minute 30 rpm / minute
speed
No steps
time
3.5.1. Requirements
Please try to ensure the following requirements: Vessel should have load (preferred) or at least ballast condition (propeller must be fully under water) Sail straight ahead during the sweep area with deep water under the keel Sail some time with low speed before starting with the sweep (to ensure that the propeller is not driven by the vessel speed) The actual vessel speed must correspond with the nominal speed according to the engine rpm. It is very important to have the power at nominal speed. If you cannot go up to nominal speed please note the power at the highest possible speed. Supply us with the following information: Vessel, engine and damper data Engine power load conditon going straight ahead or rudder laid weather condition (heavy sea, ...) additional information (not all cylinders firing, shaft generator running...) .......... (what you believe it is worth mentioning)
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OPERATION
3c) You are prompted for the communication port you want to use. Connect using: select COM1 or COM2 (depending on where the interface cable is connected) 3d) Enter the Port settings Bits per second: Data bits: 19200 8
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OPERATION
Parity: None Stop bits: 1 Flow Control: Xon/Xoff Attention: The settings for the serial communication line RS232 must be the same at the GMS and at the PC. Otherwise no data or unreadable data will be shown at the PC. If your PC is to slow for processing these data, select a lower baudrate (9600). You can check your settings by menu File Properties
Fig.23 Hyperterminal properties
Tip: To configure the serial interface the data flow must be interrupted (see description of buttons below). 3e) Start receiving of data You can interrupt and continue the data flow at the HyperTerminal with the following buttons. enables the data flow (or use menu Call Connect)
interrupts the data flow (or use menu Call Disconnect) Note: Interrupting and continuing the data flow is not the same as recording (capture) the data to a file! Now the transmitted values should be displayed in a readable format on the screen of the PC. If nothing is displayed after a waiting time of max. 1 minute (this delay can be caused by the XON/XOFF flow control) check the connections and the setup of the communication on both sides. Note: The values shown on the screen are not stored to a file till now. They are just shown to the screen.
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OPERATION
4) If data transmission is working properly, prepare for the sweep and enable file storage of transmitted data. Select the Menu Transfer Capture Text... and specify a file in which the data are stored (fileextention should be .TXT )
Fig.25 Hyperterminal file capture
5) Carry out the sweep. Write down the engine power at the end of the measurement (at the highest possible speed) 6) After completion of measurement stop recording of data by selecting menu Transfer Capture Text... Stop. Check the recorded file by opening it with a text-editor (eg. Notepad or Wordpad). The contents of the file must look like shown in the screen of the HyperTerminal 7) Disable the sending of data at the GMS (menu SERIAL PROTOCOL DISABLE). 8) Send the recorded file with E-mail to Geislinger. Please compress the file(s) by the use of a file compression utility like WinZip. 9) It is very important for GEISLINGER to receive all the additional information as specified in chapter 3.5.1, Requirements together with the measured data. Use the enclosed form Additional information to a sweep (see 8, Appendix).
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TROUBLESHOOTING
4. TROUBLESHOOTING
4.1. Nothing to see on the display
No power is supplied to the GMS. Follow the instructions in chapter 4.6, How to check the power supply of GMS. Contrast control of the LCD-display is out of visible range.
-
Press five times the CANCEL button (just to be sure that you are in main menu) Try to adjust the contrast by pressing the UP or DOWN button (press at least 5 seconds in each direction).
Follow the instructions in chapter 4.7, How to check the Junction box. Follow the instructions in chapter 4.8, How to check the sensors.
Speed is always wrong This may be an indication for a wrong programmed GMS. This means that the number of impulses which is programmed in the GMS is not the same as the number of grooves/teeth machined on the damper or coupling. Check the number in the GMS. Enter the main menu, select INFOS, select SYSTEM. You can read the programmed number of impulses in the following lines: Impulses Channel 1: (= damper/coupling inner part) Impulses Channel 2: (= damper/coupling outer part) Check the number of grooves at the damper. Therefore open the cover of the sensorholder and count the number of grooves by use of the turning gear for one revolution. If the number of grooves on the damper does not correspond with the number of impulses programmed in the GMS please contact GEISLINGER.
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TROUBLESHOOTING
It is possible that the sensor does not recognize all signals due to bad electrical connections or a wrong adjusted sensor.
-
Follow the instructions in chapter 4.7, How to check the Junction box. Follow the instructions in chapter 4.8, How to check the sensors.
Try to operate the engine in a range where no further alarms occur. See Part II of this manual, which is specific for your system for special actions in your case. Contact GEISLINGER. Please inform us about the following items:
-
Type and works-no. of GMS and GEISLINGER damper or coupling. Speed range where the alarm occurs. Monitoring function at which the alarm occurs. If somehow possible make a sweep and record the data (see chapter 3.5, Torsional vibration measurements).
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TROUBLESHOOTING
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TECHNICAL DATA
5. TECHNICAL DATA
Permissible ambient temperature System Unit Junction box Inductive Sensors Power supply Voltage: Maximum current consumption: Fuse: Outputs 55 Celsius 70 Celsius 100 Celsius 24V DC 20% 1 Ampere self healing fuse inside 4 Relay outputs (max. 24 VDC, 1 Ampere) 1 Analog output (4 .. 20 mAmp.) 1 serial communication line RS232 Electrical and environmental testings according to IACS E-10 rules and type approval from DNV
Technical standards
Junction box
8 x 45
182
134
135
M4
179
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TECHNICAL DATA
5 4 3 2 1
5 4 3 2 1
9 8 7 6
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MISCELLANEOUS
6. MISCELLANEOUS
6.1. What are torsional vibrations
Torsional vibrations are the result of the pulsing torque of a reciprocating combustion engine and the torsional elasticity of the shaftline. All system components like crankshaft, intermediate shaft, propeller shaft and optional couplings and gears have to transmit the static torque and the additional vibratory torque. The GMS (Geislinger Monitoring System) monitors the torsional vibrations.
sensor
sensor signal
high low t1 t2 t3 t4 t5 t...
A plot of the time over the angle gives a graph as shown in Fig. 29. The mean time between two teeth (constant angular velocity or rpm) can be subtracted.
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MISCELLANEOUS
time
t1
t2
t3
t4
t5
t6
t7
t8
t9
To obtain the peaks of the signal, it is necessary to do oversampling (insert additional generic points). Another necessary step is to calculate from time differences to angle differences by use of the angular velocity.
Fig. 30 Signal oversampling
t5 t1 t2 t3 t4
t6
t7
t8
t9 angle
After these calculation steps (result is shown in Fig. 30) the signal passes through a bandpass-filter (Fig. 31). The purpose of the bandpass filter is to remove accelerations (caused by the engine speed control system) by removing low orders (below the first order in case of 2-stroke engines, below the 0.5th order in case of 4-stroke engines) and to smooth the signal by interpreting the additional inserted points as high frequent interferences (this is necessary to obtain the exact amplitude of the vibratory angle).
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MISCELLANEOUS
Bandpass-filter
order
vibratory angle
max
angle min
The result of the filtered values is the vibratory angle of the synthesis of a specified range of orders (Fig. 31) depending on the filtersettings. The quality of the used filters allows filtering of just one order or half orders. The last step is to calculate the amplitude by the (maximum-minimum)/2 of the vibratory (twist) angle and check this value against safety limits. These limits are depending on the engine speed (rpm). For explanation of Alarm limits see chapter 3.4, Alarm indication .
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MISCELLANEOUS
Applications: GEISLINGER damper monitoring Monitoring of the vibratory twist angle between damper inner part and damper outer part is necessary to control the damper load. A broken oil supply or heavy wear of the damper springs leads to an increased vibratory twist. This will activate an alarm on the GMS. A blocked damper with no vibratory twist causes also an alarm, because other parts of the propulsion system (eg. crankshaft, intermediate shaft) are overloaded. Monitoring of the damper is also very useful to determine the exact condition of the damper before an engine overhaul or drydocking. If the measurements show that the damper is working
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MISCELLANEOUS
properly, it can be justified against the classification society, that no damper overhaul is necessary. In the rare case of a spare part need, they can be ordered in time.
Applications: GEISLINGER coupling monitoring One sensor is mounted on the power input side, the other on the power output side of the coupling. The GEISLINGER coupling is equipped with elastically steel spring blades. Monitoring of the vibratory twist angle between coupling inner part and coupling outer part is necessary to control the coupling load. A broken oil supply or heavy wear of the coupling springs due to overload leads to an increased vibratory twist. This will activate an alarm on the GMS. A blocked coupling with no vibratory twist causes also an alarm, because other parts of the propulsion system are overloaded. Monitoring of the coupling is also very useful to determine the exact condition of the coupling before an engine overhaul or drydocking. If the measurements show that the coupling is working properly, it can be justified against the classification society, that no coupling overhaul is necessary. In the rare case of a spare part need, they can be ordered in time. Shaft monitoring Shaft monitoring is similar to coupling monitoring. The only difference is, that the stiffness of the springs is substituted by the stiffness of the shaft. The accuracy of the measured torque increases with the distance between the sensors (=length of shaft).
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MANUFACTURER DECLARATION
7. MANUFACTURER DECLARATION
NOTICE The information in this manual is subject to change without notification. Additional pages may be inserted in future editions. The user is asked to excuse any omissions or errors in the present edition. No responsibility is assumed if accidents occur while the user is following the instructions in this manual. No resposibility is assumed for defects in the GMS firmware. The contents of this manual are protected by copyright. No part of this manual may be reproduced by any means, including translation into a different language or conversion to a different format or media, without the permission of the copyright holder. The same copyright protection applies to the GMS firmware. Document no. Revision-no. Date Language: First Edition: 5002 1.2 November 2006 English July 2002
This manual is also availabe in electronical form. Copyright 2002, 2005 by Geislinger GmbH, A-5300 Hallwang / Salzburg, AUSTRIA All rights reserved.
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APPENDIX
8. APPENDIX
The following items are appended to this manual: Blank forms sweep information and data Part II (specific information for your GMS-system) Assembly drawing Cable plan Parts list List of service stations
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APPENDIX
Damper data
Type (eg. D260/22/2) Works-no. Oil pressure (damper inlet) Oil temperature
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APPENDIX
Monitoring function1
[mrad]
Monitoring function2
[mrad]
Monitoring function3
[mrad]
Fill out also the form with the additional info. Date/Name: Vessel name:
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SPECIFIC INSTRUCTIONS
D 250/7/3
valid for H
Arrangement drawing Assembly drawing / Part list Cableplan Date: Geislinger ref.no.
4125..4128
G001612G207835G207486October 2007 4FW
This part of the Instruction manual is only a supplementation of the common part (Part I). The instructions and explanations of the monitoring functions on the next pages are specific for this installation.
Geislinger GmbH Hallwanger Landesstrasse 3 A-5300 Hallwang/Salzburg AUSTRIA Phone FAX Email Internet +43 662 66999-0 +43 662 66999-40 info@geislinger.com www.geislinger.com
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SPECIFIC INSTRUCTIONS
MCR
30
1.5 25
20
mrad
1.0 15
10
(3)
0.5 5
(2) (1)
0 30 40 50 60 70
rpm
Alarm limit Warning limit (1) Ideal operation (2) Unbalanced condition (3) Misfiring condition
80
90
100
0.0 110
deg
2/4
SPECIFIC INSTRUCTIONS
3.5
0.20
3 0.15
deg
2.5
mrad
2 0.10 1.5
1 0.05 0.5
0 30 40 50 60 70
rpm Alarm limit Warning limit Ideal operation Misfiring condition
80
90
100
0.00 110
3/4
SPECIFIC INSTRUCTIONS
0.6 10
mrad
0.4
5 0.2
0 30 40 50 60 70 80 90 100
rpm Alarm limit Warning limit Warning low limit Ideal operation Misfiring condition
0.0 110
deg
4/4
G e i s l i n g e r Co u p l i n g
Geislinger Damper
G e i s l i n g e r G e s i l co
G e i s l i n g e r Fl e x l i n k
G e i s l i n g e r M o n i to r i n g
G e i s l i n g e r Ca r b o to rq
Geislinger Vdamp