So2 Blower

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A k t i e n g e s e l l s c h a f t
Khnle, Kopp & Kausch
Operating Instruction
KK&K
Compressor

Type : SFO11

Machine no. : 1050124

Control : Inlet Guide Vane Control (IGV)

Year of manufacture : 2006

Date of operating manual : 16.11.2006

Public Limited Company
Business Unit Compressor

Post Office Box 17 28 D - 67207 Frankenthal
Heheimer Str. 2 D - 67227 Frankenthal

Telephone ++49 (0) 6233 / 85 - 0
Telefax ++49 (0) 6233 / 85 - 2309
Email compressors@agkkk.de
Internet www.agkkk.de
1050124_BD

****************************************************************************
* O P E R A T I N G D A T A *
******************************************************** Sheet 1 of 1 **
* KK&K-No. : 1050124 ***********
* Customer : Hindustan Zinc Ltd. Project : SO2 Compressor ***********
* Model : SFO 11.2 *** K ***
* Comment : *** K&K ***
* ***********
* Name : Kas Date : 27-MAR-06 ***********
* Documentno. : 1050124 BD ***********
****************************************************************************

------------------------
| OPERATING POINTS: |
------------------------
| 1: Overload conta. |
| 2: 100 % contam. |
| 3: 100 % clean |
| 4: 40 % |
| 5: Preheat |
------------------------
-------------------------------------------------------------------------------
| OPERATING POINTS | 1 | 2 | 3 | 4 | 5 |
-------------------------------------------------------------------------------
|Load [%] | 100.0| 94.7| 94.7| 39.3| 56.1|
|Standard volume flow [m/h] | 107000.| 101300.| 101300.| 42000.| 60000.|
|(1013 mbar/273K dry) | |
|Mass flow (humid) [kg/s] | 41.42| 39.22| 39.22| 16.26| 21.55|
|Standard density [kg/m] | 1.394|
|(1013 mbar/273K dry) | |
|Ambient pressure [mbar] | 970.00|
|Site level [m] | 367.|
-------------------------------------------------------------------------------
|CONDITIONS BATTERY LIMITS | |
|Inlet temperature [C] | 55.0| 55.0| 55.0| 50.0| 20.0|
|Inlet pressure abs. [mbar] | 833.00| 834.60| 855.20| 952.30| 947.10|
|Relative humidity [%] | 0.0| 0.0| 0.0| 0.0| 0.0|
|Pressure rise [mbar] | 598.00| 543.40| 488.80| 92.70| 222.90|
-------------------------------------------------------------------------------
|OPERATING DATA COMPRESSOR | |
|Operating volume flow [m/h] | 156320.| 147710.| 144150.| 52855.| 68874.|
|Inlet density [kg/m] | 0.954| 0.956| 0.980| 1.108| 1.127|
|Isentropic head [kJ/kg] | 51.007| 47.003| 42.081| 8.106| 18.344|
|Outlet temperature [C] | 115.3| 112.2| 108.3| 98.4| 64.4|
|Speed of compressor [1/min] | 5235.| 5235.| 5235.| 5235.| 5235.|
|Speed of motor [1/min] | 1480.| 1480.| 1480.| 1480.| 1480.|
-------------------------------------------------------------------------------
|POWER | |
|Power on coupling [kW] | 2509.| 2260.| 2113.| 847.| 1055.|
|Nominal motor power [kW] | 2800.0| |
-------------------------------------------------------------------------------

------------------------------------------------
|REFERENCE DOCUMENTS |
|Performance graph: 1050124 KF |
|Acoustic data : 1050124 AK |
|Starting torques : 1050124 AN |
------------------------------------------------
Seite 1
1050124_AN
**************************************************************************
* S T A R T I N G T O R Q U E S *
**************************************************************************
* Customer: Hindustan Zinc Ltd. ***********
* Project : SO2 Compressor ** K **
* KK&K no.: 1050124 ** K&K **
* Model : SFO 11.2 ***********
* ***********
**************************************************************************
Proposed nominal motor power = 2800.0 kW
Power consumption design = 2509.0 kW
Speed of compressor = 5235.0 rpm
Speed of motor = 1480.0 rpm
--------------------------------------------------------------------------
Speed [%] | Torque [Nm] *)
------------------------------------------------------------------------
| Guide vanes | Guide vanes | Guide vanes **)
| open | closed | open or closed
| Damper open | Damper open | Damper closed
|-----------------|-----------------|-----------------------
0 | (Breakaway torque) 2273 (steel)
10 | 195 | 78 | 54
20 | 778 | 311 | 218
30 | 1751 | 700 | 490
40 | 3112 | 1245 | 871
50 | 4863 | 1945 | 1362
60 | 7002 | 2801 | 1961
70 | 9531 | 3812 | 2669
80 | 12448 | 4979 | 3485
90 | 15755 | 6302 | 4411
100 | 19450 | 7780 | 5446
------------------------------------------------------------------------
*) The maximum torque in the table is decisive for the design of the
motor and refers to the maximum inlet density
rho1max = 1.1462 kg/m at the temperature T1 = 0.0 C.
The torque changes proportional to the density and inversly
proportional to the absolute temperature.
The torque has been multiplied by a factor of 1.20; this factor
results from the density ratio between the maximum density rho1max
and the design density rho1tot = 0.9540 kg/m at T1 = 55.0 C
(exception: breakaway torque).
**) Only permissible after inquiring KK&K (danger of heating and
mechanical damage!).
--------------------------------------------------------------------------
Mass moment of inertia of the compressor, gear and
coupling refered to the motor speed J = 1397.3 kgm .
==========================================================================
Drawing no.: 1050124 AN Date : 27-MAR-06
Prog. : V3.4-0197 Name : Kas
==========================================================================
Seite 1
1050124_AK
**************************************************************************
* A C O U S T I C D A T A *
**************************************************************************
* Customer: Hindustan Zinc Ltd. ***********
* Project : SO2 Compressor ** K **
* KK&K No.: 1050124 ** K&K **
* Model : SFO 11.2 ***********
* ***********
**************************************************************************
Volume flow (in) = 43.42 m/s Inlet guide vanes : yes
Inlet Temperature, = 55.0 C -position = -12.7
Inlet density = 0.9540 kg/m Outlet guide vanes : no
Inlet pressure = 833.0 mbar Number of blades = 14
Total pressure rise = 598.0 mbar Tip speed = 307.0 m/s
Series : SFO Blade passing freq. = 610.8 Hz
Impeller diameter = 1.12 m Sound velocity (out)= 378.1 m/s
Speed = 5235.0 rpm Mach number (out) = 0.812
Input power = 2509.0 kW Temperature (out) = 115.3 C
Density (out) = 1.384 kg/m
Volume flow (out) = 29.92 m/s
OCTAVE SOUND POWER LEVEL IN THE DUCTS
Measuring surface factors: a) Outlet: -2.0 dB
b) Inlet : -2.0 dB
Hz 31.5 63 125 250 500 1000 2000 4000 8000 Total
------------------------------------------------------------------------
Outlet:
dB 122.0 123.0 124.0 124.0 135.0 132.0 127.5 121.5 118.5
------------------------------------------------------------------------
dB(A) 83.0 97.0 108.0 115.5 133.0 132.5 129.0 122.5 117.0 137.0
------------------------------------------------------------------------
Inlet:
dB 121.0 122.0 122.5 122.5 135.5 132.5 127.5 120.5 117.0
------------------------------------------------------------------------
dB(A) 81.5 95.5 106.5 114.0 133.5 133.0 128.5 121.5 116.0 137.0
------------------------------------------------------------------------
OCTAVE SOUND PRESSURE LEVEL AT A DISTANCE OF 1 m
Measuring surface factors 19.0 dB (+ 1 dB in case of installation
on a steel structure)
------------------------------------------------------------------------
dB 90.0 90.0 90.0 90.0 94.0 93.5 87.5 81.5 75.5
------------------------------------------------------------------------
dB(A) 50.5 64.0 74.0 81.5 91.0 93.5 89.0 82.5 74.5 96.5
------------------------------------------------------------------------
TOLERANCES:
- Octave sound power level in the duct, inlet - 6/ + 4 dB
- Total-A-sound power level in the duct, inlet - 5/ + 2 dB
- Octave sound power level in the duct, outlet - 5/ + 4 dB
- Total-A-Sound power level in the duct, outlet - 3/ + 2 dB
- Total-A-Sound pressure level (1 m) - 3/ + 2 dB
(Octave sound pressure levels are anticipated values)
The levels indicated are based on measurements according to DIN 45635,
the duct levels indicated are based on measurements in accordance
with ISO 5136 (EN25136), with due consideration being given to the
corrections C1, C2 and C3, as well as to the connections specified
in section 7.2 of this standard: sound power level is a function of
average sound pressure level, of the cross section surface of the
measuring duct and of the product from density and sound velocity.
==========================================================================
Drawing no.: 1050124 AK Date : 27-MAR-06
Prog. : V3.4-0494 Name : Kas
==========================================================================
Seite 1
10400014104/DRW/000/D 1,0 MONTAGEZEICHNUNG VERDICHTER SFO 11,2-18
. ST ASSEMBLY DRAWING COMPRESSOR
1-500002-013 1,0 Grundrahmen SFO 11.2 G6b
040 ST BASE FRAME
S235JR
10521515301 1,0 LAGERBOCK SFM/SFO 11/14 FERTIGTEIL
060 ST BEARING SUPPORT SFM/SFO 11/14
ST 37/ST 52
10528515101 2,0 UNTERLEGBLECH FUER LAGERBOCK
061 ST PLATE FOR BEARING SUPPORT
S235JRG2+U
49005063602 8,0 Zsb.Stellplatte
065 ST ADJUSTING PLATE
S235JRG1
00035350029 4,0 SECHSKANTSCHRAUBE
070 ST HEXAGONAL BOLT
8.8
M 48X240
00035830018 4,0 SCHEIBE B
080 ST WASHER / DISC
ST
50
00035730457 2,0 KEGELSTIFT
090 ST TAPER PIN
ST
16X120
00035830357 2,0 SCHEIBE B 17 MM
ST
17
00035500451 2,0 SECHSKANTMUTTER M 16
110 ST HEXAGONAL NUT
8
M16
00080701206 0,5 CURIL K 2 500 G DOSE
115 KG CURIL K 2 500 G TIN
00035250356 3,0 VERSCHLUSSSCHRAUBE
120 ST LOCKING SCREW
ST
G 1 A
Abkrzungen / Abbreviations
Z-Pos = Zeichnungsposition / Drawing Item
M = Menge je Einheit / Quantity per unit
ME = Mengeneinheit / Code for unit of quantity (ME)
ST = Stck / Each KG = kg / Kilogramme
L = Liter / Litre M = Meter / Metre
* = separate Teileliste / Separate parts list
Datum / Date
16.11.2006
Seite / Page no
1
Gedruckt von: / Printed by
WST
Auftrags-Nr./ Job no. Benennung / Designation
2250001/10 VERDICHTER SFO
ASSY. COMPRESSOR SFO
Maschinen-Nr. / Machine no. Materialnummer / Parts list no.
1050124 10400001000
Materialnummer / Part no. M Benennung / Designation Ersatzteilcode /
Z-Pos ME Werkstoff / Material Spare part code
Teileliste
Parts list
Zeichnung(en) / Drawing(s)
00080300858 3,0 FLACHDICHTRING FORM A KAMMPROFILIERT
125 ST SEALING RING
ST 30
33X39
ST
G 2 A
145 ST SEALING RING
ST 30
60X68
19001513510 1,0 GEWINDEROHR
146 ST ...
ST 33-2
49013650194 1,0 ldunstabscheider
147 ST OIL MIST SEPARATOR
00035100157 3,0 RINGSCHRAUBE
150 ST EYEBOLT
C15E
M20
10501520207 1,0 ZSB OELFANGDECKEL SFO 11.2 LAUFRADSEITE
160 ST ASSY OIL COVER SFM 11/14
00035250202 1,0 VERSCHLUSS-SCHRAUBE
ST
G 1/2 A
00032240704 1,0 GERADE EINSCHRAUBVERSCHRAUBUNG GE
161 ST MALE STUD UNION GE
ST
ST
00018200408 1,0 ROHR (P235G1TH/ St 35.8)
161 M TUBE
P235GH+N
14X1,5
162 ST SEALING RING FORM A
ST 30
21X26
Datum / Date
16.11.2006
Seite / Page no
2
WST
1050124 10400001000
Teileliste
Parts list
8.8
M 24X 50
00035070250 4,0 SECHSKANTSCHRAUBE MIT ZAPFEN
171 ST HEX. HEAD SCREW WITH DOG POINT
8.8
M 20X 60
1-155390-009 1,0 Dichtungseinsatz 2-tlg
175 ST SEAL INSERT
ST
M 10X1
177 ST SEALING RING
ST 30
10X14
10521520206 1,0 ZSB OELFANGDECKEL SFO 2TLG MOTORSEITE
178 ST ASSY OIL COLLECT COVER (MOTOR SIDE)
EN-GJL-250
ST
G 1/2 A
ST
ST
00018200408 1,0 ROHR (P235G1TH/ St 35.8)
179 M TUBE
P235GH+N
14X1,5
ST 30
21X26
10501553907 1,0 DICHTUNGSEINSATZ 2-TLG
181 ST SEALING INSERT
S235JRG2+N
Datum / Date
16.11.2006
Seite / Page no
3
WST
1050124 10400001000
Teileliste
Parts list
8.8
M 24X 60
00035730302 2,0 KEGELSTIFT
183 ST TAPER PIN
ST
10X 75
00035830259 2,0 SCHEIBE B
ST
10,5
00035500307 2,0 Sechskantmutter
8
M 10
8.8
M 20X 60
10501502606 1,0 ZSB FESTLAGER 2-TLG 6-STEINE *
190 ST ASSY JOURNAL AND THRUST BEARING
10501502509 1,0 ZSB LOSLAGER 2-TLG *
200 ST ASSY JOURNAL BEARING
1-120502-022 1,0 Zsb. Rotor SFO 1-11,2-75 *
220 ST ASSY. ROTOR
3-655101-001 1,0 P&S-Montagepaste Molykote P37-075
220 ST LUBRICATING GREASE MOLYKOTE P37-075
GRAPHITPASTE
10115113503 1,0 GALGEN SFO11
220 ST IMPELLER LIFTING BEAM
2-367090-036 1,0 Temperatur-Transmitter (0...+150C)
240 ST RESISTANCE THERMOMETER (0...+150C)
4-230000-199 1,0 Zsb. Getriebe G6B *
240 ST GEAR
1-127460-028 1,0 Pafeder
242 ST KEY
S690QL1
Datum / Date
16.11.2006
Seite / Page no
4
WST
1050124 10400001000
Teileliste
Parts list
1-127460-029 1,0 Pafeder
243 ST KEY
S690QL
1-544000-128 1,0 Stahllamellen-Kupplung ARP-6 MCECM 275-6
250 ST COUPLING
STAHL
1-544000-223 1,0 Elastische Profilhsenkupplung
255 ST FLEXIBLE BOLT COUPLING
BOKU 4000
00035192444 17,0 ZYLINDERSCHRAUBE
265 ST CYLINDER HEAD SCREW
8.8
M20X 70
00035730003 2,0 KEGELSTIFT
275 ST TAPER PIN
ST
10X100
00035830259 2,0 SCHEIBE B
ST
10,5
8
M 10
3-350701-011 2,0 Sechskantschraube mit Zapfen
8.8
M 16X70
2-367090-036 1,0 Temperatur-Transmitter (0...+150C)
295 ST RESISTANCE THERMOMETER (0...+150C)
1-470050-001 1,0 Temperaturmeeinrichtung
295 ST TEMPERATURE MEASUREMENT DEVICE
KLEMMENK.ALU
1-470540-021 1,0 Wellenbahnmessung radial
365 ST VIBRATION MONITORING
1-470550-014 2,0 Wellenbahnmessung axial
370 ST VIBRATION MONITORING SHAFT TRAIN RADIAL
1-100500-067 1,0 Zsb. Verdichtergehuse SF0 11.2-75 VERT.
385 ST ASSY. COMPRESSOR HOUSING
EN-GJL-250
Datum / Date
16.11.2006
Seite / Page no
5
WST
1050124 10400001000
Teileliste
Parts list
00035357238 1,0 SECHSKANTSCHRAUBE M 20 x 60
8.8
M 20X 60
00035830408 1,0 SCHEIBE B
ST
21
00035730359 2,0 KEGELSTIFT
445 ST TAPER PIN
ST
13X 85
8
M 12
00035830301 2,0 SCHEIBE B
ST
13
8.8
BM 30X120
00035501159 2,0 SECHSKANTMUTTER
8
M 30
00041620604 1,0 RICHTUNGSPFEIL B 15X105
470 ST DIRECTION ARROW
X6CRNITI18-10
105X15
00035778001 2,0 HALBRUNDKERBNAGEL
475 ST SLOTTED ROUND HEAD PIN
ST
2X4
1-702000-150 1,0 Verdichterbeschriftung 1050124
480 ST COMPRESSOR MARKING
485 ST ROUND HEAD GROOVED PIN
A 2
3X6
Datum / Date
16.11.2006
Seite / Page no
6
WST
1050124 10400001000
Teileliste
Parts list
19001070633 1,0 ENTWAESSERUNGSLEITUNG DN 40
486 ST DRAIN PIPING
00080320310 1,0 DICHTUNG
487 ST GASKET
CENTELL.HD WS3822
49/92X2 40 PN 40
8.8
M 16X 40
1-180220-007 1,0 Gehuse f. Wellendichtung 220 SFO 11,2
495 ST SEAL SHELL
S2355J2G3
10501801122001 5,0 DICHTRING 3-TLG FUER WELLENDICHTUNG
495 ST SEALING RING FOR SHAFT SEALING
E 10 K
00035356276 12,0 Sechskantschraube
8.8
M 12X 55
00035870253 12,0 SICHERUNGSSCHEIBE S
501 ST CIRCLIP
FED-ST
12
ST
G 1/2 A
ST 30
21X26
1-260010-051 1,0 Zsb. Drallregler DK DK 11-75 *
545 ST ASSY. INLET GUIDE VANE
EN-GJL-250
8.8
M 20X 80
8
M 20
Datum / Date
16.11.2006
Seite / Page no
7
WST
1050124 10400001000
Teileliste
Parts list
A 2
G 1/2 A
ST 30
21X26
1-265190-039 1,0 Konsole fr Stellantrieb
560 ST CONTROL DESK FOR ACTUATOR
S235JRG2
1-240200-041 1,0 Aumamatic-Stellantrieb SAR 07.1
560 ST ACTUATING DRIVE
10002658101 1,0 GEWINDEMUFFE
560 ST SLEEVE
9SMN28+C
10002678002 1,0 KUGELGELENK VS8 A25X25/M18X1.5
560 ST SPHERIC PAIR
ST
13082656600 1,0 ZSB BUCHSE F. KUGELGELENK
560 ST BUSH
C35E
8
M 18X1,5
3-353601-288 4,0 SECHSKANTSCHRAUBE
A 2
M 16X 55
10500920145 1,0 UEBERGANGSSTUECK SFOG 11 + MESSSTUTZEN
562 ST DIFFUSER
S235JR
3-351901-019 20,0 Zylinderschraube
563 ST CHEESE HEAD SCREW
8.8
M27X90
8
M 27
Datum / Date
16.11.2006
Seite / Page no
8
WST
1050124 10400001000
Teileliste
Parts list
8.8
M 33X 90
8
M 33
1-544000-223 1,0 Elastische Profilhsenkupplung
575 ST FLEXIBLE BOLT COUPLING
BOKU 4000
10000715014 1,0 AXIALKOMPENSATOR TYP ABN 02 MIT LEITR.
600 ST EXPANSION JOINT SUCTION SIDE
X6CRNIMOTI17-12-2
10000715015 1,0 AXIALKOMPENSATOR TYP ABN 02 OHNE LEITR.
605 ST EXPANSION JOINT "DISCHARGE"
X6CRNIMOTI17-12-2
1-180180-003 1,0 Zsb. Sperrluftleitung
610 ST ASSY. STOP AIR TUBE
00032112551 1,0 ROHRDOPPELNIPPEL
610 ST DOUBLE BARREL NIPPLE
X 6 CRNITI 18 10
00032600110 2,0 VORSCHWEISSFLANSCH 150 LB
610 ST WELDING NECK FLANGE
X6CRNITI18-10
3-353601-367 4,0 Sechskantschraube
A2-70
M14X45
A2
M 14
3-803204-001 1,0 Dichtung
610 ST SEAL
AF 400
DN 10
1-280521-027 1,0 Zsb. lleitung 1050118
620 ST ASSY. OIL PIPING
10505600208 1,0 KUPPLUNGSSCHUTZ GETRIEBE-MOTOR
700 ST COUPLING GUARD
Datum / Date
16.11.2006
Seite / Page no
9
WST
1050124 10400001000
Teileliste
Parts list
10505600001 1,0 WELLENSCHUTZ-VERDICHTERSEITE
705 ST IMPELLER SIDE SHAFTGUARD
U ST 1203
1-560020-003 1,0 Kupplungsschutz Getriebe-Lagerbock
710 ST COUPLING GUARD
Datum / Date
16.11.2006
Seite / Page no
10
WST
1050124 10400001000
Teileliste
Parts list
10501555204 1,0 SEGMENTTRAEGER 2-TLG
002 ST ...
C35E
10501557205 1,0 FUTTERRING 2-TLG VERDICHTERRADSEITE
003 ST ...
GZ-CUSN 7 ZNPB
10501557201 1,0 FUTTERRING 2-TLG KUPPLUNGSSEITE
004 ST ...
GZ-CUSN 7 ZNPB
10501556707 4,0 RADIALLAGER-SEGMENT
005 ST RADIAL SEGMENT
C 10 - V 738
8.8 BESCH. OT 80
10491578801 4,0 FLACHKOPFSCHRAUBE
007 ST FLAT HEAD SCREW
5.8
10501555403 10,0 GLEITSCHUH RD 50-KOMPLETT
008 ST AXIAL SEGMENT
LAGERMETALL
10501555416 2,0 GLEITSCHUH RD 50 MIT THERMOMETERBOHRUNG
009 ST AXIAL SEGMENT WITH HOLE FOR THERMOMETER
LAGERMETALL
00035774973 1,0 STECKKERBSTIFT
010 ST TAPER GROOVED DOWEL PIN
6.8
00035774408 2,0 Steckkerbstift
6.8
Datum / Date
16.11.2006
Seite / Page no
11
WST
2250001/10 ZSB FESTLAGER 2-TLG 6-STEINE
ASSY JOURNAL AND THRUST BEARING
1050124 10501502606
Teileliste
Parts list
10501502606 /DRW/D
10501555205 1,0 SEGMENTTRAEGER 2-TLG
002 ST ...
C35E
10501556804 1,0 STUETZRING 2-TLG KUPPLUNGSSEITE
003 ST ...
GZ-CUSN 7 ZNPB
10501556802 1,0 STUETZRING 2-TLG VERDICHTERRADSEITE
004 ST ...
GZ-CUSN 7 ZNPB
10501556708 4,0 RADIALLAGER-SEGMENT
005 ST RADIAL SEGMENT
C 10 - V 738
8.8 BESCH. OT 80
10501578800 4,0 FLACHKOPFSCHRAUBE
007 ST FLAT HEAD SCREW
5.8
6.8
Datum / Date
16.11.2006
Seite / Page no
12
WST
2250001/10 ZSB LOSLAGER 2-TLG
ASSY JOURNAL BEARING
1050124 10501502509
Teileliste
Parts list
10501502509 /DRW/C
1-120300-018 1,0 Zsb. Verdichterrad SFO 1-11,2-75
002 ST ASSY. COMPRESSOR WHEEL
S500Q / S690QL1
10501213505 1,0 ZSB VERDICHTERWELLE SFO 11.2 RUNOUT=6.35
003 ST ASSY.COMPRESSOR SHAFT SFO 11.2
10111275403 1,0 DEHNSCHRAUBE EINSATZBEREICH BIS 150 @C
004 ST TENSION SCREW
42CRMO4+QT
10111283009 1,0 WELLENMUTTER BIS 250 @C, STAHL-RAD
005 ST SHAFT NUT
1.7225
10111285300 1,0 STROEMUNGSKAPPE
006 ST STREAM CAP
C35E
8.8
6.8
00080344940 1,0 O-RING
009 ST O-RING
VITON 83 FKM 592
1-127460-027 1,0 Pafeder
010 ST KEY
S690QL1
8.8
10111279100 1,0 AUSGLEICHGEWICHT
012 ST BALANCE PATCH
U ST 37
8.8
6.8
00035594554 1,0 SPANNSTIFT
018 ST SPRING DOWEL PIN
ST
Datum / Date
16.11.2006
Seite / Page no
13
WST
2250001/10 Zsb. Rotor SFO 1-11,2-75
ASSY. ROTOR
1050124 1-120502-022
Teileliste
Parts list
10401204503 /DRW/B
10500101003 /DRW/B
4-324000-006 1,0 Temperaturmesseinr. G2a .. G6b, ohne EX
010 ST TEMPERATURE MEASURING DEVICE
4-231300-016 1,0 Getriebegehuse G6b 2-teilig WB
015 ST BEARING HOUSING, 2 PARTS
EN-GJL-200
6.8
00080341225 2,0 RUNDGUMMIDICHTUNG
017 ST RUBBER O-RING SEALING
GUMMI
4-236010-023 1,0 Drosselstopfen
018 ST THROTTLE
9 SMN 28 K
49021563143 1,0 Drosselstopfen
019 ST THROTTLING PIN
9 SMN 28 K
46102360023 1,0 Getriebeschmierung li z=65..68/m=4
022 ST ...
00080322199 1,0 DICHTUNG
026 ST GASKET
CENTELL.HD WS3822
00035190976 2,0 Zylinderschraube
8.8
ST
4-150000-061 1,0 Halslager 90 b/d=1.0 KS TW links
050 ST NECK BEARING
4-150000-036 1,0 Hals-u. Spurlager 90 b/d=1.0 TW KS r/l
051 ST NECK BEARING
4-150000-014 1,0 Zsb.Halslager 120 b/d=0.8 GW (exztr.)
052 ST JOURNAL BEARING 120
4-151000-032 1,0 Hals-u. Spurlager 140 b/d=0.8 GW
053 ST JOURNAL AND THRUST BEARING
Datum / Date
16.11.2006
Seite / Page no
14
WST
2250001/10 Zsb. Getriebe G6B
GEAR
1050124 4-230000-199
Teileliste
Parts list
46100150000 /DRW/I
Z-108326 /DRW/D
Z-108327 /DRW/B
Z-119300 /DRW/A
00035710805 4,0 Zylinderstift M6 x 16
055 ST STRAIGHT PIN
ST
4-233100-215 1,0 Getriebewelle/Rad G6b SS
056 ST GEAR SHAFT/WHEEL
56NICRMOV7+QT
4-233050-104 1,0 Ritzelwelle G6b mit Run out
070 ST Shaft with RUN OUT
56NICRMOV7+QT
8.8
00035870253 2,0 SICHERUNGSSCHEIBE S
075 ST CIRCLIP
FED-ST
4-294000-039 1,0 Zahnradlpumpe VG 115 rechts 26 bar
076 ST TOOTHED GEAR OIL PUMP
00040600704 1,0 Rechteckring KI PT 125/115 x 4
077 ST SQUARE SECTION RING
GG
4-241020-034 1,0 Antriebsrad
078 ST DRIVING WHEEL
42CRMO4+QT
079 ST HEXAGON NUT
ST42KG
4-232320-034 1,0 lpumpendeckel G6b
081 ST OIL PUMP COVER
EN-GJL-200
8.8
00035712855 1,0 ZYLINDERSTIFT MIT INNENGEWINDE FORM A
083 ST STRAIGHT PIN
ST
49011674402 1,0 Stift
084 ST PIN
ST 50 K
4-232340-005 1,0 Verschludeckel
105 ST SEAL COVER
13CRMO4-5
Datum / Date
16.11.2006
Seite / Page no
15
WST
GEAR
1050124 4-230000-199
Teileliste
Parts list
46100150000 /DRW/I
Z-108326 /DRW/D
Z-108327 /DRW/B
Z-119300 /DRW/A
8.8
00080701700 1,0 LOCTITE 243
107 ST LOCTITE 243
ST
ST 30
00041620605 1,0 RICHTUNGSPFEIL A 6X32
110 ST DIRECTION ARROW
ALU
ST
46161523101 1,0 lfangdeckel G6a,G6b
112 ST Oil collecting cover
C35E
8.8
00035712855 1,0 ZYLINDERSTIFT MIT INNENGEWINDE FORM A
115 ST STRAIGHT PIN
ST
49011674402 1,0 Stift
116 ST PIN
ST 50 K
46102374402 1,0 Dichtungsring 2-teilig
120 ST SEALING RING
CK 35
ST
ST
8.8
Datum / Date
16.11.2006
Seite / Page no
16
WST
GEAR
1050124 4-230000-199
Teileliste
Parts list
46100150000 /DRW/I
Z-108326 /DRW/D
Z-108327 /DRW/B
Z-119300 /DRW/A
00035735102 2,0 KEGELSTIFT A
125 ST TAPER PIN
ST
46142323101 1,0 lfangdeckel 2-teilig (fr Verdichter)
126 ST OIL BAFFLE
CK35
46102374400 1,0 Dichtungsring
127 ST SEALING RING
CK45
8.8
8.8
00035730153 2,0 KEGELSTIFT
130 ST TAPER PIN
ST
8
4-232340-009 1,0 Verschludeckel
135 ST SEAL COVER
C35E
00035356210 4,0 SECHSKANTSCHRAUBE M 12X 30
8.8
00030620000 4,0 Thermometer B G 160 x 63
140 ST THERMOMETER
BUNTMETALLFREI
ST 30
4-109550-003 1,0 Zentrierring G6a/G6b fr Verdichter
142 ST CENTERING RING
S235JRG2
4-232340-014 1,0 Verschludeckel G6b
150 ST SEAL COVER
S235JRG2
8.8
Datum / Date
16.11.2006
Seite / Page no
17
WST
GEAR
1050124 4-230000-199
Teileliste
Parts list
46100150000 /DRW/I
Z-108326 /DRW/D
Z-108327 /DRW/B
Z-119300 /DRW/A
155 ST SEALING RING
ST 30
49014723403 1,0 Zwischenstck 6-kt G1/4,G1/2
156 ST INTERMEDIATE PIECE
ST 42 KG
49022364000 1,0 Rohr
157 ST TUBE
3-322301-080 1,0 GERADE EINSCHRAUBVERSCHRAUBUNG
158 ST MALE STUD UNION
ST
00032270058 1,0 HOCHDRUCK-SCHWENKVERSCHRAUBUNG
159 ST HP-MALE STUD UNIT
ST
00032240707 1,0 GERADE EINSCHRAUBVERSCHRAUBUNG
162 ST MALE STUD UNIT
ST
49022364002 1,0 Rohr
163 ST TUBE
00032270058 1,0 HOCHDRUCK-SCHWENKVERSCHRAUBUNG
164 ST HP-MALE STUD UNIT
ST
165 ST SEALING RING
ST 30
ST GAL ZN GLCC
ST GAL ZN GLCC
49013650194 1,0 ldunstabscheider
200 ST OIL MIST SEPARATOR
19001513510 1,0 GEWINDEROHR
201 ST ...
ST 33-2
Datum / Date
16.11.2006
Seite / Page no
18
WST
GEAR
1050124 4-230000-199
Teileliste
Parts list
46100150000 /DRW/I
Z-108326 /DRW/D
Z-108327 /DRW/B
Z-119300 /DRW/A
1-101541-034 1,0 Spiralgehuse SF011-75 FERTIGT VERTIKAL
005 ST SCROLL HOUSING
EN-GJL-250 (2.2)
00060020506 1,0 TEROSTAT-63 SILICON-DICHTSTOFF
007 ST SEALING MATERIAL TEROSTAT
00080701264 1,0 FORMBARE POLYMER-FLACHDICHTUNG TS 680
008 ST FICTILE FLAT PACKING
00032600054 2,0 BLINDFLANSCH B PN 16
010 ST BLIND FLANGE
C22.8
00080320310 2,0 DICHTUNG
015 ST GASKET
CENTELL.HD WS3822
8.8
10111020103 1,0 STUETZDECKEL SFO/SFM 11,2 einteilig
025 ST ...
EN-GJL-250
00035407687 56,0 STIFTSCHRAUBE
030 ST STUD BOLT
5.6
8
8.8
1-103101-029 1,0 Saugstutzen SFO 11.2-75 FERTIGTEIL
045 ST INLET
EN-GJL-250
8.8
1-851510-002 2,0 Unterlegblech f. Spiralgehuse SFO11.2
060 ST SHIMS FOR SCROLL HOUSING
S235JRG2+C
10115010200 2,0 ZSB ABSTUETZUNG
061 ST GUIDE PLATE
S235JRG2+N
Datum / Date
16.11.2006
Seite / Page no
1
WST
2250001/10 Zsb. Verdichtergehuse SF0 11.2-75 VERT.
ASSY. COMPRESSOR HOUSING
1050124 1-100500-067
Teileliste
Parts list
10000200301 /DRW/D
10401004501 /DRW/C
77007456000 /DRW/-
00010030006 0,0 BLECH
4 ST PLATE
S355J2G3
8.8
8.8
00035711451 2,0 ZYLINDERSTIFT
7 ST STRAIGHT PIN
ST
Datum / Date
16.11.2006
Seite / Page no
1
WST
2250001/10 Gehuse f. Wellendichtung 220 SFO 11,2
SEAL SHELL
1050124 1-180220-007
Teileliste
Parts list
Z-140164 /DRW/C
1-261051-022 1,0 Drallreglergehuse DK 11,2-75 Fertigteil
002 ST INLET GUIDE VANE HOUSING
EN-GJL-250 (2.2)
10112623600 11,0 LAGERBUCHSE
003 ST BEARING BUSH
C45E+N
00040480033 22,0 BUCHSE MB
004 ST BUSH MB
DU
3-405101-003 11,0 Wellendichtring mit Dichtlippe
005 ST SHAFT SEALING RING
1.4571/ PTFE-COMPOUND
10112630102 11,0 ZSB DREHSCHAUFEL DK11
007 ST ASSY. ADJUSTABLE VANE DK11
X6CRNIMOTI17-12-2
10112623000 11,0 AUFLAGESCHEIBE
008 ST DISC
S235JRG2+N
00035420706 22,0 SENKSCHRAUBE
009 ST COUNTERSUNK SCREW
4.8
00040780003 11,0 SICHERUNGSSCHEIBE
010 ST CIRCLIP
FED-ST
10112653000 11,0 KLEMMHEBEL
011 ST CLAMBING LEVER
C45+C
8.8
10112673300 1,0 ZEIGER KKK.NR-390
013 ST POINTER
RST 37-2
8
10112673200 1,0 GRADSCHILD
015 ST SCALE PLATE
G-ALMG 5 SI
8.8
Datum / Date
16.11.2006
Seite / Page no
19
WST
2250001/10 Zsb. Drallregler DK DK 11-75
ASSY. INLET GUIDE VANE
1050124 1-260010-051
Teileliste
Parts list
10112604100 /DRW/C
10112650000 1,0 ZSB REGELRING
017 ST ADJUSTING RING
10072655002 6,0 FUEHRUNGSROLLE
018 ST GUIDE ROLLER
C35E+N
00040480039 6,0 BUCHSE MB
019 ST BUSH MB
DU
00040490002 12,0 ANLAUFSCHEIBE
020 ST STOP DISC
DU
10072654000 6,0 BOLZEN
021 ST BOLT
9SMN28+C
10112650100 11,0 ZSB GELENKHEBEL
022 ST ASSY ARTICULATED LEVER
8.8
00035830357 44,0 SCHEIBE B 17 MM
ST
U ST 36-2
00035100100 4,0 RINGSCHRAUBE
026 ST EYEBOLT
C15E
8.8
Datum / Date
16.11.2006
Seite / Page no
20
WST
2250001/10 Zsb. Drallregler DK DK 11-75
ASSY. INLET GUIDE VANE
1050124 1-260010-051
Teileliste
Parts list
10112604100 /DRW/C

B Drawings and plans

1B001EN_ Seite 1 von 1


contents section document-no.

Installation plan 1 Z-157006

Load data for foundation 2 Z-157007

P+I diagram +Instrument list 3 Z-157199

Terminal plan 4 see chapter 9 part C

Values of alignment 5 454936

Checklist for compressor parts 6 454935
(gaps)
Instrument-List
HINDUSTAN ZINC LTD.
KKK-Job-no. 2250001 (1050124) SFO 11
Date: 19.07.06 - AUF 454515 Rev.A
TKA-Hzs corresponding to P&I diagram Z-157199
Page 1/5
Anz. Tag
No.
Instrument/Gert Hersteller Typ Einstellwert Mebe-
reich
Leistung Spannung Schutz-
art
Anschlu Funk-
tion
Bemerkung
Pos.
No.
Qty Instrument Manufacture Type Settingvalue Range Power Voltage Protec-
tion
Connection Func-
tion
Remarks
1 1 Verdichter compressor KKK SFO 11 2800 kW AD_02 G002
2 1 Getriebe gearbox KKK G6b 2800 kW
3 1 Lagerbock bearing pedestal KKK SFO 11
4.1 1 Kupplung coupling Flender ARP
275-6
Steel membrane
type with Spacer
4.2 1 Kupplung coupling KWD BOKU
4000
Flexible Compr.
Sleeve Coupling
5 1 Antriebsmotor drive motor SEC 3150 kW 11000 V
3ph / 50Hz
1495
rpm
not in KKKs scope
of supply
6.2 1 Stellantrieb
Drallregler
actuator for IGV Auma matic SAR
07.1
4 20mA 0,18 kW 415 V AC
50 Hz 3ph
IP67 4000N IGV Control with
positioner
10.1 2 Kompensator expansion joint HKS * DN 1000 1x suction
1x discharge
12 1 Differenzdruck-
schalter
Diff. Pressure
switch
FEMA 60 mbar 150
mbar
24 V DC IP65 Anti Surge
Protection
19003670707
13 1 Diffusor diffuser KKK
15.1 1 lbehlter oil reservoir LEFA 1600 l oil content
16 1 lpumpe oil pump KKK VG115 295 l/min mechanically
driven by gearbox
17.1 1 Pumpenaggregat Auxiliary pump
unit
Steimel SF8/212 290 l/min 11 kW 415 V AC
50 Hz 3ph
IP55 rated current 21,5A
starting c. = .134 A
17.2 1 Pumpenaggregat Emergency oil
pump unit
Steimel SF4/63 79 l/min 2,2 kW 110 V DC IP55 UPS rated current 26A
starting c. = ..... A
Instrument-List
HINDUSTAN ZINC LTD.
KKK-Job-no. 2250001 (1050124) SFO 11
Date: 19.07.06 - AUF 454515 Rev.A
Page 2/5
Anz. Tag
No.
reich
art
Anschlu Funk-
tion
Bemerkung
Pos.
No.
tion
Connection Func-
tion
Remarks
18 1 lheizung oil heater Elmess HF-3 Contr. 70C
Limit: 80C
3 kW 415 V AC
50 Hz 3-ph
20.1 1 Rckschlagventil non-return valve Gttgens
25 1 Doppel-lkhler Twin-oil cooler HS-Cooler KS12 110 kW cooling water:
20 m
3
/h
inlet-temp. 32C
outlet-temp. 37C:
Press.drop: 0,3 bar
25.1 1 Fuventil foot valve Gttges 4 MK
26 1 Temperaturregelv
entil
Temperature
control valve
MVA M50
27 1 Doppel-lfilter twin oil filter Internormen DU 631 25 Im
28.1 1 Regulierventil control valve F & M
Armaturen
50 l/min
Armaturen
80 l/min
Armaturen
105 l/min
28.4 1 Regulierventil control valve not in KKKs scope
of supply
28.5 1 Regulierventil control valve not in KKKs scope
of supply
Instrument-List
HINDUSTAN ZINC LTD.
KKK-Job-no. 2250001 (1050124) SFO 11
Date: 19.07.06 - AUF 454515 Rev.A
Page 3/5
Anz. Tag
No.
reich
art
Anschlu Funk-
tion
Bemerkung
Pos.
No.
tion
Connection Func-
tion
Remarks
29.1 1 Druckbegrenz-
ungs-Ventil
pressure limiting
valve
Kracht SPFV 50 8 barg 4 - 12
bar
max.
500 l
PRV
31.1 1 Druckregelventil pressure control
valve
Kracht SPFV 50 3 barg 2 - 5
bar
max.
500 l
PCV
32. 1 Druckregelventil
mit Manometer
pressure control
valve with manom.
Aircom R 105 500 mbarg

PCV Seal.-Air .....m3/h
1-180180-006
40.1 1 Manometer pressure gauge WIKA 233.50 0-10
bar
PI
40.2 1 Manometer pressure gauge WIKA 233.50 0-6 bar PI
40.3 1 Manometer pressure gauge see Pos. 32 0-1,8
bar
PI Integrated in
pos 32
41.1 1 Druckmessumfor
mer
pressure
transmitter
Yokogawa EJA 530 0 3 barg 4-20
mA
IP 65 PT
41.2 1 Druckschalter pressure switch Fanal FF4-4 2,0 barg 0,22
4bar
PSL
4 bar
PSL
4 bar
PSLL
42.1 1 Verschmutzungs-
anzeiger
differential
pressure switch
see Pos. 27 AE 70 1,5 bar 24 V DC IP65 PDSIH
50.1 1 Temperaturan-
zeige
temperature
indicator
Dr. Siebert 291 0
100C
TI upstream oil cooler
50.3 4 Temperaturan-
zeige
temperature
indicator
see Pos. 2 TI 4 x gear box
51.1 1 Temperatur-
schalter
temperature
switch
see Pos. 18 415VAC
50Hz
IP65 TSHL
51.2 1 Temperatur-
Messumformer
temperature
transmitter
WIKA TR201 0
100C
IP 65 TT downstream oil
cooler
Instrument-List
HINDUSTAN ZINC LTD.
KKK-Job-no. 2250001 (1050124) SFO 11
Date: 19.07.06 - AUF 454515 Rev.A
Page 4/5
Anz. Tag
No.
reich
art
Anschlu Funk-
tion
Bemerkung
Pos.
No.
tion
Connection Func-
tion
Remarks
53.1 3 Widerstands-
thermometer
1 x Pt100
resistance
thermometer
1 x Pt100
KKK / WIKA-
transmitters
0.....+150C Transmitter
s mounted
in the JB
TE/TT 2x bearing radial
1x bearing axial
2-367090-036
53.2 1 Temperatur-
Messumformer
temperature
transmitter
WIKA T12.10.0
0
-50
...+100C
4 20 mA
-50...
+450
C
24V DC IP65 TE/TT suction temp.. for
rotating stall
2-367090-052
53.3 8 Widerstands-
Thermometer
2 x Pt100
Resistance
thermometer
2 x Pt100
KKK / WIKA-
transmitters
0.....+150C Transmitter
s mounted
in the JB
TE 4x radial bearings
2x gear shaft axial
2x pinion sh. axial
2-367090-036
56.1 1 Durchflumesser flowmeter Krohne H 250 50 l/min 8 80
l/min
FI
56.2 1 Durchflumesser flowmeter Krohne H 250 80 l/min 18-180
l/min
FI
56.3 1 Durchflumesser flowmeter Krohne H 250 105 l/min 18-180
l/min
FI
56.4 1 Durchflumesser flowmeter FI not in KKKs scope
of supply
56.5 1 Durchflumesser flowmeter FI not in KKKs scope
of supply
58 3 Niveauzanzeiger level indicator Gerhard SNA 254 LI
59 1 Niveauschalter level switch Kuebler ARV 1,5 505mm
605mm
0-
660mm
24 V DC IP 65 LSL
LSLL
2 contacts
60.1 1 Endschalter limit switch see Pos. 6.1 GSL
61.1 1 Stellungsregler Position
transducer
see Pos. 6.1 GIC
Instrument-List
HINDUSTAN ZINC LTD.
KKK-Job-no. 2250001 (1050124) SFO 11
Date: 19.07.06 - AUF 454515 Rev.A
Page 5/5
Anz. Tag
No.
reich
art
Anschlu Funk-
tion
Bemerkung
Pos.
No.
tion
Connection Func-
tion
Remarks
64.1
64.2
64.3
64.4
4 Schwingungs-
aufnehmer
vibration pick-up BN 3300 XE Shaft vibration
(4x Blower)
64.5
64.6
2 Schwingungs-
aufnehmer
vibration pick-up BN 3300 XE Shaft vibration DE
(2x Main motor)
not in KKKs scope
of supply
65.1
65.2
2 Axiallage-
Aufnehmer
axial displacement
pick-up
BN 3300 YE Axial displacement
75 1 Steuerschrank Local Panel Nther/ approx.
1 kW
110 VAC
50Hz
IP55 LCP 1-682040-038
Bently Nevada
3500 Sys. included
* = or equivalent

B Drawings and plans

1C001EN_ page 1 of 1


see chapter 9 Part C
hL hM
Soll / SET 0,07 0,11
Ist / ACTUAL +- 0,04mm
Soll / SET 0 0
Ist / ACTUAL
sL sM
Soll / SET 0,17 -0,03
Ist / ACTUAL +- 0,04mm
Soll / SET 0 0
Ist / ACTUAL
Auftragsnr.: Maschinentyp:
ORDER-NO.: MACHINE-TYPE:
Maschinen-Nr.:
MACHINE-NO.:
Datum: 30.06.2006
Ausrichtvorgaben und Ausrichtergebnisse fr Verdichter mit
Lagerbock
SET VALUES AND ACTUAL VALUES OF ALIGNMENT FOR
COMPRESSORS WITH BEARING SUPPORT
Status: FR
AUF/454936/000/00
Ersteller: WER
1050124
Monteur:
FITTER:
Hinweis: Der Lagerbock wird vor dem Ausrichten vorne so unterbaut,
da die Welle mit montiertem Laufrad im Wasser liegt.
1050124
Toleranz
TOLERANCE
Bemerkungen:
REMARKS:
0,025 mm
/ 100 mm
SFO 1-11-75
Klaffung / GAP
Toleranz
TOLERANCE
Klaffung / GAP
0,025 mm
/ 100 mm
NOTE: BEFORE ALIGNING, SHIM THE BEARING SUPPORT AT THE FRONT SUCH THAT THE
SHAFT WITH FITTED IMPELLER IS PERFECTLY HORIZONTAL.
ausgerichtet am:
DATE OF ALIGNMENT:
Nullebene
Grundrahmen
Grundrahmen / Fundament
Lagerbock
Getriebe
E-Motor
+
-
+
-
hL hM
BASE FRAME
BASE FRAME / FOUNDATION
BEARING
SUPPORT
GEARBOX
MOTOR
ZERO LINE
sL
sM
Lagerbock
BEARING
SUPPORT
Getriebe
BASE FRAME / FOUNDATION
Grundrahmen / Fundament
E-Motor
MOTOR
Grundrahmen
BASE FRAME
GEARBOX
-
+
+
-
1.0. Eccentricbearing to be lifted at gearshaft : 0,04 mm
2.0. Assembly of impeller onto pinionshaft
2.1. Thightening torques / pressures for the shaft nut
nominal : 293 bar / Nm
actual : 0 bar / Nm
2.2. Growing with Superbolt
nominal : 1,33 mm
actual : 0 mm
2.3. Axial gap between the impeller and the shaft bush
nominal : min. 0,81 mm
max. 1,51 mm
actual : 0 mm
FITTER: 0
REMARKS: 0
ORDER-NO.: 2250001
MACHINE-NO.: 1050124
DATE OF
ALIGNMENT:
00.01.1900
MACHINE-
TYPE:
SFO 1-11-75
Checklist for compressor parts
Dok.: 454935/AUF
Status: FR
Sheet 1 of 4
Date: 30.06.2006
Created by: WER
3.0. Axial position of the impeller (viewed from suction side)
nominal : min. 0,20 mm
max. 2,2 mm
actual :
4.0. Gaps

4.1. run smoothly between the shaft and the sealing
carbon ring sealing nominal : 0,50 mm
actual :
FITTER: 0
REMARKS: 0
ORDER-NO.: 2250001
DATE OF
ALIGNMENT:
00.01.1900
MACHINE-
TYPE:
SFO 1-11-75
Dok.: 454935/AUF
Status: FR
Sheet 2 of 4
Date: 30.06.2006
Created by: WER
4.2. Gaps between impeller and suction branch nominal : min. 2,24 mm
( viewer from suction side ) max. 3,36 mm
actual gaps inlet : actual gaps outlet :
4.3. Calculation form the sheet metal
machine type 2,8 3,5 4,5
measure 2 =
- measure 1 =
- gauge x 2 =
+gap measurement = 0,70 0,90 1,10
sheet metal =
Dok.: 454935/AUF
Status: FR
Sheet 3 of 4
Date: 30.06.2006
Created by: WER
0
DATE OF
ALIGNMENT:
00.01.1900 REMARKS: 0
1,40
ORDER-NO.: 2250001
MACHINE-
TYPE:
SFO 1-11-75 FITTER:
5,6
5.0. Movable bearing at compressor housing support
Movable execution without gaps ? yes / no
6.0. Gaps between outlet guide vanes and compressor housing
nominal gap : min. 0,05 mm
max. 0,35 mm
supporting cover
outlet guide vane
actual list
blade-no. mm blade-no. mm blade-no. mm
1 11 21
2 12 22
3 13 23
4 14 24
5 15 25
6 16
7 17
8 18
9 19
10 20
Dok.: 454935/AUF
Status: FR
Sheet 4 of 4
Date: 30.06.2006
Created by: WER
SFO 1-11-75 FITTER : 0
MACHINE-NO.: 1050124 DATE OF ALIGNMENT: 00.01.1900 REMARKS : 0
scroll housing
ORDER-NO.: 2250001 MACHINE-TYPE:

C Accessories

1C001EN_ page 1 of 1

contents section KK&K-material-no.

Low speed coupling (KWD) 1 1-544000-223

High speed coupling (Flender) 2 1-544000-128

Shaft seal (Espey) 3 10501801122001

IGV-Actuator (Auma) 4 1-240200-041

Anti Surge detector (Fema) 5 1-367070-006

Oil supply Unit (Lefa) 6 1-280100-040

Vibration monitoring (Bently Nevada) 7 1-682050-013

Local Control Panel 8 1-682040-051

Operation manual
KWN 32017
Edition h

KWN32017h e.doc 04.01.2005 Page 1 of 13

Operation manual
Flexible pin type coupling
according to
KWN 22014

Author: Dipl.-Ing. . V. Hausdorf 24.01.2005 gez. V. Hausdorf
Approved: Dr.-Ing. Ch. Spensberger 24.01.2005 gez. Dr.-Ing. Ch. Spensberger
Name Date Signature

KWD Kupplungswerk Dresden GmbH
Lbtauer Strae 45 - D 01159 Dresden
Postfach 270144 D 01172 Dresden
Tel.: + 49(0)351 4999-0 Fax: + 49(0)351 4999-233
kwd@kupplungswerk-dresden.de
http://www.kupplungswerk-dresden.de
D-400439

Operation manual
KWN 32017
Edition h

KWN32017h e.doc 04.01.2005 Page 2 of 13

TABLE OF CONTENS

MANUFACTURERS DECLARATION ....................................................................................3
1. GENERAL AND SAFETY INSTRUCTIONS........................................................................5
2. TRANSPORT AND STORAGE ...........................................................................................5
3. FUNCTION...........................................................................................................................6
4. ASSEMBLY.........................................................................................................................6
4.1. MOUNTING THE COUPLING PARTS .............................................................................7
4.2. ALIGNING THE COUPLING ELEMENTS........................................................................8
4.2.1. Aligning with a hairline gauge, feeler gauge or measuring wedge........................................................9
4.2.2. Aligning by means of a dial gauge and instrument ...............................................................................10
5. COMMISSIONING.............................................................................................................10
6. MAINTENANCE AND REPAIR .........................................................................................11
6.1. DISMANTLING BOLTS TYPE A,P,H .............................................................................12
6.2. SPECIAL FEATURES ACCORDING TO TYPE H .........................................................13
7. SPARE PARTS..................................................................................................................13

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Manufacturers Declaration

Product: Flexible pin type couplings
BOKU-N according to KWN 22014

In accordance with the EU Machine Directive 98/37/EG, Appendix IIB

we

KWD
Kupplungswerk Dresden GmbH
Lbtauer Strae 45 - D 01159 Dresden
P.O. Box 270144 D 01172 Dresden

hereby declare, that the

Flexible pin type couplings BOKU-N
according to KWN 22014

described in this operation manual are intended for installation in a machine. Commissioning
of the machine is prohibited until it is established whether the machine, in which these
components are fitted complies with the EU directive (original issue 89/392/EWG, including
all subsequent amendments).
All harmonized standards published by the EU Commission in the Official Gazette of the
European Union insofar as they apply to this product have been taken into consideration.

Date/ Manufacturers signature 04.01.2005 signed C. Spensberger

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Safety and Information Symbols

Danger! Danger of injury to personnel

Attention! Follow instructions

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1. General and Safety instructions

This Operation Manual (OM) is a constituent part of the scope of delivery of the coupling.
Only the observance of all instructions and information will guarantee trouble-free operation
of the coupling within the specified parameters. The coupling must be used only under
conditions specified in the specification sheets (specification leaflet). Any deviation from this
requires prior consultation of the manufacturer as well as his approval.

The following general safety instructions must be observed at all times when working on the
coupling:

- The coupling may only be serviced, repaired or operated by authorized and properly
trained personnel.
- All work must be performed according to the principle safety first.
- As a matter of principle, any work on the coupling may only be performed at a complete
standstill. The motive power aggregate must be secured against accidental operation (for
example, by interrupting energy supply). A warning sign must be affixed to the switch-on
device when work is performed on the coupling.
- The motive power aggregate must be shut down immediately if changes are observed on
the coupling during operation.
- The coupling must be secured against accidental contact by means of appropriate
protective equipment.

Due to the emergency running properties the coupling has, metal contact may cause sparks
to form in the event of the flexible transmission elements seizing up. This characteristic must
be taken into account by the operator or project planners if the coupling is to be used in
potentially-explosive atmospheres or machinery. To eliminate the risk of explosion, care
must be taken that the permissible extent of wear is not exceeded, that the maximum
permissible deviations are observed, and overloading is avoided.

2. Transport and Storage

The contents of the delivery are listed in the delivery papers. The delivery must be checked
for completeness upon receipt. Possible transport damage and incomplete delivery must be
reported immediately in writing. The coupling is delivered in individual components or
subassemblies ready for installation.

During transport the couplings must be secured against impact, shock and contact damage.
For transport or lifting of the coupling and for installation, non-metallic load suspension
devices with a sufficient safety margin must be used exclusively.

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The couplings must be stored indoors in enclosed and dust-free storerooms, with the
exclusion of harmful influences, such as condensates, excessive humidity (< 70%) and
ozone.

In case of possible damage the coupling may not be put into operation.

The couplings are delivered with temporary corrosion protection, allowing, under the above
described conditions, storage of up to 6 months from the date of delivery.

3. Function

Flexible bolt couplings are torsionally-elastic couplings which even out radial, axial and
angular misalignments in the shafts to be connected. The torque is transmitted through the
flexible buffers and the corresponding buffer bore holes in the buffer section. The service life
of the buffer depends on the type of drive, the temperatures at the coupling and the existing
misalignments.

The couplings are supplied with the individual buffer section and in

- model A: the bolt section is complete with buffer and bolts
- model P: the brake drum is complete with buffer and bolts
- model S: the brake disk is complete with buffer and bolts
- model H: the hub and spacer are complete with buffer and bolts

4. Assembly

The fitting position and the arrangement of the coupling halves on the driving or the driven
side is optional. However, in the case of vertical fitting the appropriate measures must be
taken to secure both coupling halves axially.

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Flexible bolt couplings must be provided with a cover against unintentional touch.
4.1. Mounting the coupling parts

A distinction must be made here between models A, P, S1, S2 and model H. The following
applies to all designs:

- remove dirt and preservative residue from the bore hole and groove in the coupling parts;
- the coupling parts may be heated to facilitate assembly (remove buffers and bolts
beforehand);

- never force the coupling parts on by hitting them

- in nominal size 1000 and larger, the bolts and buffer parts or brake drums (model P) and
the hubs (model H) may be provided with threading to facilitate removal

(see picture 1 or table 1 for position and size of tapped holes.)

Table 1

Nominal size
1000 1600 2500 4000 6300 10000 16000 25000 40000 63000 100000
d1 150 183 205 230 258 273 336 384 432 432 480
d2 176 176
d3 150 183 205 230 258 273
d4 M 20 M 24 M 30
l 30 35 40

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Picture 1

Features peculiar to model H:
Spacer and hub can be separated by loosening the screwed connection. The buffer section
and the hub must be mounted as described above. The spacer can now be screwed to the
hub again. The tightening torque's are listed in table 2.

Table 2

Nominal size 4
6,3
10
16
25
40
63
100
160
250
400
630
1000
1600
2500
4.000 6300
10000
Tightening
torque (Nm)
14 34 68 117 285 558 961 1.050

4.2. Aligning the coupling elements

Having mounted the coupling elements. the axial, radial and angular alignment of the
coupling must be attained. Different methods can be used depending on the degree of
accuracy necessary. In general however the extent of the remaining alignment error has a
decisive influence on the service life of the flexible components. Once the coupling has been
aligned, the buffers and bolts must be mounted again. The nuts must be tightened with the
torque's shown in table 3.

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Table 3

Nominal size Tightening Torque
Type A, P, H Type S1, S2
4; 6,3 2,4 -
10 4 -
16 - 63 9,8 43
100 36 85
160, 250 36 172/187
400; 630 90 340/372
1000, 1600 308 1053/1142
2.500 400 2.150
4000 - 100000 400 -

The permissible axial or angular misalignment (K w) can be checked by means of the
maximum and minimum measurements of e1, the permissible radial misalignment by means
of the measurement Kr. The permissible values can be taken from table 4.

Table 4

Nominal size Maximum dim.
e 1
Minimum dim.
e 1
Kr Kw'
4; 6,3 2,5 0,5 0,2 0,5; 0,6
10 3 1 0,3 0,7
16; 25; 40; 63 4 2 0,4 0,8; 0,9; 0,9;1,1
100 5,5 1,5 0,5 1,4
160; 250 6 2 0,7 1,7; 1,9
400; 630 7 3 0,8 2,1; 2,4
1000; 1600 9 5 1,1 2,7; 3,2
2.500 15 7 1,3 3,1
4000; 6300; 10000 22 14 1,5 2,7;2,9; 3,4
Values for K r and K w' are valid for a speed of 600 rpm up to 500 rpm

4.2.1. Aligning with a hairline gauge, feeler gauge or measuring wedge

At 3 points each 120 away from the others, check the actual distance "e1" between the
buffer and the bolt part using a measuring wedge or feeler gauge and then align them to an
even measurement. The actual measurement of "e1" should lie within the limits given in table
4. the shaft ends are aligned by acquiring the same measurement "e1" and resting the
hairline gauge in the light gap on both sides.

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4.2.2. Aligning by means of a dial gauge and instrument

If the demands are higher with respect to the remaining positional deviation after alignment,
the alignment can be attained by means of a dial gauge and instrument as shown in picture
2. While aligning, turn the coupling part to which the instrument is fixed and observe the dial
gauge's needle. The positional tolerances can be found in table 4.

dial gauge 1: difference between the maximum and the minimum
deflections of the needle corresponds to Kr
dial gauge 2: difference corresponds to Kw

Picture 2

5. Commissioning

Improper use and modifications of the coupling that have not been approved by
KWD will render the manufacturers warranty null and void. This also applies to
the use of spare parts other than original spare parts by KWD.

Original KWD spare parts must be used exclusively.

Check and, if required, retighten all screw connections prior to putting the coupling into
operation.

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Finally, protection against accidental contact must be provided. If there is a change in the
noises coming from the coupling during operation or it starts to vibrate. The drive must be
turned off and the cause eliminated.

If no cause of the noise or vibration is found, consult the customer service of
the manufacturer!

The following visual checks must be performed during commissioning:

- Check that rotating parts do not contact anything
- Check for unusual noise
- Refer Trouble Shooting for instructions on how to eliminate the causes of
possible operating trouble.

6. Maintenance and repair

Maintenance on the flexible bolt coupling is restricted to checking the extent of wear in the
buffers and the actual misalignment. If the wear is extensive, (see table 5 for measuring
wear) or if the buffers are damaged, they must be replaced by a complete set.

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Tabelle 5

Nenngre Ma m d 11
6 1,35 11
8 2,85 14
10 3,25 18
14 3,2 28
16 4,6 30
22 7 40
30 6,8 60
42 9 85
65 13,5 120

In model S2 the brake disk can be removed radially without moving the coupling parts. The
buffers and the bolts must be removed first and the two locking screws loosened.

6.1. Dismantling bolts type A,P,H

The bolts are fitted with a thread for dismounting. By using these threads the dismounting of
the bolt can be facilitated. Size and length of the thread are given in the following table 6.

Table 6

Bolt Nominal size Thread Length
6 - -
8 - -
10 - -
14 M8 12
16 M8 12
22 M8 12
30 M8 12
42 M12 20
65 M24 30

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6.2. Special features according to type H

It is possible to remove the spacer from this model without moving the coupling parts. The
following steps must be taken:

1. Remove the buffers and bolts.

2. Loosen the screwed connection between the spacer and the hub.

3. Move the spacer towards the buffer part axially.

4. Take out the spacer radially.

7. Spare parts

Specified spare parts for flexible bolt couplings: buffers and bolts. The size and quantity can
be found in the product standard.

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D-400439
T:\daten-doku\standard\WD200-500\Betriebsanleitung WD200-500_e.doc

Espey Burgmann GmbH D-47445 Moers Thomas-Edison-Str. 19 Tel. +49 (0) 2841 / 9 98 27 - 0
D-47426 Moers Postfach/postbox: 30 01 44 Fax +49 (0) 2841 / 9 98 27 - 56

status 21.04.04
Assembly and Maintenance Instructions
for ESPEY Standard Shaft Seals
TYPE WD200/500
305355


status 21.04.04 page
1/11
Inhalt_2e
Table of contents
Assembly drawing
General Information on the shaft seal
Installation Instructions:
1 Preliminary Note
2 Preparation for Installation
3 Installation of the shaft sleeve
4 Installation of the shaft seal
Inspection and Repair:
5 Dismantling of the shaft seal
6 Dismantling of the shaft sleeve
Operating and Maintenance Instructions

305355


2/11
Allg_10e
General Information on Shaft Seal
Seal housing: 2-piece horizontally divided version
Seal design: Seal gas - loading
The shaft seal is a gliding carbon ring seal with movably-mounted sealing ring.
Depending on the application, the sealing rings are manufactured from a special carbon or
special PTFE compound.
The sealing rings consist of three pieces and are held together with a tension spring. In
accordance with the operating conditions, the medium-side sealing ring is designed as per the
WD200 series (3-part radially cut) and the bearing-side sealing rings as per the WD500 series
(3-part with overlapping tenons). The installation position is shown in the assembly drawing.
The sealing rings of the WD500 series are produced in an "adjustable version, i.e. with
overlapping tenons which form gas-tight joints. The surrounding hose spring and the seal gas
pressure bring the sealing ring segments into constant with the shaft/shaft sleeve. The
"adjustable version" of the sealing rings ensures an extremely high degree of sealing even
under a wide range of operating temperatures.
The shaft seal is designed for operation with seal gas.
With its radial clearance to the shaft/shaft sleeve, the sealing ring of the WD200 series ensures
a flow of the seal gas toward the medium, reliably preventing the entrance of medium/impurities
into the shaft seal.
To protect the shaft/shaft sleeve from damage, a wear guard 60 HRC must be provided.
The horizontally sectioned housing simplifies assembly of the shaft seal and the sealing
elements.
Read the installation instructions carefully. Should problems or questions nevertheless arise, we
are always available to help you with qualified advice and assembly tips.
00H0014e
Caution
Incorrect or imprecise design - related data may result in failure of the seals and
significant damage in the area around the seal.
If shaft seals are handled improperly during installation, considerable danger may result
during later operation because of high pressures and temperatures.
The seal must be mounted, operated and serviced in accordance with the relevant
accident prevention regulations.
If deep scratches, cracks or chipping is detected on the seal components during
installation, the parts must be replaced immediately.
305355


3/11
Einb_1e
Installation Instructions on the shaft seal
1 Preliminary Note
These installation instructions describe exclusively the assembly and dismantling of the
shaft seal according to the attached assembly drawing.
Read the installation directions carefully. If problems or questions should arise, the seal
manufacturer can be contacted for qualified advice and mounting tips.
00H0011e
Caution
The seal must be mounted, operated and serviced in accordance with the relevant
accident prevention regulations.
If shaft seals are handled improperly during installation, considerable danger may
result during later operation.
If deep scratches, cracks or chipping is detected on the seal components during
installation, the parts must be replaced immediately.

VoMo_7e
2 Preparing for Assembly
2.1 Also required for assembly:
Screwdrivers, wrenches and screws/bolts provided by customer
Intermediate layers (e.g. wood disks)
Lint-free cloths
If permissible, suitable lubricant for assembling shaft sleeve
Non-hardening medium and temperature-resistant sealing paste
If required, pre-heating device for heating up shaft sleeve
Suitable measuring tool
Suitable cleaning agent for cleaning the part joints (the part joints are coated with a
sealing paste during factory assembly. This paste must be replaced each time the shaft
seal in opened).
Assembly drawing
00H0001e
Note
Ensure that surrounding area is clean, dust - free and chip - free.
2.2 Unpack the shaft seal and lay the end face on a level, lint-free surface. Then unpack the
shaft sleeve and lay on the surface so that it cannot roll away.
305355


4/11
2.3 Remove part joint screws and carefully press apart the two housing halves. To avoid
damaging the part joints when pressing apart with a screwdriver, milled points are provided
in the part joints.
00H0022e
Note
Tilting or lateral movements of the parting surfaces during dismantling may result in
breakage of the seal rings.
2.4 Remove all sealing rings.
2.5 Degrease and clean the part joints with the cleaning agent.
2.6 Check whether the straight pins are mounted in the lower housing half. If not, insert them
so that they are not lost when mounting he upper housing half.
The "lower housing half" is the half which contains the thread for the part joint
screws.
2.7 Clearly arrange all parts of the shaft seal on a clean surface.
2.8 Check shaft as per the specifications.
MoH_3e
3 Assembling Shaft Sleeve
3.1 If permissible, coat shaft and shaft sleeve hole with a suitable lubricant.
3.2 Insert any existing O-ring(s), heat the shaft sleeve if necessary and quickly push onto the
shaft up to the installation position without tilting.
3.3 Check concentricity and installation position of shaft sleeve again.
3.4 If required, screw on the shaft sleeve as shown in the assembly drawing.
3.5 Clean the shaft sleeve free of grease and dust.
MoWD_9e
4 Assembling Shaft Seal
4.1 Position O-ring for the housing (if present).
4.2 Lay the lower housing half with the housing hole around the shaft from below. Lay
intermediate layers between the contact surface and the sealing flange and screw on
loosely with the mounting screws provided by the customer.
00H0036e
Note
When doing so, make sure that there is sufficient space for assembling the upper
housing half.
The "lower housing half" is the half which contains the thread for the part joint lie
screws.
Check again whether the straight pins are mounted in this half.
00H0029e
The spacing pieces serve only to provide slightly more space for movement for the upper
housing half during fitting and aligning.
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5/11
4.3 Open the tension spring of the first sealing ring and lay aside the segments, tension spring
and detent nearby. Figure 1 shows a complete sealing ring of the WD200 series.
Figure 1 (sealing ring, WD200 series, 3-piece, radially cut)

Upper housing half
Segment marking
Tensioning spring
Part joint
Detent groove
Detent Lower housing half
Sealing ring segment
4.4 Push the tension spring through the first sealing ring groove of the housing, grasp on the
other side, thread on the detent and close the spring lock.
4.5 Place the first sealing ring segment on the shaft and allow the spring to snap into the
groove provided in the sealing ring. Rotate the spring and segment on the shaft until the
segment disappears into the housing groove. Place the next segments on the shaft in the
same manner and allow the spring to snap into place. The detent must engage in the
locking groove provided in sealing ring. The sealing ring must surround the shaft in the
same position as indicated by the segment marking.
00H0060e
Note
Before opening the tension spring, the detent groove should be marked (e.g. with
white chalk), or memorize the segment with the groove for assembly later. (The
detent groove is in the segment with the longer tenon).
4.6 Open the tension spring of the next sealing ring and lay aside the segments, tension spring
and detent nearby. Figure 2 shows the entire sealing ring of the WD500 series.
305355


6/11
Figure 2 (sealing ring, WD500 series, 3-piece, with overlapping tenons)

Upper housing half
Sealing ring tenon
Tension spring
Part joint
Detent groove
Detent
Lower housing half
Sealing ring segment
4.7 Push the tension spring through the next sealing ring groove of the housing, grasp on the
other side, thread on the detent and close the spring lock.
00H0035e
Note
The sealing rings with overlapping tenons of the WD500 series must be installed in
dependence on the pressure direction. The position of the sealing ring tenons is
shown in the assembly drawing.
All information contained in the assembly drawing must be observed.
4.8 Place the first sealing ring segment on the shaft and allow the spring to snap into the
groove provided in the sealing ring. Rotate the spring and segment on the shaft until the
segment disappears into the housing groove. Place the next segments on the shaft in the
same manner and allow the spring to snap into place. The detent must engage in the
locking groove provided in sealing ring.
4.9 Check the position of the sealing ring tenons against the assembly drawing again.
305355


7/11
4.10 When all sealing rings have been mounted in the same manner, they must be rotated on
the shaft in accordance with the rotating direction of the shaft so that the detent disk
engages in the detent groove of the lower housing half (installation dependent on the
rotating direction).
00H0018d
Note
The detent groove is located on both sides in the lower housing half. When
assembling the sealing rings, watch the position of the detent disk dependent on
the rotating direction.

clockwise counter-clockwise
Sealing
ring
Detent

clockwise
Sealing
ring
counter-clockwise
Detent
4.11 Apply a thin coating of non-hardening, medium and temperature-resistant sealing paste to
the upper housing half.
00H0030e
Note
Too much sealing paste may be pressed into the seal ring grooves when the housing
halves are bolted together and result in failure of the seal.
305355


8/11
4.12 Align the sealing rings with the housing grooves and carefully lay on the upper housing half.
00H0022e
Note
4.13 Screw together both housing halves with part joint screws.
4.14 Lay O-ring (if present) in the O-ring groove of the housing. If necessary, the O-ring must be
fixed in place with a suitable grease and secured against falling out.
4.15 Remove intermediate layers, align the seal to the shaft and screw in place diagonally with
the mounting screws.
4.16 After removing the assembly aids and connecting all lines, the shaft seal is ready for
operation.

ii_1e
Inspection and Repair
During the anual machine inspection and when performing repair work, the shaft seal must be
dismantled into ist individual parts.
DeWD_1e
5 Dismantling shaft seal
5.1 The following is also required for dismantling:
Screwdrivers and wrenches
Intermediate layers (e.g. wooden spacers)
Possibly a puller for shaft sleeve
Assembly drawing
5.2 The following is also required for servicing:
Possibly replacement sealing rings and shaft sleeve (or 1 set of wearing parts as per
assembly drawing)
Suitable cleaning agent and fluff - free rags
Non-hardening, medium and temperature-resistant sealing paste
Assembly drawing
00H0024e
Caution
During work on the seal, the system must be secured to prevent starting.
305355


9/11
5.3 Separate all connections from the seal.
5.4 Loose the mounting screws, place intermediate layers between the lower housing half and
the contact surface and slightly tighten the lower mounting screws again. Remove O-ring (if
present), upper mounting screws and the part joint screws.
00H0036e
Note
When doing so, make sure that there is sufficient space for assembling the upper
housing half.
5.5 Carefully lift off the upper housing half upward. To avoid damaging the part joint when
pressing off with a screwdriver, milled points are provided in the part joint.
00H0022e
Note
5.6 On the sealing rings with overlapping tenons of the WD500 series, the joint gap clearance
must be checked. The joint gap clearance is determined by rotating the sealing ring
segments on the shaft until two joint gaps are located together. Now the remaining joint gap
clearance can be measured at the third joint. If the joint gap clearance is too low for the
corresponding operating time, the entire "sealing ring set" must be replaced.
5.7 Lift tension spring and remove the first and second sealing ring segment. Turn the spring
on the shaft until the next segment can be grasped. Remove the segment, hook open the
spring lock and pull out of the housing groove with the detent.
5.8 Remove all sealing rings as described.
5.9 Inspect the seal components for damage.
5.10 Clean reusable parts and replace the defective parts with new ones.
00H0012e
Should the sensitive carbon sealing rings be damaged, the entire sealing ring set must be
replaced.
5.11 The seal can now be completely assembled and installed as described in Sections 4.2 to
4.16.
00H0006e
If you should be uncertain as regards how to assess usability of the parts, we as the seal
manufacturer can give you qualified advice.
305355


10/11
DeH_3e
6 Dismantling Shaft Sleeve
Inspect the running surface of the shaft sleeve for damage. If the running surface is in good
condition, the seal can be reassembled (see Sections 4.2 to 4.16). A damaged shaft sleeve
must be replaced.
00H0003e
Note
Even minor running grooves and/or scratches can considerably increase the leakage
of the shaft seal.
6.1 First the entire housing must be dismantled.
6.2 Remove any detent or mounting screw(s).
6.3 Pull the shaft sleeve off the shaft with a puller. If the sleeve cannot be pulled, the shaft
sleeve must be split without damaging the shaft.
6.4 Mounting the new shaft sleeve is described in Chapter 3. Then the seal is mounted as per
Chapter 4.
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11/11
BW_8e
Operating and Maintenance Instructions
for Shaft Seal
00H0026e
Caution
Not only the service life of the shaft seal but also the safely of persons and the
machine depend heavily on the compliance with the pressures, temperatures,
speeds, etc. For which the seal was designed.
The shaft seal is designed for operation with seal media. This means it must be ensured
that the seal media pressure is always higher than the medium pressure. An equally high
or insufficient seal media pressure would allow the medium to exit and the solid particles to
enter the seal, resulting in increased wear and eventually seal failure. Excessive seal
media pressure presses the sealing rings of the WD500 series more firmly onto the shaft
than necessary and increases the operating temperature and wear.
Any existing flushing must be operating in accordance with the operating instructions for
centrifuges.
00H0037e
Note
To control the sealing air pressure, we recommend the use of a pressure regulator in
the case of constant operating pressures. In the case of varying operating
pressures, a differetial pressure regulator should be installed.
All components in the sealing air system must be designed for increased seal use
and wear during the running-phase and with respect to marginal wear.
During the annual machine inspection the shaft seal must be checked for damage (e.g.
corrosion) and cleaned. In the case of damaged sealing rings (scratches, cracks, chips),
the entire "sealing ring set" must be replaced. When new the sealing rings have a joint gap
clearance of 3 x 2 =6 mm at the level of the running diameter. If the joint gap clearance is
too small for the operating time of the sealing rings, the entire "sealing ring set" must be
replaced.
Example:
Operating time: 1 year; measured joint gap clearance: >=3mm; i.e. the sealing rings
can remain in use until the next annual inspection.
Operating time: 1 year; measured joint gap clearance: < 3mm; i.e. the sealing rings
should be replaced.
The shaft sleeve may not have scratches or run-in grooves that can be felt in the area of
the sealing rings. As O-rings are also considered wearing parts, they should also be
replaced during the inspection.
It is advisable to monitor the seal media consumption/leakage regularly or continuously. A
clear increase in the values means maintenance and/or servicing of the seal is due.
To prevent longer waiting times when maintenance or servicing is due, it is advisable to
keep a set of wearing parts in stock.
305355
F
RU
GB
D
Druckwchter
Druckbegrenzer
Pressure Switch
Pressure Limiter
Pressostates
Limiteurs de pression

Montage- und Bedienungsanleitung
Assembly- and Operating Instructions
Instructions de montage et de service

f
Grundtypen Zusatzfunktionen
Basic models Additional functions
Types de base Fonctions supplmentaires

DCM 203
DNM 205
DNS 206
VCM , VNM 307
VNS 213
DDCM 217, 513, EEx-d, EEx-i
305571
2
D
Typenschlssel
Grundausfhrung Ausfhrung mit Zusatzfunktion Ex-Ausfhrung
ABC XXX ABC XXX-YYY Ex-ABC XXX
ABC Kennzeichnung fr Baureihe durch Buchstabenkombination
XXX Kennzeichnung fr Druckbereich
YYY Kennzeichnung fr Zusatzfunktion
Ex- Kennzeichnung fr Ex-Ausfhrung
305571
3
Ausfhrung der Schaltgehuse
ABC XXX
Steckeranschlugehuse (200)
(Steckanschlu nach DIN 43 650)
ABC XXX-2
k
ABC XXX-3
Klemmenanschlugehuse (300 oder 500)
ABC XXX-5
k
Ex-ABC Ex-Schaltgert (700)
Wichtiger Hinweis:
Die Druckschalter sind Przisionsgerte, die im Werk eingestellt und justiert werden. Das Gert
deshalb nicht ffnen, die verlackten Justierschrauben nicht verstellen. Die Schaltpunkte wrden
sich verndern neue Justierung wre erforderlich.
305571
4
Inhaltsbersicht Typenkennzeichnung
1. Grundausfhrung ABC XXX
1.1 Technische Daten
1.2 Elektrischer Anschlu
1.3 Druckanschlu
1.4 Einstellen des Schaltdrucks
1.5 Elektrische Verriegelung im Schaltschrank
2. Druckwchter mit einstellbarer Schaltdifferenz ABC XXX-203
3. Druckbegrenzer mit mechanischer Verriegelung ABC XXX-205
des Schaltzustands ABC XXX-206
(Wiedereinschaltsperre)
4. Druckwchter mit vergoldeten Kontakten ABC XXX-213
5. Zweistufige Druckschalter ABC XXX-307
ABC XXX-217
6. Druckwchter in eigensicheren Steuerstromkreisen (EEx-i) ABC XXX-513
7. Druckwchter in eigensicheren Steuerstromkreisen ABC XXX-574-577
mit Leitungsbruch- und Kurzschluberwachung (EEx-i)
8. Druckwchter in Ex-Ausfhrung Ex-ABC XXX
305571
5
1. Grundausstattung der Druckwchter
Kapitel 1 beschreibt die Grundausstattung und die Montage der Druckwchter (ohne jegliche
Zusatzfunktion). Varianten und Zusatzfunktionen behandeln die Kapitel 27.
1.1 Technische Daten (gilt nicht fr Ex-Ausfhrungen)
Schalter
Einpolig umschaltend
Schaltleistung
8 (5) A, 250 V AC
Einbaulage
Senkrecht und waagrecht
Max. Umgebungstemperatur
25 bis 70C
Bei Umgebungstemperaturen unter 0C ist da-
fr zu sorgen, da im Sensor und im Schaltge-
rt kein Kondenswasser entstehen kann.
Max. Mediumstemperatur
70 C, hhere Mediumstemperaturen sind
mglich, wenn durch geeignete Manahmen
(z. B. Wassersackrohr) obige Grenzwerte am
Schaltgert nicht berschritten werden.
Schaltdifferenz
Werte siehe Datenblatt
Druckanschlu
Auengewinde G|A (Manometeranschlu)
nach DIN 16 288 und Innengewinde G[ nach
ISO 228, Teil 1. (Fr Gasanwendungen ab 4 bar
nur Flachdichtungen verwenden. Dichtung im
Gewinde ist nur bis 4 bar zulssig).
Schaltgert
Stabiles Gehuse aus seewasserbestndigem
Aluminium-Druckgu mit Steckanschlu (200)
oder Klemmenanschlu (300).
Schutzart nach EN 60 529
IP 54 (Gehuse 200
IP 65 (Gehuse 300)
Werkstoffe
Siehe Datenblatt
305571
6
Anschluplan
Bei steigendem Druck:
31 ffnet, 32 schliet
Bei fallendem Druck:
32 ffnet, 31 schliet
Verdrahtung
Die Verdrahtung erfolgt am Winkelstecker.
Der Kabelausgang ist in jeweils 4 um 90
gegeneinander versetzte Positionen mglich.
1. Schraube herausziehen
2. Den Schraubendreher in den Schlitz
einfhren und nach unten drcken.
Bei Klemmenanschlugehuse (300 und 500)
ist die Klemmleiste nach Abnahme des
Deckels zugnglich.
Achtung: Spannung abschalten.
1.3 Druckanschlu
1.31 Druckschalter
Montage: Direkt auf die Rohrleitung (Manome-
teranschlu G|) oder mit 2 Schrauben (4 mm)
an einer ebenen Flche. Anziehen nur am
Sechskant des Druckorgans, Gehuse oder
Stecker nie als Hebelarm benutzen.
Auengewinde G|HH
(Manometeranschlu)
Bei Verwendung von
Flachdichtungen Zentrier-
schraube eindrehen
(Tiefe A ca. 0,3 0,5 mm).
Innengewinde G[HH
Bei Gasanwendung:
Dichtung im Gewinde nur bis
4 bar. Bei hherem Druck
Flachdichtung verwenden.
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7
Die Einstellung des Schaltdrucks erfolgt an
der Stellspindel. Vor Verstellung ist der ober-
halb der Skala liegende Sicherungsstift um
max. 2 Umdrehungen zu lsen und nach der
Einstellung wieder anzuziehen.
Der Skalenwert entspricht dem oberen Schalt-
punkt (bei steigendem Druck). Der untere
Schaltpunkt (bei fallendem Druck) ist um die
Schaltdifferenz niedriger. Die Skala dient als
Richtwertskala, fr genaue Einstellungen ist
ein Manometer erforderlich.
Bei Klemmenanschlugehusen ist die Ein-
stellschraube nach Abnahme des Deckels
zugnglich.
Achtung: Spannung abschalten.
1.32 Differenzdruckschalter
Druckanschlu: 2 x G[ innen. Der hohe und
niedrige Druck sind entsprechend der Kenn-
zeichnung am Gert anzuschlieen.
Vertauschen der Druckanschlsse fhrt zu
Fehlfunktionen.
1.4 Einstellen des Schaltdrucks
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8
1.5 Externe elektrische Verriegelung im Schaltschrank
Ein Druckwchter kann auch als Begrenzer eingesetzt werden, wenn eine elektrische Verriegelung
nachgeschaltet ist. Nachfolgend zwei Schaltungsvorschlge.
Maximaldruckbegrenzung Minimaldruckbegrenzung
DW=Druckwchter
T1 =STOP
T2 =START
S=Signal (nach Bedarf)
K1 =Relais mit
Selbsthaltung
Sicherheits-
stromkreis
DW=Druckwchter
T1 =STOP
T2 =START
S=Signal (nach Bedarf)
K1 =Relais mit
Selbsthaltung
Sicherheits-
stromkreis
305571
2. Druckwchter mit einstellbarer Schaltdifferenz V-203
2.1 Technische Daten wie 1.1
2.2 Elektrischer Anschlu wie 1.2
2.3 Druckanschlu wie 1.3
2.4 Einstellung
Fr die Einstellung des Schaltdrucks und der Schaltdifferenz steht je eine Einstellspindel zur Ver-
fgung. Beide Spindeln sind zentrisch angeordnet. Die uere Spindel mit grerem Durchmesser
beeinflut den unteren Schaltpunkt, mit der kleinen innenliegenden Madenschraube wird die
Schaltdifferenz und damit der obere Schaltpunkt verndert.
Die Wirkungsrichtung ist durch die
Pfeilrichtung angegeben.
Reihenfolge bei der Einstellung
a) Unteren Schaltpunkt (bei fallendem Druck) an
groer Spindel nach Skala oder Manometer
einstellen
b) Mit kleiner innenliegender Schraube Schalt-
differenz (xd) und damit oberen Schaltpunkt
einstellen (bei steigendem Druck).
Bei nderung der Schaltdifferenz bleibt der
untere Abschaltpunkt unverndert, der obere
Schaltpunkt wird um die Schaltdifferenz
verschoben
RSP=SP+xd
9
305571
3. Druckbegrenzer mit mechanischer Verriegelung
des Schaltzustands
Maximaldruckbegrenzer ABC-205
Minimaldruckbegrenzer ABC-206
Anstelle des Mikroschalters mit selbstttiger Rckstellung, ist in den
Begrenzern ein bistabiler Mikrioschalter eingebaut.
Erreicht der Druck den an der Skala eingestellten Wert, schaltet der Mikro-
schalter um und bleibt in dieser Stellung. Die Sperre ist durch Eindrcken
der Entriegelungstaste (an der Skalenseite des Schaltgerts durch roten
Punkt gekennzeichnet) wieder zu lsen. Die Entriegelung kann erst dann erfolgen, wenn der Druck
um einen bestimmten Betrag abgesenkt wurde. Je nach Ausfhrung kann die Verriegelung bei
steigendem Wert ABC-205 oder bei fallendem Wert ABC206 wirksam sein.
3.2.1 Maximaldruckbegrenzung
Umschaltung und Verriegelung bei steigendem Druck.
Zusatzfunktion (205). Anschlu Steuerstromkreis an Klemme 1 und 3.
3.2.2 Minimaldruckbegrenzung
Umschaltung und Verriegelung bei fallendem Druck.
Zusatzfunktion (206). Anschlu Steuerstromkreis an Klemme 2 und 3.
ABC-205
ABC-206
10
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11
3.4 Einstellung wie 1.4
Bitte beachten:
Bei Maximaldruckbegrenzern (205) entspricht der Skalenwert dem oberen Schaltpunkt, bei Minimal-
druckbegrenzern (206) dem unteren Schaltpunkt.
4. Druckwchter mit vergoldeten Kontakten -213
Vergoldete Kontakte werden ausschlielich im Niederspannungsbereich angewendet, um die
bergangswiderstnde an den Kontakten gering zu halten.
Schaltleistung max. 24 V DC
max. 100 mA
min. 5 V DC
min. 2 mA
Bei hheren Spannungen und Strmen wird die Goldschicht an den Kontakten beschdigt.
Alle brigen Daten entsprechen der Grundausstattung.
305571
12
5. Zweistufige Druckschalter 307, 217
Zur Grundausstattung der zweistufigen Druck-
schalter gehrt ein Schaltgert mit 2 Mikro-
schaltern, jeweils einpolig umschaltend.
Mit Schalter I wird der niedrige, mit Schalter II
der hhere Druck berwacht. Es ist zu beach-
ten, da die Schaltdifferenzen der einzelnen
Mikroschalter aufgrund der Bauteiltoleranzen
nicht exakt gleich sein knnen.
Der Schaltabstand (Intervall) der beiden Mikro-
schalter ist der Abstand (in bar oder mbar)
zwischen den Schaltpunkten der beiden Mikro-
schalter.
Fr alle Ausfhrungen gilt:
Bei Vernderungen der Stellspindel zur
Schaltpunkteinstellung verndert sich der
Schaltabstand nicht, die Schaltpunkte werden
parallel verschoben.
Die Schaltdifferenz, d. h. die Hysterese der
einzelnen Mikroschalter entspricht den in der
Typenbersicht genannten Schaltdifferenzen
der jeweiligen Grundausfhrung.
Bei zweistufigen Druckschaltern ist die
Schaltdifferenz der einzelnen Mikroschalter
nicht einstellbar.
5.1 Typen 307
Der Schaltabstand zwischen den beiden
Schaltern ist nach Kundenangaben fest einge-
stellt. Bei steigendem Druck wird zuerst der
Schalter 1
(Klemmen 13)
und danach
Schalter II
(Klemmen 46)
bettigt.
Die Schaltpunkte knnen an der Stellspindel
parallel verschoben werden.
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13
5.2 Typen 217
Die beiden Mikroschalter sind intern nach
einem vorgegebenen Schaltschema verbunden
(Aufkleber neben dem Steckanschlu). Der
Schaltabstand ist nach Kundenangaben fest
eingestellt. Die Schaltpunkte knnen an der
Stellspindel parallel verschoben werden, je-
doch ist der Schaltabstand zwischen den bei-
den Mikroschaltern in vorgegebenen Grenzen
einstellbar.
Rechtsdrehung am
Stellrad I niedriger
Schaltpunkt bei
Mikroschalter I
Linksdrehung am
Stellrad II hherer
Schaltpunkt bei
Mikroschalter II
Die Stellrder I und II haben einen internen
Anschlag, damit die Mikroschalter nicht ber
den wirksamen Bereich hinaus verstellt
werden knnen.
Anschluplne 217
Bitte unbedingt Aufkleber neben dem Steck-
anschlu am Druckschalter beachten.
305571
5.3 Einstellung
Die Addition der Verstellung an den Stellrdern I und II ergibt den Schaltabstand zwischen den
beiden Mikroschaltern. nderungen an der Sollwertspindel beeinflussen den Schaltabstand nicht,
der Schaltabstand bleibt ber den gesamten Einstellbereich der Spindel konstant, die beiden
Schaltpunkte werden parallel nach unten oder oben verschoben.
1. Stellrad I nach links drehen bis Anschlag.
Stellrad II nach rechts drehen bis Anschlag.
Damit ist der kleinste Schaltabstand eingestellt.
2. Sollwertspindel nach Skala auf einen Wert einstellen, der ungefhr in der Mitte zwischen dem
gewnschten oberen und dem gewnschten unteren Schaltpunkt liegt (S).
3. Bei anliegendem Druck mit Stellrad I den unteren Schaltpunkt tiefer einstellen (Abstand a1).
4. Sinngem wie Punkt 3 mit Stellrad II oberen Stellpunkt hher einstellen (Abstand a2).
5. Falls der gewnschte obere und untere Schaltpunkt nicht erreicht werden kann, Sollwertspindel
in die jeweilige Richtung nachstellen und die Einstellung nach Punkt 3 und 4 wiederholen (S).
Beispiel:
Gewnschte Schaltpunkte: 3,8 und 3,2 bar
Einstellung nach Punkt 2: S = 3,5 bar
3. Unteren Schaltpunkt (im Beispiel 3,2 bar) an
Stellrad I einstellen (nach rechts drehen).
4. Oberen Schaltpunkt (im Beispiel 3,8 bar) an
Stellrad II einstellen (nach links drehen).
14
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15
6. Druckwchter in eigensicheren Steuerstromkreisen (EEx-i) 513
Die Klemmen und Kabeleinfhrungen sind in der bei EEx-i-Stromkreisen blichen blauen Farbe
ausgefhrt.
Die Zusatzfunktion 513 wird zusammen mit einem geeigneten Trennschaltverstrker, z. B. Ex 011,
verwendet.
Anschluplan
Gilt fr Maximaldruck-
berwachung.
Bei Minimaldruckberwachung
sind die Klemmen 3 und 2 des
Druckschalters an die Klemmen 1
und 2 des Trennschaltverstrkers
anzuschlieen.
Druckwchter mit der
Zusatzfunktion 213 werden in
gleicher Weise an den Trennschalt-
verstrker Ex 011 angeschlossen.
Ex-Zone 1 oder 2, 21 oder 22
Ex-freie Zone
305571
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7. Druckwchter / Druckbegrenzer in eigensicheren Steuerstromkreisen
mit Leitungsbruch- und Kurzschluberwachung (EEx-i)
Die Druckwchter entsprechen in allen
technischen Daten der Type DCM.
Zustzlich ist eine Widerstandskombi-
nation im Schaltgert vorhanden, die
zusammen mit dem Trennschaltverstr-
ker EX 041 die elektrischen Leitungen
zwischen Trennschaltverstrker und
Druckwchter auf Leitungsbruch und
Kurzschlu berwacht. Bei Leitungs-
bruch oder Kurzschlu schaltet das
System nach der sicheren Seite ab. Bei
Auswahl- und Anschlu ist streng zu
unterscheiden zwischen Maximaldruck-
und Minimaldruckberwachung, sowie
Wchter- und Begrenzerfunktion.
Ex-Zone 1 oder 2, 21 oder 22
Ex-freie Zone
305571
17
8. Druckwchter in EEx-d-Ausfhrung (Ex-)
Druckwchter in Ex-Ausfhrung knnen nur in der von der PTB geprften Bauform geliefert
werden. Varianten und Zusatzfunktionen sind grundstzlich nicht mglich.
8.1 Technische Daten der Ex-Schaltgerte
Zndschutzart
EX II 2 G D EEx de IIC T6 IP65 T80C
PTB-Zulassung
PTB 02 ATEX 1121
Ex-Zone
Geeignet fr Zone 1 und 2, 21 und 22
Schutzart
IP 65 bei senkrechter Einbaulage
Umgebungstemperatur
15 bis +60 C
Max. Temperatur am Schaltgert
60 C
Max. Mediumstemperatur bei Druckschaltern
60 C. Hhere Mediumstemperaturen sind
mglich, wenn durch geeignete Manahmen
(z. B. Wassersackrohr) sichergestellt ist, da die
o. g. Grenzwerte am Schaltgert nicht ber-
schritten werden.
Kabeleinfhrung
M16x 1,5
Schaltdifferenz
Nicht einstellbar, ca.-Werte siehe Datenblatt.
Einbaulage
senkrecht nach oben
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18
8.2 Elektrische Daten
Anschluplan: Die Klemmleiste ist nach Abnahme des Klemmenkastendeckels und der
Klemmenschutzkappe zugnglich. Nach Anschlu der Zuleitungen Klemmenschutzkappe
unbedingt wieder anbringen.
Bei steigendem Druck wird die 3 1 unterbrochen und
32 geschlossen.
Schaltelement: Mikroschalter, einpolig umschaltend. Bei Verwendung als Begrenzer mit
Wiedereinschaltsperre mu die Verriegelung durch eine externe Schaltung erfolgen.
Die Schaltung mu DIN 57 116, Abschnitt 8.7 entsprechen.
Schutzleiteranschlu: Nach Abnahme des Klemmenkastendeckels zugnglich.
Erdungsanschlu/ Potentialausgleich:
Auen am Schaltgert. Max. Kabelquerschnitt 4 mm
2
.
Schaltleistung:
3 A 250 V AC, 2 A 250 V AC (induktiv)
0,03 A 250 V DC, 3 A 24 V DC
305571
19
8.4 Schaltpunkteinstellung
Der Schaltpunkt ist im Rahmen der im Daten-
blatt angegebenen Bereiche an der Stellspindel
mit einem Schraubendreher einstellbar. Dazu
ist der Klemmenkastendeckel abzunehmen
(4 Innensechskant-Schrauben M4 lsen).
Zuvor ist die kleine Feststellschraube an der
Frontseite (oberhalb der Skala) zu lsen und
nach der Schaltpunkteinstellung wieder anzu-
ziehen. Rechtsdrehung an der Stellspindel
bedeutet niedriger Schaltpunkt, Linksdrehung
bedeutet hheren Schaltpunkt. Die Skala dient
als Richtwertskala, fr genaue Einstellungen ist
ein Manometer erforderlich.
8.5 Serien-Nummer
Alle Schaltgerte und die dazugehrigen
Klemmenkastendeckel sind mit der Typenbe-
zeichnung und einer Serien-Nummer gekenn-
zeichnet. Bei der Montage ist darauf zu achten,
da die Klemmenkastendeckel nicht vertauscht
werden.
Wichtig
Bei der Montage und Inbetriebnahme der Ex-
Schaltgerte sind die anerkannten Regeln der
Technik und die Richtlinien fr Installationen in
Ex-Bereichen zu beachten.
1 Potentialausgleich
2 Klemmenschutzkappe (abnehmbar)
3 Anschluklemmen
4 Kabeleinfhrung M16 x 1,5
5 Schaltpunkteinstellung
6 Feststellschraube fr Einstellspindel
7 Schutzleiteranschlu
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GB
Pressure Switch, Pressure Limiter
Assembly- and Operating Instructions f
Basic models Additional functions
DCM 203
DNM 205
DNS 206
VCM , VNM 307
VNS 213
DDCM 217
513
EEx-d
EEx-i
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Type code
Basic version Version with additional function Ex version
ABC Identification for series
XXX Identification for pressure range
YYY Identification for additional function
Ex- Identification for Ex version
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Important Note:
Pressure switches are precision instruments, set and adjusted at the factory. Do not open the
device or reset the varnished adjustment screw. This would alter the switching points and
resetting would be necessary.
23
Switching Housings
ABC XXX
Plug connection housing (200)
(Plug connection to DIN 43 650)
ABC XXX-2
k
ABC XXX-3
Terminal connection housing (300 oder 500)
ABC XXX-5
k
Ex-ABC Ex-housing (700)
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Contents Type identification
1. Basic version ABC XXX
1.1 Technical Data
1.2 Electrical connection
1.3 Pressure connection
1.4 Setting the switching pressure
1.5 Electrical interlock in the switchgear cabinet
2. Pressure monitors with adjustable switching difference ABC XXX-203
3. Pressure limiters with mechanical interlock of the ABC XXX-205
switching state ABC XXX-206
(restart lockout)
4. Pressure monitors with gold plated contacts ABC XXX-213
5. Two-stage pressure switch ABC XXX-307
ABC XXX-217
6. Pressure monitors in intrinsically safe control circuits (EEx-i) ABC XXX-513
7. Maximum pressure monitors in intrinsically safe control ABC XXX-574-577
circuits with open-circuit and short-circuit monitoring (EEx-i)
8. Pressure monitors in Ex version Ex-ABC XXX
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1. Basic equipment of the pressure monitors
Chapter 1 describes the basic equipment and the installation of the pressure monitors (without any
additional function). Chapters 27 deal with versions and additional functions.
1.1 Technical Data (not for Ex versions)
Switch
Single-pole changeover
Switching capacity
8 (5) A, 250 V AC
Installation position
Vertical and horizontal
Max. ambient temperature
25 to 70 C
Max. medium temperature
70 C, higher medium temperatures are possi-
ble if the above limiting values at the switching
device are not exceeded by suitable measures
(e. g. water pocket tube). At ambient tempera-
tures below 0C, ensure that no water conden-
sation can arise in the sensor and in the
switching device.
Switching difference
For values see data sheet
Pressure connection
External thread G|A (pressure gauge connec-
tion) according to DIN 16 288 and internal
thread G[ according to ISO 228, Part 1.
(For gas applications internal tread permissible
only up to 4 bar. Use flat gasket ring for
pressure > 4 bar.
Switching device
Sturdy housing made of sea-water resistant
aluminium die casting with plug connection
(200) or terminal connection (300).
Degree of protection acc. to EN 60 529
IP 54 (housing 200)
IP 54 (housing 300)
Materials
see data-sheet
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1.2 Electrical wiring
Connection layout
With rising pressure:
31 opens, 32 closes
With falling pressure:
32 opens, 31closes
Wiring
Wiring is on the angled plug. The cable outlet
can be in any of 4 positions, which are at 90 in
relation to each other.
1. Remove screw
2. Insert the screwdriver in the slot
and press downwards.
On devices with terminal connection housing
(300 and 500) the terminal board is available
after removing the terminal box lid.
Caution: Switch off voltage.
1.3 Pressure connection
1.31 Pressure switch
Installation: Directly on the pipeline (pressure
gauge connection G|) or with 2 screws
(4 mm) on a level surface. Tighten only on the
hexagonal of the pressure organ, never use
the housing or plug as a lever arm.
External thread G|HH
(Pressure gauge connection)
When using flat seals, turn in
the centering screw
(depth A approx. 0,30,5 mm).
Internal thread G[HH
In gas applications internal
thread only up to 4 bar
permissible. Use flat gasket
ring for pressure > 4 bar.
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1.4 Setting the switching pressure
The switching pressure is set using the setting
spindle. Before setting loosen the setscrew
located above the scale by approx. 2 turns
and tighten it again after setting.
The scale value corresponds to the upper
switching point (for rising pressure). The lower
switching point (for falling pressure) is lower by
the switching difference. The scale serves as
estimated value scale, a pressure gauge is
required for accurate settings.
On terminal connection housings the setting
screw is available after removing the cover.
Caution: Switch off voltage.
1.32 Differential pressure switch
Pressure connection: 2 x G[HH internal thread.
Connect the high and the low pressure
according marks. A mistake of the pressure
connections may lead to malfunctioning.
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1.5 External electrical interlock in the switchgear cabinet
A pressure monitor can also be used as limiter if an electrical interlock is connected in series.
Examples:
Maximal pressure limitation Minimal pressure limitation
DW=pressure monitor
T1 =STOP
T2 =START
S=signal (as required)
K1 =relay with self-hold
Safety
circuit
DW=pressure monitor
T1 =STOP
T2 =START
S=signal (as required)
K1 =relay with self-hold
Safety
circuit
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2. Pressure monitors with adjustable switching difference V-203
2.1 Technical data as for 1.1
2.2 Electrical connection as for 1.2
2.3 Pressure connection as for 1.3
2.4 Setting
On spindle each is available for setting the switch pressure and the switching difference.
Both spindles are arranged concentrically. The outer spindle with larger diameter influences the
upper switching point, the switching difference and thus the lower switching point, is changed
with the small grub screw located internally.
The action direction is indicated by
the arrow direction.
Setting sequence
a) Lower switching (with decreasing pressure),
with outer spindle, according to scale or pressure
gauge
b) Switching difference (with increasing pressure),
with small, internal grup screw, results in lower
switching point.
When the switching difference is changed, the
lower switch-off point remains unchanged, the
upper switching point is shifted by the
switching difference.
RSP=SP xd
SP=switching point RSP=switch back point
xd=switching differences (hysteresis)
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3. Pressure limiters with mechanical interlock of the
switching state
Maximum pressure limiter ABC-205
Minimum pressure limiter ABC-206
Instead of the microswitch with automatic reset, a bistable microswitch is
installed in the limiters.
When the pressure reaches the value set on the scale, the microswitch
switches over and remains in this position. The catch can be relased by
pressing in the unlocking button (marked on the scale side of the switching
device by a red dot). The limiter can not be unlocked until the pressure has
decreased by a certain amount or, in the case of interlocking at the lower switching point, is
increased again. According to version, the interlock can be effective for a rising value
ABC -205 or for a falling value ABC206.
3.1 Technical data as for 1.1
3.2 Electrical connection
3.2.1 Maximum pressure limiting
Switching over and interlocking on rising temperature.
Additional function (205). Connection of control circuit to terminal 1 and 3.
3.2.2 Minimum pressure limiting
Switching over and interlocking on falling temperature.
Additional function (206).
Connection of control circuit to terminal 2 and 3.
ABC-205
ABC-206
30
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3.4 Setting as for 1.4
Please note:
For maximum pressure limiters (205) the scale value corresponds to the upper switching point,
for minimum pressure limiters (206) to the lower switching point.
4. Pressure limiters with gold plated contact -213
Gold plated contacts are used exclusively in the low voltage range in order to keep the transit
resistance at the contacts low.
4.1 Technical Data as for 1.1
Switching capacity max. 24 V DC
max. 100 mA
min. 5 V DC
min. 2 mA
At higher voltages and currents, the gold layer on the contacts will be damaged.
All other data correspond to the basic equipment.
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5. Two stage pressure switches 307, 217
A switch unit with two microswitches both with
single-poled changeover, forms part of the
basic equipment for each two-stage pressure
switch. The first switch I monitors lower pres-
sure, the second switch II monitors higher
pressure. It should be noted that the switching
differentials of the individual microswitches
cannot be exactly identical because of their
component tolerances.
The switching interval of both microswitches
is the interval (in bar or mbar) between the
switching points of both microswitches.
Applies for all variations:
Changes to the setting spindle, to the setting of
switching pressure, do not lead to changes in
the switching intervals as the switching points
are adjusted correspondingly.
The switching differential of the individual
microswitches corresponds to the switching
differences listed under basic equipment.
The switching differential cannot be set for
individual microswitches in two-stage
pressure switches.
5.1 Model 307
The switching interval between both switches
is set according to the customers require-
ments. With increasing pressure is firstly
I microswitch
(terminal
connection 13)
and then
II microswitch
(terminal
connection 46)
activated.
The switching points can moved parallely to
the setting spindle.
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5.2 Model 217
Both microswitches are connected internally
according to the given switching schedule
(see label next to the plug connection). The
switching interval is set according to customer
specifications. The switching points can be
moved parallely to the setting spindle, however
the switching interval can be set within given
limits.
Setting wheel I CW
reduce switching
point a microswitch I
Setting wheel II CCW
raise switching point
at microswitch II
Setting wheels I and II have an internal stop
to ensure that the microswitches cannot be
adjusted past their effective range.
Electrical wiring 217
Note the sticker besides the plug connection
of pressure switch.
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5.3 Adjustment
Addition of the adjustment with setting wheels I and II provides the switching interval between the
two microswitches. Changes made at the setpoint spindle do not affect the switching interval;
the switching interval remains constant over the entire adjustment range of the spindle, the two
switching points being displaced up or down in parallel.
1. Turn setting wheel I fully CCW.
Turn setting wheel II fully CW.
The lowest switching interval is adjusted.
2. Set setpoint spindle S to a value on the scale which is central between the required top and
required bottom switching point.
3. With pressure applied, set bottom switching point with setting wheel I (a1).
4. With setting wheel II, proceed as under 3. above to set top switching point (a2).
5. If the required top and bottom switching point cannot be obtained, adjust setpoint spindle S
in the necessary direction and repeat setting as per 3. and 4. above.
Example:
Desired switching points: 3.8 and 3.2 bar
Adjustment according point 2: S = 3.5 bar
3. Set bottom switching point (3.2 bar) with setting
wheel I (turn to the right)
4. Set top switching point (3.8 bar) with setting
wheel II (turn to left).
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6. Pressure monitors in intrinsically safe control circuits (EEx-i) 513
Pressure switches which are intended for EEx-i installations are equipped with blue terminals and
cable entries.
Additional function 513 is used together with suitable isolating switching amplifier, e.g. Ex 011.
Connection diagramm
Applies for maximum pressure
monitoring. When using for minimum
pressure monitoring, terminals 3
and 2 of pressure switch must be
connected with terminals 1 and 2
of isolating switching amplifier.
Pressure monitors with additional
function 213 are connected as
abore mentioned to isolating
switching amplifier Ex 011.
Ex-Zone 1 or 2, 21 or 22
Ex-free Zone
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7. Pressure limiters / Pressure monitors in intrinsically safe control
circuits with open-circuit and short-circuit monitoring (EEx-i)
The pressure monitors corrspond in
all technical data to the Type DCM. In
addition, a resistance combination is
provided in the switching device, which,
together with the isolating amplifier
EX 041, monitors the electric cables bet-
ween isolating amplifier and pressure
monitor for open circuit or short circuit.
In the case of open circuit or short
circuit, the system switches off towards
the safe side. When choosing the type
and when connecting please strictly
distinguish between maximum pressure
and minimum pressure monitoring, as
well as monitoring and limitation
func-tion.
EX-Zone 1 or 2, 21 or 22
Ex-free Zone
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8. Pressure monitors in EEx-d version (Ex-)
Presssure monitors in Ex version can be delivered only in a design tested by the PTB.
Versions and additional functions are basically not possible.
8.1 Technical data of the Ex switching device
Type of Ex-protection
PTB-autorisation
PTB 02 ATEX 1121
Ex-Zone
Compatible for zones 1 and 2, 21 and 22
Form of protection
IP 65 (vertical position)
Ambient temperature
15 to +60 C
Max. temperature at pressure switch
60 C
Max. medium temperature for pressure
switches
60 C. Higher medium temperatures are possi-
ble if the appropriate measure (e. g. water sack
pipe) are taken so that the above mentioned
ranges are not exceeded on the switch.
Cable type
M16 x 1.5
Switching difference
Not adjustable, approximate values see data
sheet.
Fitting position
vertically upwards.
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8.2 Electrical data
Connection plan: The terminal board can be accessed after the protective casing has been
removed. After connecting the supply lines, the protective casing should in all cases be
reattached.
With increasing pressure 31 will be interrupted and 32 will be
closed.
Switching element: Single-poled, changeover microswitch.
Protection of the conductive connection: Can be accessed after removing the terminal
board casing.
Earthing connection/ potential equalisation: External on the outside of the switching unit.
The maximal cross section of the cable is 4 mm
2
.
Switching power:
3 A 250 V AC, 2 A 250 V AC (inductive)
0,03 A 250 V DC, 3 A 24 V DC
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8.4 Setting of switching point
The switching point can be set within the range
given in the datasheet by using a screwdriver
on the setting spindle.
Additionally you should remove the terminal
board casing (with 4 hexagon screw M4).
The affixing screw on the front end (above the
scale) has to be removed and should be
reattached after setting the switching point.
Turning the setting spindle clockwise gives a
lower switching point, turning anticlockwise
gives a higher switching point.
The scale should be used as a guide, for more
exact settings you should use a manometer.
8.5 Serial numbers
All switch units and their respective terminal
board casings are marked with a serial number.
When installing you should ensure that the
terminal board casings do not get mixed up.
Important notice
When installing the Ex switch units and setting
them up for operation you should comply with
the recognised rules and guidelines for
installations in Ex-areas.
1 Potential equalisation
2 Protective casing for terminals (removable)
3 Connection terminals
4 Cable inlet M16 x 1.5
5 Switching point adjustment
6 Locking bolt for setting spindle
7 Protection of the conductive connection
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F
Pressostats, Limiteurs de pression
Instructions de montage et de service f
Types de base Fonctions supplmentaires
DCM 203
DNM 205
DNS 206
VCM , VNM 307
VNS 213
DDCM 217
513
EEx-d
EEx-i
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Code de type
Excution de base Excution avec fonction Excution Ex
ABC XXX supplmentaire ABC XXX-YYY Ex-ABC XXX
ABC Identification de la srie par une combinaison de lettres
XXX Identification de la plage de pression
YYY Identification de la fonction supplmentaire
Ex- Identification de lexcution Ex
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Remarque importante:
Les manocontacteurs sont des appareils de prcision qui ont t rgls et ajusts lusine.
Cest pourquoi il est interdit douvrir lappareil et de drgler les vis dajustage laques. Sinon
les points de commutation changeraient il faudrait rajuster lappareil.
43
Excution des botiers
ABC XXX
Botier connexion fiches (200)
(prise embrochable selon DIN 43 650)
ABC XXX-2
k
ABC XXX-3
Botier connexion bornes (300 ou 500)
ABC XXX-5
k
Ex-ABC Appareil de coupure Ex (700)
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Sommaire Identification des types
1. Excution de base ABC XXX
1.1 Caractristiques techniques
1.2 Raccordement lectrique
1.3 Prise de pression
1.4 Rglage de la pression de commutation
1.5 Verrouillage lectrique dans larmoire de distribution
2. Pressostats diffrence de commutation rglable ABC XXX-203
3. Limiteurs de pression verrouillage mcanique de ltat ABC XXX-205
de commutation ABC XXX-206
(blocage contre le renclenchement)
4. Pressostats contacts or ABC XXX-213
5. Manocontacteurs deux seuils ABC XXX-307
ABC XXX-217
6. Pressostats dans des circuits scurit intrinsque (EEx-i) ABC XXX-513
7. Pressostats maximum dans des circuits scurit ABC XXX-574-577
intrinsque avec surveillance des ruptures de cbles et
des courts-circuits (EEx-i)
8. Pressostats en excution Ex Ex-ABC XXX
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1. Equipment de base des pressostats
Le chapitre 1 dcrit lquipement de base et le montage des pressostats (sans aucune fonction
supplmentaire). Les variantes et les fonctions supplmentaires sont traites dans les
chapitres 2 7.
1.1 Caractristiques techniques (pas valables pour les excutions Ex)
Contacteur
A commutation unipolaire
Puissance de coupure
8 (5) A, 250 V AC
Position de montage
Verticale ou horizontale
Temprature ambiante max.
25 70 C
A des tempratures ambiantes infrieures
0 C, il faut veiller ce que de leau de conden-
sation ne puisse pas se former dans le dtec-
teur et lappareil de coupure.
Temprature max. de lagent
70 C. Les agents peuvent avoir des tempra-
tures plus leves condition que des mesures
appropries (par ex. tuyau poche deau) em-
pchent un dpassement des valeurs limites
ci-dessus dans lappareil de coupure.
Diffrence de commutation
Voire fiche technique pour les valeurs
Prise de pression
Filet extrieur G|A (raccord pour manomtre)
selon DIN 16 288 et filet intrieur G[ selon
ISO 228, partie 1. (Pour les applications avec
des gaz partir de 4 bars, utiliser uniquement
des joints plats. Un joint nest autoris dans le
filet que jusqu 4 bars.)
Appareil de coupure
Botier robuste en aluminium coul sous pres-
sion rsistant leau de mer, avec prise embro-
chable (200) ou connexion bornes (300).
Protection selon EN 60 529
IP 54 (200)
IP 65 (300)
Matriaux
Voir fiche technique
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Plan de connexion
Quand la pression
augmente:
31 ouvre, 32 ferme
Quand la pression
diminue:
32 ouvre, 31 ferme
Cblage
Le cblage est ralis sur la fiche coude. Le
cble peut sortir en 4 endroits dcals de 90
les uns par rapport aux autres.
1. Extraire la vis.
2. Introduire le tournevis dans la fente et
appuyer vers le bas.
Sur les botiers connexion bornes (300 et
500), la plaque bornes est accessible aprs
retrait du couvercle.
Attention: Couper la tension.
1.3 Prise de pression
1.31 Manocontacteur
Montage: directement sur la conduite (raccord
pour manomtre G|) ou avec 2 vis (4 mm) sur
une surface plane. Serrer uniquement sur le
raccord six pans de lorgane de pression, ne
jamais utiliser le botier ou la fiche comme
levier.
Filet extrieur G|HH
(raccord pour manomtre)
En cas dutilisation de
joints plats, serrer la vis de
centrage (profondeur A
env. 0,30,5 mm).
Filet intrieur G[HH
Pour lapplication avec un
gaz: joint dans le filet seule-
ment jusqu 4 bars. Utiliser
un joint plat pour une
pression plus leve.
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1.32 Manocontacteur diffrentiel
Prise de pression: 2 x G[ lintrieur. La
haute et la basse pression sont raccorder
conformment lidentification marque sur
lappareil. La permutation des prises de
pression eintrane und dysfonctionnement.
1.4 Rglage de la pression de commutation
La pression de commutation se rgle sur la
broche de rglage. Avant de la modifier, des-
serrer denv. 2 tours la vis sans tete situe
au-dessus de lchelle et la resserrer aprs le
rglage.
La valeur de lchelle correspond au point de
commutation suprieur (en cas daugmentation
de la pression). Le point de commutation infri-
eur (en cas de diminution de la pression) est
plus bas de la diffrence de commutation.
Lchelle nindique que des valeurs approxima-
tives, il faut un manomtre pour les rglages
prcis.
Sur les botiers connexion bornes, la vis
de rglage est accessible aprs retrait du
couvercle.
Attention: Couper la tension.
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1.5 Verrouillage lectrique externe dans larmoire de distribution
Un pressostat peut aussi tre utilis comme limiteur si un verrouillage lectrique est mont en
aval. Ci-dessous deux propositions de circuits.
Limitation de la pression maximale Limitation de la pression minimale
DW=Pressostat
T1 =STOP
T2=DEMARRAGE
S=Signal (au besoin)
K1 =Relais
auto-maintien
Circuit de
scurit
DW=Pressostat
T1 =STOP
T2=DEMARRAGE
S=Signal (au besoin)
K1 =Relais
auto-maintien
Circuit de
scurit
48
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2. Pressostats diffrence de commutation rglable V-203
2.1 Caractristiques techniques comme 1.1
2.2 Raccordement lectrique comme 1.2
2.3 Prise de pression comme 1.3
2.4 Rglage
Deux broches permettent de rgler respectivement la pression de commutation et de la diff-
rence de commutation. Ces deux broches sont centres. La broche extrieure, de plus grand
diamtre, influe sur le point de commutation infrieur; la diffrence de commutation et, par l, le
point de commutation suprieur, sont modifis avec la petite vis sans tte situe lintrieur.
Le sens daction est indiqu par la
direction de la flche
Ordre des oprations de rglage
a) Rgler le point de commutation infrieur (en cas
de diminution de la pression) sur la grande
broche dapres lchelle ou le manomtre
b) Avec la petite vis intrieure, rgler la diffrence
de commutation (xd) et, par l, le point de
commutation suprieur (en cas daugmentation
de la pression).
Quand la diffrence de commutation varie, le
point de commutation infrieur ne change pas
tandis que le point de commutation suprieur
est dplac de la diffrence de commutation.
RSP=SP+xd
SP = point de commutation
RSP = point de renclenchement
xd = diffrence de commutation (hystrsis)
P
r
e
s
s
i
o
n
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3. Limiteurs de pression verrouillage mcanique
de ltat de commutation
Limiteurs de la pression maximale ABC-205
Limiteurs de la pression minimale ABC-206
Un microrupter bistable est mont dans les limiteurs la place du
microrupteur initialisation automatique.
Lorsque la pression atteint la valeur rgle sur lchelle, le microrupteur
commute et reste dans cette position. On peut supprimer le blocage en
appuyant sur la touche de dverrouillage (repre par und point rouge sur
le ct de lchelle de lappareil de coupure). Le dverrouillage ne peut avoir lieu que si la pres-
sion a diminu dune certaine valeur, ou a t de nouveau augmente en cas de verrouillage au
point de commutation infrieur. Le verrouillage peut, suivant lexcution, tre actif une valeur
croissante ABC-205 ou une valeur dcroissante ABC206.
3.2.1 Limitation de la pression maximale. Commutation et verrouillage
en cas daugmentation de la pression. Fonction supplmentaire (205).
Connexion du circuit de commande aux bornes 1 et 3.
3.2.2 Limitation de la pression minimale. Commutation et verrouillage
en cas de diminution de la pression. Fonction supplmentaire (206).
Connexion du circuit de commande aux bornes 2 et 3.
ABC-205
ABC-206
50
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3.4 Rglage comme 1.4
Prire dobserver:
Pour les limiteurs de la pression maximale (205), la valeur de lchelle correspond au point de
commutation suprieur et pour les limiteurs de la pression minimale (206), au point de commuta-
tion infrieur.
4. Pressostats contacts or -213
Des contacts or sont utiliss exclusivement dans le domaine de la basse pression, pour restreindre
les pertes de tension au passage sur les contacts.
Puissance de coupure 24 V DC max.
100 mA max.
5 V DC min.
2 mA min.
Des tensions et intensits plus leves endommagent la couche dor sur les contacts.
Toutes les donnes correspondent lquipement de base.
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5.1 Types 307
Lintervalle de commutation entre les deux rup-
teurs a t rgl dfinitivement daprs les indi-
cations du client. Lors dune augmentation
de la pression, le
rupteur I est ac-
tionn en premier
(bornes 13) et
ensuite le
rupteur II
(bornes 46)
Les points de commutation peuvent tre
dplacs paralllement sur la broche de
rglage.
52
5. Manocontacteurs deux seuils 307, 217
Lquipement de base des manocontacteurs
deux seuils comprend un appareil de coupure
2 microrupteurs, chacun commutation
uni-polaire.
La basse pression est contrle par le rupteur
I et la pression plus leve, par le rupteur II.
II faut considrer que les diffrences de com-
mutation des microrupteurs ne peuvent pas
etre exactement identiques en raison des
tolrances des composants.
Lintervalle de commutation des deux micro-
rupteurs est lintervalle (en bars ou mbars)
entre leurs points de commutation.
Valable pour toutes les excutions:
Lintervalle de commutation ne change pas
lors de modifications opres sur la broche de
rglage pour rgler la pression de commuta-
tion; les points de commutation sont dplacs
paralllement.
La diffrence de commutation, c.-.-d. lhyst-
rsis des diffrents microrupteurs correspond
aux diffrences de commutation indiques
dans le tableau des types pour lexcution de
base respective.
Sur les manocontacteurs deux seuils, on ne
peut pas rgler la diffrence de commutation
des microrupteurs.
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5.2 Types 217
Les deux microrupteurs sont relis intrieure-
ment selon un schma des connexions impos
(tiquette colle ct de la prise embrocha-
ble). Lintervalle de commutation a t rgl
dfinitivement daprs les indications du client.
Les points de commutation peuvent tre dpla-
cs paralllement sur la broche de rglage,
toutefois lintervalle de commutation entre les
deux microrupteurs peut tre rgl entre des
limites assignes.
Rotation droite de
la molette I point de
commutation bas
pour microrupteur I
Rotation gauche
de la molette II
point de commutation
plus haut pour microrupteur II.
Les molettes I et II ont une bute interne afin
que les microrupteurs ne puissent pas tre
ajusts au-del du domaine efficace.
Plans de connexion 217
Prire dobserver absolument ltiquette colle
ct de la prise embrochable.
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5.3 Rglage
Laddition des rglages effectus sur les molettes I et II donne lintervalle de commutation entre
les deux microrupteurs. Les modifications opres sur la broche de valeur de consigne ninfluent
par sur lintervalle de commutation, qui reste constant dans toute la plage de rglage de la broche;
les deux points de commutation sont dplacs paralllement vers le bas ou vers le haut.
1. Molette I tourner gauche jusqu la bute.
Molette II tourner droite jusqu la bute.
Le plus petit intervalle de commutation est rgl de cette manire.
2. Rgler la broche de valeur de consigne, daprs lchelle, sur une valeur qui se situe approxi-
mativement au milieu entre les points de commutation suprieur et infrieur dsirs (S).
3. Une fois la pression admise, abaisser le point de commutation infrieur avec la molette I
(intervalle a1)
4. Elever de flaon analogue le point de commutation suprieur avec la molette II (intervalle a2).
5. Si le point de commutation suprieur ou infrieur dsir ne peut pas tre atteint, rajuster la
broche de valeur de consigne dans le sens correspondant et rpter le rglage comme
indiqu aux points 3 et 4 (S)
Exemple:
Points de commutation dsirs: 3,8 et 3,2 bars
Rglage suivant point 2: S = 3,5 bar
3. Rgler le point de commutation infrieur (3,2 bars
dans lexemple) sur la molette I (tourner droite).
4. Rgler le point de commutation suprieur
(3,8 bars dans lexemple) sur la molette II
(tourner gauche).
305571
55
6. Pressostats dans des circuits scurit intrinsque (EEx-i) 513
Les bornes et entres de cble ont la couleur bleue habituelle dans les circuits EEx-i.
Les fonctions supplmentaires 513 sont utilises en liaison avec un amplificateur de section-
nement appropri, par ex. Ex 011.
Plan de connexion
Valable pour la surveillance de la
pression maximale.
Pour la surveillance de la pression
minimale, raccorder les bornes 2
et 3 du manocontacteur aux bornes
1 et 2 de lamplificateur de section-
nement.
Les pressostats avec les fonction
supplmentaires 213, sont
raccords de la meme manire
lamplificateur de sectionnement
Ex 011.
Ex-Zone 1 ou 2, 21 ou 22
305571
56
7. Pressostats dans des circuits scurit intrinsque avec surveillance
des ruptures de cbles et des courts-circuits (EEx-i)
Les pressostats correspondent, dans
toutes les caractristiques techniques,
au type DCM. Lappareil de coupure
comporte en plus une combinaison de
rsistances qui surveille, avec lamplifi-
cateur de sectionnement Ex 041, les
ruptures et les courts-circuits des
cbles lectriques entre lamplificateur
de sectionnement et le pressostat. En
cas de rupture de cble ou de court-
circuit, le systme arrte vers le ct
sr. Lors du choix et du raccordement
de lappareil, il convient de faire une
distinction stricte entre le contrle de
la pression maximale et de la pression
minimale.
Ex-Zone 1 ou 2, 21 ou 22
305571
57
8. Pressostats en excution EEx-d (Ex)
Les pressostats en excution Ex ne peuvent tre fournis que dans la construction contrle par
le PTB (Office fdral physico-technique). Des variantes et des fonctions supplmentaires sont
impossibles par principe.
8.1 Caractristiques techniques des appareils de coupure Ex
Protection contre linflammation
Homologation par le PTB
PTB 02 ATEX 1121
Zone Ex
Conviennent aux zones 1 et 2, 21 et 22
Protection
IP 65 en position de montage verticale
Temprature ambiante
15 +60 C
Temprature max. sur lappareil de coupure
60 C
Temprature max. de lagent pour les
manocontacteurs
60 C. Les agents peuvent avoir des tempra-
tures plus leves si des mesures appropries
(par. ex. tuyau poche deau) garantissent
que les valeurs limites ci-dessus ne sont pas
dpasses sur lappareil de coupure.
Entre de cble
M16 x 1,5
Diffrence de commutation
Non rglable, voir fiche technique pour les
valeurs approximatives.
Position de montage
Verticale, dirige en haut.
305571
58
8.2 Caractristiques lectriques
Plan de connexion: la plaque bornes est accessible aprs retrait du couvercle de la
bote bornes et du capuchon de protection des bornes. Remettre absolutement ce
capuchon aprs le raccordement des cbles dalimentation.
Lors dune augmentation de la pression, la connexion 31 est
interrompue et la 32 ferme.
Elment de coupure: microrupteur, commutation unipolaire. En cas dutilisation comme
limiteur avec blocage contra le renclenchement, le verrouillage doit tre activ par un
circuit externe conforme la norme DIN 57116, paragraphe 8.7
Connexion de la terre / Compensation de potentiel: lextrieur sur lappareil de coupure.
Section max. du cble 4 mm
2
.
Puissance de coupure: 3 A 250 V CA, 2 A 250 V CA (inductif)
0,03 A 250 V CC, 3 A 24 V DC
8.4 Rglage du point de commutation
Le point de commutation peut tre rgel avec un tournevis sur la broche de rglage,
lintrieur des plages indiques dans la fiche technique. Dposer pour cela le couvercle de
la bote bornes (desserrer les 4 vis M 4 six pans creux). Desserrer auparavant la petite
vis darretage situe sur la face frontale (au-dessus de lchelle) et la resserrer aprs le
rglage du point de commutation.
305571
59
Le point de commutation est abaiss
quand on tourne la broche de rglage
droite et il est lev quand on la tourne
gauche. Lchelle sert indiquer des
valeurs approximatives, il faut un
manomtre pour des rglages prcis.
8.5 Numro de srie
Tous les appareils de coupure et le
couvercles des botes bornes corres-
pondants sont identifis par la dsigna-
tion du type et un numro de srie. Lors
du montage, veiller ne pas intervertir
les couvercles des botes bornes.
Important
Les rgles admisses de la technique et
les directives pour installations dans des
domaines Ex sont observer lors du
montage et de la mise en service des
appareils de coupure Ex.
1 Compensation de potentiel
2 Capuchon de protection des bornes
(amovible)
3 Bornes de connexion
4 Entre de cble M16x 1,5
5 Rglage du point de commutation
6 Vis darrtage pour broche de rglage
7 Connexion du fil de protection
305571
60
305571
61
RU
,
f

DCM 203
DNM 205
DNS 206
VCM , VNM 307
VNS 213
DDCM 217
513
EEx-d
EEx-i
305571
62

ABC
XXX
YYY
Ex-
305571

ABC XXX
(200)
( 43 650)
ABC XXX-2
k
ABC XXX-3
(300 500)
ABC XXX-5
k
Ex-ABC
(700)
:
,
-. : ,
, !
, .
63
305571
64

1. ABC XXX
1.1
1.2
1.3
1.4
1.5
2. ABC XXX-203
3. ABC XXX-205
ABC XXX-206
( )
4. ABC XXX-213
5. ABC XXX-307
ABC XXX-217
6. ABC XXX-513
(EEx-i)
7. ABC XXX-574-577

(EEx-i)
8. Ex-ABC XXX
305571
65
1.
1
( ). - . 2 - 7.
1.1 ( )

8 (5) A, 250 .

.
-25 ... 70 C

0 C ,

.
.
70 C,
,
(, )

.

.

G | (
) 16 288
G [ 228, 1. (
, 4 ,
.

4 ).

(200)
(300)
EH 60 529
IP 54 ( 200); IP 65 ( 300)
.
305571
1.2

: 3-1 ,
3-2 .

: 3-2 ,
3-1 .

.
4 ,
90.
1.
2.
.
66

(300 500)
.
: .
G |
( )

-

( . 0,3 0,5 ).
G [
:

4 .

.
1.3
1.31
:
( G|) -
2 (4 ) .
-
.
.
305571
67
1.32
: 2 G [,
.

.

.
1.4

.

, , .
2 .
.

(
).
(
)
.
.
.

.
: .
305571
68
1.5
,
. .

DW =
T1 =
T2 =
S = (
)
K1 =
DW =
T1 =
T2 =
S = (
)
K1 =
305571

)
( )
.
) ,

(xd) , ,
(
).
2.
...V...-203
2.1 1.1
2.2 1.2
2.3 1.3
2.4

. .
. ,
,
, .
.
.
SP
RSP
Xd ()

,

.
RSP= SP + xd
69
305571
70
3.

ABC-205
ABC-206

.
,
.
(
).
, .
ABC-205
ABC-206.
3.1 1.1
3.2
3.2.1
.
(205).
1 3.
3.2.2
.
(206).
2 3.
ABC-205
ABC-206
305571
71
3.3 1.3
3.4 1.4
:
(205)
,
(206) .
4. -213
,
.
4.1 1.1
. 24 .
. 100 A
. 5 .
. 2 A

.
.
305571
72
5. 307, 217

2 ,
.
I ,
II .
,

-
.
()

( )

.
:

.
.
, ..

,
.

.
5.1 307

.
I
( 13), II
( 46).

.
305571
73
5.2 217

( c
).

.

.

.

I

I.

II
II.
I II
,

.
217
o

.
305571
74
: : 3,8 3,2 .
. 2: S = 3,5 .
3. ( : 3,2 )
I ( ).
4. ( : 3,8 )
II ( ).
5.3
I II
.
.
.
.
1. I .
II .
.
2. ,

(S).
3. I
( 1).
4. . 3 II
( 2).
5. ,

. 3 4 (S).
305571
EEx-i .
513
, . Ex 011.

.

3 2

1 2
.
P
213

Ex 011 .
75
6. P
(Exx-i) 513
1 2, 21 22

305571
76
7. /

(EEx-i)

DCM.
,
,

EX 041

.

.

,
.
1 2, 21 22

III II I
(VDE 0660, 209)
305571
77
8. EEx-d (Ex-)
Ex ,
PTB. B
.
8.1

PTB
PTB 02 ATEX 1121

1 2, 21 22

IP 65 -

-15 ... +60 C
.
60 C
.

60 C.
,
(.
) ,

.

M16 x 1,5

,
. .

305571
78
8.2
:
.
.
3 - 1
3 - 2.
: , .

.
57 116, 8.7.
:
.
/ :
. . 4mm
2.
:
3 A 250 B , 2 A 250 B . ()
0,03 A 250 B . , 3 A 24 B .
8.3 1.3
305571
79
8.4

, .
( 4
4).

( )
.

, -
.
.
.
8.5

.
,
.
!

.
1
2
()
3
4 16 x 1,5
5
6

7
305571
FEMA Regelgerte FEMA Controls
Honeywell GmbH Honeywell GmbH
Bblinger Strae 17 Bblinger Strae 17
D-71101 Schnaich D-71101 Schnaich
Telefon 0 7031/ 637-02 Phone 07031/ 637-02
Telefax 07031/ 637-850 Fax 07031/ 637-850
7156.719/19
MU2B-0238GE51 R1005 www.fema.biz
Manufactured for and on behalf of the Environmental and Combusition Controls Division of
Honeywell Technologies Srl, Ecublens, Route du Bois 37, Switzerland
by its Authorized Representative:
305571
HKS GmbH - Manufacturers of expansion fittings, hoses, exhaust systems and silencers
Lademannbogen 3, D-22339 Hamburg, Phone: +49 (0)40 / 53 93 83-0, Fax: +49 (0)40 / 5 38 15 27, E-mail: info@hks-hh.de
__________________________________________________________________________________________________________________________
Operating instructions for

HKS stainless steel bellows-type expansion fittings

Due to their moving parts and mechanisms, expansion fittings are susceptible to damage of all kinds and
from inappropriate loadings when in use. To ensure their reliability, and in turn, that of the entire
installation or pressurising system, the following notes and instructions must be read through carefully
and completely, and followed and adhered to without fail. If they give rise to doubt or appear to be
incomplete, HKS should be consulted in every case.

Installation instructions, entry into service

1) HKS expansion fittings may only be installed and put into service by trained, experienced personnel.
Their reliability in use is conditional on expert installation.
2) Before starting work, remove the packaging completely and inspect the fitting for any possible
damage in transit or storage including, in particular, corrosion resulting from surface damage. The
hollows between the bellows, inside and out, must likewise be free of any foreign bodies or matter.
Only fittings in perfect condition may be installed. If in doubt, consult HKS.
3) The connecting pipes must be precisely aligned and securely installed to prevent the fitting from
being buckled.
4) If the fitting is equipped with fixed flanges, the screw holes must be aligned with those in the
connecting flanges.
5) Only 1 (one) fitting may be installed between 2 (two) fixed points. Any expansion in the section
between these two points must be less than the maximum expansion capability of the fitting, as
shown in the accompanying drawing.
6) Install the fitting as near as possible to a fixed point. In this way, only one plain bearing will be
needed on the other side of the fitting; otherwise, a plain bearing will be needed on both sides. The
interval between the supporting points and the fitting is approximately twice the nominal diameter
(ND). The use of a protective outer pipe with a type AS fitting or an inner guide pipe with a type AF
fitting does not replace a plain bearing or fixed point.
7) The configurations and measurements of fixed points and plain bearings are to be determined by a
structural engineer or static stress analyst on the basis of the maximum forces and moments which
will occur. The plain bearings in the guide section must be sufficiently long to prevent seizing.
8) The length of the installation (LE) depends on the operating conditions. If prestressing is necessary,
this length (LE) should be greater than the face-to-face length (L).
9) Fittings must not be subjected to torsion. This must be borne in mind, in particular, when fittings are
installed with fixed flanges and screw fastenings. As a fundamental principle, care must be taken
when installing any type of expansion fitting to ensure that any stresses in the pipeline cannot induce
any torsional effect on the expansion fitting.
10) If the fitting is used as a vibration absorber without prestressing, the installation length (LE) is the
same as the face-to-face length (L).
11) Observe the direction of flow when installing expansion fittings with an inner guide pipe.
12) If lifting gear is used for installation purposes, slings etc. must not be attached to the vulnerable parts
of the fitting, e.g. the bellows.
13) Do not carry out any pressure or leak testing of the system until the fixed points and guide bearings
have been correctly installed.
306321
__________________________________________________________________________________________________________________________
14) During installation, take care to ensure that the bellows of the fittings are not damaged (e.g. through
welding spatter, thermal stresses, mechanical damage, dents, scratches, shocklike stresses, falling
objects, dirt, etc.) and that no foreign bodies get into the corrugations. The latter must be clean inside
and out and remain in that condition to enable the fitting to function properly.
15) Prestressing equipment must not be removed until the installation of the fitting has been fully
completed.
16) As far as possible, transit screws etc. should likewise be removed only on the completion of the
installation.
17) Insulators may only be attached after prior consultation with HKS and must not be mounted to the
bellows.
18) No electrical currents may be directed through the fitting, e.g. through welding operations, otherwise
the metal bellows may be damaged beyond use.
19) Fittings should be installed in such a way as to permit unrestricted visual inspections at regular
intervals for freedom from damage. Any visible defects, e.g. dents, cracks, corrosion, discoloration or
irregular deformations must be notified to HKS and/or the fitting replaced without delay.
20) Pressure surges (hammering) in the system must be avoided.
21) All the generally applicable safety precautions and accident prevention regulations in force must be
observed without fail.

Operation

HKS stainless steel expansion fittings may only be used within the limits of the parameters for the layout
given in the accompanying drawing, i.e.:

1) The highest operating pressure must not exceed the specified design pressure.
2) The maximum operating temperature must not exceed the specified design temperature.
3) The maximum expansion absorption capability must not exceed the specified axial or lateral
expansion. A combination of these is only permissible subject to corresponding reduction factors and
with the prior written approval of HKS.
4) The specified number of load reversals must not be exceeded.
5) To ensure the reliable operation of the fitting and, in turn, the entire installation, all the data and
instructions are to be observed and adhered to.

Maintenance

As a rule, HKS stainless steel expansion fittings require no particular maintenance. Nevertheless,
thorough visual inspections should be carried out at regular intervals. If it is possible for the corrugations
of the bellows to become contaminated, regular cleaning should be carried out to protect the material of
the fitting (and the environment) with cleaning agents and implements approved for stainless steel.
If corrosive substances come into contact with the bellows, either from outside or inside, they must be
completely cleaned off, without delay, with adequate quantities of clean water.

The bushes at the joints of stainless steel expansion fittings mounted in the open air must be smeared
with a viscous, water resistant, bearing grease at intervals appropriate to the ambient conditions. Ball
joint expansion fittings should also be greased occasionally to prevent seizing.
306321
__________________________________________________________________________________________________________________________

When making enquiries or ordering spare parts, please specify the type and serial number of the product
(stamped into the rating plate) without fail.

Repairs

If, in an exceptional case, an expansion fitting needs to be repaired, any work on or modifications to the
metal bellows and the connecting parts of the fitting (e.g. welding, cutting or soldering operations) may
only be carried out by HKS personnel or companies authorised by HKS to do so. As a rule, HKS will be
able to rectify the damage within a short period of time by fitting a new bellows which is a standard stock
part. In this case, HKS should be given detailed information as to the cause of the damage and the
operating conditions on the site so that, if appropriate, HKS can suggest measures for improvement.

When making enquiries or ordering spare parts, please specify the type and serial number of the product
(stamped into the rating plate) without fail.

Guarantee

HKS guarantees its product in accordance with the statutory regulations of the Federal Republic of
Germany (specified on the delivery note and invoice).

Damage attributable to natural wear, overstressing or unsuitable treatment is excluded from the
guarantee.

Environmental protection

To protect the environment, the product, accessories and packaging should be disposed of through a
recycling centre.

Date: 2001
306321
Part number 129766-01
Revision K, August 2002
3500 Monitoring System
Rack Installation and Maintenance
Manual
3500 Rack Installation and Maintenance Manual
ii
Copyright 1999, 2000, 2001, 2002 Bently Nevada, LLC
All Rights Reserved.
The information contained in this document is subject to change without notice.
Bently Trademarks
The following are trademarks of Bently Nevada LLC in the United States and other countries:
Actionable Information
SM
, Actionable Information to the Right
People at the Right Time
SM
, ADRE, Bently ALIGN, Bently
BALANCE, Bently DOCUVIEW , Bently LUBE, Bently
Nevada, Bently PERFORMANCE, CableLoc, ClickLoc,
Data Manager, Decision Support
SM
, DemoNet, Dynamic
Data Manager, Dynamic Transmitor, Engineer Assist,
FieldMonitor, FluidLoc, flexiTIM, flexiTAM, Helping You
Protect and Manage All Your Machinery, HydroVU, Key ,
Keyphasor, Machine Condition Manager 2000,
MachineLibrary, Machine Manager, MicroPROX, Move
Data, Not People, Move Information, Not Data, NSV,
Preformalign, PROXPAC, Proximitor, REBAM, SE,
Seismoprobe, ServoFluid, Smart Monitor, Snapshot,
System 1, System Extender, TDXnet, TDIXconnX,
Tecknowledgy, TipLoc, TorXimitor, Transient Data
Manager, Trendmaster, TrimLoc, VAM, Velomitor,
XLerometer The Bently Nevada Corporation Orbit Design,
Bently Balance and Design, System 1 Enabled and Design, and
M-Squared and Design are all trademarks or registered marks of
Bently Nevada Corporation in the United States and other
countries.
Contacting Bently Nevada
The following ways of contacting Bently Nevada are provided for those times when you cannot
contact your local Bently Nevada representative:
Mailing Address 1631 Bently Parkway South
Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 782 9259
Internet www.bently.com
iii
Additional Information
Note:
This manual does not contain all the information
required to operate and maintain the 3500 Monitoring
System. Refer to the following manuals for other
required information.
3500 Monitoring System Rack Configuration and Utilities Guide ( 129777-01)
guidelines for using the 3500 Rack Configuration software for setting the operating parame-
ters of the module
guidelines for using the 3500 test utilities to verify that the input and output terminals on the
module are operating properly
3500 Monitoring System Computer Hardware and Software Manual (128158-01)
instructions for connecting the rack to 3500 host computer
procedures for verifying communication
procedures for installing software
guidelines for using Data Acquisition / DDE Server and Operator Display Software
procedures and diagrams for setting up network and remote communications
3500 Field Wiring Diagram Package (130432-01)
diagrams that show how to hook up a particular transducer
lists of recommended wiring
Operation and Maintenance Manuals for all the modules installed in the rack
iv
v
Contents
1 Receiving and Handling Instructions
1.1 Receiving Inspection ................................................................................................ 1
1.2 Handling and Storing Considerations....................................................................... 1
1.3 Disposal Statement .................................................................................................. 1
2 General Information
2.1 Common Features.................................................................................................... 4
2.1.1 Hot Insertion or Removal of Modules ........................................................... 4
2.1.2 External and Internal Termination ................................................................ 4
2.2 Components of the System...................................................................................... 6
2.3 Standard Rack Relay Options: ................................................................................. 8
2.3.1 Individual Relays .......................................................................................... 9
2.3.2 Bussed Relays............................................................................................ 11
2.3.3 Triple Modular Redundant (TMR) System.................................................. 12
2.4 Intrinsic Safety The 3500 Internal Barrier System............................................. 16
3 Initial Rack Installation
3.1 General Installation Procedure............................................................................... 19
3.2 Installation Checklist............................................................................................... 19
3.3 Weatherproof Housing Installation ......................................................................... 19
3.3.1 General Description.................................................................................... 20
3.3.2 Rack Temperature Derating ....................................................................... 21
3.3.3 Panel Cutout ............................................................................................... 22
3.3.4 Conduit Fitting Option................................................................................. 24
3.3.5 Air Purge Option......................................................................................... 25
3.3.6 Installation Instructions ............................................................................... 28
3.4 Rack Installation..................................................................................................... 29
3.4.1 Rack Ventilation.......................................................................................... 29
3.4.2 Panel Mount ............................................................................................... 30
3.4.3 Rack Mount ................................................................................................ 35
3.4.4 Bulkhead Mount.......................................................................................... 41
3.5 External Termination Blocks................................................................................... 44
3.6 Intrinsically Safe Installation................................................................................... 47
3.7 High Electromagnetic Noise Environment and European Conformance (CE) Rack
Installation .............................................................................................................. 49
3.7.1 Wiring ......................................................................................................... 52
3.7.2 Considerations for CE Installation to a Public Power Supply ..................... 52
3.7.3 Considerations for I.S. systems.................................................................. 53
3.7.4 Additional Notes ......................................................................................... 53
3.8 Set rack jumpers and switches............................................................................... 54
3.9 Wiring Requirements.............................................................................................. 55
3.10 Software Portion of the Rack Installation ............................................................... 56
3500/42M Operation and Maintenance Manual
vi
4 Module Installation and Removal
4.1 Installation of Modules ........................................................................................... 57
4.1.1 Power Supplies .......................................................................................... 57
4.1.2 Full-height modules.................................................................................... 58
4.1.3 Half-height modules ................................................................................... 59
4.2 Removal of Modules .............................................................................................. 60
4.2.1 Power Supplies .......................................................................................... 60
4.2.2 Full-height modules.................................................................................... 61
4.2.3 Half-height modules ................................................................................... 62
4.3 Replacing Modules................................................................................................. 63
4.3.1 Main Modules............................................................................................ 63
4.3.2 I/O Modules................................................................................................ 63
5 Maintenance
5.1 General Maintenance Instructions ......................................................................... 64
5.2 Choosing a Maintenance Interval........................................................................... 64
6 Ordering Information
6.1 Rack Ordering Information..................................................................................... 65
6.2 Weatherproof Housing Ordering Information ......................................................... 65
6.3 Earthing Module Ordering Information................................................................... 66
6.4 Spares.................................................................................................................... 67
7 Specifications
7.1 Dimensions (overall) .............................................................................................. 68
7.2 Weight .................................................................................................................... 69
7.3 Environmental (All 3500 Components) .................................................................. 70
Section 1 -- Receiving and Handling Instructions
1.1 Receiving Inspection 1
1.1 Receiving Inspection
Visually inspect the system for obvious shipping damage. If shipping damage
is apparent, file a claim with the carrier and submit a copy to Bently Nevada
LLC.
1.2 Handling and Storing Considerations
Handling and storing of printed circuit boards is extremely critical. Circuit
boards contain devices that are susceptible to damage when exposed to elec-
trostatic charges. Damage caused by obvious mishandling of the board will
void the warranty. To avoid damage, observe the following precautions in the
order given.
Application Alert
Machinery protection will be lost when all the power is
removed from the rack.
Do not discharge static electricity onto the circuit board. Avoid tools or
procedures that would subject the circuit board to static damage. Some
possible causes include ungrounded soldering irons, nonconductive plas-
tics, and similar materials.
Personnel must be grounded with a suitable grounding strap (such as 3M
Velostat No. 2060) before handling or performing maintenance on a
printed circuit board.
Transport and store circuit boards in electrically conductive bags or foil.
Use extra caution during dry weather. Relative humidity less than 30%
tends to multiply the accumulation of static charges on any surface.
When performed properly, modules may be removed from or installed into the
rack while power is applied to the rack. Refer to Module Installation and
Removal on page 57 for the proper procedure.
1.3 Disposal Statement
Customers and third parties that are in control of product at the end of its life or
at the end of its use are solely responsible for proper disposal of product. No
person, firm, corporation, association or agency that is in control of product
shall dispose of it in a manner that is in violation of United States state laws,
United States federal laws, or any applicable international law. Bently Nevada
Corporation is not responsible for disposal of product at the end of its life or at
the end of its use.
2
Monitoring and computerized vibration information systems provide the infor-
mation needed to assess the mechanical condition of rotating and reciprocat-
ing machinery. These systems continuously measure and monitor a variety of
supervisory parameters, providing crucial information for early identification of
machinery problems such as imbalance, misalignment, shaft crack, and bear-
ing failures. As such, they are an efficient and effective means of satisfying
plant management, engineering, and maintenance concerns for:
Increasing plant safety by minimizing the occurrence of hazardous condi-
tions or catastrophic failures.
Improving product quality by minimizing process variances caused by
improperly operating equipment.
Maximizing plant availability by servicing only those machines that require
it and having more efficient turnarounds.
Reducing plant operating costs by minimizing unplanned shutdowns and
by making more efficient use of maintenance resources.
For protection of critical machinery, it is highly recommended to permanently
install continuous monitoring systems. The term "protection" means that the
system can shut down machinery on alarm, without human interaction. These
systems include applicable transducers, each with its own dedicated monitor-
ing circuitry and alarm setpoints. The 3500 Monitoring System is the newest
addition to the family of continuous monitoring systems offered by Bently
Nevada Corporation.
3500 Monitoring System: Designed using the latest in proven microproces-
sor technology, the 3500 is a full-feature monitoring system. In addition to
meeting the above stated criteria, the 3500 adds benefit in the following areas:
Enhanced Operator Information
Improved integration to plant control computer
Reduced installation and maintenance cost
Improved reliability
Intrinsic Safety option
Enhanced Operator Information: The 3500 was designed to both enhance
the operator's information and present it in a way that is easy for the operator
to interpret. These features include:
Improved Data Set
- Overall Amplitude
- Probe Gap Voltage
- 1X Amplitude and Phase
- 2X Amplitude and Phase
- Not 1X Amplitude
Windows Based Operator Display Software
Section 2 -- General Information
3
Data displayed at multiple locations
Improved integration to plant control computer:
Communication Gateways supporting multiple protocols
Time synchronized vibration and process information
Reduced installation and maintenance cost:
Reduced cabling costs
Downward product compatibility
Improved space utilization
Easier configuration
Reduced spare parts
Improved serviceability
Improved reliability:
Redundant power supplies available
Triple Modular Redundant (TMR) monitors and relay cards available
Redundant Gateway and Display Modules permitted
Intrinsic Safety Option: To monitor equipment located in hazardous atmo-
spheres, the 3500 Monitoring System has a range of I/O modules with internal
zener barriers. These modules provide an Intrinsically Safe interface between
the 3500 rack and the transducers located in the hazardous area.
Multiple Output Interfaces: Monitor options (such as full scale ranges,
transducer inputs, recorder outputs, alarm time delays, alarm voting logic, and
relay configuration) can be conveniently adjusted in the field via software.
Modular system design employs plug-in components which allow easy servic-
ing and expansion.
The following three independent interfaces are available with the 3500 sys-
tem:
Data Manager Interface (Transient Data Interface External or Dynamic
Data Interface External)
Configuration/Data port
Communications Gateway (support for Programmable Logic Controllers,
Process Control Computers, Distributed Control Systems, and PC-based
Control Systems)
These interfaces allow monitored parameters and their statuses to be easily
viewed in the following ways:
Bently Nevada System 1 Software
Bently Nevada 3500 Operator Display Software
Remote Display Panel
DCS or PLC display
Front panel coaxial connectors provide dynamic transducer signals for conve-
nient connection to diagnostic or predictive maintenance instruments.
4 2.1 Common Features
2.1 Common Features
The common features of the modules in the 3500 rack include hot insertion or
removal of modules and external and internal termination of the wiring.
2.1.1 Hot Insertion or Removal of Modules
When performed properly, any module can be removed and replaced while
the system is under power without affecting the operation of any unrelated
modules. If the rack has two power supplies, removing or inserting a power
supply will not disrupt the operation of the 3500 rack. See Module Installation
and Removal on page 57 for the proper procedure.
2.1.2 External and Internal Termination
External Termination uses multi-conductor cables to connect the I/O modules
to the terminal blocks. These blocks make it easier to connect many wires to
the rack in tight areas. External Termination is not available on I/O modules
with internal zener barriers.
(1) To Transducers.
(2) External Termination Blocks.
(3) External Termination I/O Modules.
Internal Termination lets you connect transducers directly to the I/O modules.
2.1 Common Features 5
(1) To Transducers.
(2) Internal Termination I/O Modules.
6 2.2 Components of the System
2.2 Components of the System
The 3500 Monitoring System consists of modules that fit into a rack as shown
in the following figure (full-size rack shown)
3
:
(1) One or Two Power Supplies.
(2) Rack Interface Module (standard, Tran-
sient Data Interface (TDI), Triple Module
Redundant (TMR) and TMR TDI).
(3) Monitoring Slot Positions
- Monitor Module
- Keyphasor Module (2 maximum)
- Relay Module
- Communication Gateway Module
- Display Module
1
- 3500/04-01 Earthing Module
, 2
Notes:
1
For System Face Mount option, the Display Interface Module must be
inserted in slot 15.
2
One Earthing Module is required per rack if Internal Barrier I/O's are used.
3
The Mini-rack has 7 module positions available beyond the Power Supplies
and RIM.
2.2 Components of the System 7
This section lists the function of each module. Refer to the individual opera-
tion and maintenance manuals for the available options, detailed description,
operation and maintenance.
Weatherproof Housing: Protects the 3500 rack from adverse environmental
effects, such as excessive moisture, dirt and grime, and even unclean air.
The weatherproof housing will not accommodate a Display Unit or VGA
Display.
Rack: Two 3500 racks are available: the full-size 19-inch rack and the com-
pact 12-inch Mini-rack. Each rack requires the Power Supplies and Rack
Interface Module (RIM) to be installed in certain locations. The full-size
version offers 14 additional rack positions and the Mini-rack offers 7 addi-
tional rack positions for use with any combination of modules. Both racks
offer Standard (non-redundant) and Triple Modular Redundant (TMR) con-
figurations. The TMR system also restricts the location of certain modules.
The following modules may be installed in the 3500 rack:
Power Supply: The Power Supply is a half-height module available in AC
and DC versions. One or two power supplies can be installed in the rack.
Each power supply has the capacity to power a fully loaded rack. When
two power supplies are installed in a rack, the supply in the lower slot acts
as the primary supply and the supply in the upper slot acts as the backup
supply. If the primary supply fails, the backup supply will provide power to
the rack without interrupting rack operation. Any combination of power
supply types is allowed. Overspeed Detection and TMR Monitors require
dual power supplies.
Rack Interface Module: The Rack Interface Module is a full-height module
that communicates with the host (computer), a Bently Nevada Communi-
cation Processor, and with the other modules in the rack. The Rack Inter-
face Module also maintains the System Event List and the Alarm Event
List. This module can be daisy chained to the Rack Interface Module in
other racks and to the Data Acquisition / DDE Server Software. The 3500
Monitoring System Computer Hardware and Software Manual shows how
to daisy chain the Rack Interface Modules together. Rack Interface Mod-
ules are available in Standard, Triple Modular Redundant and Transient
Data Interface versions.
Communication Gateway Module: The Communication Gateway Modules
are full-height modules that allow external devices (such as a DCS or a
PLC) to retrieve information from the rack and to set up portions of the
rack configuration. More than one Communication Gateway Module can
be installed in the same rack. Communication Gateway Modules are avail-
able for a variety of network protocols.
Monitor Module: The Monitor Modules are full-height modules that collect
data from a variety of transducers. Any combination of Monitor Modules
can be installed in the 3500 rack.
Relay Module: Relay Modules offer relays that can be configured to close or
open based on channel statuses from other monitors in the 3500 rack.
Relay modules are available in 4 channel, 16 channel, and 4 channel Tri-
ple Modular Redundant.
8 2.3 Standard Rack Relay Options:
The TMR Relay Module is a half-height 4-channel module that operates in
a Triple Module Redundant (TMR) system. Two half-height TMR Relay
Modules must operate in the same slot. If the upper or lower Relay Mod-
ule is removed or declared as not OK, then the other Relay Module will
control the Relay I/O Module.
Keyphasor Module: The Keyphasor Module is a half-height module that pro-
vides power for the Keyphasor transducers, conditions the Keyphasor sig-
nals, and sends the signals to the other modules in the rack. The
Keyphasor Module also calculates the rpm values sent to the host (com-
puter) and external devices (DCS or PLC) and provides buffered Keypha-
sor outputs. Each Keyphasor Module supports two channels and two
Keyphasor Modules may be placed in a 3500 rack (four channels maxi-
mum). If two Keyphasor Modules are used, they must be placed in the
same full-height slot and will share a common I/O module.
Display Module: 3500 features multiple display options. The Display Inter-
face Module can display rack data on an LCD based Interface unit or a 3
rd
party modbus based display unit. The VGA Display Module will display
rack data on certain touch screen VGA Displays. The Integrated PC dis-
play is a complete rack mount touch screen PC pre-loaded with rack con-
figuration software and display utilities.
Earthing Module: The Earthing Module is a full-height module that provides
a low resistance connection (must be less than 1 ) from the 3500 rack to
the plants intrinsically safe earth ground. The module is used in conjunc-
tion with the 3500 internal zener barrier I/O modules. One Earthing Module
is required per rack when internal barrier I/O modules are used.
2.3 Standard Rack Relay Options:
The standard (or nonTMR) 3500 rack can be configured to have individual
relays, bussed relays, or a combination of individual and bussed relays.
2.3 Standard Rack Relay Options: 9
2.3.1 Individual Relays
A rack with individual relays contains one or more relay cards for each monitor
module. There are many ways to configure the monitor and relay modules
within a 3500 rack.
Example 1:
One relay module is used with one monitor module.
The Alarm Types are ORed in the above example.
Example 2:
Two relay modules are used with one monitor module.
Monitor
Monitor
Channel
Alarm
Type
Relay
Module
Relay
Channel
1
1
1
2
Alert
Alert
1 1
1
1
1
2
Danger
Danger
1 2
1
1
3
4
Alert
Alert
1 3
1
1
3
4
Danger
Danger
1 4
Monitor
Monitor
Channel
Alarm
Type
Relay
Module
Relay
Channel
1 1 Alert 1 1
1 2 Alert 1 2
1 3 Alert 1 3
1 4 Alert 1 4
1 1 Danger 2 1
1 2 Danger 2 2
1 3 Danger 2 3
1 4 Danger 2 4
Example 3:
One relay module is used with one monitor module.
The Alarm Types are ORed in the above example.
The following figure shows a typical Individual Relay layout for a standard
3500 rack. The monitors and relay modules can be placed in any slot as long
as one monitor is linked to one (or more) relay module(s) in the Rack Configu-
ration Software.
Figure 2-1. Typical Standard 3500 Rack with Individual Relays (Full-size
rack shown)
Monitor
Monitor
Channel
Alarm
Type
Relay
Module
Relay
Channel
1
1
1
1
1
2
3
4
Alert
Alert
Alert
Alert
1 1
1
1
1
1
1
2
3
4
Danger
Danger
Danger
Danger
1 2
2.3.2 Bussed Relays
Bussed Relays is a configuration where a number of monitor channels share a
single relay. Use the Rack Configuration Software to define the combination
of alarms that will trigger the relay. The following figure shows a typical
Bussed Relay layout for a standard 3500 rack. The monitors and relay mod-
ules can be placed in any slot as long as the monitors are linked to the relay
module in the Rack Configuration Software.
Figure 2-2. Typical Standard 3500 Rack with Bussed Relays (Full-size
rack shown)
2.3.3 Triple Modular Redundant (TMR) System
Figure 2-3. Typical TMR 3500 System (Full-size rack shown)
For applications that require high system reliability, the 3500 rack is capable of
Triple Modular Redundancy (TMR). The goal of a TMR setup is such that no
single point failure of any component will disable machinery protection for crit-
ical machine points. When a TMR system is configured properly, every func-
tion of the rack is done in duplicate or triplicate to facilitate this goal.
2.3.3.1 Requirements for a 3500 TMR rack:
Rack Jumper must be set to TMR position (see Rack Jumper section of
this manual)
The TMR version of the 3500/20 or 3500/22 Rack Interface Module (TMR
RIM or TMR TDI RIM) must be used.
Two 3500/15 Power Supplies are required. These power supplies should
be connected to independent sources of power. In the event of a failure on
the primary supply, the monitors will use the secondary supply.
TMR monitors are the same as regular monitors only installed in sets of 3
in adjacent slots. The 3 monitors will monitor the same machine point.
Only one monitor is configured in 3500 Rack Configuration Software, the
other two monitors will automatically be configured the same as the first.
The TMR group can use separate transducers for each monitor (discrete).
All I/O modules support TMR with discrete transducers.
Some 3500 monitors are capable of sharing a common transducer across
the triple (bussed). To use bussed transducers the following conditions
must be met:
- The TMR I/O Module for that monitor must be used. If a TMR I/O Mod-
ule is not available for that monitor, discrete transducers must be used.
- The TMR I/O Module must support the desired channel measurement.
- The Bussed ET Block for that monitor must be used.
- Intrinsic Safety Barriers cannot be used with bussed transducers
Application Alert
When using bussed transducers a single point failure
in the transducer or field wiring can cause a loss of
machinery protection.
For truly redundant keyphasors, use 2 3500/25 keyphasor monitors. Con-
figure such that the primary and secondary keyphasors reside on different
keyphasor modules. Non-redundant keyphasors are allowed. There can
be a maximum of 2 keyphasor modules per rack.
Independent monitors may be installed in a TMR rack for monitoring less
critical machine points.
Both standard and TMR relay modules may be used in a TMR rack. The
3500/34 TMR Relay Module can only be configured with to drive relays
from channels in a TMR group. Standard relay modules can only drive
relays from channels in an independent monitor.
Redundant Display modules and Communication Gateways are permitted
but not required. Some modules do have configuration restrictions for
placing multiple modules in a rack; see the Operation and Maintenance
manual for the appropriate module.
2.3.3.2 Features of a properly configured 3500 TMR rack:
Duplicate Power Supplies, All monitors capable of switching between pri-
mary and backup supplies without interruption of monitoring.
Triplicate inter-monitor communication networks between RIM, Relay
Module and TMR groups.
Triplicate alarm voting logic and circuitry
Triplicate relay voting logic and control circuitry
Duplicate processing of alarm information from monitors in the rack
2.3.3.3 TMR Relay Module
A 3500/34 TMR Relay Module consists of 2 half-height Monitors and 1 full size
I/O module. The 2 monitors are configured identically and perform the same
monitoring function redundantly. The I/O module contains triplicate relays and
control logic.
2.3.3.4 Inside a TMR rack
1. Dual 3500 power supplies Independently supply redundant power to each
component in the system
2. TMR Monitor group. Each Channel's status is determined independently in
each monitor
3. Triplicate transducers monitor a single point. Typical for 4 channels. (Dis-
crete transducer inputs shown)
4. 2 3500/34 half-height cards process alarm events from the other monitor
cards in duplicate.
5. TMR Relay I/O module has triplicate relay logic
6. TMR Relay I/O module features 2 out of 3 relay voting.
Figure 2-4.
2.3.3.5 TMR Individual Relays
The following figure shows a typical TMR rack with Individual Relays. This
configuration requires that three identical monitors be placed next to each
other and that the monitors be linked to one relay module using the Rack Con-
figuration Software.
Figure 2-5. Typical TMR 3500 Rack with Individual Relays (Full-size rack
shown)
16 2.4 Intrinsic Safety The 3500 Internal Barrier System
2.3.3.6 TMR Bussed Relays
The following figure shows a typical TMR rack with Bussed Relays. This con-
figuration requires that three identical monitors be placed next to each other
and that the monitor groups be linked to one relay module in the Rack Config-
uration Software.
Figure 2-6. Typical TMR 3500 Rack with Bussed Relays (Full-size rack
shown)
(1) TMR Group 1.
(2) TMR Group 2.
(3) TMR Group 3.
2.4 Intrinsic Safety The 3500 Internal Barrier
System
To provide Intrinsically Safe (I.S.) vibration and process variable monitoring,
the 3500 system has a range of I/O modules with internal zener barriers.
When these modules are installed in a 3500 rack with an Earthing Module,
they provide an integrated solution for explosion protection for approved
Bently Nevada transducer systems that are located within all classifications of
hazardous areas (surface industries other than mining).
The following items are required for a 3500 Internal Barrier System:
2.4 Intrinsic Safety The 3500 Internal Barrier System 17
One 3500/04-01 Earthing Module is required per rack when Internal Barrier I/
O modules are used. The Earthing Module does occupy one slot position in
the rack.
The 3500/15 Power supplies must have their grounding configuration changed
from the default factory setting. See the 3500/15 Operation and Maintenance
Manual (PN 129767-01) for instructions.
Any RS-232 connection to any 3500 Module must be isolated (Monitors sup-
porting RS232 connections include: Rack Interface Modules, Communication
Gateways, 3500/95 PC Display). See the 3500/20 Operation and Mainte-
nance Manual (PN 129768-01) for instructions. This does not apply to RS422
and RS485 connections to the rack (Monitors supporting RS422 and/or
RS485 connections include 3500/20, 3500/90, 3500/92, 3500/93, 3500/95).
The 3500/94 VGA Display is not for use in Internal Barrier Systems
Bussed transducers are not allowed in Internal Barrier Systems (see TMR
section of this manual for more information)
The following are features of the 3500 Internal Barrier System:
The Earthing Module enables dual I.S. Earth connections for cables with
cross-sectional areas up to 10 mm
2
. This module lets you test I.S. Earth
continuity online.
The design of the internal barrier I/O modules provides the necessary 2
inches (50 mm) of separation between safe and hazardous area field wir-
ing.
Field wiring connectors are green for safe areas and blue for hazardous
areas. In addition the pitch of the connectors is different. This helps to
avoid incorrect field wiring installation.
Quick connect/disconnect connectors provide simplified field wiring instal-
lation and removal.
Standard and internal barrier I/O modules can be located in the same
3500 rack. We recommend that you group the modules together as
shown in the diagram below to facilitate connection to field wiring.
18 2.4 Intrinsic Safety The 3500 Internal Barrier System
(1) Earthing Module.
(2) Internal Barrier I/O Modules.
Section 3 -- Initial Rack Installation
3.1 General Installation Procedure 19
3 Initial Rack Installation
This section shows how to install a new 3500 rack.
3.1 General Installation Procedure
1. Review the Installation Checklist (see Installation Checklist on page 19)
2. Install the Weatherproof Housing (if required) (see Weatherproof Housing
Installation on page 19)
3. Install the rack (see Rack Installation on page 29)
4. Set the jumpers and switches on rack (see Set rack jumpers and
switches on page 54)
5. Install the External Termination Blocks (if required) (see External Termi-
nation Blocks on page 44)
6. Install the modules (see Module Installation and Removal on page 57)
7. Wire the transducers, relay, and power to the rack and modules (see Wir-
ing Requirements on page 55)
8. Perform the Software Portion of the Rack Installation (see Software Por-
tion of the Rack Installation on page 56)
3.2 Installation Checklist
Use the following items to plan a 3500 rack installation:
What are the power requirements?
Does the rack fit in the proposed location?
Can the rack be mounted in the proposed location?
Is there enough air circulation in the proposed location?
Is a weatherproof housing required?
What termination is required (internal or external)?
Is a telephone line required?
Is good rack grounding available?
If Internal Barriers are to be fitted, is there an Intrinsically Safe Earth?
3.3 Weatherproof Housing Installation
This section describes the 3500 weatherproof housing and provides
instructions for proper installation.
20 3.3 Weatherproof Housing Installation
3.3.1 General Description
The 3500/06 weatherproof housing is an enclosure designed to meet NEMA 4
requirements and to contain one 3500 series rack (rack mount option only).
The housing is not designed to accommodate a Display Unit or VGA display. It
is available in painted steel or stainless steel versions, with or without conduit
fittings, and with or without air purge accessories. Access to the front of the
rack is provided by a hinged door. Access to the rear of the rack is provided by
a bolted-on cover.
1. 16.70 inches (424.2 mm).
2. 23.43 inches (595.1 mm) full-size,
16.43 (417.3 mm) for the Mini-rack.
3. 16.20 inches (411.5 mm).
4. 3.75 inches (95.3 mm).
5. 21.00 inches (533.4 mm).
6. Panel to which the housing is
mounted.
7. Thread-seal washers supplied with the
housing. To be used under all internal
heads of mounting bolts or nuts to
obtain a water-tight seal.
8. The housing door will latch in this 90
degree position.
9. The housing door will latch in this
135 degree position.
10. The door must be opened to this
position to latch or unlatch the door
in the two shown latching positions.
11. Hinged door for access to front of
rack.
12. Bolted cover for access to rear of
rack.
3.3 Weatherproof Housing Installation 21
CAUTION
The hinged door will NOT latch in the 180 degree
position shown in the diagram above. Do not leave
the door unsupported in this position or else
serious injury could result.
3.3.2 Rack Temperature Derating
Because the housing restricts ventilation to the rack, the maximum ambient
temperature of the rack must be derated. Derating is based on how many
watts the rack is dissipating. Refer to the chart below.
(1) Temperature rise above ambient, degrees
C.
(2) Temperature rise above ambient, degrees
F.
(3) Power dissipated in Watts.
3.3.3 Panel Cutout
The following diagram shows the recommended panel cutout for the 3500/06
weatherproof housing for a full size rack.
1. 21.050 inches (534.7 mm).
2. 16.525 inches (419.7 mm).
3. 10.525 inches (267.3 mm).
4. 4.525 inches (114.9 mm).
5. 0.25 inches (6.4 mm) radius, maxi-
mum (4 places).
6. 13.27 inches (337.1 mm).
7. 6.635 inches (168.5 mm).
8. 0.57 inches (14.5 mm).
9. 12.13 +/- 0.06 inches (308.1 +/- 0.2
mm).
10. 4.37 inches (111.0 mm).
11. 5.00 inches (127.0 mm).
12. 0.50 inches (12.7 mm).
13. 4.87 inches (123.7 mm).
14. 9.75 inches (247.7 mm).
15. 20.05 inches (509.3 mm).
16. 0.281 inches (7.14 mm) diameter clear-
ance hole for 0.250 inches diameter bolt
or mounting studs. 8 places for housing.
12 places for housing and air purge
gauge assembly.
17. This 4-hole pattern is only used when
installing the air purge gauge assembly.
Dimensions are +/- 0.02 inches (+/- 0.51 mm) unless specified otherwise.
The following diagram shows the recommended panel cutout for the 3500/06
weatherproof housing for a Mini-rack.
Dimensions are +/- 0.02 inches (+/- 0.51 mm) unless specified otherwise.
3.3.4 Conduit Fitting Option
The conduit fitting option provides four 1 NPT weatherproof hubs. The
conduit is supplied by the customer, and the percentage of fill should not
exceed 40% as specified in National Electrical Code, 1975, Chapter 9, Tables
1 and 2. The upper conduits are to be used for transducer power, signal input
and recorder output. The lower conduits are to be used for rack power input
and relay wiring. Power input and relay wiring should NOT be mixed with
transducer and recorder wiring. The following diagrams show the hubs
installed onto the housing.
1. 14.050 inches (356.87 mm).
2. 11.525 inches (292.74 mm).
3. 7.025 inches (178.44 mm).
4. 2.525 inches (64.135 mm).
5. 0.25 inches (6.4 mm) radius, maxi-
mum (4 places).
6. 13.27 inches (337.1 mm).
7. 6.635 inches (168.5 mm).
8. 0.57 inches (14.5 mm).
9. 12.13 +/- 0.06 inches (308.1 +/- 0.2
mm).
10. 4.37 inches (111.0 mm).
11. 5.00 inches (127.0 mm).
12. 0.50 inches (12.7 mm).
13. 4.87 inches (123.7 mm).
14. 9.75 inches (247.7 mm).
15. 13.05 inches (331.47 mm).
16. 0.281 inches (7.14 mm) diameter clear-
ance hole for 0.250 inches diameter bolt
or mounting studs. 8 places for housing.
12 places for housing and air purge
gauge assembly.
17. This 4-hole pattern is only used when
installing the air purge gauge assembly.
(1) 1.03 inches (26.2 mm), 4 places.
(2) 19.55 inches (496.6 mm) full size, 12.55
inches (318.77 mm) for Mini-rack.
(3) Customer-supplied conduit, 4 places.
(4) Weatherproof conduit hub. Also shown in
cross-section A-A.
(5) Rear view of housing with rear cover and
typical 3500 rack installed.
(6) O-ring seal.
(7) Housing wall. Arrow points to inside sur-
face of the housing.
(8) Lock ring.
(9) Collar.
3.3.5 Air Purge Option
There are two air purge options:
1. The fittings only option provides four 1 NPT Pour seal type fittings and
one NPT weatherproof hub, with fittings to reduce down to NPT
(female) for air input.
2. The fittings and gauge option provides the fittings listed above, a gauge
assembly, a bulkhead connector and a connecting tube.
When either of the air purge options is required, the conduit fitting option is
also required.
Static purge pressure (the pressure required to insure that a hazardous
atmosphere does not enter the housing) must be above 0.2 inches of water
(0.05 Kilopascals) for installations that require N.F.P.A. 495-1982
specification. For installations that require Canadian Electrical Code C22.1-
1986 specification, pressure must be above 0.25 Kilopascals (1.0 inches of
water). This is measured on the gauge (after housing has been purged) with
valve in the closed position.
Application Alert
This housing is NOT equipped with over pressure
protection. Maximum working pressure should not
exceed 2.49 Kilopascals (10 inches of water).
Purge flow rate (the time required to purge 5 or 10 volumes of air through the
housing) is determined by:
1. Turn the valve to its vent position and read the gauge to determine hous-
ing purge pressure.
2. Find that pressure on the appropriate chart provided below.
3. Determine the size of the housing that is being purged and read from that
column the length of time required to purge the system with your housing
pressure. This number, in minutes, should be permanently marked in the
space provided on the warning label on the housing door.
(1) Use this table for 5X purge per N.F.P.A.
496-1982.
(2) Use this table for 10X purge per Canadian
Electrical Code C22.1-1986, Part 1.
(3) Pressure in inches of water.
(4) Flow (in cubic feet per minute) through air
purge valve.
(5) Time (in minutes) for purging weather-
proof housing.
(6) Pressure in Kilopascals.
(7) Flow (in cubic meters per hour) through air
purge valve.
All tests and recommendations are in accordance with specifications and
requirements made by N.F.P.A. in pamphlet 496-1982 for type Y purge, or
Canadian Electrical Code C22.1-1986, Part 1. For additional information on
purge requirements, refer to the above standards.
The following diagrams show installation of the air purge fittings and gauge.
(1) 3.00 inches (76.2 mm).
(2) 6.00 inches (152.4 mm).
(3) Purge warning label.
(4) 10.50 inches (266.7 mm).
(5) 3.25 inches (88.6 mm).
(6) Drill a 0.43 inches diameter mounting
hole.
(7) Locknut.
(8) Bulkhead fitting.
(9) Connecting tube.
(10) 0.50 inches (12.7 mm).
(1) 31.05 inches (788.7 mm) full size, 24.05
inches (610.87 mm) for Mini-rack.
(2) 5.75 inches (146.1 mm).
(3) Sealing compound.
(4) Weatherproof housing wall, inside surface.
(5) Packing fiber, 2 places.
(6) Pour seal fitting.
(7) Adapter.
(8) Conduit hub.
3.3.6 Installation Instructions
1. Create the appropriate panel cutout for the options to be used.
2. Install the weatherproof housing into the panel cutout.
3.4 Rack Installation 29
3. Secure the housing to the panel with eight inch bolts. Be sure to use the
provided thread seals to ensure a water-tight seal.
4. If required, install the optional fittings and gauge.
5. Install the 3500 system rack per the instructions for a rack-mount system.
6. Remove the rear access cover of the housing.
7. Install the field wiring to the rack.
8. Secure all fittings.
9. Install the housings rear access cover.
Perform the necessary installation tests.
3.4 Rack Installation
This section provides instructions for the proper mounting of each type (Panel
Mount, Rack Mount and Bulkhead Mount) of 3500 full-size and mini-racks.
When mounting a rack, check that the rack is mounted to a grounded surface
and that the features on the front panels of the main modules are accessible.
Be sure to also provide for maintenance access to the I/O modules.
3.4.1 Rack Ventilation
The top and bottom of the rack are perforated to allow cooling air in and
heated air to escape. In order to help ensure adequate ventilation, maintain
the minimum clearances at the top and bottom of the rack as shown below.
30 3.4 Rack Installation
(1) Minimum top clearance = 2.00 inches
(50.4 mm).
(2) Minimum bottom clearance = 2.00 inches
(50.4 mm).
3.4.2 Panel Mount
A 3500 Panel Mount rack is shown in the following diagram. A Panel Mount
rack allows you to install a 3500 rack behind a panel through a sheet metal
cutout and clamp into place.
3.4.2.1 Panel Mount Full-Size Rack
Figure 3-1. Dimensions of a Panel Mount 3500 Full-Size Rack
(1) 10.470 inches (265.94 mm).
(2) 19.000 inches (482.60 mm).
(3) 17.400 inches (441.96 mm).
(4) 9.700 inches (246.38 mm).
(5) 13.750 inches (349.25 mm), 16.650
inches (422.91 mm) if used with internal
barriers
CAUTION
Clamps must not be used as handles while
carrying or installing the rack. The clamps may
fall off resulting in injury to personnel and damage
to the rack.
The required dimensions for the panel cutout, is shown in the following
diagram.
(1) 17.80 +/- 0.06 inches (452.1 +/- 1.5 mm).
(2) 0.125 inches (3.2 mm) radius, maximum.
(3) 9.90 +/- 0.60 inches (251.5 +/- 1.5 mm).
3.4.2.2 Panel Mount Mini-Rack
Figure 3-2. Dimensions of a Panel Mount 3500 Mini-Rack
(1) 10.470 inches (265.94 mm).
(2) 12.000 inches (304.80 mm).
(3) 10.400 inches (264.16 mm).
(4) 9.700 inches (246.38 mm).
(5) 13.750 inches (349.25 mm), 16.650
barriers
CAUTION
Clamps must not be used as handles while
carrying or installing the rack. The clamps may
fall off resulting in injury to personnel and damage
to the rack.
The required dimensions for the panel cutout, is shown in the following
diagram.
(1) 10.80 +/- 0.06 inches (274.3 +/- 1.5 mm).
(2) 0.125 inches (3.2 mm) radius, maximum.
(3) 9.90 +/- 0.60 inches (251.5 +/- 1.5 mm).
3.4.2.3 Instructions for installing panel mount rack
1. Cut panel cutout to the required dimensions.
2. If installed, remove the panel mount clamps from the rack. Slide rack
through panel cutout.
3. Assemble the clamp.
(1) Rear of Rack.
(2) Clamp.
4. Align the rack in the cutout.
5. Tighten the clamping screws.
3.4.3 Rack Mount
3.4.3.1 Full-Size Rack Mount
A Rack Mount 3500 full-size rack is shown in the following diagrams. A Rack
Mounted 3500 system allows you to install the rack into a standard 19-inch
EIA cabinet.
Figure 3-3. Dimensions of a Rack Mount 3500 Full-Size Rack
(1) 10.470 inches (265.94 mm).
(2) 7.500 inches (190.50 mm).
(3) 18.008 inches (457.40 mm).
(4) 19.000 inches (482.60 mm).
(5) 17.400 inches (441.96 mm).
(6) 9.700 inches (246.38 mm).
(7) 13.750 inches (349.25 mm), 16.650
barriers
3.4.3.2 Instructions for installing rack mount 3500 full-size rack
Install the 3500 rack using No. 10 flat washers (4 places) and 10-32 screws (4
places) at the locations shown by the arrows in the diagram below.
3.4.3.3 Mini-Rack Mount
A Rack Mount 3500 mini-rack is shown in the following diagrams. The Mini-
Rack Mounted 3500 system also allows you to install the rack into a standard
19-inch EIA cabinet with the use of the mini-rack Adapter Panel.
Figure 3-4. Dimensions of a Rack Mount 3500 Mini-Rack
(1) 10.470 inches (265.94 mm).
(2) 7.500 inches (190.50 mm).
(3) 11.008 inches (279.60 mm).
(4) 12.000 inches (304.80 mm).
(5) 10.400 inches (264.16 mm).
(6) 9.700 inches (246.38 mm).
(7) 13.750 inches (349.25 mm), 16.650
barriers
3.4.3.4 Instructions for installing a rack mount 3500 Mini-rack
Install the Mini-rack adapter panel into the EIA rack using No. 10 flat washers
(4 places) and 10-32 screws (4 places). Next, install the 3500 Mini-rack onto
the adapter panel using No. 10 flat washers (4 places) and 10-32 screws (4
places).
(1) 3500 Mini-rack
(2) Adapter Panel
(3) Standard 19-inch EIA rack
3.4.4 Bulkhead Mount
A Bulkhead Mount 3500 rack is shown in the following diagrams. Use a 3500
Bulkhead rack when you want to attach the rack to a wall or want to be able to
change the field wiring from the front of the rack.
Note:
The 3500/05 Mini-rack is not available in the Bulkhead
Mount option
Figure 3-5. Dimensions of a Bulkhead Mount 3500 rack
(1) 19.000 inches (482.60 mm).
(2) 18.094 inches (459.59 mm).
(3) 5.250 inches (133.35 mm).
(4) 7.500 inches (190.50 mm).
(5) 5.250 inches (133.35 mm).
(6) 20.970 inches (532.64 mm).
(7) 10.500 inches (266.70 mm).
3.4.4.1 Instructions for installing bulkhead mount 3500 rack
Install the 3500 rack using No. 10 flat washers (8 places) and 10-32 screws (8
places) in the locations shown in the diagram below.
44 3.5 External Termination Blocks
3.5 External Termination Blocks
External and Internal Termination on page 4 briefly described when External
Termination (ET) Blocks and I/O modules would be used and shows a
diagram of the components assembled.
The diagram below shows some of the common DIN rail types that the ET
Blocks can mount to.
3.5 External Termination Blocks 45
(1) U-shaped rail. Dimension A = 35mm and
dimension B = 7.5mm. This rail is referred
to as U-Rail(7.5) in this section.
(2) U-shaped rail. Dimension A = 35mm and
dimension B = 15mm. This rail is referred
to as U-Rail(15) in this section.
(3) G-shaped rail. Dimension A = 32mm and
dimension B = 15mm. This rail is referred
to as G-Rail in this section.
The diagram below shows a Euro-style ET Block mounted on G-Rail.
46 3.5 External Termination Blocks
The diagram below shows a Terminal-strip (or barrier type) ET Block mounted
on G-Rail.
Either ET Block type can be mounted on any of the rail types mentioned
above. For a more detailed picture of a particular ET Block, refer to the manual
of the applicable 3500 monitor.
The table below lists the available ET Blocks and their dimensions. The
location of the dimensions are shown in the diagrams above. All dimensions
are in mm.
Part Number L W
H U-Rail(7.5)
H U-Rail (15)
H G-Rail
C1 C2
128710 68 77 51
59
57
39 39
3.6 Intrinsically Safe Installation 47
3.6 Intrinsically Safe Installation
For correct operation of an I.S. installation, you must maintain a low resistance
path to the I.S. earth point of the plant. Either one or two cables of less than 1
ohm combined resistance must be connected to the Earthing Module in order
to provide a connection between the rack and the plant I.S. earth. These
cables must have a cross-sectional area of between 4 mm
2
and 10 mm
2
.
The optimum solution is to use two cables to connect from the Earthing
Module to plant I.S. earth. This connection lets you test the continuity of the
I.S. earth connection on-line. If one cable is disconnected from the Earthing
Module then the resistance of the two cables can be measured using a
suitable milli-ohm meter. A total resistance of less than 2 ohms will ensure that
the parallel combination of the two cables is less than 1 ohm. Continuity
between the shield of the field wiring from the hazardous area and the
Earthing Module should also be verified.
If the Earthing Module is positioned in the rack such that it would be difficult to
remove one of the I.S. earth cables in order to perform on-line testing, then the
125808
128702
133900
141208
68 77 58
66
63
39 39
128718
133932
136603
140993
90 77 58
66
63
39 39
128726 90 77 51
59
57
39 39
133916 113 77 58
66
63
39 39
128015
133892
133924
136595
141001
113 77 51
59
57
39 39
132242 153 90 67
75
73
46 43
133908
141216
153 90 60
68
65
46 43
132234 178 90 60
68
65
46 43
48 3.6 Intrinsically Safe Installation
standard slotted set screws may be replaced with the Allen headed set screws
provided.
Please refer to Bently Nevada drawing number 138547 for additional
information regarding the installation requirements for an Intrinsically Safe
System.
To avoid ground loops, the system must provide a single point ground. In
Intrinsically Safe applications the 3500 Rack is floated and referenced to an
intrinsically safe ground instead of earth ground. RS-232 communications are
referenced to earth ground, and therefore to keep the rack isolated from earth
ground, a serial data isolator must be used. RS-485 uses an isolated ground
and no additional isolation is required.
The following diagram shows the connections for testing the I.S. earth
resistance.
Figure 3-6. Testing I.S. earth resistance.
3.7 High Electromagnetic Noise Environment and European Conformance (CE) Rack Installation 49
3.7 High Electromagnetic Noise Environment
and European Conformance (CE) Rack
Installation
For the high electromagnetic noise environment or CE installation, the system
rack, EMI shield, and cables must be thoroughly grounded to provide a ground
path for electromagnetic energy (see figures below). The Bulkhead Rack and
External Termination Blocks must be mounted inside an Electromagnetic
Interference (EMI) shielded area.
Figure 3-7. Typical Installation - Standard Rack with Internal Termination
I/O Modules (Top View of Full-Size Rack Shown).
(1) Grounded Cabinet.
(2) 3500 Monitoring System.
(3) Front of Rack.
(4) Field Wiring Cables with Both Foil and
Braid Shield.
(5) Cable Shields Terminated to EMI Shield.
50 3.7 High Electromagnetic Noise Environment and European
Figure 3-8. Typical Installation - Standard Rack with External Termina-
tion I/O Modules, External Termination Blocks Installed Inside the Cabi-
net (Top View of Full-Size Rack Shown).
(1) External Termination Blocks, Mounted
Inside EMI Shielded Area.
(2) EMI Shielded Area.
(4) Front of Rack.
Braid Shielding.
Figure 3-9. Typical Installation - Standard Rack with External Termina-
tion I/O Modules, External Termination Blocks Installed in a Junction
Box (Top View of Full-Size Rack Shown).
(1) Grounded Cabinet.
(3) Front of Rack.
(4) Multi-Conductor Cables with Both Foil and
Braid Shielding.
(6) External Termination Block Junction Box.
Is Also an EMI Shielded Area.
Braid Shielding.
Figure 3-10. Typical Installation - Bulkhead Rack with Internal Termina-
tion I/O Modules (Top View Shown).
(3) Front of Rack.
Braid Shielding.
(5) Cable Shields Terminated to EMI shield.
Figure 3-11. Typical Installation - Bulkhead Rack with External Termina-
tion I/O Modules, External Termination Blocks Installed Inside the Cabi-
net (Top View Shown).
(3) Front of Rack.
52 3.7 High Electromagnetic Noise Environment and European
(4) External Termination Blocks, Mounted
Inside EMI Shielded Area.
Braid Shielding.
Figure 3-12. Typical Installation - Bulkhead Rack with External Termina-
tion I/O Modules, External Termination Blocks Installed in a Junction
Box (Top View Shown).
(3) Front of Rack.
(4) Multi-conductor Cable with Both Foil and
Braid shielding.
(5) Cable Shields Terminated to EMI shield.
(6) External Termination Block Junction Box.
Is Also an EMI Shielded Area.
Braid Shielding.
3.7.1 Wiring
All wiring exiting the metal cabinet or EMI shielded area must be shielded.
Acceptable EMI shielding includes metal conduit or multi-conductor cables
with both foil and braid shielding. In places where cables enter shielded
areas, the cable shield should make good electrical contact with the EMI
shield and any subsequent junction enclosure. This contact drains off EMI
energy from the cable before the cable enters the shielded area.
3.7.2 Considerations for CE Installation to a Public Power Supply
For systems installed in areas that require compliance to EN61000.3.2, the
equipment shall only be used in industrial environment with a connection to
the industrial power supply network. If the system is connected to the public
power supply mains, EN61000.3.2 must be met by using a third party device
that provides power factor correction.
3.7.3 Considerations for I.S. systems
3.7.3.1 Field Wiring to the Hazardous Area
This should be of steel wire armored construction and should be connected to
the EMI shielded area using a suitable cable gland. The inner cores should
have an overall screen of foil with a drain wire to connect to the barrier shield
terminal of the I/O module. Cables manufactured to BS5308 Part 1, or similar
national or international standards, are suitable.
3.7.3.2 Connecting the I.S. Earth
To ensure that EMI is not picked up by or radiated from the I.S. earth cables,
install a feed-through capacitor on each I.S. earth cable. These capacitors
must be installed at the boundary of the EMI shielded area. A Schaffner
FN7000 Series or similar bulkhead mounting type is recommended.
Critical filter parameters are:
500 V isolation.
25 A continuous rated current.
Less than 0.1ohm resistance.
At least 47 nF capacitance.
Screw terminals with locking washers at each end.
CAUTION
The series resistance of the filter has to be taken
into account when planning the installation of the
I.S. cables, since the total resistance of the
combination of cables and filters must be less
than 1 ohm.
3.7.4 Additional Notes
Larger scale factors are less susceptible to EMI than smaller scale factors.
Larger full-scales are less susceptible to EMI than smaller full-scale.
Monitors with narrow bandwidth filter configurations are less susceptible to
EMI than monitors configured with wide bandwidth.
Larger Keyphasor or hysteresis settings are less susceptible to EMI than
smaller hysteresis settings.
Shorter Alarm delay times may increase monitor susceptibility to transient
EMI.
54 3.8 Set rack jumpers and switches
Environments with higher levels of EMI than tested may cause unpredict-
able monitor readings and may cause system malfunction.
3.8 Set rack jumpers and switches
Set the following jumpers and switches before operating the rack:
Rack address switch (on the front of the Rack Interface Module)
Transducer jumpers on each I/O Module, as required
Certain I/O Modules have switches to control their mode of operation.
Examples include:
- RIM and Comm Gateway I/Os that support both RS232 and RS422
have a protocol selection switch
- Overspeed and non-TMR Relay I/Os have Normally Energized/De-
energized Relay mode switches
- Comm Gateway I/Os that support RS485 have termination mode
switches
Setup phone connection to rack / host (if you use an internal or external
modem)
Phone cable to internal modem in rack
OR
Phone cable to modem and RS-232 cable from modem to rack
TMR / SIM jumper on the inside of the 3500 Rack backplane between the
Power Supply and the Rack Interface Module as shown in the diagrams
below.
3.9 Wiring Requirements 55
(1) Ten-legged jumper must be placed in this
position for Standard 3500 rack.
(2) Ten-legged jumper must be placed in this
position for TMR 3500 rack.
Note:
If the ten-legged jumper is not installed in one of the
above positions, the rack will not operate correctly.
3.9 Wiring Requirements
Refer to the individual module manuals and field wiring diagrams for detailed
instructions for connecting components to the I/O module. Refer to the
weatherproof housing section for information specific to those installations.
Refer to the high electromagnetic noise environment section for information
applicable to those installations.
Connect the I/O modules in the 3500 rack to the following items.
Transducers (match the selected transducer jumpers)
Keyphasor transducers
Power
Connect the external devices to the following terminals.
Relay outputs
OK Relay on the back of the Rack Interface I/O Module
56 3.10 Software Portion of the Rack Installation
System Contacts (Trip Multiply, Inhibit, Rack Reset, etc)
3.10 Software Portion of the Rack Installation
Now that the hardware portion of the 3500 rack installation is complete, refer
to 3500 Monitoring System Rack Configuration and Utilities Guide to configure
and verify the 3500 Monitoring System. The following steps should be
performed in the order presented to configure your rack.
Verify the Rack Communication
Upload Default Configuration from the rack
Customize the Rack Configuration
Download the Configuration to rack
Adjust the Scale Factor, Zero Position, and Manual Keyphasor Thresh-
old
Download any adjustments
Perform Rack Verification
Section 4 -- Module Installation and Removal
4.1 Installation of Modules 57
4 Module Installation and Removal
This section shows how to install and remove the individual modules (includ-
ing I/O modules) in a 3500 rack.
In all discussions, the main module is the part that gets installed in the front of
the rack-mount and panel-mount racks or in the bottom of the bulkhead rack.
They have the blue overlays with the model number printed on them.
The input or I/O modules are the parts that get installed at the rear of the rack-
mount and panel-mount racks or in the top of the bulkhead rack. This is where
the power and field wiring connections are made.
4.1 Installation of Modules
The following section describes how to install modules in a 3500 rack. It is
assumed that the applicable slot is empty. Power to the rack does not need to
be removed before installing a module if the procedures below are followed.
4.1.1 Power Supplies
The following lists general steps for installing the 3500/15 power supplies.
Refer to the specific manual for the power supply for details and safety consid-
erations. Verify that the main module and the Power Input Module (PIM) are
compatible before proceeding.
1. Install the PIM.
- Configure the PIM for Single Point Ground, if necessary.
- Attach power cord to the PIM, if it is deemed to be more convenient at
this time. Be sure that the power cord is not live.
- Place the PIM into place at the back (or top for bulkhead racks) of the
rack. Tighten the screws to pull the PIM securely against the rack.
2. Install the main module.
- Slide the main module into place. Ensure that the module is properly in
the guides provided on the rack.
- Tighten the screws securely.
Note:
It is important to tightly secure the thumb screws to
ensure each module is Chassis grounded. Loose
thumb screws may allow noise to show on the channel
readings.
3. Verify operation.
- When appropriate, apply power to the PIM and verify operation of the
power supply.
58 4.1 Installation of Modules
4.1.2 Full-height modules
The following lists general steps for installing any full-height 3500 module.
Refer to the specific manual for the module for details and safety consider-
ations. Verify that the main module and the I/O module are compatible before
proceeding.
1. Install the I/O module.
- Configure the I/O module for available options, if necessary.
- Place the I/O module into place at the back (or top for bulkhead racks)
of the rack. Tighten the screws to pull the I/O module securely against
the rack.
- Attach field wiring to the I/O module, if appropriate at this time.
- Ensure that the ejectors are in their normal position, flush with the front
of the module.
- Slide the main module into place, ensuring that they are properly in the
guides provided on the floor and roof of the rack chassis.
4.1 Installation of Modules 59
Note:
readings.
4.1.3 Half-height modules
The following lists general steps for installing any half-height 3500 module
other than the power supplies. Refer to the specific manual for the module for
details and safety considerations. Verify that the main module and the I/O
module are compatible before proceeding.
1. Install the half-height card guide. This may require removing other mod-
ules in the rack in order to make room for getting the guide into place.
2. Install the I/O module.
- Configure the I/O module for available options, if necessary.
60 4.2 Removal of Modules
- Place the I/O module into place at the back (or top for bulkhead racks)
of the rack. Tighten the screws to pull the I/O module securely against
the rack.
- Attach field wiring to the I/O module, if appropriate at this time.
- Slide the main module into place, ensuring that they are properly in the
guides provided on card guide and the rack chassis.
Note:
readings.
4.2 Removal of Modules
The following section describes how to remove the modules in a 3500 rack.
Power to the rack does not have to be removed if the following procedures are
followed.
4.2.1 Power Supplies
The following lists general steps for removing the 3500/15 power supplies.
Refer to the specific manual for the power supply for details and safety consid-
erations.
1. Remove power to the PIM.
- Remove power to the PIM that is to be removed. Observe applicable
safety precautions while handling the power cables.
2. Remove the main module.
- Loosen the screws to the main module so that they are free of the rack
chassis, but still attached to the main module.
- Use the loose screws as handles to pull the main module out of the
rack.
- Use caution when handling because the unit may still be carrying a
charge.
3. Remove the PIM.
- Loosen the screws holding the PIM to the rack. As the screws are
loosened, they will push the PIM away from the rack.
- Use caution when handling because the unit may still be carrying a
charge.
4.2 Removal of Modules 61
4.2.2 Full-height modules
The following lists general steps for removing any full-height 3500 module.
Refer to the specific manual for the module for details and safety consider-
ations.
1. Remove the main module.
- Use the ejectors to pry the main module loose from the backplane con-
nectors.
- Once freed from the backplane, the main module can be removed
completely from the rack.
2. Remove the field wiring from the I/O module.
- See the applicable manual for removing the connector headers or
computer-type cables.
3. Remove the I/O module.
- Loosen the screws holding the I/O module to the rack. As the screws
are loosened, they will push the I/O module away from the rack.
62 4.2 Removal of Modules
4.2.3 Half-height modules
The following lists general steps for removing any half-height 3500 module
other than the power supplies. Refer to the specific manual for the module for
details and safety considerations.
1. Remove the main modules. It does not matter if the upper or lower main
module is removed first.
- Use the loose screws as handles to pull the main module out of the
rack.
2. Remove the half-height card guide.
- See the applicable manual for removing the connector headers or
computer-type cables.
4. Remove the I/O module.
- Loosen the screws holding the I/O module to the rack. As the screws
are loosened, they will push the I/O module away from the rack.
4.3 Replacing Modules 63
4.3 Replacing Modules
When replacing modules, whether main or I/O, power does not need to be
removed from the rack if the following procedures are followed. Refer to appli-
cable steps in the procedures above for removing or installing a module.
4.3.1 Main Modules
This assumes that only the main module of a monitor or power supply is to be
replaced. Prior to removing any module, refer to the applicable manual to see
how rack behavior may be affected, and for any special handling requirements
required for personal safety.
1. If necessary, upload and save the configuration of the module to be
replaced.
2. Remove the main module from the rack.
3. Install the new main module into the rack.
4. If necessary, configure the new main module.
4.3.2 I/O Modules
This assumes that only the I/O module of a monitor or the PIM of a power sup-
ply is to be replaced. Prior to removing any module, refer to the applicable
manual to see how rack behavior may be affected, and for any special han-
dling requirements required for personal safety.
1. If necessary, upload and save the configuration of the module to be
replaced.
2. Remove the main module from the rack.
4. Remove the old I/O module from the rack.
5. Install the new I/O module into the rack.
6. Connect the field wiring to the new I/O module.
7. Install the main module into the rack.
8. If necessary, re-configure the main module.
64 5.1 General Maintenance Instructions
5 Maintenance
5.1 General Maintenance Instructions
The boards and components inside of 3500 modules cannot be repaired in the
field. Maintaining a 3500 rack consists of testing module channels to verify
that they are operating correctly. Modules that are not operating correctly
should be replaced with a spare.
When performed properly, modules may be removed from or installed into the
rack while power is applied to the rack. Refer to Initial Rack Installation on
page 19 for the proper procedure.
The 3500 Monitoring System is a high precision instrument that requires no
calibration. The functions of the 3500 modules, however, must be verified at
regular intervals. All modules in the 3500 Monitoring System should be veri-
fied at these maintenance intervals. The procedures in the Maintenance and
Troubleshooting sections of the module manuals describe the verification and
troubleshooting process.
5.2 Choosing a Maintenance Interval
Use the following approach to choose a maintenance interval:
Start with an interval of one year and then shorten the interval if any of the
following conditions apply:
- the monitored machine is classified as critical
- the 3500 rack is operating in a harsh environment such as in extreme
temperature, high humidity, or in a corrosive atmosphere
At each interval, use the results of the previous verifications and ISO Pro-
cedure 10012-1 to adjust the interval.
Section 6 -- Ordering Information
6.1 Rack Ordering Information 65
6.1 Rack Ordering Information
3500/05-AXX-BXX-CXX-DXX-EXX
A: Rack Size
0 1 19-inch Rack (14 Module Slots)
0 2 12-inch Mini-Rack (7 Module Slots)
B: Mounting Options
0 1 Panel Mount Option, Full-Size Rack
0 2 Rack Mount Option, Full-Size Rack (mounts
to19-inch EIA Rack)
0 3 Bulkhead Mount Option (Not available in
Mini-Rack)
0 4 Panel Mount Option, Mini-Rack
0 5 Rack Mount Option, Mini-Rack
C: Agency Approval
Option
0 0 None
0 1 CSA-NRTL/C
D: Reserved
0 0
E: European
Compliance Option
0 0 None
0 1 CE
6.2 Weatherproof Housing Ordering Information
3500/06-AXX-BXX-CXX-DXX
Note:
The 3500/06 Weatherproof Housing does not provide
a smaller version designed specifically for the 3500/05
Mini-rack. Use of the Mini-rack in the Weatherproof
Housing will require installation of the Mini-rack
Adapter Panel. A Door Only option does exist for the
Mini-Rack.
66 6.3 Earthing Module Ordering Information
Note:
The 3500/06 Weatherproof Housing is not designed to
accommodate a Display Unit or a VGA Display.
A: Housing Type
0 1 Painted Steel Housing
0 2 Stainless Steel Housing
0 3 Painted Steel Door Only, Full-Size Rack
0 4 Stainless Steel Door Only, Full-Size Rack
0 5 Painted Steel Door Only, Mini-Rack
0 6 Stainless Steel Door Only, Mini-Rack
B: Conduit Fitting
Option
0 0 No Fittings Required
0 1 Conduit Fittings Requi r ed
C: Air Purge Option
0 0 No Air Purge Accessories Required
0 1 Air Purge Fittings Only
0 2 Air Purge Fittings and Gauge
D: Agency Approval
Option
0 0 None
6.3 Earthing Module Ordering Information
3500/04-AXX
A: Module Type
0 1 Earthing Module
Note:
This option requires one monitor slot position in the
rack.
Section 6 -- Ordering Information
6.4 Spares 67
6.4 Spares
Part Number: Descripti on
00517016: TMR/SIM j umper (i nstal led on the 3500 backplane)
00530843: 3500/42 Prox/Seismic I/O Module four pin connector shunt
131150-01: Power Suppl y Blank Front Panel
131151-01: Hal f-height Blank Front Panel
130944-01: Full-hei ght Blank Front Panel
130768-01: Bl ank Slot Assembly (Front and Rear)
136719-01: Earthing Module
138257-01: Earthing Module Front Panel Assy
144863-01: Adapter Panel , Mini -rack, 19-inch
Half Height Module Adapter:
125388-01: Chassis
125565-01: Card Guide
04300111: Screws (order 3 per adapter )
68 7.1 Dimensions (overall)
7 Specifications
7.1 Dimensions (overall)
Panel Mount Full-Size Rack:
Width: 482.6 mm (19.0 i n)
Height: 265.9 mm (10.47 in)
Depth: 349.3 mm (13.75 in)
Depth with internal
barriers: 423.0 mm (16.65 in)
Rack Mount Full-Size Rack:
Width: 482.6 mm (19.0 i n)
Height: 265.9 mm (10.47 in)
Depth: 349.3 mm (13.75 in)
Depth with internal
Bulkhead Mount Rack:
Width: 482.6 mm (19.0 i n)
Height: 532.6 mm (20.97 in)
Depth: 266.7 mm (10.50 in)
Depth with internal
Panel Mount Mini-Rack:
Width: 304.8 mm (12.0 i n)
Height: 265.9 mm (10.47 in)
Depth: 349.3 mm (13.75 in)
Depth with internal
Section 7 -- Specifications
7.2 Weight 69
Rack Mount Mini-Rack:
Width: 304.8 mm (12.0 i n)
Height: 265.9 mm (10.47 in)
Depth: 349.3 mm (13.75 in)
Depth with internal
Weatherproof Housing:
Width: 595.1 mm (23.43 in)
Height: 424.2 mm (16.70 in)
Depth: 628.7 mm (24.75 in)
7.2 Weight
Basic (Unloaded Full-Size Rack):
Panel Mount
Configuration: 7.03 kg (15.5 lb)
Rack Mount
Bulkhead Mount
Standard Fully
Loaded Full-Size
System:
Panel Mount
Rack Mount
Bulkhead Mount
70 7.3 Environmental (All 3500 Components)
Internal Barrier
System (typical fully
loaded
configuration): This wil l add approxi matel y 4.00 kg (8.96 lb) to the above
wei ghts.
Basic (Unloaded Mini-Rack):
Panel Mount
Rack Mount
Standard Fully Loaded Mini-Rack System:
Panel Mount
Rack Mount
Internal Barrier
Mini-Rack System
(typical fully loaded
configuration): This wil l add approxi matel y 2.39 kg (5.27 lb) to the above
wei ghts.
7.3 Environmental (All 3500 Components)
Temperature:
Operating: -30 C to 65 C (-22 F to 150 F)
Operating (Internal
Barriers): 0 C to 65 C (32 F to 150 F)
Storage: -40 C to 85 C (-40 F to 185F)
Humidity: 0% to 95% non-condensing
Mechanical:
Impact: 10 g for 11 ms
7.3 Environmental (All 3500 Components) 71
Shipping: per mil Std 810D - Category G equipment
Vibration, Sinusoidal: 3 g at 5 to 100 Hz
72 7.3 Environmental (All 3500 Components)
Revision G, April 2002
3500/15
AC AND DC POWER
SUPPLIES
OPERATION AND
MAINTENANCE MANUAL
Copyright 2001 Bently Nevada LLC.
The following are trademarks of Bently Nevada LLC. in the United States and other
countries:
Actionable Information, Actionable Information to the
Right People at The Right Time, ADRE, Bently
Nevada, CableLoc, Data Manager, Decision
Support, DemoNet, Dynamic Data Manager,
Dynamic Transmitor, Engineer Assist,
FieldMonitor, FluidLoc, FlexiTIM, FlexiTAM,
Helping you Protect and Manage All Your Machinery,
HydroVU, Key , Keyphasor, Machine Condition
Manager 2000, MachineLibrary, MicroPROX,
Move Data, Not People, Move Information, Not
Data, Performance Manager, PROXPAC,
Proximitor, REBAM, Seismoprobe, System 1,
TDIXconnX, Tecknowledgy, TipLoc,
TorXimitor, Transient Data Manager,
Trendmaster, TrimLoc, VAM, Velomitor,
Xlerometer
The Bently Nevada LLC Orbit Design is a trademark of
Bently Nevada Corporation in the United States and
other countries.
The following ways of contacting Bently Nevada LLC are provided for those times when you
cannot contact your local Bently Nevada representative:
Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 782 9259
3500/15 Operation and Maintenance
iii
Note:
This manual does not contain all the information required to
operate and maintain the AC and DC Power Supplies. Refer
to the following manuals for other required information.
3500 Monitoring System Rack Installation and Maintenance Manual (129766-01)
general description of a standard system
general description of a Triple Modular redundant (TMR) system
instructions for installing and removing the module from a 3500 rack
drawings for all cables used in the 3500 Monitoring System
3500 Monitoring System Rack Configuration and Utilities Guide (129777-01)
guidelines for using the 3500 Rack Configuration software for setting the operating
parameters of the module
guidelines for using the 3500 test utilities to verify that the input and output terminals on
the module are operating properly
instructions for connecting the rack to a 3500 host computer
iv
Contents
1 Receiving and Handling Instructions.........................................1
1.1 Receiving Inspection ..................................................................................................1
1.2 Handling and Storing Considerations .........................................................................1
1.3 Disposal Statement ....................................................................................................1
2 General Information.....................................................................2
2.1 Power Supply Versions...............................................................................................3
2.2 Single Power Supply ..................................................................................................3
2.3 Redundant Power Supplies ........................................................................................3
2.4 CE Compliance information........................................................................................3
2.5 Low Voltage Directive Compliance .............................................................................4
3 Configuration Information...........................................................5
3.1 Software Configuration Options..................................................................................5
4 Power Input Module Description................................................6
4.1 AC Power Input Module (Low Voltage version)...........................................................6
4.2 AC Power Input Module (High Voltage version)..........................................................7
4.3 DC Power Input Module (High Voltage version)..........................................................8
4.4 DC Power Input Module (Low Voltage version) ..........................................................9
4.5 Connecting Single Point Ground ..............................................................................10
5 Maintenance...............................................................................12
6 Troubleshooting.........................................................................13
6.1 LED Fault Conditions................................................................................................13
7 Ordering Information.................................................................14
8 Specifications ............................................................................15
3500/15 Operation and Maintenance 1 Receiving and Handling Instructions
1
Visually inspect the module for obvious shipping damage. If shipping damage is
apparent, file a claim with the carrier and submit a copy to Bently Nevada
Corporation.
Circuit boards contain devices that are susceptible to damage when exposed to
electrostatic charges. Damage caused by obvious mishandling of the board will
order given.
Application Alert
Machinery protection may be lost when this module is
possible causes include ungrounded soldering irons, nonconductive plastics,
and similar materials.
Velostat No. 2060) before handling or maintaining a printed circuit board.
Use extra caution during dry weather. Relative humidity less than 30% tends
to multiply the accumulation of static charges on any surface.
When performed properly, this module may be installed into or removed from
the rack while power is applied to the rack. Refer to the Rack Installation and
Maintenance Manual (part number 129766-01) for the proper procedure.
Customer and third parties that are in control of product at the end of its life or at
the end of its use are solely responsible for proper disposal of product. No
person, firm, corporation, association or agency that is in control of product shall
dispose of it in a manner that is in violation of United States state laws, United
States federal laws, or any applicable international law. Bently Nevada
the end of its use.
2 General Information 3500/15 Operation and Maintenance
2
The 3500 Power Supplies are half-height modules and must be installed in the
specially designed slots at the left side of the rack. The 3500 rack can contain
one or two power supplies (any combination of AC and DC). Either supply can
power a full rack. If installed, the second supply acts as a backup for the
primary supply. Removing or inserting a power supply module will not disrupt
operation of the rack as long as a backup supply is installed.
The 3500 Power Supplies accept a wide range of input voltages and converts
them to voltages acceptable for use by other 3500 modules.
1) The Supply OK LED on the front of
each power supply module indicates
if all of the output voltages from that
supply are within specification.
3500/15 Operation and Maintenance 2 General Information
3
2.1 Power Supply Versions
Three Power Supply versions are available with the 3500 Monitoring System: the
AC Power Supply, the High Voltage DC Power Supply, and the Low Voltage DC
Power Supply.
The 3500 AC Power Supply accepts two ranges of AC input voltages by using
two versions of the Power Input Module (PIM). The High Voltage AC PIM
accepts inputs from 175 to 264 Vac rms. The Low Voltage AC PIM accepts
inputs from 85 to 132 Vac rms.
The High Voltage DC supply supports DC inputs from 88 to 140 Vdc. The Low
Voltage DC Supply supports DC inputs from 20 to 30 Vdc.
2.2 Single Power Supply
The 3500 will operate under fully loaded conditions with a single power supply.
When a single power supply is used, it is recommended that the supply be
located in the upper position.
2.3 Redundant Power Supplies
When two power supplies are installed in a rack, the supply in the lower slot acts
as the primary supply and the supply in the upper slot acts as the backup supply.
If the primary supply fails, the backup supply will provide power to the rack
without interrupting rack operation.
Each supply provides power on an independent power distribution network. This
ensures that any failure in one power distribution network (example: short in +5
volt supply) will not affect the second supply.
Note:
Redundant power supplies are required for Triple Modular
Redundant (TMR) applications.
2.4 CE Compliance information
For systems installed in areas that require compliance to EN61000.3.2, the
equipment shall only be used in industrial environment with a connection to the
industrial power supply network. If the system is connected to the public power
supply mains, EN61000.3.2 must be met by using a third party device that
provides power factor correction.
4
2.5 Low Voltage Directive Compliance
To comply with EN 61010-01 Low Voltage Directive the PIM Connector Shield
should be orientated properly. If the shield is not installed the same as the figure
below carefully remove the shield and replace it in the correct orientation.
Failure to correctly place the connector shield will make the power terminals
accessible to an operator.
Connector Shield Standard Rack Connector Shield Bulkhead Rack
3500/32 and 3500/34 Operation and Maintenance 3 Configuration Information
5
3 Configuration Information
The process of identifying the type of Power Supply and setting operating
parameters is called configuration. To configure a Power Supply, use this
section to gather configuration information, then use the Rack Configuration
Software to set the options and download the settings to the rack. The Rack
Configuration and Utilities Guide explains how to connect a computer to a rack
and run the Rack Configuration Software.
3.1 Software Configuration Options
The Power Supply configuration field is on the option screen of the Rack
Interface Module.
Any combination of the following Power Supply options can be used in the upper
and lower slots of the rack:
None
AC High Voltage
AC Low Voltage
DC High Voltage
DC Low Voltage
4 I/O Modules Description 3500/15 Operation and Maintenance
6
4 Power Input Module Description
The Power Input Module is half-height and connects the power source to the
Power Supply. Install the Power Input Module behind the Power Supply (in a
Rack Mount or a Panel Mount rack) or above the Power Supply (in a Bulkhead
rack). For example, if the Power Supply is installed in the upper slot then its
Power Input Module must be installed in the upper slot. Removing or inserting a
Power Input Module will not disrupt operation of the 3500 rack as long as the
other Power Supply and its associated Power Input Module are installed.
4.1 AC Power Input Module (Low Voltage version)
Use the AC Power Input Module (Low Voltage version) when the rack will be
powered by low voltage AC (85 to 132 Vac, rms).
Refer to the 3500 Field Wiring Diagram Package for
connecting the power to this Power Input Module.
CAUTION
Proper rack chassis grounding requires that
this metal strap remain connected. Failure to
follow this warning could expose personnel to
dangerously high voltage levels that could
cause shock, burns, or death.
3500/15 Operation and Maintenance 4 I/O Modules Description
7
4.2 AC Power Input Module (High Voltage
version)
Use the AC Power Input Module (High Voltage version) when the rack will be
powered by high voltage AC (175 to 264 Vac, rms).
CAUTION
8
4.3 DC Power Input Module (High Voltage
version)
Use the DC Power Input Module (High Voltage version) when the rack will be
powered by high voltage DC (88 to 140 Vdc).
CAUTION
9
4.4 DC Power Input Module (Low Voltage version)
Use the DC Power Input Module (Low Voltage version) when the rack will be
powered by low voltage DC (20 to 30 Vdc).
CAUTION
10
4.5 Connecting Single Point Ground
To avoid ground loops, the system must provide a single point ground. The
Power Input Modules come with a switch that lets you control where the system
is grounded. If two Power Supplies are installed then both switches need to be
set to the same position. A CLOSED switch grounds the system through the
GND terminal on the Terminal Strip connector. If the system is grounded at
another location, such as when internal/external barriers are used, you need to
be sure the switch is OPENED. The following figure and steps show how to set
the switch to the desired position. For most racks the switch will be set to
CLOSED at the factory; if Internal Barriers are installed at the factory the switch
will be set to the OPENED position.
1) When the switch is
pushed to this side the
switch is in the
CLOSED position.
2) When the switch is
pushed to this side the
switch is in the
OPENED position.
3) Grounding switch.
Depending on model,
this switch could be
located directly above or
below the input
connector.
CAUTION
High voltage may be present on the AC and DC Power
Supplies for several minutes after removal from the rack.
11
Note:
For systems with internal/external barriers, refer to the 3500
Field Wiring Diagram Package for grounding requirements.
1) Remove the line cord protection cover from the Terminal Strip connector.
2) Remove the Phillips screw from the side. The screw holds the sheet metal
cover on the Power Input Module.
3) Loosen the two screws that hold the Chassis ground clip. The screws are
located below the Terminal Strip connector. Remove the Chassis ground clip.
4) While disengaging the sheet metal tab on the bottom of the sheet metal
cover, slide the sheet metal cover over the Terminal Strip connector.
5) Slide the switch to the desired position.
6) Replace the cover and the Chassis ground clip on the Power Input Module.
6 Troubleshooting 3500/32 and 3500/34 Operation and Maintenance
12
5 Maintenance
This section shows how to verify that the Power Supplies and Power Input
Modules are operating correctly.
When performed properly, this module may be removed from the rack while
power is applied to the rack. Refer to the Rack Installation and Maintenance
Manual (part number 129766-01) for the proper procedure.
If a problem is detected with a Power Supply or a Power Supply has been
removed or installed, one of the following messages will be entered in the
System Event List:
Message Description
Supply OK / Installed A Power Supply has been installed or a Power
Supply has gone from a not OK condition to an
OK condition.
Supply Faulted /
Removed
A Power Supply has been removed or a Power
Supply has gone not OK.
3500/15 Operation and Maintenance 6 Troubleshooting
13
6 Troubleshooting
This section describes how to troubleshoot a problem with the Power Supply or the
Power Input Module.
WARNING
AC LINE connected voltage is present. This voltage could cause shock,
burns or death. Use proper isolation techniques.
WARNING
Power Supply shield may be hot when the rack is operating at elevated
temperatures or under full load.
WARNING
High voltage may be present on the AC and DC Power Supplies for several
minutes after removal from the rack.
6.1 LED Fault Conditions
If the Power Supply OK LED is off, check the following items:
1) Verify that the correct voltage is connected to the Power Input Module.
2) Verify that the installed Power Input Module matches the installed Power
Supply. For example, an AC Power Input Module with the AC version of the
Power Supply.
3) Check to see if the fuse on the Power Input Module has blown. If the fuse is
blown, replace it. A blown fuse may be due to:
a) Severe over voltage on the Power Input Module.
b) A fault within the 3500 Power Supply.
4) If steps 1 through 3 do not solve the problem:
a) Install a new Power Supply. If the Power Supply OK LED comes on,
the original Power Supply is faulty.
b) If the problem persists, the Power Input Module may be damaged.
Contact Bently Nevada Corporation.
8 Specifications 3500/15 Operation and Maintenance
14
A B C
Part number 3500/15 - - -
A Power Supply Type (Top Slot)
0 1 Low Voltage AC (85 to 132 Vac)
0 2 High Voltage AC (175 to 264 Vac)
0 3 High Voltage DC (88 to 140 Vdc)
0 4 Low Voltage DC (20 to 30 Vdc)
B Power Supply Type (Bottom Slot)
0 0 No supply (used when only one supply is required)
0 1 Low Voltage AC (85 to 132 Vac)
0 2 High Voltage AC (175 to 264 Vac)
0 3 High Voltage DC (88 to 140 Vdc)
0 4 Low Voltage DC (20 to 30 Vdc)
C Agency Approval Option
0 0 None
0 1 CSA-NRTL/C
Spares
AC Power Supply Module 127610-01
High Voltage AC Power Input Module (PIM) 125840-01
Low Voltage AC Power Input Module (PIM) 125840-02
Replacement Fuse (Both AC PIMs) 01720025
High Voltage DC Power Supply Module 129486-01
High Voltage DC Power Input Module (PIM) 129478-01
Replacement Fuse (High Voltage DC PIM) 01720025
Low Voltage DC Power Supply Module 133292-01
Low Voltage DC Power Input Module (PIM) 133300-01
Replacement Fuse (Low Voltage DC PIM) 01720045
Power Supply Module Manual 129767-01
3500/15 Operation and Maintenance 8 Specifications
15
8 Specifications
INPUTS
Low Voltage AC: Input: 85 to 132 Vac rms (120 to 188 Vac, pk)*
Frequency: 47 to 63 Hertz.
Input Current: 4.5 A rms Max
Input Power: 194 W Max
Efficiency: .8 min, typical
Power Factor: .5 min, typical
Volt-Amps 388 VA, Max
* Installations using AC Power Input Modules (PIM) prior to rev R and/or AC
Power Supply Module prior to rev M require voltage input:: 85 to 125 Vac rms
High Voltage AC: Input: 175 to 264 Vac rms (247 to 373 Vac, pk)**
Frequency: 47 to 63 Hertz.
Input Current: 2.3 A rms Max
Power Factor: .5 min, typical
Volt-Amps 388 VA, Max
** Installations using AC Power Input Modules (PIM) prior to rev R and/or AC
Power Supply Module prior to rev M require voltage input:: 175 to 250 Vac rms
Low Voltage DC: Input: 20-30 Vdc
Input Current: 10 A Max
High Voltage DC: Input: 88-140 Vdc
Input Current: 2.5 A Max
Out of Range Protection: For all power supply versions, an undervoltage
will not harm either the supply or the PIM.
However, an overvoltage will cause the fuse to
open on the PIM.
Note:
Max input power = (max. output power)/(min efficiency)
Max volt-amps = (max input power)/(min power factor)
16
OUTPUTS
Front Panel LEDs:
Supply OK LED: Indicates when the power supply is operating
properly.
ENVIRONMENTAL LIMITS
Temperature: -30 C to 65 C (-22 F to 149 F) operating
-40 C to 85 C (-40 F to 185 F) storage
Humidity: 95 % non-condensing
CE MARK DIRECTIVES:
EMC Directives:
EN50081-2:
Radiated Emissions: EN 55011, Class A
Conducted Emissions: EN 55011, Class A
EN50082-2:
Electrostatic Discharge: EN 61000-4-2, Criteria B
Radiated Susceptibility: ENV 50140, Criteria A
Conducted Susceptibility: ENV 50141, Criteria A
Electrical Fast Transient: EN 61000-4-4, Criteria B
Surge Capability: EN 61000-4-5, Criteria B
Magnetic Field: EN 61000-4-8, Criteria A
Power Supply Dip: EN 61000-4-11, Criteria B
Radio Telephone: ENV 50204, Criteria B
Low Voltage Directives:
Safety Requirements: EN 61010-01
APPROVALS
CSA-NRTL/C: Class I, Division 2, Groups A through D
17
PHYSICAL
Power Supply Module:
Dimensions (Height x Width x Depth):
120.7 mm x 50.8 mm x 251.5 mm
(4.75 in x 2.0 in x 9.9 in)
Weight: 1.39 kg (3.06 lbs)
Power Input Modules:
120.7 mm x 25.4 mm x 114.3 mm
(4.75 in x 1.0 in x 4.5 in)
RACK SPACE REQUIREMENTS
Power Supply Module: Two special half-height slots are located on the
left side of the rack. Each slot accommodates
one power supply. Both slots can be filled with a
power supply at the same time allowing for
redundant power supplies.
Power Input Module: Special half-height module located directly
behind the associated power supply.
MISCELLANEOUS
Minimum Loading: No minimum rack load is required.
18
Part No. 129768-01
Revision D, November 2000
3500/20
RACK INTERFACE
MODULE
OPERATION AND MAINTENANCE
MANUAL
Copyright 2000 Bently Nevada Corporation
The following are trademarks of Bently Nevada Corporation in the United States and other
countries:
Actionable Information, Actionable Information to the
FieldMonitor, FluidLoc, FlexiTIM, FlexiTAM,
Move Data, Not People, Move Information, Not
TDIXconnX, Tecknowledgy, TipLoc,
Xlerometer
The Bently Nevada Corporation Orbit Design is a
trademark of Bently Nevada Corporation in the United
States and other countries.
The following ways of contacting Bently Nevada Corporation are provided for those times
when you cannot contact your local Bently Nevada representative:
Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 782 9259
.
iii
3500 Monitoring System Rack Configuration and Utilities Guide (129777-01)
NOTICE:
This manual does not contain all the information required to operate and
maintain the Rack Interface Module. Refer to the following manuals for
other required information.
3500/20Operation and Maintenance
iv
Contents
1 Receiving and Handling Instructions.........................................1
1.1 Receiving Inspection ..................................................................................................1
1.2 Handling and Storing Considerations .........................................................................1
1.3 Disposal Statement ....................................................................................................1
2 General Information.....................................................................2
2.1 Triple Modular Redundant (TMR) Description ............................................................3
2.2 Statuses .....................................................................................................................3
2.3 LED Descriptions........................................................................................................5
3 Configuration Information...........................................................6
3.1 Software Configuration Options..................................................................................6
3.1.1 Rack Interface Module Configuration Considerations..........................................6
3.1.2 Rack Interface Module Configuration ..................................................................6
3.1.3 Security Options Configuration.........................................................................10
3.2 Switches...................................................................................................................11
3.2.1 Software Switches.............................................................................................12
3.2.2 Hardware Switches............................................................................................13
4 I/O Module Description..............................................................15
4.1 Rack Interface Input/Output (I/O) Modules) ..............................................................16
4.1.1 Connecting a Rack Interface I/O Module to a Host Computer ...........................18
4.1.2 Daisy Chaining Rack Interface I/O Modules ......................................................24
4.1.3 Wiring Euro Style Connectors ...........................................................................25
4.1.4 Cable Pin Outs ..................................................................................................26
4.2 Data Manager I/O Modules.......................................................................................32
4.2.1 Cable Pin Outs ..................................................................................................33
5 Maintenance...............................................................................37
5.1 RIM Host Port Test Utility .........................................................................................37
5.2 Performing Firmware Upgrades................................................................................37
5.2.1 Installation Procedure........................................................................................37
5.3 Real-Time Clock Replacement .................................................................................40
6 Troubleshooting.........................................................................42
6.1 Verification ...............................................................................................................42
6.2 LED Fault Conditions................................................................................................42
6.3 System Event List Messages....................................................................................44
6.4 Alarm Event List Messages ......................................................................................56
7 Ordering Information.................................................................58
8 Specifications ............................................................................62
3500/20 Operation and Maintenance 1 Receiving and Handling Instructions
1
Corporation.
void the warranty. To avoid damage, observe the following precautions.
Application Alert
Host communication
and rack configuration
capabilities will be lost
when this module is
the rack while power is applied to the rack. Refer to the Rack Installation and
the end of its use.
2
The Rack Interface Module (RIM) is the primary interface into the 3500 rack. It
supports a Bently Nevada proprietary protocol used to configure the rack and
retrieve machinery information. The RIM must be located in slot 1 of the rack
(next to the power supplies). The RIM provides the connections needed to
support current Bently Nevada Communications Processors (Transient Data
Interface External (TDIX) and Dynamic Data Interface External (DDIX)).
Although the RIM does provide certain functions common to the entire rack, the
RIM is not part of the critical monitoring path. The RIM's operation (or non-
operation) has no effect on the proper, normal operation of the overall
monitoring system.
Front View Rear View
1) LEDs: Indicate the operating status of the module (See section 2.3 )
2) Hardware Switches: (See section 3.2.2 )
3
3) Configuration Port: Configure or retrieve machinery data from only this rack
using RS-232 protocol.
4) Rack Interface I/O Module: Daisy chain or configure racks using RS-232
and RS-422 protocol (See section 4.1 )
5) Data Manager I/O Module: Connect two Bently Nevada Communication
Processors to the 3500 rack. (See section 4.2 )
RIM Features
Contacts
Rack Reset
Trip Multiply
Alarm Inhibit
OK Relay
Security
Password
Key Switch
Communications Ports
Front Panel Configuration Port
Rear Panel Host Port
Rear Panel Rack RS-422 Port
Data Manager Ports
Event Lists
Alarm Event List
System Event List
2.1 Triple Modular Redundant (TMR) Description
For TMR applications, the 3500 system requires a TMR version of the RIM. In
addition to all the standard RIM functions, the TMR RIM also performs "monitor
channel comparison." The 3500 TMR configuration executes monitoring voting
using the setup specified in the monitor options. Using this method the TMR
RIM continually compares a specified output of 3 redundant monitors. If the
TMR RIM detects that the information from one of those monitors is no longer
equivalent (within a configured percent) to the remaining two, it will flag the
monitor as being in error and place an event in the System Event List.
2.2 Statuses
The Rack Interface Module returns both module and channel statuses. This
section describes the available statuses and where they can be found.
Module Status
OK
This indicates if the Rack Interface Module is functioning correctly. A not OK
status is returned under any of the following conditions:
Hardware Failure in the module
Communication Failure with any module
If any of the following security options have been configured and their
conditions met:
Rack Address is changed while the RIM is in Run Mode.
4
A module was inserted into or removed from the rack.
The Key Switch was changed from Run to Program Mode.
Node Voltage Failure
OK Relay coil check Failed
If the Module OK status goes not OK then the system OK Relay on the Rack
Interface I/O Module will be driven not OK.
Configuration Fault
This indicates if the Rack Interface Module configuration is invalid.
Channel Status
OK
This indicates whether or not a fault has been detected on the channel or
within the module. If the Channel OK status goes not OK then the system
OK Relay on the Rack Interface I/O Module will be driven not OK.
The following table shows where the statuses can be found.
Statuses Communication
Gateway
Module
Rack
Configuration
Software
Operator
Display
Software
Module OK X X
Module Configuration Fault X
Channel OK X X
5
2.3 LED Descriptions
The LEDs on the front panel of the Rack Interface Module indicate the operating
status of the module as shown in the following figure. Refer to Section 6.2 for all
of the available LED conditions.
1) OK: Indicates that the Rack Interface Module and the I/O modules are
operating correctly.
2) TX/RX: Flashes at the rate that messages are sent.
3) TM: Indicates whether the rack is in the Trip Multiply mode.
4) Config OK: Indicates that Any module in the rack is unconfigured or has a
configuration error or the stored configuration of the Rack Interface Module
does not match the physical configuration of the rack or a security option
condition was not met.
3 Configuration Information 3500/20 Operation and Maintenance
6
This section describes how the Rack Interface Module is configured using the
Rack Configuration Software. It also describes any configuration considerations
associated with this module. Refer to the 3500 Monitoring System Rack
Configuration and Utilities Guide and the Rack Configuration Software for the
details on how to operate the software.
3.1 Software Configuration Options
This section shows the configuration screens of the Rack Configuration Software
that are associated with the Rack Interface Module and discusses the
configuration considerations. It will show a copy of the software screen and will
explain the options that are available.
3.1.1 Rack Interface Module Configuration Considerations
The Rear Port I/O option and the Power Supply option specified on the Rack
Interface Module option screen must match the physical components of the
system. If a configuration mismatch is found, the rack will not accept the
downloaded configuration
3.1.2 Rack Interface Module Configuration
This section describes the options available on the Rack Interface Module
configuration screen.
3500/20 Operation and Maintenance 3 Configuration Information
7
Config ID
Contains a unique six-character identifier which is entered when a configuration is
downloaded to the 3500 rack.
Rear Port
The port on the Rack Interface I/O Module labelled HOST that is used to connect
this 3500 rack to the 3500 host computer or the 3500 rack daisy chained closer to
the 3500 host computer.
I/O Option
The two types of Rack Interface I/O Modules that are available for the 3500
Monitoring System are the RS-232/RS-422 I/O Module and Modem I/O
Module. The RS-232/RS-422 I/O Module contains a 9-pin host connector
which contains either RS-232 or RS-422 level signals, dependent upon the
position of the I/O Module switch. The Modem I/O Module has an RJ11
connector and contains an internal modem.
External Modem
The following external modems are directly supported by the Rack Interface
Module when configured with an RS-232/RS-422 I/O Module:
None
Hayes Ultra 9600
Hayes Optima 9600
Motorola FasTalkII 9600
Custom
Initialization String
The command that sets up and starts the modem. If you select a modem from
the list, the default initialization string will be displayed in this field. If you select
Custom, enter an initialization string from information found in the modem's
documentation.
Byte Timeout
The number of byte times which the communication line must be idle before a
communication is considered complete. One byte time is a function of the
baud rate selected. The range of values is 3 to 255.
Connect Password
Provides read only access to the 3500 rack. If the password entered in this field
does not match the password entered in the Rack Configuration Software
"Connect" screen or in the Data Acquisition/DDE Server Software "Setup" screen,
no communication with the 3500 rack will be allowed. This password is stored in
non-volatile memory in the Rack Interface Module.
8
Configuration Password
Provides configuration write access to the 3500 rack. If the password entered in
this field does not match the password entered in the Rack Configuration Software
"Download" screen, the 3500 rack will not accept new configurations. This
password is also required to change setpoints in the 3500 rack from the Operator
Display Software. This password is stored in non-volatile memory in the Rack
Interface Module.
Front Port
The port on the front of the Rack Interface Module labelled CONFIGURATION
PORT that is primarily used to configure the 3500 rack with a personal computer.
This port may also be used to retrieve machinery data for display using the Data
Acquisition/DDE Server Software and the Operator Display Software. This port
supports RS-232 only and provides access to only one rack.
External Modem
The following external modems are directly supported by the Rack Interface
Module:
None
Hayes Ultra 9600
Hayes Optima 9600
Motorola FasTalkII 9600
Custom
Initialization String
The command that sets up and starts the modem. If you select a modem from
the list, the default initialization string will be displayed in this field. If you select
Custom, enter an initialization string from information found in the modem's
documentation.
Byte Timeout
The number of byte times which the communication line must be idle before a
communication is considered complete. One byte time is a function of the
baud rate selected. The range of values is 3 to 255.
Static Data Considerations
Each static data port can access six monitor slots in the 3500 rack. And each
monitor slot in the 3500 rack is limited to 32 PPLs.
Dynamic Signal Option
Identifies which monitors provide dynamic data to the DYNAMIC connectors on the
Data Manager I/O Module. This field defines how the 3500 rack will provide
machinery data to the Communication Processors (TDIX or DDIX).
The following table shows the different options that are available. Keep the
following in mind:
Dynamic Port 2 is always assigned to slots 8 through 13.
If a slot contains something other than a monitor, then no data for that slot is
returned.
No data can be returned from the modules installed in slots 14 and 15.
9
Dynamic Signal Option Monitors Assigned to Data
Manager Ports
Slots 2-7 assigned to Data Manager Port 1
Rack Type: Standard
Number of Communication Processors: 2
Slots 14 and 15 can not return any data since each
TDIX and DDIX can only be connected to a maximum
of 24 channels.
Slots 2, 4, 6, 8, 10, 12 assigned to Data
Manager Port 1
Rack Type: Standard
Use this option when the rack is setup with multiple
monitor/relay pairs.
Slots 2, 5, 8, 11 assigned to Data Manager
Port 1
Rack Type: TMR with Bussed Relay
If a monitor is removed from slots 2, 5, 8 or 11 then
no data is returned to the Communication Processor
from that monitor group. Monitor Groups
Slots 2, 6, 10 assigned to Data Manager
Port 1
Rack Type: TMR with Individual Relays
If a monitor is removed from slots 2, 6 or 10 then no
data is returned to the Communication Processor
from that monitor group. Monitor Groups
Legend
Monitors
Assigned to Data
Manager Port 1
Monitors
Assigned to
Data Manager
Port 2
10
Agency Approvals
The following Agency Approvals are available for the 3500 rack:
None
CSA-NRTL/C
CE Approval
Select this box if the CE mark is applicable to the racks installation.
Rack Mounting Option
Select the type of 3500 rack that is installed or is going to be installed. Refer to
the 3500 Monitoring System Rack Installation and Maintenance Manual for a
description of the various mounting options.
Power Supply
The following power supplies can be installed in the 3500 rack:
Upper Position in Slot Lower Position in Slot
No Power Supply
AC High Voltage
AC Low Voltage
DC High Voltage
No Power Supply
AC High Voltage
AC Low Voltage
DC High Voltage
3.1.3 Security Options Configuration
This Section describes the options available on the Rack Interface Module
Security Option Configuration screen.
Change Setpoints in Program Mode Only
This will only allow changes to setpoints in any of the monitors if the keylock is in
the program mode position. If the key is in the run position, setpoint changes will
not be allowed.
11
Disable Front Communication Port of RIM
This option disables all write functions through the front communication port on the
Rack Interface Module when selected. When in this mode the Rear
Communication Port is still active.
Drive Rack NOT OK Relay if Rack Address is Changed in Run Mode
With this option selected the NOT OK Relay will go into a NOT OK state if the
Rack Address is changed at any time while the key switch is in the run position.
Drive Rack NOT OK Relay if a Module is Removed From the Rack
When selected this option will force the NOT OK Relay into a NOT OK state if any
module is removed from its slot in the Rack.
Drive Rack NOT OK Relay if Key Switch is Changed From Run to Program
Mode
The Rack NOT OK Relay will go into a NOT OK state any time that the key switch
is changed from Run to Program mode when this option is selected.
3.2 Switches
Switches let you control the operation of the 3500 rack and control access to the
configuration of the rack. This section lists the software and hardware switches
that are available for the Rack Interface Module.
12
3.2.1 Software Switches
The Rack Interface Module supports one software module switch - Configuration
Mode. The switch lets you temporarily inhibit monitor and channel functions. This
switch can be set on the Software Switches screen under the Utilities Option on
the main screen of the Rack Configuration Software.
No changes will take effect until the Set button is pressed.
Module Switch
Configuration Mode
A switch that allows the rack to be configured. To set the rack in configuration
mode, enable () this switch and set the key switch on the front of the Rack
Interface Module in the PROGRAM position. When downloading a Rack
Interface Module configuration, this switch will automatically be enabled and
disabled by the Rack Configuration Software. If the connection to the rack is
lost during the configuration process, use this switch to remove the module
from Configuration Mode.
The module switch number is used in the Communication Gateway Module.
Module Switch Number Switch Name
1 Configuration Mode
13
3.2.2 Hardware Switches
The Rack Interface Module has three hardware switches that are found on the
front panel.
Key Switch
The Key Switch is used to prevent unauthorized changes to the configuration
settings. When the switch is in the RUN position, the 3500 rack cannot be
configured. When the switch is in the PROGRAM position, the 3500 rack can be
configured and the rack continues to operate normally. By removing the key, you
can lock the Rack Interface Module in the RUN or PROGRAM position.
Rack Reset
Note
An RS-232/RS-422 I/O Module or a Modem I/O Module must be installed for
the Rack Reset switch to function correctly.
When the Rack Reset switch is pressed, any monitors in the rack will clear latched
alarms and reset Timed OK Channel Defeat indications. If the Configuration LED
is blinking at 5 Hz, it will be stopped. This switch performs the same function as
the Rack Reset contact on the Rack Interface I/O Module.
Rack Address
The host computer uses the Rack Address to identify 3500 racks that are linked in
a daisy chain. Set the rack address by using a 6-position DIP switch which
provides for 63 possible addresses. All racks in a daisy chain must have a unique
rack address. The following diagram and table show how to select the address
110001 (49 decimal).
LSB - Least Significant Bit
MSB - Most Significant Bit
Note: The white area shows the direction
of the switch.
14
Available Rack Address
Switch Addresses Switch Addresses Switch Addresses
MSB LSB MSB LSB MSB LSB
654321 _____ 654321 _____ 654321 _____
000000 1* 010110 22 101011 43
000001 1 010111 23 101100 44
000010 2 011000 24 101101 45
000011 3 011001 25 101110 46
000100 4 011010 26 101111 47
000101 5 011011 27 110000 48
000110 6 011100 28 110001 49
000111 7 011101 29 110010 50
001000 8 011110 30 110011 51
001001 9 011111 31 110100 52
001010 10 100000 32 110101 53
001011 11 100001 33 110110 54
001100 12 100010 34 110111 55
001101 13 100011 35 111000 56
001110 14 100100 36 111001 57
001111 15 100101 37 111010 58
010000 16 100110 38 111011 59
010001 17 100111 39 111100 60
010010 18 101000 40 111101 61
010011 19 101001 41 111110 62
010100 20 101010 42 111111 63
010101 21
* The address 000000 is reserved for the host. Setting the switches to 000000 will
select a Rack Address of 1 just as 000001 will.
3500/20 Operation and Maintenance 5 Maintenance
15
4 I/O Module Description
The Rack Interface Module uses two I/O module types, the Rack Interface I/O
Module and the Data Manager I/O Module. These I/O modules let you connect a
3500 host computer and Communication Processors (TDIX or DDIX) to a 3500
rack and let you daisy chain racks together.
This section describes how to use the connectors on the I/O modules, lists what
cables to use, and shows the pin outs of the cables.
Only one Rack Interface I/O Module can be installed at a time behind the Rack
Interface Module (in a Rack Mount or a Panel Mount rack) or above the Rack
Interface Module (in a Bulkhead rack). See Section 4.1
Also, one Data Manager I/O Module may be installed between the Power Input
Modules and the Rack Interface I/O Module (in a Rack Mount or a Panel Mount
rack) or above the Power Supplies between the Power Input Modules and the
Rack Interface I/O Module (in a Bulkhead rack). See Section 4.2
5 Maintenance 3500/20 Operation and Maintenance
16
4.1 Rack Interface Input/Output (I/O) Modules)
The two types of Rack Interface I/O Modules that are available for the 3500
Monitoring System are the RS-232/RS-422 I/O Module and the Modem I/O
Module. The features below are common to both I/O Modules.
The Rack Interface I/O module must be installed behind the Rack Interface
Module (in a Rack Mount or Panel Mount rack) or above the Rack Interface
Module (in a Bulkhead rack).
1) OK RELAY: The OK Relay
is normally energized and is
used to indicate whether the
3500 Monitoring System is
OK.
2) RACK RS-422: Used to
daisy chain to the next 3500
rack. Up to 12 racks can be
daisy chained together. Only
RS-422 can be used for this
connection.
3) EXTERNAL CONTACTS:
Trip Multiply
Rack Alarm Inhibit
Rack Reset
17
OK RELAY
The following items will cause the OK Relay to go NOT OK:
Removing the Rack Interface Module from the 3500 rack
Plugging a module into the 3500 rack (during self-test)
Transducer going not OK (except Keyphasor)
Hardware failure within a module
Configuration Failure
Slot ID Failure
Any module in the 3500 rack which has detected a fault
Communication Failure with any module.
If any of the following security options have been configured and their
conditions met:
Rack Address is changed while the RIM is in Run Mode.
Any module is inserted or removed from the rack.
The Key Switch is changed from Run Mode to Program Mode.
The following diagrams show the different ways the OK Relay can be wired:
Normally Energized
No Power With Power/ With Power/
(Shelf state) OK Condition not OK Condition
NO means Normally Open.
ARM means Armature.
NC means Normally Closed.
RACK RS-422
Used to daisy chain to the next 3500 rack in the chain. The cable will go between
the RACK RS-422 connector on this rack and the HOST connector on the next
3500 rack. Only RS-422 can be used for this connection. Refer to Section 4.1.2
EXTERNAL CONTACTS
These require dry contact inputs. To enable a specific function, short the desired
contact to a system common (COM).
Trip Multiply (TM)
Used to signal when the rack should be in Trip Multiply.
18
Rack Alarm Inhibit (INHB)
Used to prevent an alarm from being declared on any monitor or relay in the 3500
rack. This is typically used when performing maintenance functions.
Rack Reset (RST)
Used to signal when the modules in the 3500 rack are to be reset. This contact
has the same function as the Rack Reset switch on the front panel of the Rack
Interface Module.
4.1.1 Connecting a Rack Interface I/O Module to a Host Computer
The 3500 rack can use two types of Rack Interface I/O Modules which let you
connect a host computer to a rack in a number of ways.
RS-232/RS-422 HOST Connector
Connect to the host computer using RS-
232, RS-422 (with a converter) or external
Modem. Also used to connect to the
previous rack in the daisy chain using RS-
422 ONLY.
Use the RS-232/RS-422 switch to select
whether the HOST connector uses RS-232
or RS-422 protocol.
Internal Modem Connector
Connect to the host computer using a RJ11
compatible modular plug to link into the
phone system.
19
Note
RS-232 signals are referenced to earth ground. This reference through the
RS-232 cable has the potential of causing grounding problems. To avoid
grounding problems when using RS-232 communications use serial data
isolator P/N 02200633
4.1.1.1 Connecting a Rack Interface I/O Module to a Host Computer via RS-
232
The communication rate is limited by the baud rate selected between the 3500
host computer and the first Rack Interface Module. The switch on the Rack
Interface I/O Module connected to the 3500 host computer must be in the RS-232
position.
1) Host Computer
2) Cable 130118-XXXX-XX is available in various lengths up to 30
meters (100 ft).
Refer to Section 7 for the specific options of the cable listed above.
20
4.1.1.2 Additional Information for Connecting a Rack Interface I/O Module to a
Host Computer via RS-232 in Intrinsically Safe Application
To avoid ground loops, the system must provide a single point ground. In Intrinsically Safe
applications the 3500 Rack is floated and referenced to an intrinsically safe ground instead
of earth ground. RS-232 communications are referenced to earth ground, and therefore to
keep the rack isolated from earth ground, a serial data isolator must be used.
1) Host Computer
meters (100 ft).
3) Serial Data Isolator P/N 02200633
21
4.1.1.3 Connecting a Rack Interface I/O Module to a Host Computer via RS-
422
The communication rate is limited by the baud rate selected between the 3500 host
computer and the first Rack Interface Module. The switch on the Rack Interface I/O Module
connected to the 3500 host computer must be in the RS-422 position.
For lengths of 150 meters (500 ft) or less, use
cable
130120-XXXX-XX (PVC Insulation) or cable
131106-XXXX-XX (Teflon Insulation).
For lengths greater than 150 meters (500 ft), use
one cable
130120-XXXX-XX (PVC Insulation) or cable
131106-XXXX-XX (Teflon Insulation) along with as
many
RS-422 extension cables 130121-XX-XX (150
meters (500ft)
standard length) to create a cable up to the
maximum
1220 meters (4000 ft).
RS-232/RS-422 Converter
For 110 Vac use part number 02230411.
For 220 Vac use part number 02230412.
Cable 130119-01 is available in a 3 meter (10 ft)
length.
Refer to Section 7 for the specific options of the
cables listed above.
22
4.1.1.4 Connecting a Rack Interface I/O Module to a Host Computer via an
External Modem
The communication rate is limited by the baud rate selected between the 3500
host computer and the first Rack Interface I/O Module. The switch on the Rack
Interface I/O Module connected to the modem must be in the RS-232 position.
1) Cable 02290860 is available in 3 meter (10ft) length.
23
4.1.1.5 Connecting a Rack Interface I/O Module to a Host Computer via an
Internal Modem
The communication rate is limited by the baud rate selected between the host
computer and the first Rack Interface I/O Module.
1) Cable 02290860 is available in 3 meter (10ft) length.
2) Phone Line
Refer to Section 7 for the specific options of the cables listed above.
24
4.1.2 Daisy Chaining Rack Interface I/O Modules
This section shows how to daisy chain Rack Interface I/O Modules together.
To host
computer (See
Section 4.1.1 ).
Take note of the following items when daisy chaining Rack Interface I/O Modules:
Use the HOST port to connect to the host computer or to the rack in the
daisy chain that is closer to the host computer.
Use the RACK RS-422 port to connect to the rack that is farther from the
host computer.
Use the following cables for the connection between the racks in the daisy
chain:
- For lengths of 150 meters (500 ft) or less, use cable
130122-XXXX-XX (PVC Insulation) or cable 131107-XXXX-XX
(Teflon Insulation).
- For lengths greater than 150 meters (500 ft), use one cable
130122-XXXX (PVC Insulation) or cable 131107-XXXX-XX (Teflon
Insulation) along with as many RS-422 extension cables
130121-XX-XX (150 meters (500 ft) standard length) to create a
cable up to 1220 meters (4000 ft) in length.
25
4.1.3 Wiring Euro Style Connectors
To remove a terminal block from its base, loosen the screws attaching the
terminal block to the base and then grip the block firmly and pull. Do not pull the
block out by its wires because this could loosen or damage the wires or
connector.
Typical I/O module
Refer to the 3500 Field Wiring Diagram Package for the recommended wiring.
Also, do not remove more than 6 mm (0.25 inches) of insulation from the wires.
26
4.1.4 Cable Pin Outs
Cable Number 02290860
Host Computer (or Rack Interface Module) to External Modem Cable
Cable Number 130118-XXXX-XX
Host Computer to 3500 Rack RS-232 Interface Cable
27
Host Computer to 3500 Rack Cable RS-422 PVC
Host Computer to 3500 Rack Cable RS-422 Teflon
28
Cable Number 130119-01
Host Computer to RS-232/422 Converter Cable
RS-232/422 Converter to 3500 Rack Cable (RS-422) - PVC Insulation
29
Cable Number 130121-XX-XX
RS-422 Extension Cable
RS-422 3500 Rack to 3500 Rack Cable - PVC Insulation
30
RS-232/422 Converter to 3500 Rack Cable (RS-422) - Teflon Insulation
RS-422 3500 Rack to 3500 Rack Cable - Teflon Insulation
31
Integrated PC Display to 3500 Rack Cable, RS-422, PVC Insulated
Integrated PC Display to 3500 Rack Cable, RS-422, Teflon Insulated
32
4.2 Data Manager I/O Modules
The Data Manager I/O Module must be installed behind the Power Supplies
between the Power Input Modules and the Rack Interface I/O Module (in a Rack
Mount or Panel Mount rack) or above the Power Supplies between the Power
Input Modules and the Rack Interface I/O Module (in a Bulkhead rack). The
function of the Data Manager I/O module is to connect the 3500 rack to TDIX or
DDIX Communication Processors. Each port can connect up to 24 channels,
from the 3500 rack to the Communication Processor. Refer to the table on page
9 for the different options that are available.
1) Used to transfer the static information from Port
1 of this 3500 rack to the static connector on the
Communication Processor.
2) Used to transfer the dynamic information from
Port 1 of this 3500 rack to the dynamic connector
on the Communication Processor.
3) Used to transfer the information from Port 2 of
this 3500 rack to the static connector on the
Communication Processor.
4) Used to transfer the dynamic information from
Port 2 of this 3500 rack to the dynamic connector
on the Communication Processor.
Note: The 3500 Monitoring System supports the
DDIX and TDIX
Communication Processors.
Note: The Data Manager I/O will cease to operate if
the Rack Interface Module is removed.
33
4.2.1 Cable Pin Outs
3500 Static to TDIX Cable
3500 Static to DDIX Cable
34
Cable Number 02290160
Dynamic Data Cable DDIX/TDIX
Note: The signals passed through cable 02290160 depend on which dynamic port the cable
is connected to on the Data Manager I/O and which 3500 Dynamic options are selected. The
following table describes what signals are passed through Dynamic ports 1 and 2 depending
on the options chosen.
35
Signal Pin Out Tables for Dynamic Connectors 1 and 2
Dynamic 1
Connector
Pin Number
3500 System Dynamic Signal Option
1 2 3 4
1 NONE NONE NONE NONE
7 2,1 2,1 2,1 2,1
14 2,2 2,2 2,2 2,2
18 2,3 2,3 2,3 2,3
16 2,4 2,4 2,4 2,4
11 3,1 4,1 5,1 6,1
21 3,2 4,2 5,2 6,2
25 3,3 4,3 5,3 6,3
23 3,4 4,4 5,4 6,4
2 4,1 6,1 8,1 10,1
9 4,2 6,2 8,2 10,2
4 4,3 6,3 8,3 10,3
6 4,4 6,4 8,4 10,4
20 5,1 8,1 11,1 NONE
3 5,2 8,2 11,2 NONE
19 5,3 8,3 11,3 NONE
5 5,4 8,4 11,4 NONE
24 6,1 10,1 NONE NONE
10 6,2 10,2 NONE NONE
13 6,3 10,3 NONE NONE
12 6,4 10,4 NONE NONE
15 7,1 12,1 NONE NONE
22 7,2 12,2 NONE NONE
17 7,3 12,3 NONE NONE
8 7,4 12,4 NONE NONE
Legend: [2,1] refers to Rack Slot 2, Monitor Channel 1
36
Dynamic 2
Connector
Pin Number
3500 System Dynamic Signal Option
1 2 3 4
1 NONE NONE NONE NONE
7 8,1 NONE NONE NONE
Legend: [2,1] refers to Rack Slot 2, Monitor Channel 1
37
5 Maintenance
This section shows how to verify that the Rack Interface Module and the I/O
modules are operating correctly.
When performed properly, this module may be installed into or removed from the
rack while power is applied to the rack. Refer to the Rack Installation and
5.1 RIM Host Port Test Utility
Use the RIM Host Port Test Utility to verify that the HOST ports on the Rack
Interface Module and the Rack Interface I/O Module are operating properly.
Before running the RIM Host Port Test Utility, connect Cable 130118-XXXX-XX
(Host to 3500 Rack RS-232 Interface Cable) between the Configuration Port
connector on the front of the Rack Interface Module or to the HOST connector on
the Rack Interface I/O Module and the computer that has the utility installed.
Refer to the 3500 Monitoring System Rack Configuration and Utilities Guide and
the Rack Configuration Software for the details of this utility.
5.2 Performing Firmware Upgrades
Occasionally it may be necessary to replace the original firmware that is shipped
with the 3500/20 Rack Interface Module (RIM). The following instructions
describe how to remove the existing firmware and replace it with upgrade
firmware. The RIM will need to be reconfigured using the 3500 Rack
Configuration software after having its firmware upgraded.
The following items will be required to perform a firmware upgrade to the RIM:
Large Flathead Screwdriver.
Grounding Wrist Strap.*
Small Flathead Screwdriver
Upgrade Firmware IC.*
*Refer to Section 7 (Ordering Information) for part numbers. Users may use their
own grounding wrist strap.
5.2.1 Installation Procedure
The following steps will need to be followed to complete the RIM firmware
upgrade:
Ensure that the Rack Interface Modules configuration is saved using the 3500
Rack Configuration software.
Refer to Section 1.2 (Handling and Storing Considerations) before handling
the RIM or the upgrade firmware IC.
38
Remove the RIM from the 3500 rack.
Remove the Top Shield from the RIM.
Remove the original firmware IC from the RIM PWA.
Install the upgrade firmware IC into the socket on the RIM PWA.
Replace the RIM Top Shield.
Replace the RIM into the 3500 system.
Reconfigure the RIM using the 3500 Rack Configuration software.
Detailed instructions for some of the steps listed above are provided on the
following pages. Please review completely before proceeding.
Top Shield Removal
1) Top Shield.
2) Standoff.
3) Screwdriver.
Step 1. Place the large flathead screwdriver under the top shield and on the ridge
of the rear standoffs and lift upward on the screwdriver to pop the cover loose
from the rear standoffs.
Step 2. Move the top shield up and down to work it loose from the two front
standoffs.
39
Original Firmware IC Removal
Step 1. Insert the small flathead screwdriver under the lip of either end of the IC.
The diagram shows the approximate location of the chip to be removed, but not
necessarily its orientation.
Step 2. Slightly lift the one end of the chip by gently prying with the screwdriver.
Move to the other end of the chip and repeat. Continue this process until the chip
comes loose from the socket.
40
Upgrade Firmware IC Installation
Install the upgrade firmware IC into the PWA. Be sure that the notched end of
the IC is matched to the notched end of the socket. Ensure that the IC is firmly
seated in the socket.
Top Shield Replacement
Replace the top shield. Be sure that the notch on the top shield is positioned at
the top left corner of the module as shown in the diagram under Top Shield
Removal. Align the holes in the top shield with the standoffs and press down
around each standoff until they snap in place.
5.3 Real-Time Clock Replacement
CAUTION
Dispose of the Real-Time
Clock component
properly. Do not
incinerate!
The Real-Time Clock component on the Rack Interface Module uses an internal
Lithium battery that needs to be replaced every 3 to 10 years. The replacement
interval depends on environmental conditions such as operating temperature. A
41
discharged Lithium battery may cause loss of operating information if the power
to the rack is lost. The Real-Time Clock component is socketed for easy
replacement. Refer to the System Event List Messages in Section 6 for the
message that will be displayed when the Real-Time Clock must be replaced.
Contact your nearest Bently Nevada Corporation office for replacement. To
replace the Real-Time Clock, follow the instructions in section 5.2 (Performing
Firmware Upgrades) with the following exceptions:
The approximate location of the clock component on the Pwa is shown below:
The component and socket line up as shown below:
6 Troubleshooting 3500/20 Operation and Maintenance
42
6 Troubleshooting
This section describes how to troubleshoot a problem with the Rack Interface
Module or the I/O modules by using the information provided by the verification
screen, the LEDs, the System Event List, and the Alarm Event List. You can
display the verification screen and the two event lists by using the Rack
Configuration Software.
6.1 Verification
To perform the Rack Interface Module's verification:
1. Connect a computer running the Rack Configuration Software to the 3500
rack (if needed).
2. Select Utilities from the main screen of the Rack Configuration Software.
3. Select Verification from the Utilities menu.
4. Select the Rack Interface Module and select the channel you want to verify.
5. Press the Verify button.
6. Select the Front Port or the Rear Port to get the status.
7. The Module OK State will show the Rack Interface Module's status and the
Channel OK State will show the channel's status.
The following table shows how to use the LEDs to diagnose and correct
problems.
OK Led TX/RX Condition Solution
1 Hz 1 Hz Rack Interface Module is
not configured or in
Configuration Mode.
Reconfigure the Rack
Interface Module.
5 Hz Rack Interface Module has
detected an internal fault
and is not OK.
Check the System Event
List.
ON Flashing Rack Interface Module is
No action is required.
Not
flashing
Rack Interface Module not
List.
= behavior of the LED is not related to the condition.
43
TM LED Condition Solution
ON Rack is in Trip Multiply (due to
hardware or software).
OFF Rack is not in Trip Multiply. No action is required.
Config OK
LED
Condition Solution
ON Configuration
information for every
module in the rack is
valid.
5 Hz One of the selected
security options has
had its condition met.
Check the System Event List. Press
the Rack Reset switch to clear.
OFF At least one module
has a configuration
fault.
A non-configured
active Power Supply is
present in the rack.
Check System Event List for which
module(s) need to be reconfigured.
OR
Reconfigure module(s) that are
flashing OK and TX/RX LEDs at 1 Hz.
Remove Power Supply or change
RIM configuration to include
additional Power Supply.
44
6.3 System Event List Messages
This section describes the System Event List Messages that are entered by the
Rack Interface Module.
Example of a System Event List Message
Sequence
Number
Event
Information
Event
Number
Class Event
Date
DDMMYY
Event
Time
Event
Specific
Slot
0000000123 Device Not
Communicating
32 1 02/01/90 12:24:31:99 5L
Sequence Number: The number of the event in the System Event List (for
example 123).
Event Information: The name of the event (for example Device Not
Communicating).
Event Number: Identifies a specific event.
Class: Used to display the severity of the event. The following
classes are available:
Class Value Classification
0
1
2
3
Severe/Fatal Event
Potential Problem Event
Typical Logged Event
Reserved
Event Date: The date the event occurred.
Event Time: The time the event occurred.
Event Specific: Provides additional information for the events that use
this field.
Slot: Identifies the module that the event is associated with.
If a half-height module is installed in the upper slot or a
full-height module is installed, the field will be 0 to 15.
If a half-height module is installed in the lower slot,
then the field will be 0L to 15L. For example, the
module is installed in the lower position of slot 5 (5L).
45
The following System Event List Messages may be placed in the list by the Rack
Interface Module and are listed in numerical order. If an event marked with a star
(*) occurs...
the host link on the back of the Rack Interface I/O Module supplying the
message will not communicate with the host computer
the other Rack Interface Modules in the daisy chain will still be able to
communicate with the host computer
both ports of the Data Manager I/O Module will stop communicating
If you are unable to solve any problems, contact your nearest Bently Nevada
Corporation office.
Flash Memory Failure
Event Number: 11
Event Classification: Potential Problem
Action: Replace the Rack Interface Module as soon as possible.
Real Time Clock Failure
Event Number: 12
Event Classification: Severe/Fatal Event
Action: Replace the Real Time Clock in the Rack Interface Module
immediately.
Internal Network Failure
Event Number: 30
Action: Replace the Rack Interface Module immediately.
Resync Internal Network (Resynchronize Internal Network)
Event Number: 31
Action: Check to see if one of the following components is faulty:
the Rack Interface Module
the rack backplane
Device Not Communicating
Event Number: 32
the module installed in the slot
the rack backplane
Device Is Communicating
Event Number: 33
the module installed in the slot
the rack backplane
46
Config Token Acquired (Configuration Token Acquired)
Event Number: 50
Event Classification: Typical logged event
Event Specific: Front,
Back,
DM1 (Data Manager port 1),
ComGate (Communication Gateway)
The specified port can download configuration, change setpoints, set
software switches, enable/disable Rack Alarm Inhibit, enable/disable
Trip Multiply, or perform Rack Reset.
Action: No action required.
Config Token Released (Configuration Token Released)
Event Number: 51
Event Specific: Front,
Back,
ComGate (Communication Gateway)
The specified port can no longer download configuration, change
setpoints, set software switches, enable/disable Rack Alarm Inhibit,
enable/disable Trip Multiply, or perform Rack Reset.
Config Token Expired (Configuration Token Expired)
Event Number: 52
the connection between the Rack Interface Module and the
computer running the Rack Configuration Software
the computer running the Rack Configuration Software
Config Token Override (Configuration Token Override)
Event Number: 53
Event Classification: Typical Logged Event
Fail Relay Coil Sense
Event Number: 55
Action: Check to see if the Rack Interface I/O Module is installed. If
installed, check to see if one of the following components is faulty:
the Rack Interface I/O Module
47
Pass Relay Coil Sense
Event Number: 56
Action: Check to see if the Rack Interface I/O Module is installed. If
installed, check to see if one of the following components is faulty:
the Rack Interface I/O Module
I/O Module Mismatch
Event Number: 60
Action: Verify that the Rack Interface I/O Module installed matches the
Rack Interface I/O Module selected in the Rack Configuration
Software. If the correct Rack Interface I/O Module is installed,
there could be a fault with the installed Rack Interface I/O Module.
Rack Type Mismatch
Event Number: 61
Action: Verify that the rack selection jumper, installed on the rack
backplane, matches the rack type selected in the software. If the
jumper is installed in the correct position, there could be a fault
with the rack backplane.
HW Rack Alm Inh Active (Hardware Rack Alarm Inhibit Active)
Event Number: 70
HW Rack Alm Inh Inactive (Hardware Rack Alarm Inhibit Inactive)
Event Number: 71
HW override of SW Inh (Hardware override of Software Inhibit)
Event Number: 72
HW Trip Multiply Active (Hardware Trip Multiply Active)
Event Number: 73
48
HW Trip Mult Inactive (Hardware Trip Multiply Inactive)
Event Number: 74
HW override of SW TM (Hardware override of Software Trip Multiply)
Event Number: 75
HW Rack Reset Active (Hardware Rack Reset Active)
Event Number: 76
HW Rack Reset Inactive (Hardware Rack Reset Inactive)
Event Number: 77
SW Rack Alm Inh Active (Software Rack Alarm Inhibit Active)
Event Number: 78
SW Rack Alm Inh Inactive (Software Rack Alarm Inhibit Inactive)
Event Number: 79
SW Trip Multiply Active (Software Trip Multiply Active)
Event Number: 80
SW Trip Mult Inactive (Software Trip Multiply Inactive)
Event Number: 81
SW Rack Reset (Software Rack Reset)
Event Number: 82
49
Rack Address changed
Event Number: 90
Key Switch in Run Mode
Event Number: 91
Key Switch in Prgm Mode (Key Switch in Program Mode)
Event Number: 92
Fail Main Board +5V-A (Fail Main Board +5V - upper Power Supply)
Event Number: 100
Action: Verify that noise from the power source is not causing the
problem. If the problem is not caused by noise, check to see if
one of the following components is faulty:
the Power Supply installed in the upper slot
Pass Main Board +5V-A (Pass Main Board +5V - upper Power Supply)
Event Number: 101
Fail Main Board +5V-B (Fail Main Board +5V - lower Power Supply)
Event Number: 102
the Power Supply installed in the lower slot
50
Pass Main Board +5V-B (Pass Main Board +5V - lower Power Supply)
Pass Main Board +5V-B
Event Number: 103
* Fail Main Board +5V-AB (Fail Main Board +5V - upper and lower Power
Supplies)
Event Number: 104
Event Classification: Severe / Fatal Event
Pass Main Board +5V-AB (Pass Main Board +5V - upper and lower Power
Supplies)
Event Number: 105
Event Number: 106
one of the following components is faulty
51
Event Number: 107
Event Number: 108
Event Number: 109
Supplies)
Event Number: 110
52
Pass Main Board +15V-AB (Pass Main Board +15V - upper and lower
Power Supplies)
Event Number: 111
Fail Main Board -24V-A (Fail Main Board -24V - upper Power Supply)
Event Number: 112
Pass Main Board -24V-A (Pass Main Board -24V - upper Power Supply)
Event Number: 113
Fail Main Board -24V-B (Fail Main Board -24V -upper and lower Power
Supply)
Event Number: 114
Pass Main Board -24V-B (Pass Main Board -24V - lower Power Supply)
Event Number: 115
53
* Fail Main Board -24V-AB (Fail Main Board -24V - upper and lower Power
Supplies)
Event Number: 116
Pass Main Board -24V-AB (Pass Main Board -24V - upper and lower
Power Supplies)
Event Number: 117
Device Configured
Event Number: 300
Event Number: 301
Action: Replace the Rack Interface Module immediately.
Event Number: 301
Action: Download a new configuration to the Rack Interface Module. If the
problem still exists, replace the Rack Interface Module as soon as
possible.
Module Entered Cfg Mode (Module Entered Configuration Mode)
Event Number: 302
54
Software Switches Reset
Event Number: 305
Action: Download the software switches to the Rack Interface Module. If
the software switches are not correct, replace the Rack Interface
Module as soon as possible.
Init Real Time Clock (Initialize Real Time Clock)
Event Number: 306
Action: Replace the Real-Time Clock component in the Rack Interface
Module as soon as possible.
Monitor TMR PPL Failed (Monitor TMR Proportional value Failed)
Event Number: 310
Action: Replace the monitor installed in the slot as soon as possible.
Monitor TMR PPL Passed (Monitor TMR Proportional value Passed)
Event Number: 311
Action: Replace the monitor installed in the slot as soon as possible.
Module Reboot
Event Number: 320
Module Removed from Rack
Event Number: 325
Module Inserted in Rack
Event Number: 326
Supply OK/Installed
Event Number: 330
Action: Determine if a power supply has been installed. Verify that there is
not a problem with the power source. If there are no problems with the power
source, replace the power supply as soon as possible.
55
Supply Faulted/Removed
Event Number: 331
Action: Determine if a power supply has been removed. Verify that there
is not a problem with the power source. If there are no problems
with the power source, replace the power supply as soon as
possible.
Rack/RIM Powered Down (Rack or Rack Interface Module Powered Down)
Event Number: 340
Rack/RIM Powered Up (Rack or Rack Interface Module Powered Up)
Event Number: 341
Modem Reinitialized
Event Number: 350
Device Events Lost
Event Number: 355
Module Alarms Lost
Event Number: 356
Rack Time Changed
Event Number: 360
Module Entered Calibr. (Module Entered Calibration Mode)
Event Number: 365
Module Exited Calibr. (Module Exited Calibration Mode)
Event Number: 366
56
Config Password Changed (Configuration Password Changed)
Event Number: 400
Connect Password Changed
Event Number: 401
6.4 Alarm Event List Messages
The following Alarm Event List Messages are returned by the different module
types installed in the 3500 rack.
Communication
Gateway Module
When the message will occur
Entered not OK
Left not OK
module went not OK
module returned to the OK state
Keyphasor Module When the message will occur
Entered not OK
Left not OK
module went not OK
57
Monitor Module When the message will occur
Entered Alert / Alarm 1
Left Alert / Alarm 1
Entered Danger / Alarm 2
Left Danger / Alarm 2
Entered not OK
Left not OK
A proportional value in the channel has entered
Alert / Alarm 1 and changed the channel Alert /
Alarm 1 status
A proportional value in the channel has left
Alarm 1 status
A proportional value in the channel has entered
Danger / Alarm 2 and changed the channel
Danger / Alarm 2 status
A proportional value in the channel has left
module went not OK
Rack Interface Module When the message will occur
Entered not OK
Left not OK
module went not OK
Relay Module When the message will occur
Entered not OK
Left not OK
Relay Activated
Relay Deactivated
module went not OK
condition for driving the relay channel met
condition for driving the relay channel is not met
anymore
7 Ordering Information 3500/20 Operation and Maintenance
58
A B C
Part number 3500/20 - XX - XX - XX
A Rack Interface Type
01 Standard RIM (Use for standard monitoring applications)
02 TMR RIM (Use only for application that requires a Triple Modular
Redundant Configuration)
B Type of I/O Module
01 I/O Module with built-in Modem
02 I/O Module with RS-232/RS-422 Interface
C Agency Approval Option
00 None
01 CSA-NRTL/C
Spares
Standard Rack Interface Module 125744-02
TMR Rack Interface Module 125744-01
RIM I/O Module with Modem Interface 135031-01
RIM I/O Module with RS-232/RS-422 Interface 125768-01
Data Manager I/O Module 125760-01
RIM Module Manual 129768-01
I/O Module Connector Header, Euro Style, 6 Pin 00580437
I/O Module Connector Header, Euro Style, 3 Pin 00580440
Grounding Wrist Strap (single use only) 04425545
Real Time Clock IC 00801286
Serial Data Isolator 02200633
*Firmware IC 128755-01
*Firmware ICs are available only for PWA 125744-01 revision P or later, or for
PWA 125744-02 revision N or later.
Cables
RS-232 Modem cable from: 02290860
3500 Rack External Modem
Host Computer to External Modem
Host Computer to RS-232/422
Converter Cable RS-232 130119-01
TDIX - Static Data Cable 129386-01
DDIX - Static Data Cable 129387-01
DDIX/TDIX - Dynamic Data Cable 02290160
RS-232 to RS-422 Converter 110 VAC 02230411
3500/20 Operation and Maintenance 7 Ordering Information
59
Host Computer to 3500 Rack Cable RS-232
A B
Part number 130118 - XXXX - XX
A Cable Length
0010 10 feet (3 meters)
0025 25 feet (7.5 meters)
100 100 feet (30.5 meters)
B Assembly Instructions
01 Not Assembled
02 Assembled
Host Computer to 3500 Rack Cable RS-422 PVC
A B
A Cable Length
0100 100 feet (30.5 meters)
01 Not Assembled
02 Assembled
Host Computer to 3500 Rack Cable RS-422 Teflon
A B
A Cable Length
0100 100 feet (30.5 meters)
01 Not Assembled
02 Assembled
7 Ordering Information 3500/20 Operation and Maintenance
60
RS-232/422 Converter to 3500 Rack Cable RS-422 PVC Insulated
A B
A Cable Length
0100 100 feet (30.5 meters)
0500 500 feet (152 meters)
01 Not Assembled
02 Assembled
RS-232/422 Converter to 3500 Rack Cable RS-422 Teflon Insulated
A B
A Cable Length
0100 100 feet (30.5 meters)
0500 500 feet (152 meters)
01 Not Assembled
02 Assembled
3500 Rack to 3500 Rack Cable RS-422 PVC Insulated
A B
A Cable Length
0100 100 feet (30.5 meters)
0500 500 feet (152 meters)
01 Not Assembled
02 Assembled
3500/20 Operation and Maintenance 7 Ordering Information
61
3500 Rack to 3500 Rack Cable RS-422 Teflon Insulated
A B
A Cable Length
0100 100 feet (30.5 meters)
0500 500 feet (152 meters)
01 Not Assembled
02 Assembled
Extension Cable RS-422 (Used with Cables 130120, 131106, 130122 and
131107 for lengths greater than 500 feet [152
meters])
A B
Part number 130121 - XX - XX
A Assembly Instructions
01 Not Assembled
02 Assembled
B Insulation
01 PVC Insulated
02 Teflon Insulated
62
8 Specifications
INPUTS
Power Consumption: 4.75 watts maximum
Data:
Front panel: 38.4 kbaud maximum RS-232 serial communications
I/O modules: 38.4 kbaud maximum RS-232/RS-422 serial
communications
14.4 kbaud internal modem communications
OUTPUTS
Front Panel LEDs:
OK LED: Indicates when the RIM is operating properly.
TX/RX LED: Indicates when the RIM is communicating with other
modules in the 3500 rack.
TM LED: Indicates when the 3500 rack is in Trip Multiply.
CONFIG OK LED: Indicates that the 3500 rack has a valid
configuration.
Data Manager I/O
Dynamic Data Port: Provides Multiplexed Buffered Transducer signals
through the Data Manager I/O Module.
Output Impedance: 600 Ohms
Note: The combined parallel impedance of all loads
connected to Dynamic Data Port and Buffered
Transducer Outputs should be a minimum of 6K
Ohms. A smaller load impedance than this could
affect the accuracy of the readings.
Static Data Port: Makes Static Data available to Communication
Processor.
Output Impedance: 1K Ohms
I/O Module OK Relay: Relay to indicate when the 3500 rack is operating
normally or when a fault has been detected within the
rack. User can select either an "OPEN" or
"CLOSED" contact to annunciate a not OK condition.
This relay always operates as "Normally Energized."
OK relay (resistive load): Max switched power: DC: 120 W AC: 600 VA
Max switched current: 5 A
Min switched current: 100 mA @ 5 Vdc
Max switched voltage: DC: 30Vdc AC: 120 Vac
Contact life: 100,000 @ 5 A, 24 Vdc or 120 Vac
Environmental sealing: Epoxy sealed
Normally closed contacts: Arc suppressors are provided (250 Vrms).
63
64
CONTROLS
Front Panel:
Rack reset button: Clears latched alarms and Timed OK Channel Defeat
in the rack. Performs same function as "Rack Reset"
contact on I/O module.
Address switch: Used to set the rack address. 63 possible
addresses.
Configuration Keylock: Used to place 3500 rack in either RUN mode or
PROGRAM mode. RUN mode allows for normal
operation of the rack and locks out configuration
changes. PROGRAM mode allows for normal
operation of the rack and also allows for local or
remote rack configuration. Key can be removed
from rack in either position, allowing switch to
remain in either RUN or PROGRAM positions.
Locking switch in the RUN position allows you to
restrict unauthorized rack configuration. Locking
switch in PROGRAM position allows remote
configuration of a rack at any time.
I/O Module System Contacts:
Trip multiply: Used to place 3500 rack in Trip Multiply.
Alarm inhibit: Used to inhibit all alarms in the 3500 rack.
Rack reset: Used to clear latched alarms and Timed OK
Channel Defeat.
Maximum Current: <1 mA DC, Dry Contact to Common
RS-232/RS-422 Switch (RS-232/RS-422 I/O module only):
Used to select between RS-232 and RS-422 for
communications with the Bently Nevada host
software.
COMMUNICATIONS
Front Panel:
Communications: RS-232 only
Protocol: Bently Nevada developed
Baud rate: 38.4 kbaud maximum (auto baud capable)
Purpose: Permits data collection and 3500 rack configuration
Cable length: 30 m (100 ft) maximum
RS-232/RS-422 I/O Module:
Communications: RS-232, RS-422, or external modem
Baud rate: 38.4 kbaud maximum (auto baud capable)
Cable length:
RS-232: 30 m (100 ft) maximum
RS-422: 1200 m (4000 ft) maximum
Modem: Consult modem manufacturer, typical 3.0 m (10
ft)
65
Modem I/O Module:
Communications: Hayes AT-compatible
Baud rate: Up to 14.4k baud
Cable length: 2.1 m (7 ft) maximum modem to phone jack
Rack Connector:
Communications: RS-422 only
Baud rate: 38.4 kbaud maximum
Purpose: Allows multiple 3500 racks to be daisy chained
together for communications with 3500 Host
Software
Cable length: 1200 m (4000 ft) maximum
Data Manager I/O Module (2 sets of ports):
Communications: Bently Nevada developed
Baud rate: 9600 baud only
Purpose: Permits static and dynamic data collection by
Bently Nevada Transient Data Interface External
or Dynamic Data Interface External Communication
Processors
Cable length: 3.0 m (10 ft) maximum
Rack Interface Module and RS232/RS422 I/O
Operating Temperature -30
o
C to 65
o
C (-22
o
F to 150
o
F)
Storage Temperature -40
o
C to 85
o
C (-40
o
F to 185
o
F)
Modem I/O Module
Operating Temperature 0
o
C to 50
o
C (32
o
F to 122
o
F)
Storage Temperature -40
o
C to 85
o
C (-40
o
F to 185
o
F)
Humidity: 95% non-condensing
CE MARK DIRECTIVES:
EMC Directives:
EN50081-2:
EN50082-2:
66
Low Voltage Directives:
APPROVALS
CSA-NRTL/C: Class I, Division 2, Groups A through D
PHYSICAL
RIM:
241.3 mm x 24.4 mm x 241.8 mm
(9.50 in x 0.96 in x 9.52 in)
RS-232/RS-422 I/O:
241.3 mm x 24.4 mm x 99.1 mm
(9.50 in x 0.96 in x 3.90 in)
Modem I/O:
241.3 mm x 24.4 mm x 99.1 mm
(9.50 in x 0.96 in x 3.90 in)
Data Manager I/O:
241.3 mm x 24.4 mm x 99.1 mm
(9.50 in x 0.96 in x 3.90 in)
67
RACK SPACE REQUIREMENTS:
RIM Main Board: 1 full-height front slot
RIM I/O Modules: 1 full-height rear slot
Data Manager I/O Modules: 1 full-height rear slot
Revision G, October 2001

3500/32 AND 3500/34
4 CHANNEL RELAY
MODULE AND TMR
RELAY
MODULE

OPERATON AND
MANTENANCE MANUAL

Copyright 2001 BentIy Nevada Corporation
AII Rights Reserved.


The following are trademarks of Bently Nevada Corporation in the United States and other
countries:

Actionable nformation, Actionable nformation to the
FieldMonitor, FluidLoc, FlexiTM, FlexiTAM,
Move Data, Not People, Move nformation, Not
TDXconnX, Tecknowledgy, TipLoc,
Xlerometer

The Bently Nevada Corporation Orbit Design is a
trademark of Bently Nevada Corporation in the United
States and other countries.

The following ways of contacting Bently Nevada Corporation are provided for those times
when you cannot contact your local Bently Nevada representative:

Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 782 9259
nternet www.bently.com

3500/32 and 3500/34 Operation and Maintenance
iii
AdditionaI Information

NOTICE:
This manuaI does not contain aII the information required to operate and
maintain the 4 ChanneI ReIay ModuIe and the TMR ReIay ModuIe. Refer
to the foIIowing manuaIs for other required information.

3500 Monitoring System Rack InstaIIation and Maintenance ManuaI (129766-01)

3500 Monitoring System Rack Configuration and UtiIities Guide (129777-01)

3500 Monitoring System Computer Hardware and Software ManuaI (128158-01)

3500 FieId Wiring Diagram Package (130432-01)
iv
Contents

1 Receiving and HandIing Instructions....................................... 1
1.1 Receiving nspection................................................................................................ 1
1.2 Handling and Storing Considerations ....................................................................... 1
1.3 Disposal Statement .................................................................................................. 1
2 GeneraI Information .................................................................. 2
2.1 The 4 Channel Relay Module................................................................................... 3
2.2 Triple Modular Redundant (TMR) Description .......................................................... 6
2.3 Statuses................................................................................................................. 10
2.4 LED Descriptions ................................................................................................... 13
2.4.1 4 Channel Relay Module................................................................................. 13
2.4.2 TMR Relay Module.......................................................................................... 13
3 Configuration Information....................................................... 14
3.1 Hardware Considerations....................................................................................... 14
3.2 Entering Alarm Drive Logic..................................................................................... 14
3.2.1 Relay Module Configuration Considerations.................................................... 15
3.2.2 Relay Module Configuration Options............................................................... 16
3.3 Software Switches.................................................................................................. 19
4 I/O ModuIe Description............................................................ 21
4.1 4 Channel Relay /O Module (nternal Termination) ............................................... 21
4.2 TMR Relay /O Module (nternal Termination) ....................................................... 23
4.3 Wiring Euro Style Connectors ................................................................................ 25
5 Maintenance............................................................................. 26
5.1 Verifying a 3500 Rack - Relay Module ................................................................... 26
5.1.1 Choosing a Maintenance nterval .................................................................... 26
5.1.2 Required Test Equipment ............................................................................... 27
5.1.3 Typical Verification test setup.......................................................................... 27
5.1.4 Using the Rack Configuration Software........................................................... 29
5.1.5 Standard Relay Channels ............................................................................... 30
5.1.6 TMR Relay Channels ..................................................................................... 31
5.1.7 f a Channel Fails a Verification Test............................................................... 32
5.2 Performing Firmware Upgrades ............................................................................. 33
5.2.1 4 Channel Relay Firmware nstallation Procedure........................................... 33
5.2.2 TMR Relay Firmware nstallation Procedure ................................................... 36
6 TroubIeshooting ...................................................................... 40
6.1 Self-test.................................................................................................................. 40
6.2 LED Fault Conditions ............................................................................................. 41
6.3 System Event List Messages ................................................................................. 42
6.4 Alarm Event List Messages.................................................................................... 49
7 Ordering Information............................................................... 50
7.1 4 Channel Relay Module........................................................................................ 50
v
7.2 TMR Relay Module.................................................................................................51
8 Specifications.......................................................................... 52
8.1 3500/32 4 Channel Relay Module.........................................................................52
8.2 3500/34 TMR Relay Module ...................................................................................55

vi
3500/32 and 3500/34 Operation and Maintenance 1 Receiving and Handling nstructions
1
1 Receiving and HandIing Instructions
Visually inspect the module for obvious shipping damage. f shipping damage is
Corporation.
1.2 HandIing and Storing Considerations
order given.

AppIication AIert

Machinery protection
wiII be Iost when this
moduIe is removed
from the rack.

the rack while power is applied to the rack. Refer to the Rack nstallation and
1.3 DisposaI Statement
the end of its use.

2 General nformation 3500/32 and 3500/34 Operation and Maintenance
2
2 GeneraI Information

The 3500 system is available with two types of relay modules. The first type is
the 4 Channel Relay Module. The 4 Channel Relay Module is used for most
monitoring applications. t uses a single relay to drive the output for each
channel. See section 2.1 for additional information on the 4 Channel Relay
Module.

For applications that require high availability, the 3500 also supports a Triple
Modular Redundant (TMR) Relay Module. The TMR Relay Module uses three
independent relays to drive a single relay output. The TMR Relay Module works
in conjunction with a TMR Rack nterface Module and three monitor modules
configured as a TMR set to provide 2 out of 3 voting for inputs. See section 2.2
for additional information on the TMR Relay Module.

3500/32 and 3500/34 Operati and Maintenance 2 General nformation
3
1) LEDs indicate the status of the relay channels.
2) Terminals for connecting relay contacts to external devices.
3) Switches that control how the relay contacts work.
4) 4 Channel Relay and /O Modules
5) TMR Relay and /O Modules

2.1 The 4 ChanneI ReIay ModuIe
The 4 Channel Relay Module is a full-height module that provides four relay
outputs. Any number of 4 Channel Relay Modules can be placed in any of the
slots to the right of the Rack nterface Module.

Each relay output is fully programmable using AND and OR voting. The Alarm
Drive Logic for each relay channel can use alarming inputs (alerts and dangers)
from any monitor channel in the rack. This Alarm Drive Logic is programmed
using the Rack Configuration Software.

The three common types of Alarm Drive Logic are bussed relays, individual
relays, and independent relays. Bussed relays use an Alarm Drive Logic that
ORs the Alerts or Dangers for all channels in the rack to drive a single relay.
ndividual relays use Alarm Drive Logic that ORs the Alerts or Dangers for
channel pairs (channel 1 and channel 2 or channel 3 and channel 4) in a monitor
to drive a single relay. ndependent relays use Alarm Drive Logic that cause
each alarm level (Alert and Danger) from a channel to drive a separate relay
channel. The following examples show the drive logic for these three types of
logic.

S = Monitor Slot A1 = Alert/Alarm 1
C = Channel A2 = Danger/Alarm 2
4

Bussed ReIays (AIert and Danger)

##A1 = Any Active Alert ##A2 = Any Active Danger

((S02C##A1) OR (S03C##A1) OR ... OR (S15C##A1)) Trip Relay Channel 1
((S02C##A2) OR (S03C##A2) OR . OR (S15C##A2)) Trip Relay Channel 2

Bussed Relays

5

IndividuaI ReIays (AIert and Danger)

(S02C01A1) OR (S02C02A1) Trip Relay Channel 1 (Alert Relay)
(S02C01A2) OR (S02C02A2) Trip Relay Channel 2 (Danger Relay)

(S02C03A1) OR (S02C04A1) Trip Relay Channel 3 (Alert Relay)
(S02C03A2) OR (S02C04A2) Trip Relay Channel 4 (Danger Relay)

ndividual Relays

6

Independent ReIays (AIert and Danger)

(S02C01A1) Trip Relay Module in slot 3 Channel 1


ndependent relays require that you install two 4 Channel Relay Modules for
each monitor module.

ndependent Relays

2.2 TripIe ModuIar Redundant (TMR) Description
For applications that require high system reliability, the 3500 rack is capable of
Triple Modular Redundancy (TMR). The goal of a TMR setup is such that no
single point failure of any component will disable machinery protection for critical
machine points. When a TMR system is configured properly, every function of
the rack is done in duplicate or triplicate to facilitate this goal.

7
Requirements for a 3500 TMR rack:
Rack Jumper must be set to TMR position (see 3500 Rack nstallation
and Maintenance manual).

The TMR version of the 3500/20 Rack nterface Module (TMR RM)
must be used.

Two 3500/15 Power Supplies are required. These power supplies should
be connected to independent sources of power. n the event of a failure
on the primary supply, the monitors will use the secondary supply.

TMR monitors are the same as regular monitors only installed in sets of 3
in adjacent slots. The 3 monitors will monitor the same machine point.
Only one monitor is configured in 3500 Rack Configuration Software, the
other two monitors will automatically be configured the same as the first.

The TMR group can use separate transducers for each monitor
(discrete). Some 3500 monitors are capable of sharing a common
transducer across the triple (bussed). Any /O module can be used for
discrete transducers. The TMR /O module for that monitor must be used
for bussed transducers. Channel pair types not supported by the TMR /O
must use discrete transducers; see the Operation and Maintenance
manual for the desired monitor. Some monitors do not have TMR /O
modules; these monitors cannot be used with bussed transducers.

AppIication AIert

When using bussed
transducers a singIe
point faiIure in the
transducer or fieId
wiring can cause a Ioss
of machinery
protection.

For truly redundant keyphasors, use 2 3500/25 keyphasor monitors.
Configure such that the primary and secondary keyphasors reside on
different keyphasor monitors. Non-redundant keyphasors are allowed.

ndependent monitors may be installed in a TMR rack for monitoring less
critical machine points.

Both the 3500/32 and 3500/34 may be used in a TMR rack. The 3500/34
TMR Relay Monitor can only be configured with to drive relays from
channels in a TMR group. The 3500/32 4 channel Relay Monitor can
only drive relays from channels in an independent monitor.

8
Redundant Display modules and Communication Gateways are permitted
but not required. Some modules do have configuration restrictions for
placing multiple modules in a rack; see the Operation and Maintenance
manual for the appropriate module.

Features of a properIy configured 3500 TMR rack:
Duplicate Power Supplies, All monitors capable of switching between
primary and backup supplies without interruption of monitoring.
Triplicate inter-monitor communication networks between RM, Relay
Module and TMR groups.
Triplicate alarm voting logic and circuitry
Triplicate relay voting logic and control circuitry
Duplicate processing of alarm information from monitors in the rack

How the TMR ReIay ModuIe functions:
A 3500/34 TMR Relay Module consists of 2 half-height Monitors and 1 full size
/O module. The 2 monitors are configured identically and perform the same
monitoring function redundantly. The /O module contains triplicate relays and
control logic.
9

10

TMR ReIay ModuIe:
The TMR Relay Module drives 3 independent Alarm Contact Signals for each of
the 4 relay channels, based on the user programmed Alarm Drive Logic. Alarm
Drive Logic is programmed for each relay channel via the 3500 Rack
Configuration Software. The TMR Relay Module evaluates each data path
independently, produces three Alarm Contact Signals, and passes these Alarm
Contact Signals to the TMR Relay /O Module. f the OK Status for a data path
is Not OK, the Alarm Contact Signal Associated with that data path is set as
nvalid.

TMR ReIay I/O ModuIe:
The TMR Relay /O Module contains 12 relays arranged in 4 channel groups of 3
relays each. This arrangement provides 2 out of 3 relay voting for each of the 4
relay channels. For each relay channel, the TMR Relay Module provides 3
Alarm Contact Signals. Each Alarm Contact Signal is input to one of the relays
in the channel group. These relay channel groups are electrically designed to
provide the 2 out of 3 voting as listed in the table below. Additionally, each TMR
Relay Module provides an OK status that is evaluated on the TMR Relay /O
Module. f the module is Not OK, the Alarm Contact Signals from that module
are not evaluated.

Legs in
Alarm
Legs Not
in Alarm
Legs
Faulted
Alarm
Status
3 0 0 Alarm
2 1 0 Alarm
1 2 0 No Alarm
0 3 0 No Alarm
2 0 1 Alarm
1 1 1 Alarm
0 2 1 No Alarm
1 0 2 Alarm
0 1 2 No Alarm
0 0 3 Alarm*
* Default is No Alarm but can be configured for Alarm
Note: Relays will alarm if both TMR relay modules are removed regardless of
configuration.
2.3 Statuses
The 4 Channel Relay Module and the TMR Relay Module return both module
and channel statuses. This section describes the available statuses and where
they can be found.

11
ModuIe Status
OK
This indicates if the 4 Channel Relay Module or TMR Relay Module is
functioning correctly. A not OK status is returned under any of the following
conditions:
Slot D Failure

f the Module OK status goes not OK, then the system OK Relay on the Rack
nterface /O Module will be driven not OK.

Configuration FauIt
This indicates if the 4 Channel Relay Module or the TMR Relay Module
configuration is invalid.

Bypass
This indicates if any of the channels in the 4 Channel Relay Module or the
TMR Relay Module has been bypassed. Any of the following conditions can
cause the Relay Module to be bypassed:
A channel has never been configured
The Relay Module is in configuration mode
A Fatal error was found during self-test
Rack Alarm nhibit has occurred
A channel has an invalid configuration
Any active channel is bypassed

AIarm 1 Active
This indicates that one or more of the channels of the 4 Channel Relay
Module or the TMR Relay Module is in alarm.

ChanneI Status
OK
This indicates that no fault has been detected by the associated 4 Channel
Relay Module channel or associated TMR Relay Module channel. f the
Channel OK status goes not OK, then the system OK Relay on the Rack

Bypass
This indicates if the associated 4 Channel Relay Module channel or
associated TMR Relay Module channel has been bypassed. Any of the
following conditions can cause the channel to be bypassed:
The channel has never been configured
The Relay Module is in configuration mode
A Fatal error was found during self-test
Rack Alarm nhibit has occurred
The channel has an invalid configuration
The channel is bypassed

12
ChanneI Off
This indicates if the associated 4 Channel Relay Module channel or
associated TMR Relay Module channel has been turned off. The Relay
channels may be turned off (inactivated) using the Rack Configuration
Software.

AIarm 1 Active
This indicates if the associated 4 Channel Relay Module channel or the
associated TMR Relay Module channel is in alarm.


Statuses

Communication
Gateway
ModuIe

Rack
Configuration
Software

Operator
DispIay
Software

Module OK

X

X

Module Configuration Fault

X

Module Bypass

X

Module Alert/Alarm 1 Active

X

X

Channel OK

X

X

X

Channel Bypass

X

X

X

Channel Off

X

X

Channel Alert/Alarm 1 Active

X

X

13

The LEDs on the front panel of the 4 Channel Relay Module and the TMR Relay
Module indicate the operating status of the module as shown in the following
figures. Refer to Section 6.2 for all of the available LED conditions.

2.4.1 4 ChanneI ReIay ModuIe

1) OK
ndicates that the 4 Channel Relay Module and the
4 Channel Relay /O Module are operating
correctly.
2) TX/RX
Flashes at the rate that messages are received.
3) ChanneI AIarm
ndicates that an alarm condition has occurred with
this relay.

2.4.2 TMR ReIay ModuIe

1) OK
ndicates that the TMR Relay Module and the
TMR /O Module are operating correctly.
2) TX/RX
Flashes at the rate that messages are
received.
3) ChanneI AIarm
ndicates that an alarm condition has
occurred with this relay.

3 Configuration nformation 3500/32 and 3500/34 Operation and Maintenance
14

Configure 3500 relay modules by using the Relay Association screen to enter
alarm drive logic for each relay channel and by using the Software Switches
screen to set software switches. This section defines the options on these
configuration screens. The Rack Configuration and Utilities Guide (part number
129777-01) shows how to operate the screens.

3.1 Hardware Considerations
The Slots in the rack are numbered from 0 to 15, counting from left to right. The
power supplies go into slot 0 and the Rack nterface module goes into slot 1.
Slots 2 through 15 are called "monitoring positions. The 3500/32 or 3500/34
module can be installed into any of the monitoring positions. However, if the
3500/20 Rack nterface Module and Data Manager /O are to be used to
interface to DDX, TDX or TDXnet, refer to the manual on the 3500/20 for slot
restrictions this may place on your configuration.
3.2 Entering AIarm Drive Logic

Use the Relay Association screen to enter the alarm logic that controls what
alarms cause the channels in the relay to drive the output.

Relay Association Screen for a Standard Relay

3500/32 and 3500/34 Operati and Maintenance 3 Configuration nformation
15

Relay Association Screen for a TMR Relay
3.2.1 ReIay ModuIe Configuration Considerations
Add monitor modules to the rack configuration before configuring the Relay
Module.
Activate only the Relay Module channels that will be used.
Only monitor modules may be used in the alarm drive logic.
Only the first monitor module of a TMR group needs to be added to the
alarm drive logic.
For the TMR Relay Module, if a channel has an alarm that is part of AND
voting and that channel is bypassed, the bypassed channel is removed from
the voting logic. Alarms will not be inhibited because of the bypass. The 4
Channel Relay Module is configurable.
Prior to downloading, the configuration software will determine if the number
of instructions exceeds the limit of your relay module. The 4-channel relay
monitor is limited to a combined total of 60 tokens, instructions and elements
for the 4 channels. The TMR Relay monitor is limited to 10 tokens,
instructions and elements per channel.
16

3.2.2 ReIay ModuIe Configuration Options

AvaiIabIe Monitors
A field that shows the monitors in the rack.

Rack Type
The type of Rack nterface Module installed in the rack. Standard indicates that
a 4 Channel Relay Module is installed. TMR indicates that a TMR Relay Module
is installed.

Config ID
A unique six character identifier which is entered when a configuration is
downloaded to the 3500 rack.

ReIay SIot
The location in the 3500 rack of the relay module being configured.

Active
A check box that applies to the selected channel in the Channel Association
group. The relay channel drives the output only when this box is enabled ()
and the alarm drive logic for the channel is true.

Latching ReIays (onIy appIies to 4 ChanneI Standard ReIay)
When this option is selected, the corresponding relay alarm channel will hold the
alarm state until it receives a rack reset or the relay is reconfigured.

Standard ReIay ChanneI Association / TMR ReIay ChanneI Association
A group for selecting the channel to be configured and activated.

ReIay NE/NDE Switch Status (onIy appIies to 4 ChanneI ReIay ModuIe)
ndicates how the relay hardware switches are set on the Relay /O Module.
This status is only available after the relay has been uploaded.

AIarm on 3 FauIts (onIy appIies to TMR ReIay ModuIe)
This option lets you enable or disable alarming on three faults. The default is to
not alarm if all three legs (monitors) of a TMR Monitor set are in fault. An alarm
will occur if both TMR monitors are removed, regardless of configuration.

AppIication AIert

Do not enabIe AIarm on
3 FauIts if the reIays are
associated to Zero
Speed channeIs.
17

AvaiIabIe Monitor ChanneIs/AIarms
When a monitor is selected, this area shows all the alarms that are available for
the monitor.

AIarm Drive Logic
Build the alarm drive logic in this area using the available monitor alarms.

AND Voting Setup
This option allows you to determine the AND voting for a standard relay.

AND Voting Setup Screen

18
NormaI AND Voting (DefauIt)
With this option selected, if an alarming parameter is Not OK or bypassed (either
by user selection or monitor failure), then the parameter will be removed from
the relay logic.

True AND Voting
Selecting True AND logic causes Not OK and bypassed parameters to remain in
the relay logic. Using 'True And' logic will not drive an alarm if an alarming
parameter being And-ed is Not OK or in bypass.

Important: Care must be taken when selecting AND the voting to be used;
consider the configuration settings for the channel to be used as an alarm
parameter. Not OK Channel Defeat (single channel measurements), Not OK
Channel Pair Defeat (paired channel measurements), Timed OK Channel Defeat
and Latching vs. Non-Latching Not OK modes all affect the circumstances that
cause a channel to be "Not OK" or bypassed. The following channel types have
special scenarios to consider:

Thrust Position: Monitor reports an Alarm (not a "Not OK" condition) to the
relay monitor for a transducer not OK.

Overspeed, Zero-Speed, Rotor Speed: These channel types have optional "OK
Voltage Checks" that will determine if the monitor will or will not report a Not OK
status to the Relay Monitor due to a transducer voltage error.

Eccentricity: "Direct Channel Above 600 RPM" affects bypass and Not OK
status.

19

3.3 Software Switches
Software switches for relay modules let you temporarily bypass or inhibit relay
module and channel functions. Set these switches on the Software Switches
screen under the UtiIities Option on the main screen of the Rack Configuration
Software. Switch settings take affect only after you press the Set button.

Configuration Mode
A switch that allows the 4 Channel Relay Module or the TMR Relay Module to be
configured. To configure a relay module, enable () this switch and set the key
switch on the front of the Rack nterface Module in the PROGRAM position.
When downloading a configuration from the Rack Configuration Software, this
switch will automatically be enabled and disabled by the Rack Configuration
Software. f the connection to the rack is lost during the configuration process,
use this switch to remove the module from Configuration Mode.

The monitor switch number is used in the Communication Gateway Module.

ModuIe Switch Number

Switch Name

1

Configuration Mode
20

Bypass
When enabled (), the channel will be turned off.

The channel switch number is used in the Communication Gateway Module.

ChanneI Switch Number

Switch Name

1

Bypass

3500/32 and 3500/34 Operation and Maintenance 4 /O Modules Description
21
4 I/O ModuIe Description

This section describes the /O modules that are associated with the 4 Channel
Relay Module and the TMR Relay Module. This section also describes how to
use the connectors on the Relay /O Module and describes where to install each
/O module.
4.1 4 ChanneI ReIay I/O ModuIe (InternaI
Termination)
The 4 Channel Relay /O Module contains four sets of relay contacts (one for
each channel) and can be setup so each channel is Normally Energized or
Normally De-energized. The 4 Channel Relay /O Module must be installed
behind the 4 Channel Relay Module (in a Rack Mount or a Panel Mount rack) or
above the 4 Channel Relay Module (in a Bulkhead rack).

1) Terminals for connecting double-
pole, double-throw (DPDT) relays.
2) DP switches for configuring the
relays for Normally Energized (NE)
or Normally De-energized (NDE).
The numbers refer to relay channel.
For example, 1 is for relay Channel
1.

4 /O Modules Description 3500/32 and 3500/34 Operation and Maintenance
22

Note
Relay contacts are marked NC (Normally Closed), NO (Normally Open), and
ARM (Armature). NC and NO define the state of the relay contacts with no
power applied to the relay coil (de-energized).

Normally Energized Normally De-energized
(NE) (NDE)

1) No Power/ No Alarm (shelf state)
2) With Power/ No Alarm
3) With Power/ n Alarm

23
4.2 TMR ReIay I/O ModuIe (InternaI Termination)
Each relay channel in the TMR Relay /O Module contains a set of relay contacts
that are setup so that each channel is always Normally Energized. The TMR
Relay /O Module must be installed behind the TMR Relay Modules (in a Rack
Mount or a Panel Mount rack) or above the TMR Relay Modules (in a Bulkhead
rack).

1) Relay connections for
relay Channel 1 and relay
Channel 2.
2) Relay connections for
relay Channel 3 and relay
Channel 4.

4 /O Modules Description 3500/32 and 3500/34 Operation and Maintenance
24

Note
Relay contacts are marked NO (Normally Open) and ARM (Armature). NO
defines the state of the relay contacts with no power applied to the relay coil
(de-energized).

Normally Energized
(NE)

1) No Power/ No Alarm (shelf state)
2) With Power/ No Alarm
3) With Power/ n Alarm

25
4.3 Wiring Euro StyIe Connectors
terminal block to the base, grip the block firmly and pull. Do not pull the block
out by its wires because this could loosen or damage the wires or connector.

Typical /O Module

Do not remove more than 6 mm (0.25 in) of insulation from the wires.

5 Maintenance 3500/32 and 3500/34 Operation and Maintenance
26
5 Maintenance

field. Maintaining a 3500 rack consists of testing module channels to verify that
they are operating correctly. Modules that are not operating correctly should be
replaced with a spare.

rack while power is applied to the rack. Refer to the Rack nstallation and

This section shows how to verify the operation of the 3500/32 4 Channel Relay
Module and the 3500/34 TMR Relay Module.

5.1 Verifying a 3500 Rack - ReIay ModuIe
The 3500 Monitoring System is a high precision instrument that requires no
calibration. The functions of Relay Module channels, however, must be verified
at regular intervals. At each maintenance interval, we recommend that you use
the procedures in this section to verify the operation of all active channels in the
Relay Module.

Section
Number

Topic

Page
Number
5.1.1 Choosing a Maintenance nterval 26
5.1.2 Required Test Equipment 27
5.1.3 Typical Verification Test Setup 27
5.1.4 Using the Rack Configuration Software 29
5.1.5 Standard Relay Channels 30
5.1.6 TMR Relay Channels 31

5.1.1 Choosing a Maintenance IntervaI
Start with an interval of one year and then shorten the interval if any of the
following conditions apply:
o Monitored machine is classified as critical
o 3500 rack is operating in a harsh environment such as in extreme
temperature, high humidity, or in a corrosive atmosphere

At each interval, use the results of the previous verifications and SO
Procedure 10012-1 1992(E) to adjust the interval.

3500/32 and 3500/34 Operation and Maintenance 5 Maintenance
27
5.1.2 Required Test Equipment
The test equipment needed to simulate the inputs for the relay channel will
depend on the type of monitor providing inputs to the Relay Alarm Drive Logic.
This equipment can be found under Required Test Equipment in the
Maintenance section of the specific monitor manual.

5.1.3 TypicaI Verification test setup
The following figure shows the typical test setup for verifying a Relay Module.
The test equipment is used to simulate the transducer signal to selected
monitors and the laptop computer is used to observe the output from the rack.

1) 3500 Rack
2) Test Equipment
3) RS-232 communications
4) Laptop Computer

Transducers can be connected to a 3500 rack in a variety of ways. Depending
on the wiring option for the /O module of your monitor, connect the test
equipment to the Monitor Module and Relay Module using one of the following
methods:
28

1) Connect test equipment here.
2) nputs
3) Monitor /O Module (nternal Termination)
4) External Termination Block (Euro Style Connectors)
5) External Termination Block (Terminal Strip Connectors)
29

1) Outputs
2) Connect test
equipment here.

4 Channel Relay /O TMR Relay /O Module
Module (nternal (nternal Termination)
Termination)

5.1.4 Using the Rack Configuration Software
The laptop computer that is part of the test setup uses the Rack Configuration
Software to display output from the rack and to reset certain operating
parameters in the rack. To perform the test procedures in this section you must
be familiar with the following features of the Rack Configuration Software.
upload and save configuration files
display the Verification screen

The Rack Configuration and Test Utilities Guide (part number 129777-01)
explains how to perform these operations.

Note
Save the original rack configuration before doing any maintenance
or troubleshooting procedures.

30
The Verification screen displays relay channel output from a 3500 rack as shown
in the following figure. nformation such as Alarm Drive Logic, Channel Alarm
State and Channel OK State are used to verify relay channels.

5.1.5 Standard ReIay ChanneIs
Verify relay channels by forcing alarms from the monitors that provide inputs for
the Relay Alarm Drive Logic. When the logic is true, the Channel Alarm State
will change to Alarm on the Verification screen and the alarm relay for that
channel will change state. Verify only those channels that are active and
configured.

To verify that a 4 Channel Relay channel is working correctly.
1. Run the Rack Configuration Software on the test computer.

2. Choose Verification from the Utilities menu. A screen prompting for the
slot and channel number of the relay to be tested will appear.

3. Choose the proper Slot number and Channel number and then click on the
Verify button. The Verification screen will appear.

4. Verify that the Channel OK State status on the Relay Verification screen
reads OK.

5. Use the Relay Verification screen to determine what inputs must be
simulated.

6. Simulate the required Alarm Drive Logic inputs to cause the relay to change
states.
31

For example, a 3500 Rack with the following configuration:

SIot Number

ModuIe Type

1
2
3
4
5

Rack nterface Module
3500/42 4 Channel Monitor
3500/42 4 Channel Monitor
3500/42 - 4 Channel Monitor
3500/32 - 4 Channel Standard Relay

A relay channel with the following Alarm Drive Logic:
( S02C01A1 * S03C01A1 ) + S04C01A2

Send test signals to the monitors in the rack to cause Slot 2 Channel 1 AND
Slot 3 Channel 1 to be in Alert OR cause Slot 4 Channel 1 to be in Danger.

7. Verify that the Channel Alarm State status on the Relay Verification screen
changes to Alarm. Verify that the relay contacts change state.

8. f the Relay channel does not respond correctly, check the inputs to ensure
they meet the Alarm Drive Logic requirements. f the module still does not
meet specifications, go to Section 5.1.7 (f a Channel Fails a Verification
Test).

9. Select the next channel to be tested by using the Channel drop down list on
the Verification screen. Repeat steps 4 through 8 to test the next relay
channel.

5.1.6 TMR ReIay ChanneIs
The TMR Relay Module contains two half-height TMR Relay Modules that work
with one TMR Relay /O module in one slot of the 3500 rack. The two half-
height TMR Relay Modules work in parallel. Both see the same inputs at the
same time and perform the same function within the same time frame. The
inputs to the two TMR Relay Modules are from one or more groups of three 4-
channel monitors. Each channel from each monitor in the group of three is
redundant.

Verify relay channels by forcing alarms from the monitors that provide inputs for
the Relay Alarm Drive Logic. When the logic is true, the Channel Alarm State
will change to Alarm on the Verification screen and the alarm relay for that
channel will change state. Verify only those channels that are active and
configured.

To verify that a TMR Relay channel is working correctly.

1. Run the Rack Configuration Software on the test computer.

2. Choose Verification from the Utilities menu. A screen prompting for the
slot and channel number will appear.
32

3. Choose the proper Slot number and Channel number of the relay to be
tested then click on the Verify button. The Verification screen will appear.

4. Verify that the Channel OK State status on the Relay Verification screen
reads OK.

5. Use the Relay Verification screen to determine what inputs must be
simulated.

6. Simulate the required Alarm Drive Logic inputs to cause the relay to change
states.

For example, for a 3500 Rack with the following configuration:

SIot Number

ModuIe Type

1
2
3
4
5
6
7
8

Rack nterface Module
3500/34 - TMR Relay Module

|
|-- TMR group
|

|
|--TMR group
|

For a relay channel with the following Alarm Drive Logic:
S02C01A1 * S06C01A1

Send test signals to the monitors in the rack to cause Slot 2 Channel 1, Slot
3 Channel 1, and Slot 4 Channel 1 AND Slot 6 Channel 1, Slot 7 Channel 1,
and Slot 8 Channel 1 to be in Alert.

7. Verify that the Channel Alarm State status on the Relay Verification screen
changes to Alarm. Verify that the relay contacts change state.

8. f the Relay channel does not respond correctly, check the inputs to ensure
they meet the Alarm Drive Logic requirements. f the module still does not
meet specifications, go to Section 5.1.7 (f a Channel Fails a Verification
Test).

9. Select the next channel to be tested by using the Channel drop down list on
the Verification screen. Repeat steps 4 through 8 to test the next relay
channel.
5.1.7 If a ChanneI FaiIs a Verification Test
When handling or replacing circuit boards always be sure to adequately protect
against damage from Electrostatic Discharge (ESD). Always wear a proper wrist
strap and work on a grounded, conductive work surface.

1. Save the configuration for the module using the Rack Configuration
Software.
33

2. Replace the module with a spare. Refer to the installation section in the
3500 Monitoring System Rack nstallation and Maintenance Manual (part
number 129766-01).

3. Return the faulty module to Bently Nevada Corporation for repair.

4. Download the configuration for the spare module using the Rack

5. Verify the operation of the spare.


with the 3500/32 4 Channel Relay Module and the 3500/34 TMR Relay Module.
The following instructions describe how to remove the existing firmware and
replace it with upgrade firmware. The monitor will need to be reconfigured using
the 3500 Rack Configuration software after having its firmware upgraded.
The following items will be required to perform a firmware upgrade to the
monitor:
Phillips Screwdriver.
Small Flathead Screwdriver.
C Removal Tool.*
Upgrade Firmware C.*
*Refer to Section 7 (Ordering nformation) for part numbers. Users may use their
own grounding wrist strap or C removal tool.
5.2.1 4 ChanneI ReIay Firmware InstaIIation Procedure
The following steps will need to be followed to complete the monitor firmware
upgrade:
Ensure that the monitor's configuration is saved using the 3500 Rack
Configuration software.
the monitor or the upgrade firmware C.
Remove the monitor from the 3500 rack.
Remove the Top Shield from the monitor.
Remove the original firmware C from the monitor PWA.
nstall the upgrade firmware C into the socket on the monitor PWA.
Replace the monitor Top Shield.
34
Replace the monitor into the 3500 system.
Reconfigure the monitor using the 3500 Rack Configuration software.

Top ShieId RemovaI

1) Top Shield.
2) Standoff.
3) Screwdriver.

Step 1. Place the large flathead screwdriver under the top shield and on the
ridge of the rear standoffs and lift upward on the screwdriver to pop the cover
loose from the rear standoffs.

standoffs.
35

OriginaI Firmware IC RemovaI

Step 1. nsert the removal tool in one of the two slots at the corner of the socket
on the PWA. The diagram shows the approximate location of the chip to be
removed, but not necessarily its orientation.

Step 2. Slightly lift the corner of the chip by gently pulling back on the tool. Move
to the other slotted corner and repeat. Continue this process until the chip comes
loose from the socket.
36

Upgrade Firmware IC InstaIIation

nstall the upgrade firmware C into the PWA. Be sure that the keyed corner on
the C is matched to the keyed corner of the socket. Ensure that the C is firmly

Top ShieId RepIacement
the top left corner of the module as shown in the diagram under "Top Shield
5.2.2 TMR ReIay Firmware InstaIIation Procedure
The following steps will need to be followed to complete the monitor firmware
upgrade:
Ensure that the monitor's configuration is saved using the 3500 Rack
Remove the original firmware C from the monitor PWA.
nstall the upgrade firmware C into the socket on the monitor PWA.

37
ShieId RemovaI

Step 1. Remove the 4 screws (item 1) that hold the shield and PWA together
using a Phillips screwdriver.

Step 2. Remove the shield (item 3) from PWA.
38

Step 1. nsert the removal tool in one of the two slots at the corner of the socket
on the PWA. The diagram shows the approximate location of the chip to be
removed, but not necessarily its orientation.

Step 2. Slightly lift the corner of the chip by gently pulling back on the tool. Move
to the other slotted corner and repeat. Continue this process until the chip comes
loose from the socket.

39

nstall the upgrade firmware C into the PWA. Be sure that the keyed corner on
the C is matched to the keyed corner of the socket. Ensure that the C is firmly

ShieId RepIacement
Replace the shield. Align the holes in the shield with the standoffs and replace
the 4 Phillips-head screws to fasten the shield to the PWA.

40
6 TroubIeshooting

This section describes how to use the module self-test, the LEDs, and System
Event List to troubleshoot a problem with the 4 Channel Relay Module, the TMR
Relay Module, or the /O module.
6.1 SeIf-test
To perform a self-test:
rack (if needed).

2. Select UtiIities from the main screen of the Rack Configuration Software.

3. Select System Events/ModuIe SeIf-test from the Utilities menu.

4. Press the ModuIe SeIf-test button on the System Events screen.

AppIication AIert
Machinery protection wiII be
Iost whiIe the seIf-test is
being performed.

5. Select the slot that contains the relay module and press the OK button. The
relay module will perform a full self-test and the System Events screen will be
displayed. The list will not contain the results of the self-test.

6. Wait 30 seconds for the module to run a full self-test.

7. Press the Latest Events button. The System Events screen will be updated
to include results of the self-test.

8. Verify if the relay module passed self-test. f the module failed the self test,
refer to Section 6.3.

3500/32 and 3500/34 Operation and Maintenance 6 Troubleshooting
41
6.2 LED FauIt Conditions
problems with the 4 Channel Relay Module and the TMR Relay Module.

OK Led

TX/RX

Condition

SoIution

1 Hz

1 Hz

Relay Module is not configured.

Reconfigure the Relay
Module.

5 Hz

Relay Module or the Relay /O
Module has detected an internal
fault and are not OK.

List.

ON

Flashing

Relay Module and the Relay /O
Module are operating correctly.


OFF

Relay Module is not operating
correctly.

Replace the Relay
Module.

Not
flashing

Relay Module is not
communicating correctly or the
Relay Module is not associated
with any monitors in the rack that
are communicating.

List.


AIarm LED

Condition

SoIution

ON

Channel is in Alarm.


OFF

Channel is not in Alarm.


42

4 Channel Relay Module and the TMR Relay Module and gives an example of
one.

Example of a System Event List Message:

Sequence
Number

Event
nformation

Event
Number

Class

Event
Date
DDMMYY

Event
Time

Event
Specific

Slot

0000000123

EEPROM
Memory Failure

13

1

02/01/90

12:24:31:99

5

example 123).

Event nformation: The name of the event (for example EEPROM Memory
Failure).

Event Number: dentifies a specific event.

Class: Used to display the severity of the event. The
following classes are available:

CIass VaIue

CIassification

0
1
2
3

Severe/Fatal Event
Typical logged Event
Reserved



this field.

Slot: dentifies the module that the event is associated with.
f a half-height module is installed in the upper slot or a
f a half-height module is installed in the lower slot then
the field will be 0L to 15L. For example, a half-height
module installed in the lower position in slot 5 would be
5L.

43
The following System Event List Messages may be placed in the list by the 4
Channel Relay Module and the TMR Relay Module and are listed in numerical
order. f an event marked with a star (*) occurs the relays on the 4 Channel
Relay /O Module and the TMR Relay /O Module will not be driven. f you are
unable to solve any problems contact your nearest Bently Nevada Corporation
office.

EEPROM Memory FaiIure
Event Number: 13
Action: Replace the Relay Module as soon as possible.

InternaI Network FaiIure
Event Number: 30
Action: Replace the Relay Module immediately.

Event Number: 32
the Relay Module
the rack backplane

Event Number: 33
the Relay Module
the rack backplane

FaiI ReIay CoiI Sense
Event Number: 55
Action: Check to see if the Relay /O Module is installed. f installed,
check to see if one of the following components is faulty:
the Relay Module
the Relay /O Module

Pass ReIay CoiI Sense
Event Number: 56
the Relay Module
the Relay /O Module

44

FaiI Main Board +5V-A (Fail Main Board +5V - upper Power Supply)
Event Number: 100
problem. f the problem is not caused by noise, check to see if
the Relay Module

Event Number: 101
the Relay Module

FaiI Main Board +5V-B (Fail Main Board +5V - lower Power Supply)
Event Number: 102
the Relay Module

Event Number: 103
the Relay Module

* FaiI Main Board +5V-AB (Fail Main Board +5V - upper and lower Power
Supplies)
Event Number: 104
the Relay Module

45

Pass Main Board +5V-AB (Pass Man Board +5V - upper and lower Power
Supplies)
Event Number: 105
the Relay Module

Configuration FaiIure
Event Number: 301
Action: Replace the Relay Module immediately.

Event Number: 301
Action: Download a new configuration to the Relay Module. f the
problem still exists, replace the Relay Module as soon as
possible.

Event Number: 305
Action: Download the software switches to the Relay Module. f the
software switches are not correct replace the Relay Module as
soon as possible.

* FaiI I/O Board +5V-AB (Fail /O Board +5V - upper and lower Power
Supplies)
Event Number: 390
the Relay /O Module
the Relay Module

46

Pass I/O Board +5V-AB (Pass /O Board +5V - upper and lower Power
Supplies)
Event Number: 391
the Relay /O Module
the Relay Module

FaiI I/O Board +14V-A (Fail /O Board +14V - upper Power Supply)
Event Number: 392
the Relay /O Module
the Relay Module

Pass I/O Board +14V-A (Pass /O Board +14V - upper Power Supply)
Event Number: 393
the Relay /O Module
the Relay Module

FaiI I/O Board +14V-B (Fail /O Board +14V - lower Power Supply)
Event Number: 394
the Relay /O Module
the Relay Module

47

Pass I/O Board +14V-B (Pass /O Board +14V - lower Power Supply)
Event Number: 395
the Relay /O Module
the Relay Module

* FaiI I/O Board +14V-AB (Fail /O Board +14V - upper and lower Power
Supplies)
Event Number: 396
the Relay /O Module
the Relay Module

Pass I/O Board +14V-AB (Pass /O Board +14V - upper and lower Power
Supplies)
Event Number: 397
the Relay /O Module
the Relay Module

FaiI I/O ModuIe DIP Sw (Fail /O Module DP switch)
Event Number: 398
Action: Verify that the Relay /O Module is installed. f the Relay /O
Module is installed, replace the Relay /O Module as soon as
possible.

Pass I/O ModuIe DIP Sw (Pass /O Module DP switch)
Event Number: 399
Action: Verify that the Relay /O Module is installed. f the Relay /O
Module is installed, replace the Relay /O Module as soon as
possible.

48

Pass ModuIe SeIf-test
Event Number: 410

EnabIed Ch Bypass (Enabled Channel Bypass)
Event Number: 416
Event Specific: Ch x

DisabIed Ch Bypass (Disabled Channel Bypass)
Event Number: 417

InvaIid AIm Drive Logic (nvalid Alarm Drive Logic)
Event Number: 451
Action: Download a new configuration to the Relay Module. f the
problem still exists replace the Relay Module as soon as possible.

FaiI SIot Id Test
Event Number: 461
Action: Verify that the Relay Module is fully inserted in the rack. f the
Relay Module is installed correctly, check to see if one of the
following components is faulty:
the Relay Module
the rack backplane

Pass SIot Id Test
Event Number: 462
Action: Verify that the Relay Module is fully inserted in the rack. f the
Relay Module is installed correctly, check to see if one of the
following components is faulty:
the Relay Module
the rack backplane
49

6.4 AIarm Event List Messages
The following messages may be placed in the Alarm Event List by the 4 Channel
Relay Module and the TMR Relay Module.

AIarm Event List Message

When the message wiII occur

Entered not OK

Left not OK

Relay Activated

Relay Deactivated

module went not OK


condition for driving the relay channel met

condition for driving the relay channel is no longer
met

7 Ordering nformation 3500/32 and 3500/34 Operation and Maintenance
50

This section contains the ordering information for the 3500/32 4 Channel Relay
Module and the 3500/34 TMR Relay Module.

7.1 4 ChanneI ReIay ModuIe

A B
Part number 3500/32- -
A Output ModuIe
01 4 Channel Relay /O Module

B Agency ApprovaI Option
00 None
01 CSA-NRTL/C

Spares
4 Channel Relay Module 125712-01
4 Channel Relay /O Module 125720-01
Relay nternal Termination Headers 00580436
Relay Module Manual 129771-01
Firmware C 132319-01
C Removal Tool 04400037
3500/32 and 3500/34 Operation and Maintenance 7 Ordering nformation
51

7.2 TMR ReIay ModuIe

A B
Part number 3500/34 - -
A TMR ReIay ModuIe Type
01 TMR Relay Module
B Agency ApprovaI Option
00 No Approvals Required
01 CSA-NRTL/C

Spares
TMR Relay Module 125696-01
TMR Relay /O Module 125704-01
Relay nternal Termination Headers 00580438
Relay Module Manual 129771-01
Firmware C 132317-01
Grounding Wrist Strap(single use only) 04425545
C Removal Tool 04400037
Half-height Module Adapter
Chassis 125388-01
Card Guide 125565-01
Screws (order 3 per adapter) 04300111

Note
When ordered as a new system, the TMR relay module includes two half-
height modules with required mounting hardware. When the spare is ordered,
a single half-height TMR Relay Module is shipped.

8 Specifications 3500/32 and 3500/34 Operation and Maintenance
52
8 Specifications

This section contains the specifications for the 3500/32 4 Channel Relay Module
and the 3500/34 TMR Relay Module.

8.1 3500/32 4 ChanneI ReIay ModuIe

TYPE
Two single-pole, double-throw (SPDT) relays connected in a double-pole,
double-throw (DPDT) configuration.

ENVIRONMENTAL SEALING
Epoxy-sealed

ARC SUPPRESSORS
250 Vrms, installed as standard.

CONTACT RATINGS (resistive Ioad):
Max switched power: DC: 120 W AC: 600 VA



Max switched voltage: DC: 30 Vdc AC: 250 Vac

3500/32 and 3500/34 Operation and Maintenance 8 Specifications
53

54

CONTACT LIFE
100,000 @ 5 A, 24 Vdc or 120 Vac

OPERATION
Each channel is switch selectable for Normally De-energized or Normally
Energized.

Temperature: -30
o
C to 65
o
C (-22
o
F to 150
o
F) operating
-40
o
C to 85
o
C (-40
o
F to 185
o
F) storage


ELECTROMAGNETIC COMPATIBILITY

EN50081-2:

EN50082-2:



Low VoItage Directives:
Safety Requirements: EN61010-01

APPROVALS
CSA-NRTL/C: Class , Division 2, Groups A through D

55

PHYSICAL
Main Module:
241 mm x 24.4 mm x 242 mm
(9.50 in x 0.96 in x 9.52 in)

/O Module:
241 mm x 24.4 mm x 99.1 mm.
(9.50 in x 0.96 in x 3.90 in)

Main Module: 1 full-height front slot

/O Module: 1 full-height rear slot

8.2 3500/34 TMR ReIay ModuIe

TYPE
Three Double-pole, double-throw (DPDT) relays connected in a single-pole,
single-throw (SPST) configuration.

ENVIRONMENTAL SEALING
Epoxy-sealed

ARC SUPPRESSORS
Not Supported

CONTACT RATINGS (resistive Ioad)
Max switched power: DC: 60 W, AC: 125 VA



Max switched voltage: 150 Vdc or 220 Vac

56

57

CONTACT LIFE
100,000@ 1.5 A, 24 Vdc or 1 A, 120 Vac

OPERATION
Each channel is Normally Energized.

Temperature: -30
o
C to 65
o
C (-22
o
F to 150
o
F) operating
-40
o
C to 85
o
C (-40
o
F to 185
o
F) storage


ELECTROMAGNETIC COMPATIBILITY

EN50081-2:

EN50082-2:



Safety Requirements: EN61010-01

APPROVALS
CSA-NRTL/C: Class , Division 2, Groups A through D

58
PHYSICAL
Main Module:
120.4 mm. x 24.6 mm x 241.8 mm
(4.74 in x 0.97 in x 9.52 in)

/O Modules:
241 mm x 24.4 mm x 99.1 mm
(9.50 in x 0.96 in x 3.90 in)

Main Module: 1 half-height front slot

/O Modules: 1 full-height rear slot

Revision D, June 2002
3500/42M
Proximitor/Seismic Monitor
Module
Operation and Maintenance Manual
ii
Copyright 2002 Bently Nevada, LLC
The following are trademarks of Bently Nevada, LLC in the United States and other
countries:
ACM, Actionable Information
, Actionable
Information to the Right People at the Right Time
,
ADRE , Asset Condition Management, Asset
Condition Monitoring, Bently ALIGN, Bently
BALANCE, Bently DOCUVIEW, Bently LUBE,
Bently PERFORMANCE, Bently Nevada ,
CableLoc, ClickLoc, Data Manager , Decision
Support
SM
, DemoNet, Dynamic Data Manager,
Engineer Assist, FieldMonitor, flexiTIM,
FluidLoc, Helping You Protect and Manage All
Your Machinery , HydroScan , HydroView,
Key , Keyphasor, Machine Condition
Manager 2000, MachineLibrary, Machine
Manager, MicroPROX, Move Data, Not People,
Move Information, Not Data, NSv, Prime Spike,
PROXPAC, Proximitor, REBAM , RuleDesk,
SE, Seismoprobe, Smart Monitor , Snapshot,
System 1, System Extender, TDXnet,
TDIXconnX, TipLoc, TorXimitor, Transient Data
Manager, Trendmaster , TrimLoc, Velomitor
Bently Nevadas orbit logo and other logos associated
with the trademarks in bold above, are also all
trademarks or registered trademarks of Bently Nevada,
LLC in the United States and other countries.
The following ways of contacting Bently Nevada are provided for those times when you
cannot contact your local Bently Nevada representative:
Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 782 9259
iii
Notice:
This manual does not contain all the information required to operate and maintain the
3500/42M Proximitor/Seismic Monitor Module module. Refer to the Following
manuals for other require information.
instructions for installing the removing the module from a 3500 rack
3500 Monitoring System Rack Configuration and Utilities Guide ( 129777-01)
Guidelines for using the 3500 test utilities to verify that the input and output terminals on
3500 Monitoring system Computer Hardware and Software Manual (128158-01)
iv
Contents
1. Receiving and Handling Instructions .....................................1-1
2. General Information.................................................................2-1
3. Monitor Configuration..............................................................3-1
4. I/O Module Descriptions ..........................................................4-1
5. Monitor Verification .................................................................5-1
6. Troubleshooting.......................................................................6-1
7. Radial Vibration General Information .....................................7-1
8. Radial Vibration Configuration................................................8-1
9. Radial Vibration Verification....................................................9-1
10. Thrust Position General Information....................................10-1
11. Thrust Position Configuration...............................................11-1
12. Differential Expansion General Information.........................12-1
13. Differential Expansion Configuration ...................................13-1
14. Thrust Position and Differential Expansion Verification.....14-1
15. Eccentricity General Information..........................................15-1
16. Eccentricity Configuration ....................................................16-1
17. Eccentricity Verification ........................................................17-1
18. REBAM General Information.................................................18-1
19. REBAM Configuration............................................................19-1
20. REBAM Verification ...............................................................20-1
21. Velocity General Information.................................................21-1
22. Velocity Configuration...........................................................22-1
v
23. Velocity II Configuration........................................................23-1
24. Velocity Verification...............................................................24-1
25. Acceleration General Information.........................................25-1
26. Acceleration Configuration ...................................................26-1
27. Acceleration II Configuration ................................................27-1
28. Acceleration Verification.......................................................28-1
29. Shaft Absolute General Information.....................................29-1
30. Shaft Absolute Configuration ...............................................30-1
31. Shaft Absolute Radial Vibration Options .............................31-1
32. Shaft Absolute Radial Vibration Verification .......................32-1
33. Shaft Absolute Velocity Options...........................................33-1
34. Shaft Absolute Velocity Verification.....................................34-1
35. Circular Acceptance Region General Information...............35-1
36. Circular Acceptance Region Configuration .........................36-1
37. Circular Acceptance Region Verification.............................37-1
38. Specifications.........................................................................38-1
39. Ordering Information .............................................................39-1
vi
Blank Page
Section 1 - Receiving and Handling Instructions
- 1-1 -
1. Receiving and Handling Instructions
Table of Contents
1.1 Receiving Inspection...................................................................................... 1-2
1.2 Handling and Storing Considerations............................................................. 1-2
1.3 Disposal Statement........................................................................................ 1-2
3500/42M Operation and Maintenance
- 1-2 -
apparent, file a claim with the carrier and submit a copy to Bently Nevada.
order given:
Application Alert
Machinery protection will be lost when
this module is removed from the rack.
Use extra caution during dry weather. Relative humidity less than 30 %
tends to multiply the accumulation of static charges on any surface.
States federal laws, or any applicable international law. Bently Nevada is not
responsible for disposal of product at the end of its life or at the end of its use.
Section 2 - General Information
- 2-1 -
2. General Information
Table of Contents
2.1 Introduction.................................................................................................... 2-2
2.2 Views of the Front Panel and I/O Modules ..................................................... 2-3
2.3 Triple Modular Redundant (TMR) Description................................................ 2-6
2.4 Available Data................................................................................................ 2-6
2.4.1 Statuses ......................................................................................... 2-6
2.4.2 Proportional Values ........................................................................ 2-9
2.5 LED Descriptions ......................................................................................... 2-10
2.6 Monitor Versions.......................................................................................... 2-11
- 2-2 -
2.1 Introduction
The 3500/42M Proximitor/Seismic Monitor is a 4-channel monitor that accepts
input from proximity and seismic transducers, conditions the signal to make
various vibration and position measurements, and compares the conditioned
signals with user-programmable alarms. Each channel of the 3500/42M can be
programmed using the 3500 Rack Configuration Software to perform any of the
following functions:
Radial Vibration
Thrust Position
Eccentricity
Differential Expansion
Acceleration
Velocity
Shaft Absolute
REBAM
Note
The monitor channels are programmed in pairs and can
perform up to two of these functions at a time. Channels
1 and 2 can perform one function, while channels 3 and
4 perform another (or the same) function.
The primary purpose of the 3500/42M monitor is to provide:
1. Machinery protection by continuously comparing monitored parameters
against configured alarm setpoints to drive alarms.
2. Essential machine information for both operations and maintenance
personnel.
Each channel, depending on configuration, typically conditions its input signal
into various parameters called "proportional values". Alert setpoints can be
configured for each active proportional value and Danger setpoints can be
configured for any two of the active proportional values.
The 3500/42M is shipped from the factory unconfigured. When needed, the
3500/42M can be installed into a 3500 rack and configured to perform the
required monitoring function. This lets you stock a single monitor for use as a
spare for many different applications.
- 2-3 -
2.2 Views of the Front Panel and I/O Modules
Front and rear view of the Proximitor/Seismic Monitor
(1) Status LEDs
(2) Buffered Transducer Outputs
(3) I/O Module with Internal Terminators
(4) I/O Module with External Terminators
(5) TMR I/O Module with External Terminators
- 2-4 -
Additional I/O Modules of the Proximitor/Seismic Monitor
(1) Prox/Velom I/O Module, Internal Terminations
(2) Prox/Velom I/O Module, External Terminations
(3) Shaft Absolute I/O Module, Internal Terminations
(4) Saft Absolute I/O Module, External Terminations
- 2-5 -
Barrier I/O Modules for the Proximitor/Seismic Monitor
(1) Barrier I/O module for connecting two Proximitor sensors.
(2) Barrier I/O module for connecting one Proximitor sensor and one
Velomitor sensor.
(3) Barrier I/O module for connecting two Velomitor sensors.
- 2-6 -
2.3 Triple Modular Redundant (TMR) Description
When used in a TMR configuration, 3500/42M monitors and I/O modules must
be installed adjacent to each other in groups of three. When used in this
configuration, two types of voting are employed to ensure accurate operation and
to avoid single point failures.
The first level of voting occurs on the TMR Relay Module. With this voting, the
selected alarm outputs for the three monitors are compared in a 2 out of 3
method. Two monitors must agree before the relay is driven. Refer to the
3500/32 & 34 Relay Module Operation and Maintenance Manual for more
information on this voting.
The second type of voting is referred to as "Comparison" voting. With this type
of voting, the proportional value outputs of each monitor in the group are
compared with each other. If the output of one monitor differs from the output of
the other monitors in the group by a specified amount, that monitor will add an
entry to the System Event list. Configure comparison voting by setting
Comparison and % Comparison in the Rack Configuration Software.
Comparison: The enabled proportional value of the TMR monitor group that is
used to determine how far apart the values of the three monitors can be to each
other before an entry is added to the System Event List.
% Comparison: The highest allowed percent difference between the middle
value of the three monitors in a TMR group and the individual values of each
monitor.
For TMR applications, two types of input configurations are available: bussed or
discrete. Bussed configuration uses the signal from a single nonredundant
transducer and provides that signal to all modules in the TMR group through a
single 3500 Bussed External Termination Block.
Discrete configuration requires three redundant transducers at each
measurement location on the machine. The input from each transducer is
connected to separate 3500 External Termination Blocks or directly to the I/O
module with internal terminations.
2.4 Available Data
The Proximitor/Seismic Monitor returns specific proportional values dependent
upon the type of channel configured. This monitor also returns both monitor and
channel statuses which are common to all types of channels.
2.4.1 Statuses
The following statuses are provided by the monitor. This section describes the
available statuses and where they can be found.
2.4.1.1 Monitor Status
OK: This indicates if the monitor is functioning correctly. A not OK status is
returned under any of the following conditions:
Module Hardware Failure
- 2-7 -
Transducer Failure
Slot ID Failure
Channel not OK
If the Monitor OK status goes not OK, then the system OK Relay on the Rack
Interface I/O Module will be driven not OK.
Alert/Alarm 1: This indicates whether the monitor has entered Alert/Alarm 1. A
monitor will enter the Alert/Alarm 1 state when any proportional value provided
by the monitor exceeds its configured Alert/Alarm 1 setpoint.
Danger/Alarm 2: This indicates whether the monitor has entered Danger/Alarm
2. A monitor will enter the Danger/Alarm 2 state when any proportional value
provided by the monitor exceeds its configured Danger/Alarm 2 setpoint.
Bypass: This indicates when the monitor has bypassed alarming for one or more
proportional values at a channel. When a channel bypass status is set, this
monitor bypass status will also be set.
Configuration Fault: This indicates if the monitor configuration is valid.
Special Alarm Inhibit: This indicates whether all the nonprimary Alert/Alarm 1
alarms in the associated monitor channel are inhibited. The Channel Special
Alarm Inhibit function is active when:
The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed
(active).
A Channel Special Alarm Inhibit software switch is enabled.
2.4.1.2 Channel Status
OK: This indicates that no fault has been detected by the associated monitor
channel. There are two types of channel OK checking:
Transducer Input Voltage
Transducer Supply Voltage.
A channel OK status will be deactivated if any of the two OK types goes not OK.
Alert/Alarm 1: This indicates whether the associated monitor channel has
entered Alert/Alarm 1. A channel will enter the Alert/Alarm 1 state when any
proportional value provided by the channel exceeds its configured Alert/Alarm 1
setpoint.
Danger/Alarm 2: This indicates whether the associated monitor channel has
entered Danger/Alarm 2. A channel will enter the Danger/Alarm 2 state when
any proportional value provided by the channel exceeds its configured
Danger/Alarm 2 setpoint.
Bypass: This indicates that the channel has bypassed alarming for one or more
of its proportional values. A channel bypass status may result from the following
conditions:
- 2-8 -
A transducer is not OK, and the channel is configured for Timed OK
Channel Defeat.
The Keyphasor associated with the channel has gone invalid causing all
proportional values related to the Keyphasor signal (for example 1X
Amplitude, 1X Phase, Not 1X, ...) to be defeated and their associated
alarms bypassed.
The monitor has detected a serious internal fault.
A software switch is bypassing any channel alarming function.
The Special Alarm Inhibit is active and causing enabled alarms not to be
processed.
Special Alarm Inhibit: This indicates whether all the nonprimary Alert/Alarm 1
alarms in the associated monitor channel are inhibited. The Channel Special
Alarm Inhibit function is active when:
The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed
(active).
A Channel Special Alarm Inhibit software switch is enabled.
Off: This indicates whether the channel has been turned off. The monitor
channels may be turned off (inactivated) using the Rack Configuration Software.
Channel not monitoring: This indicates that alarming has been disabled for this
channel due to a configuration error, I/O error, or hardware problem. Check the
system events list for more information.
Channel Signal Path Not OK: This indicates the monitor cannot receive a valid
signal for this channel due to a transducer not o.k. or a hardware problem. Check
the system events list for more information.
- 2-9 -
The following table shows where the statuses can be found:
Statuses
Communication
Gateway Module
Rack
Configuration
Software
Operator
Display
Software
Monitor OK X X
Monitor Alert/Alarm 1 X X
Monitor Danger/Alarm 2 X X
Monitor Bypass X
Monitor Configuration Fault X
Monitor Special Alarm Inhibit X
Channel OK X X X
Channel Alert/Alarm 1 X X X
Channel Danger/Alarm 2 X X X
Channel Bypass X X X
Channel Special Alarm Inhibit X X X
Channel Off X X
Channel Not Monitoring X
Channel Signal Path Not OK X
2.4.2 Proportional Values
Proportional values are vibration measurements used to monitor the machine.
The number and type of proportional values varies by channel type. Refer to the
section on the applicable channel type for information about the proportional
values for each channel type.
- 2-10 -
The LEDs on the front panel of the Proximitor/Seismic Monitor indicate the
operating status of the module as shown in the following figure. Refer to the
channel type configuration sections in this manual for all of the available LED
conditions.
(1) OK: Indicates that the Proximitor/Seismic Monitor and the I/O
Module are operating correctly.
(2) TX/RX: Flashes at the rate that messages are received and
transmitted.
(3) Bypass: Indicates that some of the monitor functions are
temporarily suppressed.
- 2-11 -
2.6 Monitor Versions
The 3500/42M monitor is an enhanced replacement of the original 3500/42
monitor. It can be distinguished from the original by the model designation of
3500/42M on the front panel. The 3500/42M can be used in the same
applications and as a direct replacement for the 3500/42. The M refers to the
enhanced machine management capabilities. The monitor supports current and
future Bently Nevada machine management systems.
(1) Model Number
- 2-12 -
Blank Page
Section 3 - Configuration Considerations
- 3-1 -
3. Monitor Configuration
Table of Contents
3.1 Introduction.................................................................................................... 3-2
3.2 Configuration Options .................................................................................... 3-2
3.2.1 Reference Information .................................................................... 3-2
3.2.2 Slot Input/Output Module Type ....................................................... 3-3
3.2.3 Channel Pair 1 and 2 and Channel Pair 3 and 4............................. 3-4
3.2.4 Keyphasor Association................................................................. 3-4
3.3 Software Switches ......................................................................................... 3-5
3.3.1 Module Switches............................................................................. 3-6
3.3.2 Channel Switches........................................................................... 3-6
- 3-2 -
3.1 Introduction
This section describes how the 3500/42M Proximitor/Seismic Monitor is
configured using the Rack Configuration Software. It also describes any
configuration restrictions associated with this module. Refer to the 3500
Monitoring System Rack Configuration and Utilities Guide and the Rack
Configuration Software for the details on how to operate the software.
3.2 Configuration Options
3.2.1 Reference Information
These fields contain information that indicates which module you are configuring.
Slot: The location of the monitor in the 3500 rack (2 through 15).
Rack Type: The type of Rack Interface Module installed in the rack (Standard or
TMR).
Configuration ID: A unique six-character identifier. The identifier can be entered
when downloading a configuration to the 3500 rack.
- 3-3 -
3.2.2 Slot Input/Output Module Type
The I/O field lets you identify the type of I/O Module that is attached to the
monitor (The option selected must agree with the I/O module installed).
Discrete I/O: Used when each monitor channel is connected to its own
transducer. This applies to both standard and TMR installations.
Prox/Seismic I/O Module (Internal Termination): The transducer field
wiring is connected directly to the I/O module.
Prox/Seismic I/O Module (External Termination): The transducer field
wiring is connected to an External Termination Block and then routed from
the External Termination Block to the I/O module through a 25-pin cable.
The recorder field wiring is connected to an External Termination Block and
then routed from the External Termination Block to the I/O module through a
9-pin cable.
Prox/Velom I/O (Internal Termination): The transducer field wiring is
connected directly to the I/O module. Note that selecting the Prox/Velom
Internal I/O option will disable certain transducer type options.
Prox/Velom I/O (External Termination): The transducer field wiring is
connected to an External Termination Block and then routed from the
External Termination Block to the I/O module through a 25-pin cable. The
recorder field wiring is connected to an External Termination Block and then
routed from the External Termination Block to the I/O module through a 9-pin
cable. Note that selecting the Prox/Velom External I/O option will disable
certain transducer type options.
Barrier Proximitor I/O (4 Prox/Accel): The transducer field wiring is
connected directly to the Proximitor/Seismic Monitor Internal Barrier I/O
Module. Note that selecting the Prox/Accel Internal Barrier I/O option will
disable certain transducer type options.
Barrier Prox/Seismic I/O (2 Prox/Accel, 2 Velom): The transducer field
wiring is connected directly to the Proximitor/Seismic Monitor Internal Barrier
I/O Module. Note that selecting the Prox/Velom Internal Barrier I/O option will
disable certain transducer type options.
Barrier Seismic I/O (4 Velom): The transducer field wiring is connected
directly to the Proximitor/Seismic Monitor Internal Barrier I/O Module. Note
that selecting the Velom Internal Barrier I/O option will disable certain
transducer type options.
Bussed I/O: Used when one transducer input signal is bussed to three identical
adjacent monitors and three TMR I/O Modules. This option is used when
redundant transducers and field wiring are not required.
TMR I/O Prox/Seismic I/O: A single set of four transducers are sent to three
identical adjacent monitors. Each transducer is connected to a Bussed
External Termination Block and then the Bussed External Termination Block
is connected to the Proximitor/Seismic TMR I/O Modules using three 25-pin
cables. The recorder field wiring is connected to an External Termination
Block and then routed from the External Termination Block to the
Proximitor/Seismic TMR I/O Module through a 9-pin cable.
- 3-4 -
3.2.3 Channel Pair 1 and 2 and Channel Pair 3 and 4
The fields within these boxes pertain to both channels of the channel pair.
Channel Pair Type: The type of monitoring which is to be performed by the
channel pair. The following Channel Pair types are available in the monitor:
Radial Vibration
Thrust Position
Eccentricity
REBAM
Acceleration
Velocity
Acceleration II
Velocity II
Shaft Absolute Radial Vibration
Shaft Absolute Velocity
Circular Acceptance Region
3.2.4 Keyphasor Association
No Keyphasor: Can be used when a Keyphasor is not available. If this is
marked then the only data that will be available is Direct and Gap. This field will
automatically be marked for channel pairs which do not require a Keyphasor
transducer (for example Thrust Position and Differential Expansion).
Primary: The Keyphasor channel selected that is normally used for
measurement. When this Keyphasor transducer is marked invalid, the backup
Keyphasor transducer will provide the shaft reference information.
Backup: The Keyphasor channel selected that will be used if the primary
Keyphasor fails. If you do not have a backup Keyphasor, select the same
Keyphasor channel as the primary Keyphasor.
- 3-5 -
Note
For TMR applications, set Channel Pair 1 and
2 as primary Keyphasor and Channel Pair 3
and 4 as backup Keyphasor.
Active: Select whether the functions of the channel will be turned on () or off
().
Options: A button to display the configuration options for the selected channel
type.
3.3 Software Switches
The Proximitor/Seismic Monitor supports two module software switches and four
channel software switches. These switches let you temporarily bypass or inhibit
monitor and channel functions. Set these switches on the Software Switches
screen under the Utilities Option on the main screen of the Rack Configuration
Software.
- 3-6 -
3.3.1 Module Switches
Configuration Mode: A switch that allows the monitor to be configured. To
configure the monitor, enable () this switch and set the key switch on the front
of the Rack Interface Module in the PROGRAM position. When downloading a
configuration from the Rack Configuration Software, this switch will automatically
be enabled and disabled by the Rack Configuration Software. If the connection
to the rack is lost during the configuration process, use this switch to remove the
module from Configuration Mode.
Monitor Alarm Bypass: When enabled, the monitor does not perform alarming
functions. All proportional values are still provided. The monitor switch number
is used in the Communication Gateway and Display Interface Modules.
Monitor Switch
Number
Switch Name
3 Monitor Alarm Bypass
3.3.2 Channel Switches
Alert Bypass: When enabled, the channel does not perform Alert alarming
functions.
Danger Bypass: When enabled, the channel does not perform Danger alarming
functions.
Special Alarm Inhibit: When enabled, all nonprimary Alert alarms are inhibited.
Bypass: When enabled, the channel provides no alarming functions and
supplies no proportional values.
The channel switch number is used in the Communication Gateway and Display
Interface Modules.
Channel Switch
Number
Switch Name
1 Alert Bypass
2 Danger Bypass
3 Special Alarm Inhibit
4 Bypass
Section 4 - I/O Module Descriptions
- 4-1 -
4. I/O Module Descriptions
Table of Contents
4.1 Introduction.................................................................................................... 4-2
4.2 Prox/Siesmic I/O Modules.............................................................................. 4-3
4.3 Prox/Velomitor I/O Module .......................................................................... 4-4
4.4 Shaft Absolute I/O Modules ........................................................................... 4-5
4.5 Internal Barrier I/O Modules ........................................................................... 4-6
4.6 TMR I/O Module............................................................................................. 4-8
4.7 Setting the I/O Jumper ................................................................................... 4-9
4.8 Wiring Euro Style Connectors ...................................................................... 4-11
4.9 External Termination Blocks ........................................................................ 4-12
4.9.1 External Termination Blocks for Standard Applications................. 4-12
4.9.2 External Termination Blocks for TMR Applications........................ 4-13
4.10 Cable Pin Outs............................................................................................. 4-14
- 4-2 -
4.1 Introduction
I/O Modules receive signals from the transducers and route the signals to the
Proximitor/Seismic Monitor. The I/O module supplies power to the transducers
and provides a 4 to 20 mA recorder output for each transducer input channels.
Only one I/O module can be installed at any one time and must be installed
behind the monitor (in a rack mount or panel mount rack) or above the monitor
(in a Bulkhead rack).
I/O modules can have either internal or external terminations. Internal termination
requires that you wire each transducer and recorder directly to the I/O module.
External termination lets you simplify the wiring to the I/O modules in a 3500 rack
by using a 25-pin cable to route the signals from the four transducers and a 9-pin
cable to route the signals from the recorders to the I/O module. With external
termination I/O modules you can position the transducer wiring in any convenient
location by using External Termination blocks.
The 3500/42M Proximitor/Seismic Monitor can operate with the following types
of I/O modules:
Internal Termination External
Termination
External Termination
Block
Proximitor/Siesmic
I/O module
Proximitor/Velomitor
I/O module
Proximitor/Siesmic
Internal Barrier I/O
module
Shaft Absolute I/O
module
Proximitor/Siesmic
I/O module
Proximitor/Velomitor
I/O module
Proximitor/Siesmic
TMR I/O module
Shaft Absolute I/O
module
Terminal strip connectors
Euro Style connectors
This section describes the connectors, jumpers, and switches for each type of
I/O module, lists what cables should be used, and shows the pin outs of the
cables. The 3500 Field Wiring Diagram Package (part number 130432-01)
shows how to connect transducers and recorders to the I/O module or the
External Termination Block.
- 4-3 -
4.2 Prox/Siesmic I/O Modules
Prox/Seismic I/O Module
Internal Termination (left) and External Termination (right)
(1) Connection to transducers associated with channel 1 and 2
(2) Jumper for selecting the type of transducer connected to channel 1 and
2
(4) Jumper for selecting the type of transducer connect to channel 3 and 4
(5) Connect the I/O module to an External Termination block, use cable
129525-XXX-XX
(6) Connect the I/O module to the Recorder External Termination Block,
use cable 129529-XXXX-XX
- 4-4 -
(7) Connect to switches and recorders: INHB/RET is used to inhibit all
non-primary Alert/Alarm 1 functions for all four channels. COM/REC is
used to connect each channel to a recorder.
4.3 Prox/Velomitor I/O Module
Prox/Velomitor I/O Module
(2) Jumper for selecting the type of transducer connected to channel 1
and 2
(4) Jumper for selecting the type of transducer connect to channel 3
and 4
- 4-5 -
129525-XXX-XX
non-primary Alert/Alarm 1 functions for all four channels. COM/REC
is used to connect each channel to a recorder.
4.4 Shaft Absolute I/O Modules
Shaft Absolute I/O Module
(1) Connection to transducers associated with channel 1 and 3. Buffered
Shaft Absolute Output is also available.
and 2
- 4-6 -
(3) Switch for selecting the scale factor to match the transducers
connected to channel 1 and 2
(4) Connection to transducers associated with channel 2 and 4. Buffered
Shaft Absolute Output is also available.
(5) Jumper for selecting the type of transducer connect to channel 3 and
4
129525-XXX-XX
4.5 Internal Barrier I/O Modules
The Internal Barrier I/O modules require that each transducer be connected to
the Barrier I/O module individually. This module provides four channels of
intrinsically safe signal conditioning for Proximitor and/or Seismic transducers
and has two internally mounted zener barrier modules, one for each pair of
transducer channels. A 3500 Earthing Module is required for systems that use
Internal Barrier I/O Modules to provide an intrinsically safe earth connection for
intrinsically safe applications. Refer to the Rack Installation and Maintenance
Manual for system requirements when using Internal Barrier I/O Modules
- 4-7 -
Internal Barrier I/O Modules
- 4-8 -
4.6 TMR I/O Module
TMR I/O Module
(1) Connect the I/O module to the External Termination Block using cable
129525-XXXX-XX
and 2
and 4
(4) Connect the I/O module to the Recorder External Termination Blocks
using cable 129529-XXXX-XX
The Proximitor/Seismic TMR I/O Module is used in a TMR rack. Four
transducers are bussed to three monitors so that each transducer is shared by
three channels, one channel from each monitor. Four External Termination
Blocks are required: one is a Bussed Proximitor/Seismic External Termination
- 4-9 -
Block used to wire the transducers; the other three are Recorder External
Termination Blocks used to wire the recorders.
4.7 Setting the I/O Jumper
The I/O jumper on the I/O module is used to identify the type of transducer
connected to the I/O module.
Note
The connector shunt must be installed vertically on the top or bottom group of
terminal posts to select the corresponding transducer type. WARNING - Do not
place shunt over NOT USED terminal posts. The connector shunt must be
placed over the terminal posts for which the channel pair is configured, even
when the channel pair is inactivated.
Jumper configurations for the Prox/Seismic I/O module
(1) Proximitor transducer/ Accelerometer
(2) Velomitor sensor
(3) Seismoprobe without barrier
(4) Seismoprobe with barrier
- 4-10 -
Jumper configurations for the Shaft Absolute I/O module
Jumper configurations for the Shaft Absolute I/O module
(2) Seismoprobe
Jumper configurations for the TMR I/O module
(2) Discrete Velomitor sensor
- 4-11 -
(3) Bussed Velomitor sensor
(4) Not used never place a jumper over these terminal posts
4.8 Wiring Euro Style Connectors
terminal block to the base, grip the block firmly and pull. Do not pull the block out
by its wires because this could loosen or damage the wires or connector.
Typical I/O Module
Do not remove more than 6 mm (0.25 in) of insulation from the wires.
- 4-12 -
4.9 External Termination Blocks
External termination blocks let you position the connectors for transducer wiring
at a convenient location and then use multi-pin cables to route the signals to the
3500/42M I/O modules. The different types of termination blocks have different
labels and part numbers. Refer to Spares in section "Ordering Information" for
a complete list of the part numbers for all available termination blocks for the
3500/42M.
External Termination Blocks for
the Prox/ Seismic I/O Module
External Termination Blocks for the
Prox/ Velomitor I/O Module
Proximitor/ Seismic External
Termination Block
Bussed Proximitor/ Seismic External
Termination Block
Recorder External Termination Block
Proximitor/ Velomitor External
Termination Block
Recorder External Termination Block
Each type of External Termination Block comes with either Terminal Strip or Euro
Style connectors. The field wiring diagram package (Bently Nevada part number
130432-01) shows how to connect the transducer wiring to all of these blocks.
4.9.1 External Termination Blocks for Standard Applications
The following figures show what these termination blocks look like.
(1) Terminals for the transducer field wiring
(2) Connector for the cable to an external termination I/O module
- 4-13 -
4.9.2 External Termination Blocks for TMR Applications
The Proximitor/Seismic External Termination Blocks are used for TMR
applications with discrete transducers. One termination block is connected to
each 3500/42M monitor in the TMR group. See the above section for standard
installations.
Bussed External Termination Blocks are used for TMR applications that do not
use redundant transducers. These blocks let you route the signal from a single
transducer to three redundant 3500/42M monitors. The following figures show
the Bussed External Termination Blocks.
(1) Terminals for connecting signals from a single transducer
(2) Connectors for sending the signal from the same transducer to three
redundant Prox/Siesmic monitors
- 4-14 -
4.10 Cable Pin Outs
The following diagrams show how to wire the connectors to the end of cables
that must be routed through conduit.
Note
Signal labels shown will vary. The following figure
shows labels for Proximitor/Velomitor ET blocks.
Transducer Signal to External Termination Block
Cable part number 129525-XXXX-XX
- 4-15 -
3500 Recorder Output to External Termination Block
Cable part number 129529-XXXX-XX
- 4-16 -
Blank Page
Section 5 - Monitor Verification
- 5-1 -
5. Monitor Verification
Table of Contents
5.1 Introduction.................................................................................................... 5-2
5.2 Choosing a Maintenance Interval ................................................................... 5-2
5.3 Typical Verification Test Setup....................................................................... 5-2
5.4 Using the Rack Configuration Software.......................................................... 5-3
5.5 Verify Recorder Outputs................................................................................. 5-5
5.6 Adjusting the Scale Factor and Zero Position................................................. 5-6
5.6.1 Adjusting the Scale Factor .............................................................. 5-7
5.6.2 Zero Position Adjustment Description ............................................. 5-7
5.6.3 Adjusting the Zero Position............................................................. 5-9
5.7 If a Channel Fails a Verification Test............................................................ 5-10
5.8 Performing Firmware Upgrades ................................................................... 5-10
- 5-2 -
5.1 Introduction
rack while power is applied to the rack. Refer to the Rack Installation and
Refer to the section of a particular channel type for information on verifying the
operation of that channel type.
5.2 Choosing a Maintenance Interval
1. Start with an interval of one year and then shorten the interval if any of
the following conditions apply:
the monitored machine is classified as critical.
the 3500 rack is operating in a harsh environment such as in extreme
temperature, high humidity, or in a corrosive atmosphere.
2. At each interval, use the results of the previous verifications and ISO
Procedure 10012-1 to adjust the interval.
5.3 Typical Verification Test Setup
The following figure shows the typical test setup for verifying a
Proximitor/Seismic Monitor. The test equipment is used to simulate the
transducer signal and the laptop computer is used to observe the output from the
rack.
General Layout for Maintenance
(1) Voltmeter
(2) Power supply
- 5-3 -
(3) 3500 rack
(4) Laptop computer running 3500 Rack Configuration Software
Transducers can be connected to a 3500 rack in a variety of ways. Depending
on the wiring option for the I/O module of your monitor, connect the test
equipment to the monitor using one of the following methods:
(1) Connect test equipment here.
(2) Proximitor/Seismic I/O Module
(3) External Termination Block with Euro Style connectors
(4) External Termination Block with Terminal Strip connectors
5.4 Using the Rack Configuration Software
The laptop computer that is part of the test setup uses the Rack Configuration
Software to display output from the rack and to reset certain operating
parameters in the rack. To perform the test procedures in this section you must
be familiar with the following features of the Rack Configuration Software.
upload, download, and save configuration files
enable and disable channels and alarms
bypass channels and alarms
display the Verification screen
The Rack Configuration and Test Utilities Guide (part number 129777-01)
explains how to perform these operations.
- 5-4 -
Note
It is important to save the original rack configuration before doing any
Maintenance and/or Troubleshooting Procedures. It may be necessary during
these procedures to change setpoints, etc. which must be restored to their
original values at the conclusion of the procedures. At that time the original
configuration should be downloaded to the rack.
The following figures show how the Verification screen displays output from a
3500 rack:
(1) OK Limit Verification Fields: These fields display output for
verifying OK limits.
(2) Current Value Verification Fields: The current proportional value
is displayed in this box. These fields display output for verifying
channel output.
(3) Alarm Verification Fields: These fields display output for verifying
channel alarms. Alert/Alarm 1 alarms are displayed in yellow in the
bar graph and with the word Alarm under the current value box.
Danger/Alarm 2 alarms are displayed in red in the bar graph and
with the word Alarm under the current value box.
- 5-5 -
Any channel bar graph value that enters Alert/Alarm 1 or Danger/Alarm 2 will
cause the alarm lines in the Channel Status box to indicate an alarm. Any
channel that enters alarm will cause the alarm lines in the Module Status box to
indicate an alarm.
Setpoints are indicated by lines on the bargraph display:
Danger/Alarm 2 Over = Solid Red Line
Alert/Alarm 1 Over = Solid Yellow Line
Alert/Alarm 1 Under = Dashed Yellow Line
Danger/Alarm 2 Under = Dashed Red Line
Zero Position Voltage: The Zero Position Voltage is the voltage input that will
cause the reading on the bar graph display and current value box to be zero.
The Zero Position volts value is displayed in the Z.P. Volts box above each
channel value bar graph
5.5 Verify Recorder Outputs
The following test equipment and procedure should be used in the verification of
the recorder outputs. Recorder outputs for the 3500/42M Proximitor/Seismic
Monitor Module are 4 to 20 mA.
(1) Connect test equipment here.
(2) Proximitor/Seismic I/O Module
(3) External Termination Block with Euro Style connectors
(4) External Termination Block with Terminal Strip connectors
- 5-6 -
1. Disconnect the COM and REC field wiring from the channel terminals on
the I/O module.
2. Connect a multimeter to the COM and REC outputs of the I/O module.
The multimeter should have the capability to measure 4 to 20 mA.
3. If the proportional value is not Gap: Set the proportional value that the
recorder is configured for to full-scale. (Refer to the proportional value of
the channel type you are testing) Verify that the recorder output is
reading 20 mA 1 %. Go to step 4.
4. If the proportional value is Gap: Set the Gap proportional value to -
18.00 Vdc (Refer to the proportional value of the channel type you are
testing). Verify that the recorder output is reading 16 mA 1 %.
5. Set the proportional value that the recorder is configured for to mid-scale.
Verify that the recorder output is reading 12 mA 1 %.
6. Set the proportional value that the recorder is configured for to bottom-
scale. Verify that the recorder output is reading 4 mA 1 %.
7. Disconnect transducer input and verify that the recorder output matches
the set monitor clamp value 1 %.
8. If you can not verify the recorder output, the recorder configuration and
connections should be checked. If the monitor recorder output still does
not verify properly, go to If a channel fails a Verification Test in this
section.
9. Disconnect the multimeter and reconnect the COM and REC field wiring
to the channel terminals on the I/O module.
10. Repeat steps 1 through 8 for all configured recorder channels.
5.6 Adjusting the Scale Factor and Zero Position
This section shows how to adjust the transducer scale factor and the transducer
position, or "zero". The Scale Factor Adjustment can be used to accommodate
any deviations in transducer scale factor as measured on the installed
transducers. Do not use the procedure to compensate for any errors within the
monitor and the I/O module. If a monitor does not meet specifications, exchange
it with a spare and return the faulty module to Bently Nevada for repair. The
newly installed spare module should be properly configured and tested.
Adjusting the scale factor affects the readings of all configured parameters
associated with the channel. If you change the scale factor, be sure to use the
new value when calculating inputs for verification of channel values.
The Zero Position Adjustment is used for Thrust, Eccentricity, and Differential
Expansion measurements as well as for Gap measurements when Gap is
configured to read in displacement units (not volts). Adjust the zero position after
the probe is gapped and its target is in the proper position.
Both adjustment procedures consist of using the Rack Configuration Software to
upload the configuration from the rack, change the setting for scale factor or zero
position, and then downloading the new configuration back to the rack. You can
adjust these settings using the following two methods:
- 5-7 -
1. enter a new value in the scale factor box on the transducer screen or the zero
position box on the Channel Options screen.
2. use Adjust to get immediate feedback from the channel on the Adjust
screen.
The advantage of using the Adjust screen is that you can use the bar graphs to
see the effect of your adjustments on the output signals of the channel. The
following procedures show how to use the methods.
5.6.1 Adjusting the Scale Factor
1. Connect the configuring computer to the rack using one of the methods listed
in the 3500 Monitoring System Rack Configuration and Utilities Guide (part
number 129777-01).
2. Run the Rack Configuration Software.
3. Initiate communication with the rack by clicking on the Connect option in the
File menu and then selecting the connection method that you used in step 1.
4. Upload the configuration from the rack by clicking on the Upload option in the
File menu.
5. Click on the Options button on the 3500 System Configuration screen.
6. Select the monitor you want to adjust. The Monitor screen will appear.
7. Select the Options button under the appropriate Channel. The configured
Channel Options screen will appear.
8. Select the Customize button in the Transducer Selection box. A Transducer
screen will appear.
9. Enter a value for scale factor in the Scale Factor box. If you go to the Adjust
screen by selecting Adjust, be sure to adjust the input to the channel away
from the Zero Position so you can adjust the scale factor and see the results.
10. Return to the 3500 System Configuration screen by clicking on the OK
buttons of the successive screens. The new scale factor is now added to the
configuration for this channel.
11. Download the new configuration to the appropriate monitor by selecting
Download from the File menu. The new setting for scale factor will take
effect when the "Download successful" prompt appears.
5.6.2 Zero Position Adjustment Description
When adjusting the Zero Position voltage, you are defining the transducer
voltage corresponding to the position of the zero indication on a bar graph
display (refer to the following figure).
- 5-8 -
For maximum amount of zero adjustment, gap the transducer as close as
possible to the ideal zero position voltage based on the full-scale range and
transducer scale factor. For a mid-scale zero, as in the example, the ideal gap is
the center of the range. Refer to the transducer information of the applicable
channel type for the appropriate center voltage
When increasing or decreasing the zero position voltage, you are actually
mapping the monitor full scale range to a portion of the transducer linear range.
The zero position voltage adjustment range is dependent upon the full-scale
range of the proportional value being adjusted, the transducer scale factor, and
the transducer Ok limits. The following example shows how these parameters
are related to the zero position voltage range.
Parameter name Setting
Channel pair type Thrust Position
Direct Full-scale range -40-0-40 mils
Transducer Type 3300 8mm
Scale Factor 200 mV/mil
OK limits -19.04 (upper)
-1.28 (lower)
-25
-20
-15
-10
-5
0
5
10
15
20
25
Thrust Position
Bargraph
- 5-9 -
5.6.3 Adjusting the Zero Position
1. Connect the configuring computer to the rack using one of the methods listed
in the 3500 Monitoring System Rack Configuration and Utilities Guide (part
number 129777-01).
2. Run the Rack Configuration Software.
3. Initiate communication with the rack by clicking on the Connect option in the
File menu and then selecting the connection method that you used in step 1.
4. Upload the configuration from the rack by clicking on the Upload option in the
File menu.
5. Select the Options button on the 3500 System Configuration screen.
6. Select the monitor you want to adjust. The Monitor screen will appear.
7. Select the Options button under the appropriate Channel. The Channel
Options screen will appear.
8. Enter the voltage in the Zero Position or the Gap Position box. Changes are
limited to the values listed adjacent to the box. If you go to the Adjust screen
by selecting Adjust, you can adjust the Zero Position and see the results.
9. Return to the 3500 System Configuration screen by clicking on OK buttons in
the successive screens. The new Zero Position or Gap Position is now
added to the configuration for this channel.
10. Download the new configuration to the appropriate monitor by selecting the
Download option in the File menu and then selecting the appropriate
monitor. The new setting for Zero Position will take effect when the
"Download successful" prompt appears.
-1.28
-19.04
-10.16
-9.33
-10.99
Lower Ok Limit
Upper Ok Limit
Max Zero Adj
Min Zero Adj
Center of Range
Position
Range
-20
-10
0
10
20
30
-2.99V
40
-30
-40
-18.99V
Scale at max
zero adj
-20
-10
0
10
20
30
-1.33V
40
-30
-40
-17.33V
Scale at min
zero adj
Zero
- 5-10 -
5.7 If a Channel Fails a Verification Test
When handling or replacing circuit boards, always be sure to adequately protect
against damage from Electrostatic Discharge (ESD). Always wear a proper wrist
strap and work on a grounded conductive work surface.
1. Save the configuration for the module using the Rack Configuration
Software.
2. Replace the module with a spare. Refer to the installation section in the
3500 Monitoring System Rack Installation and Maintenance Manual (part
number 129766-01).
3. Return the faulty board to Bently Nevada for repair.
4. Download the configuration for the spare module using the Rack
5. Verify the operation of the spare.
Occasionally it may be necessary to upgrade the original firmware that is shipped
with the 3500/42M Proximitor Monitor. The following instructions describe how to
upgrade the existing firmware using the 3500 Configuration software. The
monitor will need to be reconfigured using the 3500 Rack Configuration software
after having its firmware upgraded.
CAUTION!
During the following procedure power to the rack cannot be interrupted
and the monitor that is being upgraded cannot be removed from the
rack. If either of these occurs the monitor may become inoperable.
1. Start the 3500 Configuration software and connect to the rack.
2. Upload and save the current configuration of the monitor, the upgrade
process will erase any configuration in the monitor.
3. Under the Utilities menu option select Update Firmware.
- 5-11 -
4. Select the module to be updated and click on the OK button.
5. The software will request the file to be downloaded. Select the file and
click on the Open button.
6. The software will now download the file.
7. After the download is completed reload the configuration to the monitor. If
the process fails the monitor will revert to its old code. Under no
circumstances should the monitor be removed until it has finished the
process.
- 5-12 -
Blank Page
Section 6 - Troubleshooting
- 6-1 -
6. Troubleshooting
Table of Contents
6.1 Introduction.................................................................................................... 6-2
6.2 Self-Test ........................................................................................................ 6-2
6.3 LED Fault Conditions..................................................................................... 6-3
6.4 System Event List Messages ......................................................................... 6-4
6.4.1 Example of a System Event List Message...................................... 6-4
6.4.2 List of messages............................................................................. 6-4
6.5 Alarm Event List Messages.......................................................................... 6-17
6.6 Gateway Status Bits..................................................................................... 6-18
- 6-2 -
6.1 Introduction
This section describes how to troubleshoot a problem with the Monitor by using
the information provided by the self-test, the LEDs, the System Event List, and
the Alarm Event List.
6.2 Self-Test
To perform the monitor self-test:
rack (if needed).
2. Select Utilities from the main screen of the Rack Configuration Software.
3. Select System Events/Module Self-test from the Utilities menu.
4. Press the Module Self-test button on the System Events screen.
Application Alert
Machinery protection will be lost while the self-
test is being performed.
5. Select the slot that contains the monitor and press the OK button. The
monitor will perform a full self-test and the System Events screen will be
displayed. The list will not contain the results of the self-test.
6. Wait 30 seconds for the module to run a full self-test.
7. Press the Latest Events button. The System Events screen will be
updated to include the results of the monitor self-test.
8. Verify if the monitor passed the self-test. If the monitor failed the self-test,
refer to System Event List Messages.
- 6-3 -
problems.
OK LED TX/RX BYPASS Condition Solution
1 Hz 1 Hz XXX Monitor is not
configured, is in
Configuration Mode, or
in Calibration Mode.
Reconfigure the
Monitor, or exit
Configuration, or
Calibration Mode.
5 Hz XXX XXX Monitor error Check the System
Event List for severity.
ON Flashing XXX Module is operating
correctly
No action required.
OFF XXX XXX Monitor is not operating
correctly or the
transducer has faulted
and has stopped
providing a valid signal.
Check the System
Event List and the
Alarm Event List.
2 Hz XXX XXX Monitor is configured for
Timed OK Channel
Defeat and has been not
OK since the last time
the RESET button was
pressed.
Press the Reset
button on the Rack
Interface Module.
Check the System
Event List.
Not
flashing
XXX Monitor is not operating
correctly.
Monitor is not
executing alarming
functions. Replace
immediately.
XXX OFF Alarm Enabled No action required.
XXX ON Some or all Alarming
Disabled
No action required.
XXX = Behavior of the LED is not related to the condition.
- 6-4 -
monitor and gives an example of one.
6.4.1 Example of a System Event List Message
Sequence
Number
Event
Information
Event
Number
Class Event Date
DDMMYY
Event Time Event
Specific
Slot
0000000123 Device Not Com-
municating
32 1 02/01/90 12:24:31:99 5L
example 123).
Event Information: The name of the event (for example Device Not
Communicating).
Event Number: Identifies a specific event.
Class: Used to display the severity of the event. The following classes are
available:
Class Value Classification
0
1
2
3
Severe/Fatal Event
Reserved
Event Specific: It provides additional information for the events that use this
field.
Slot: Identifies the module that the event is associated with. If a half-height
module is installed in the upper slot or a full-height module is installed, the field
will be 0 to 15. If a half-height module is installed in the lower slot, then the field
will be 0L to 15L. For example, a module installed in the lower position in slot 5
would be 5L.
6.4.2 List of messages
The following System Event List Messages may be placed in the list by the
monitor and are listed in numerical order. If an event marked with a star (*)
occurs the monitor will stop alarming. If you are unable to solve any problems
contact your nearest Bently Nevada office.
- 6-5 -
Flash Memory Failure
Event Number: 11
Action: Replace the Monitor Module as soon as possible.
EEPROM Memory Failure
Event Number: 13
Event Classification: Potential Problem or Severe / Fatal Event
Action: Replace the Monitor Module as soon as possible.
Event Number: 32
the Monitor Module
the rack backplane
Event Number: 33
the Monitor Module
the rack backplane

* Neuron Failure
Event Number: 34
Action:Replace the Monitor Module immediately. Monitor Module will stop
alarming.
* I/O Module Mismatch
Event Number: 62
Action: Verify that the type of I/O module installed matches what was
selected in the software. If the correct I/O module is installed, there may be a
fault with the Monitor Module or the Monitor I/O module. Monitor Module will
stop alarming.
I/O Module Compatible
Event Number: 63
fault with the Monitor Module or the Monitor I/O module.
- 6-6 -
* Fail I/O Jumper Check
Event Number: 64
fault with the Monitor Module or the Monitor I/O module. Monitor Module will
stop alarming.
Pass I/O Jumper Check
Event Number: 65
fault with the Monitor Module or the Monitor I/O module.
Event Number: 100
Action: Verify that noise from the power source is not causing the problem.
If the problem is not caused by noise, check to see if one of the following
components is faulty:
the Monitor Module
Event Number: 101
the Monitor Module
Event Number: 102
the Monitor Module
- 6-7 -
Event Number: 103
the Monitor Module
Supplies)
Event Number: 104
the Monitor Module
Monitor Module will stop alarming.
Supplies)
Event Number: 105
the Monitor Module
Event Number: 106
the Monitor Module
- 6-8 -
Event Number: 107
the Monitor Module
Event Number: 108
the Monitor Module
Event Number: 109
the Monitor Module
Supplies)
Event Number: 110
the Monitor Module
- 6-9 -
Pass Main Board +15V-AB (Pass Main Board +15V - upper and lower
Power Supplies)
Event Number: 111
the Monitor Module
Fail Main Board -24V-A (Fail Main Board -24V - upper Power Supply)
Event Number: 112
the Monitor Module
Pass Main Board -24V-A (Pass Main Board -24V - upper Power Supply)
Event Number: 113
the Monitor Module
Fail Main Board -24V-B (Fail Main Board -24V - lower Power Supply)
Event Number: 114
the Monitor Module
Pass Main Board -24V-B (Pass Main Board -24V - lower Power Supply)
Event Number: 115
the Monitor Module
- 6-10 -
* Fail Main Board -24V-AB (Fail Main Board -24V - upper and lower Power
Supplies)
Event Number: 116
the Monitor Module
Pass Main Board -24V-AB (Pass Main Board -24V - upper and lower
Power Supplies)
Event Number: 117
the Monitor Module
Fail Main Board -24V-A or B (Fail Main Board -24V Pre-Regulation)*
Event Number: 158
the Monitor Module
*This event will only be return by the 3500/40M and only if the rack is
configured for two power supplies.
Pass Main Board -24V-A or B (Pass Main Board -24V Pre-Regulation)*
Event Number: 159
the Monitor Module
* This event will only be return by the 3500/40M and only if the rack is
configured for two power supplies.
- 6-11 -
* Fail Main Board +3.3V-AB (Fail Main Board +3.3V)
Event Number: 162
the Monitor Module
Pass Main Board +3.3V-AB (Pass Main Board +3.3V)
Event Number: 163
Action: Verify that noise from the power source is not causing the problem. If
the problem is not caused by noise, check to see if one of the following
the Monitor Module
* Fail Main Board +2.5V-AB (Fail Main Board +2.5V)
Event Number: 164
the Monitor Module
Pass Main Board +2.5V-AB (Pass Main Board +2.5V)
Event Number: 165
the Monitor Module
Device Configured
Event Number: 300
- 6-12 -
* Configuration Failure
Event Number: 301
Action: Download a new configuration to the Monitor Module. If the problem
still exists replace the Monitor Module immediately.
Event Number: 301
Action: Download a new configuration to the Monitor Module. If the problem
still exists replace the Monitor Module as soon as possible.
* Module Entered Cfg Mode (Module Entered Configuration Mode)
Event Number: 302
Event Number: 305
Action: Download the software switches to the Monitor Module. If the
software switches are not correct, replace the Monitor Module as soon as
possible.
Internal Cal Reset (Internal Calibration Reset)
Event Number: 307
Event Specific: Ch pair x
Action: Replace Monitor Module immediately.
Monitor TMR PPL Failed (Monitor TMR Proportional value Failed)
Event Number: 310
Action: Replace the Monitor Module.
Monitor TMR PPL Passed (Monitor TMR Proportional value Passed)
Event Number: 311
Action: Replace the Monitor Module.
Module Reboot
Event Number: 320
- 6-13 -
* Module Removed from Rack
Event Number: 325
Action: No action required. Monitor Module will stop alarming.
Module Inserted in Rack
Event Number: 326
Device Events Lost
Event Number: 355
Action: No action required. This may be due to the removal of the Rack
Interface Module for an extended period of time.
Module Alarms Lost
Event Number: 356
Action: No action required. This may be due to the removal of the Rack
Interface Module for an extended period of time.
* Module Entered Calibr. (Module Entered Calibration Mode)
Event Number: 365
Module Exited Calibr. (Module Exited Calibration Mode)
Event Number: 366
Pass Module Self-test
Event Number: 410
* Enabled Ch Bypass (Enabled Channel Bypass)
Event Number: 416
Action: No action required. Alarming has been inhibited by this action.
- 6-14 -
Disabled Ch Bypass (Disabled Channel Bypass)
Event Number: 417
* Enabled Alert Bypass
Event Number: 420
Disabled Alert Bypass
Event Number: 421
* Enabled Danger Bypass
Event Number: 422
Disabled Danger Bypass
Event Number: 423
* Enabled Special Inh (Enabled Special Inhibit)
Event Number: 424
Disabled Special Inh (Disabled Special Inhibit)
Event Number: 425
* Enabled Mon Alarm Byp (Enabled Monitor Alarm Bypass)
Event Number: 426
- 6-15 -
Disabled Mon Alarm Byp (Disabled Monitor Alarm Bypass)
Event Number: 427
* Fail Slot Id Test
Event Number: 461
Action: Verify that the Monitor Module is fully inserted in the rack. If the
Monitor Module is installed correctly, check to see if one of the following
the Monitor Module
the rack backplane
Pass Slot Id Test
Event Number: 462
Action: Verify that the Monitor Module is fully inserted in the rack. If the
Monitor Module is installed correctly, check to see if one of the following
the Monitor Module
the rack backplane
* Enabled Test Signal
Event Number: 481
Disabled Test Signal
Event Number: 482
Switch To Primary Kph
Event Number: 491
Action: Check to see if one of the following is faulty:
the secondary Keyphasor transducer on the machine
the Monitor Module
- 6-16 -
Switch To Backup Kph
Event Number: 492
the primary Keyphasor transducer on the machine
the Monitor Module
* Kph Lost
Event Number: 493
both Keyphasor transducers on the machine
the Monitor Module
the Keyphasor Module
For vector and Keyphasor based, alarms the Monitor Module will stop
alarming.
DSP Reset Attempted
Event Number: 501
Action: If the message is seen repeatedly in the System Event List, then
replace the Monitor Module immediately.
* DSP Self-test Failure
Event Number: 502
Action: Replace the Monitor Module immediately. Monitor Module will stop
alarming.
* DSP Self-test Failure
Event Number: 503
Action: Replace the Monitor Module immediately. Monitor Module will stop
alarming.
- 6-17 -
6.5 Alarm Event List Messages
The following Alarm Event List Messages are returned by the monitor.
Alarm Even List
Message
When the Message will occur
Entered Alert/ Alarm 1 A proportional value in the channel has entered
Alarm 1 status
Left Alert/ Alarm 1 A proportional value in the channel has left Alert /
Alarm 1 and changed the channel Alert / Alarm 1
status
Entered Danger/ Alarm 2 A proportional value in the channel has entered
Left Danger/ Alarm 2 A proportional value in the channel has entered
Entered not OK Module went not OK
Left not OK Module returned to the OK state
- 6-18 -
6.6 Gateway Status Bits
The following status bits are reported to other monitors and are visible in places
such as Modbus registers in the communication Gateway. Whenever one of
these status registers is unexpectedly set, the system events list should be
consulted for more information.
Gateway Status Bit When the Message will occur
Channel not OK Module went not OK
Channel Alert/Alarm1 A proportional value in the channel has entered
Alarm 1 status
Channel Danger/ Alarm 2 A proportional value in the channel has entered
Channel in Bypass Channel Bypass switch for this channel has
been set
Channel Off Channel is inactive
Channel Trip Multiply Mode Channel has been placed in Trip Multiply
Special Alarm Inhibit The alarm inhibit switch has been set for this
channel
Channel Not Monitoring Alarming has been disabled for this channel
KPH Not OK Keyphasors associated with this channel are
invalid
Signal Path Not OK Monitor is not receiving a transducer signal
Section 7 - Radial Vibration General Information
- 7-1 -
7. Radial Vibration General Information
Radial vibration is the dynamic motion of a shaft or casing in a direction
perpendicular to the shaft axis. 3500 Radial Vibration channels measure this
motion by using signals from proximity probes.
In a 3500 Monitoring System, Radial Vibration channels are programmed in
pairs. These channels, depending on configuration, typically condition the input
signals into various parameters called proportional values. These values, along
with a Keyphasor signal provide phase measurements. When 2 proximity
probes are positioned in XY or orthogonal orientation the dynamic data can be
used to create plots such as orbit, full spectrum and shaft centerline for
enhanced machinery management.
The channels also provide setpoints that can be used for alarming. Alert
setpoints can be configured for each active proportional value and Danger
setpoints can be configured for any two of the active proportional values.
- 7-2 -
Blank Page
Section 8 - Radial Vibration Configuration
- 8-1 -
8. Radial Vibration Configuration
Table of Contents
8.1 Introduction.................................................................................................... 8-2
8.2 Configuration Considerations......................................................................... 8-2
8.3 Configuration Options .................................................................................... 8-3
8.3.1 General Parameters and Buttons.................................................... 8-3
8.3.2 Reference Information .................................................................... 8-4
8.3.3 Enable ............................................................................................ 8-4
8.3.4 Delay .............................................................................................. 8-7
8.3.5 Transducer Selection...................................................................... 8-7
8.3.6 Alarm Mode .................................................................................. 8-10
8.3.7 Transducer Orientation ................................................................. 8-11
8.3.8 Barriers......................................................................................... 8-11
8.4 Alarm Setpoints ........................................................................................... 8-11
8.4.1 Available Setpoints ....................................................................... 8-13
8.4.2 Alarm Hysteresis........................................................................... 8-13
- 8-2 -
8.1 Introduction
This section discusses the Configuration Considerations and the Rack
Configuration Software screens associated with the Radial Vibration Channel.
8.2 Configuration Considerations
Consider the following items before configuring a Radial Vibration Channel:
Internal Barrier I/O Modules and External barriers are not currently supported
with 7200 11 mm or 14 mm, or 3000 Proximitors, or the 3300 16 mm HTPS.
When "No Keyphasor" is selected, the 1X Amplitude (Ampl) and Phase Lag,
2X Amplitude (Ampl) and Phase Lag, Not 1X Amplitude (Ampl), and S
max
Amplitude (Ampl) can not be selected.
If a Keyphasor channel is selected, a Keyphasor Module must be installed in
the rack.
The 1X and 2X Phase values can be enabled only if the selected Keyphasor
channel is configured for an events per revolution equal to 1 will.
The full scale options allowed for each proportional value is dependent upon
the transducer type.
If a Non-Standard transducer is selected, the setpoint OK limits are set to 1
volt from the Upper and Lower OK limits that are selected.
There are two selections for 3000 Series transducers:
o 3000(-24V) Proximitor Select this option when connecting a 3000
Series proximitor directly to a 3500 monitor. A default scale factor of
285 mV/mil will be selected. This may be adjusted 15 %. Note that
the buffered transducers on the front of the monitors and to the Data
Manager are not compensated and should be interpreted at 285
mV/mil.
Series proximitor directly to a 3500 monitor, but supplying proximitor
power from an external 18 volt source. A default scale factor of 200
mV/mil will be selected. This may be adjusted 15 %. Note that the
buffered transducers on the front of the monitors and to the Data
mV/mil.
Setpoints may only be set on proportional values which are enabled.
Monitors must be configured in channel pairs (for example, Channels 1 and 2
may be configured as Radial Vibration and Channels 3 and 4 may be
configured as Thrust Position).
When a full-scale range is modified, the setpoints associated with this
proportional value should be readjusted.
It is best to set the Scale Factor value and the Trip Multiply value before the
Zero Position value.
- 8-3 -
3000 (-18V), 3000 (-24V), and 3300 RAM Proximitors have limited linear
ranges. Therefore, you should use caution when selecting the Full-scale
range of the Direct, 1X Amplitude (Ampl), 2X Amplitude (Ampl), Not 1X
Amplitude (Ampl) and S
max
Amplitude (Ampl) PPLs. Full-scale value x Trip
Multiply should not exceed the linear range of the transducer.
This section describes the options available on the Radial Vibration Channel
8.3.1 General Parameters and Buttons
Timed OK Channel Defeat: This prevents a channel from returning to an OK
status until that channel's transducer has remained in an OK state for 30
seconds. This feature is always enabled in the Radial Vibration Channels. The
option protects against false trips caused by intermittent transducers.
CP Mod: Selecting the CP Mod button Channel Options Dialog Box, allows a
Custom channel configuration to be downloaded to the monitor. Custom
configuration data is stored in a Custom Products Modification File. Custom
Products Modification files follow the naming convention <modification #.mod>.
These files must be located in the \3500\Rackcfg\Mods\ directory. When a CP
Mod file is selected, a window is displayed which describes the function of the
modification. CP Mod files are available through Bently Nevada's Custom
Products Division. Contact your local Bently Nevada Sales Representative for
details.
- 8-4 -
Zero Position (Gap): Represents the zero position (in volts) when the gap scale
is to read the engineering units of displacement. To ensure maximum amount of
zero adjustment, the probe should be gapped as close as possible to the center
gap voltage specified in the OK Limit table. This field is not available for Voltage
Gap Scale.
Adjust Button: Adjust the Zero Position voltage. When this button is clicked, a
utility starts that helps you set the gap zero position voltage. Since this utility
provides active feedback from the 3500 rack, a connection with the rack is
required. Refer to Adjusting the Scale Factor and Zero Position in the "Monitor
Verification" section of the manual.
Trip Multiply: The value selected to temporarily increase the alarm (Alert and
Danger) setpoint values. This value is normally applied by manual (operator)
action during startup to allow a machine to pass through high vibration speed
ranges without monitor alarm indications. Such high vibration speed ranges may
include system resonances and other normal transient vibrations.
Direct Frequency Response: The upper and lower corners for the band-pass
filter used with direct vibration measurements. The available ranges are 240 to
240,000 cpm and 60 to 36,000 cpm.
Transducer Jumper Status (on I/O Module): Returns the position of the
Transducer Jumper on the I/O Module. Refer to Setting the I/O Jumper in the
"I/O Module Descriptions" section of the manual, if applicable.
Channel: The number of the channel being configured (1 through 4).
Rack Type: Identifies the type of Rack Interface Module installed in the rack
(Standard or TMR).
8.3.3 Enable
An enabled proportional value specifies that the value will be provided by the
channel ( enabled, disabled).
Direct: Data which represents the overall peak to peak vibration. All frequencies
within the selected Direct Frequency Response are included in this proportional
value.
Gap: The physical distance between the face of a proximity probe tip and the
observed surface. The distance can be expressed in terms of displacement
(mils, micrometres) or in terms of voltage. Standard polarity convention dictates
that a decreasing gap results in an increasing (less negative) output signal.
1X Ampl: In a complex vibration signal, notation for the amplitude component
that occurs at the rotative speed frequency.
1X Phase Lag: In a complex vibration signal, notation for the phase lag
component that occurs at the rotative speed frequency.
having a frequency equal to two times the shaft rotative speed.
- 8-5 -
component having a frequency equal to two times the shaft rotative speed. 2X
phase lag is the angular measurement from the leading or trailing edge of the
Keyphasor pulse to the following positive peak of the 2X vibration signal.
Not 1X Ampl: In a complex vibration signal, notation for the amplitude
component that occurs at frequencies other than rotative speed.
S
max
Ampl: Single peak measurement of unfiltered XY (orthogonal) probes, in
the measurement planes, against a calculated "quasi zero" point. Only one S
max
Ampl value is returned per channel pair (channel 1 or channel 3).
Full Scale Range: Each selectable proportional value provides the ability to set
a full scale value. If the desired full scale value is not in the pull down list, then
the custom selection can be chosen.
The values in the following table are the same for all transducer types.
Direct
1X Ampl
2X Ampl
Not 1X Ampl
S
max
Ampl
0-3 mil pp
0-5 mil pp
0-10 mil pp
0-15 mil pp
0-20 mil pp
0-100 m pp
0-150 m pp
0-200 m pp
0-400 m pp
0-500 m pp
Custom
- 8-6 -
Gap Full-scale Ranges by Transducer Type
33005 mm Proximitor
3300 XL 8 mm Proximitor
33008 mm Proximitor
72005 mm Proximitor
72008 mm Proximitor
720011 mm Proximitor
330016 mm HTPS
Nonstandard
3000 (-18V) Proximitor
3300 RAM Proximitor
-24 Vdc
15-0-15 mil
25-0-25 mil
300-0-300 m
600-0-600 m
Custom
-24 Vdc
15-0-15 mil
25-0-25 mil
50-0-50 mil
300-0-300 m
600-0-600 m
1000-0-1000 m
Custom
-24 Vdc
15-0-15 mil
300-0-300 m
Clamp Value: The value that a proportional value goes to when that channel or
proportional value is bypassed or defeated (For example when a problem occurs
with the transducer). The selected value can be between the minimum and
maximum full-scale range values. (1X and 2X Phase Lag have available values
of 0 to 359 degrees.) Only the values available from the Recorder Outputs,
Communication Gateway and Display Interface Module are clamped to the
specified value when the proportional value is invalid.
Recorder Output: The proportional value of a channel that is sent to the 4 to 20
mA recorder. The recorder output is proportional to the measured value over the
channel full scale range. An increase in the proportional value that would be
indicated as upscale on a bar graph display results in an increase in the current
at the recorder output.
If 1X Phase Lag or 2X Phase Lag are selected then the two options available are
with and without Hysteresis. If the channel is Bypassed, the output will be
clamped to the selected clamp value or to 2 mA (if the 2 mA clamp is selected).
The Hysteresis option helps prevent the Recorder Output from jumping from Full
to Bottom Scale when the phase measurement is near 0 or 359 degrees. When
the Hysteresis option is checked, the recorder signal operates as follows:
The recorder output is scaled such that 4 mA corresponds to 0 degrees and
20 mA corresponds to 380 degrees (360 plus 20 degrees).
The transition of a phase measurement that is increasing does not occur until
the measurement has gone 20 degrees past 360 degrees. At this point, the
recorder signal switches from 20 mA to a signal that corresponds to 20
degrees or 4.842 mA.
The transition of a phase measurement that is decreasing occurs at 0
degrees (4 mA). At this point, the recorder signal switches from 4 mA to a
signal that corresponds to 360 degrees or 19.158 mA.
- 8-7 -
8.3.4 Delay
The time which a proportional value must remain at or above an over alarm level
or below an under alarm level before an alarm is declared as active.
Alert: First level alarm that occurs when the transducer signal level exceeds the
selected Alert/Alarm 1 setpoint. This setpoint can be set on the Setpoint screen.
The Alert time delay is always set at one second intervals (from 1 to 60) for all
available proportional values.
Danger: Second level alarm that occurs when the transducer signal level
exceeds the selected Danger/Alarm 2 setpoint. This setpoint can be set on the
Setpoint screen.
100 ms option: The 100 ms (typical) option applies to the Danger time delay
only and has the following results:
If the 100 ms option is off ():
The Danger time delay can be set at one second intervals (from 1 to 60).
The Danger time delay can be set for up to two available proportional values.
If the 100 ms option is on ():
The Danger time delay is set to 100 ms.
The Danger time delay can only be set for the primary proportional value.
8.3.5 Transducer Selection
Type: The following transducer types are available for the Radial Vibration
Channel (non-barrier I/O module):
3300 Transducers
3300 5 mm Proximitor
3300 RAM Proximitor
3300 16 mm HTPS
7200 Transducers
3000 Transducers
3000 (-18 V) Proximitor
Nonstandard
- 8-8 -
The following transducer types are available for the Radial Vibration Channel
(barrier I/O module):
3300 Transducers
3300 RAM Proximitor
7200 Transducers
Nonstandard
Customize button: Used to adjust the Scale Factor for transducers. Refer to
"Adjusting the Scale Factor and Zero Position" in the "Monitor Verification"
section of the manual. Also, note that:
If Non-standard is selected as the transducer type, the OK Limits can also be
adjusted.
The Non-standard transducer's scale factor must be between 85 and 230
mV/mil.
There must be at least 2 volts between the Upper and Lower OK Limits.
- 8-9 -
Scale Factor by Transducer Type
Scale Factor
Transducer Without
Barriers
With Bently
Nevada
Internal
Barriers
Standard
I/O With
Barriers
Discrete
TMR I/O
With
Barriers
Bussed
TMR I/O
With
Barriers
3300 XL 8 mm
3300 5 and 8
mm
7200 5 and 8
mm
200 mV/mil 200 mV/mil 192 mV/mil 200 mV/mil 199 mV/mil
3300 XL 11
mm
100 mV/mil 100 mV/mil 96 mV/mil 100 mV/mil 100 mV/mil
7200 11 mm *100 mV/mil * * * *
7200 14 mm *100 mV/mil * * * *
3000 (-18 V) *200 mV/mil * * * *
3000 (-24 V) *285 mV/mil * * * *
3300 RAM 200 mV/mil 200 mV/mil 192 mV/mil 200 mV/mil 199 mV/mil
3300 16 mm
HTPS
100 mV/mil * * * *
Note: 15 % scale factor adjustment allowed
* Barriers are not supported with this transducer option.
- 8-10 -
OK Limits by Transducer Type
Upper Lower Center Gap Voltage
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
3300 XL 8 mm
3300 XL 11 mm
3300 5 mm
3300 8 mm
7200 5 mm
7200 8 mm
-16.75 -16.75 -2.75 -2.75 -9.75 -9.75
7200 11 mm -19.65 * -3.55 * -11.6 *
7200 14 mm -16.75 * -2.75 * -9.75 *
3000 (-18 V) -12.05 * -2.45 * -7.25 *
3000 (-24 V) -15.75 * -3.25 * -9.5 *
3300 RAM -12.55 -12.15 -2.45 -2.45 -7.5 -7.3
3300 16 mm
HTPS
-16.75 * -2.75 * -9.75 *
Note: With Barriers includes BN Internal Barrier I/O Modules.
8.3.6 Alarm Mode
Latching: Once an alarm is active it will remain active even after the proportional
value drops below the configured setpoint level. The channel will remain in
alarm until it is reset using one of the following methods:
the reset switch on the front of the Rack Interface Module
the contact on the Rack Interface I/O Module
the Reset button in the Operator Display Software
the reset command through the Communication Gateway Module
the reset command through the Display Interface Module
the reset command in the Rack Configuration Software
Nonlatching: When an alarm is active it will go inactive as soon as the
proportional value drops below the configured setpoint level.
Alert should be the first level alarm that occurs when the transducer signal level
exceeds the selected value. Danger should be the second level alarm that
- 8-11 -
occurs when the transducer signal level exceeds the selected value. The Alert
and Danger values are set on the Setpoint screen.
8.3.7 Transducer Orientation
Degrees: The location of the transducer on the machine. The range for
orientation angle is 0 to 180 degrees left or right as observed from the driver to
the driven end of the machine train. Refer to the following figure:
This drawing is for horizontal shafts
(1) Shaft
(2) Driver end
(3) Driven end
(4) 0
(5) 90 right
(6) 180
(7) 90 left
8.3.8 Barriers
Select the MTL 796(-) Zener External option, or Galvanic Isolators if external
safety barriers are connected between the monitor and the transducer. If using
an Internal Barrier I/O Module, select the internal option. These devices are
used to restrict the amount of energy that can flow into a hazardous area.
8.4 Alarm Setpoints
This section lists the available setpoints for the Radial Vibration channel. A
setpoint is the level within the full-scale range that determines when an alarm
occurs. The 3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for
every proportional value on each channel. The channel will drive an Alert/Alarm
1 indication if one or more of the channel proportional values exceeds its
setpoints. The 3500 Monitoring System also allows up to four Danger/Alarm 2
setpoints (two over setpoints and two under setpoints) to be set for up to two of
the proportional values. You may select any two of the available proportional
values for the channel.
- 8-12 -
Note
The setpoint over and under limits can only be placed
within the OK limits of the specified transducer.
Use the following screen in the Rack Configuration Software to adjust
Alert/Alarm 1 and Danger/Alarm 2 setpoints for Radial Vibration channels.
- 8-13 -
8.4.1 Available Setpoints
The following tables list the Alert/Alarm 1 and Danger/Alarm 2 setpoints available
for each Radial Vibration channel pair. The setpoint number is used in the
Communication Gateway and Display Interface Modules.
Setpoint
Number
Radial Vibration
1 Over Direct
2 Over Gap
3 Under Gap
4 Over 1X Ampl
5 Under 1X Ampl
6 Over 1X Phase Lag
7 Under 1X Phase Lag
8 Over 2X Ampl
9 Under 2X Ampl
10 Over 2X Phase Lag
12 Over Not 1X Ampl
13 Over S
max
Ampl
14 Danger (configurable)
8.4.2 Alarm Hysteresis
The alarming hysteresis for all channel configurations is 1/64 of Full Scale.
When a channel exceeds an alarm setpoint, it must fall back below the setpoint
less the hysteresis before it can go out of alarm.
For example, for a channel configuration with a 010 mils full scale and an alarm
setpoint at 6 mils. The hysteresis = 10 mils/64 = 0.16 mils. The channel input,
therefore, must fall below 6 mils - 0.16 mils (5.84 mils) before the channel is out
of alarm.
- 8-14 -
Blank Page
Section 9 - Radial Vibration Verification
- 9-1 -
9. Radial Vibration Verification
Table of Contents
9.1 Introduction.................................................................................................... 9-2
9.2 Test Equipment and Software Setup.............................................................. 9-2
9.2.1 Test Equipment Setup .................................................................... 9-3
9.2.2 Verification Screen Setup ............................................................... 9-5
9.3 Test Alarms.................................................................................................... 9-5
9.3.1 Direct .............................................................................................. 9-5
9.3.2 Gap................................................................................................. 9-6
9.3.3 1X Amplitude (1X Ampl).................................................................. 9-7
9.3.4 1X Phase........................................................................................ 9-8
9.3.5 2X Amplitude (2X Ampl)................................................................ 9-10
9.3.6 2X Phase...................................................................................... 9-11
9.3.7 Not 1X Amplitude (Not 1X)............................................................ 9-12
9.3.8 S
max
Amplitude............................................................................. 9-13
9.4 Verify Channel Values ................................................................................. 9-14
9.4.1 Direct ............................................................................................ 9-15
9.4.2 Gap............................................................................................... 9-16
9.4.4 1X Phase...................................................................................... 9-19
9.4.6 2X Phase...................................................................................... 9-22
9.4.7 Not 1X Amplitude.......................................................................... 9-24
9.4.8 S
max
Amplitude............................................................................. 9-25
9.5 Test OK Limits ............................................................................................. 9-27
- 9-2 -
9.1 Introduction
The following sections describe how to test alarms, verify channels, and test OK
limits for channels configured as Radial Vibration. The output values and alarm
setpoints are verified by varying the input vibration signal level (both peak to
peak amplitude and DC voltage bias) and observing that the correct results are
reported in the Verification screen on the test computer.
Radial Vibration channels can be configured for the following channel values and
alarms:
Alarms
Channel Values Over Under
Direct X
Gap X X
1X Amplitude and Phase X X
Not 1X Amplitude X
S
max
Amplitude
X
9.2 Test Equipment and Software Setup
The following test equipment and software setup can be used as the initial set up
needed for all the Radial Vibration channel verification procedures (Test Alarms,
Verify Channels, and Test OK Limits).
WARNING!
High voltage present. Contact could cause shock, burns,
or death. Do not touch exposed wires or terminals.
Application Alert
Tests will exceed alarm setpoint levels causing alarms to
activate. This could result in a relay contact state change.
- 9-3 -
Application Alert
Disconnecting the field wiring will cause a not OK
condition.
9.2.1 Test Equipment Setup
Simulate the transducer signal by connecting the power supply, function
generator, and multimeter to COM and SIG of channel 1 with polarity as shown
in the figure below. Set the test equipment as follows:
Power
Supply
Function Generator Keyphasor
Multiplier/Divider
-7.00 Vdc Waveform: sinewave
DC Volts: 0 Vdc
Frequency: 100 Hz
Amplitude level: Minimum
(above zero)
Multiply Switch: 001
Divide Switch: 001
- 9-4 -
The equipment shown in the dashed box is required for 1X Amplitude and
Phase, 2X Amplitude and Phase, Not 1X Amplitude, and S
max
Amplitude.
Test equipment for Radial Vibration
(1) Keyphasor Signal
(2) Keyphasor I/O Module
(3) 40 k
(4) 100 F
(5) Keyphasor Mulitplier/Divider
(6) Typical I/O module
(7) Simulated input signal
(8) Function generator
(9) Mulitmeter
(10) Power supply
- 9-5 -
9.2.2 Verification Screen Setup
Run the Rack Configuration Software on the test computer. Choose Verification
from the Utilities menu and choose the proper Slot number and Channel number
then click on the Verify button.
Note
Timed OK Channel Defeat is enabled for Radial Vibration
channels. It will take 30 seconds for a channel to return
to the OK status from a not OK condition.
9.3 Test Alarms
The general approach for testing alarm setpoints is to simulate the vibration and
Keyphasor signal with a function generator. The alarm levels are tested by
varying the vibration signal (both peak to peak amplitude and DC voltage bias)
and observing that the correct results are reported in the Verification screen on
the test computer. It is only necessary to test those alarm parameters that are
configured and being used. The general test procedure to verify current alarm
operation will include simulating a transducer input signal and varying this signal:
to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and
to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and
to produce a nonalarm condition.
When varying the signal from an alarm condition to a nonalarm condition, alarm
hysteresis must be considered. Adjust the signal well below the alarm setpoint
for the alarm to clear.
9.3.1 Direct
1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on
the I/O module.
2. Connect test equipment and run software as described in "Test Equipment
and Software Setup" on page 9-2.
3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the
divide setting is one. Adjust the function generator amplitude to produce a
reading that is below the Direct setpoint levels on the Direct bar graph display
of the Verification screen.
4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the
OK LED is on, the bar graph indicator for Direct is green, and the Current
Value field contains no alarm indication.
5. Adjust the function generator amplitude such that the signal just exceeds the
Direct Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Direct
- 9-6 -
changes color from green to yellow and that the Current Value Field indicates
an Alarm.
bar graph indicator for Direct remains yellow and that the Current Value Field
still indicates an Alarm.
Direct Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
changes color from yellow to red and that the Current Value Field indicates
an Alarm.
bar graph indicator for Direct remains red and that the Current Value Field
9. Adjust the function generator amplitude such that the signal reads below the
Over Alarm setpoint levels. If the nonlatching option is configured, observe
that the bar graph indicator for Direct changes color to green and that the
Current Value Box contains no indication of alarms. Press the RESET switch
on the Rack Interface Module (RIM) to reset latching alarms.
10. If you cant verify any configured alarm, recheck the configured setpoints. If
the monitor still does not alarm properly or fails any other part of this test, go
to "If a Channel Fails a Verification Test" found in the "Monitor Verification"
section of the manual.
11. Disconnect the test equipment and reconnect the PWR, COM, and SIG field
wiring to the channel terminals on the I/O module. Verify that the OK LED
comes on and the OK relay energizes. Press the RESET switch on the Rack
Interface Module (RIM) to reset the OK LED.
12. Repeat steps 1 through 11 for all configured channels.
9.3.2 Gap
the I/O module.
3. Adjust the power supply to produce a voltage that is within the Gap setpoint
levels on the Gap bar graph display of the Verification screen.
OK LED is on, the bar graph indicator for Gap is green and that the Current
Value field has no alarm indication.
5. Adjust the power supply voltage such that the signal just exceeds the Gap
Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm
time delay expires and verify that the bar graph indicator for Gap changes
color from green to yellow and that the Current Value Field indicates an
Alarm.
bar graph indicator for Gap remains yellow and that the Current Value Field
- 9-7 -
7. Adjust the power supply such that the signal just exceeds the Gap Over
Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time
delay expires and verify that the bar graph indicator for Gap changes color
from yellow to red and that the Current Value Field indicates an Alarm.
bar graph indicator for Gap remains red and that the Current Value Field still
indicates an Alarm.
9. Adjust the power supply voltage such that the signal reads below the Over
Alarm setpoint levels. If the nonlatching option is configured, observe that
the bar graph indicator for Gap changes color to green and that the Current
Value Box contains no indication of alarms. Press the RESET switch on the
Rack Interface Module (RIM) to reset latching alarms.
10. Repeat steps 5 through 9 to test the Under Alert/Alarm 1 and Under
Danger/Alarm 2 setpoints by adjusting the power supply to exceed the Under
Alarm setpoint levels.
11. If you can not verify any configured alarm, recheck the configured setpoints.
If the monitor still does not alarm properly or fails any other part of this test,
go to "If a Channel Fails a Verification Test" found in the "Monitor
9.3.3 1X Amplitude (1X Ampl)
Note
The Keyphasor must be triggering and have a
valid rpm value to check this parameter.
the I/O module.
reading that is within the 1X Ampl setpoint levels on the 1X Ampl bar graph
display of the Verification screen.
OK LED is on, the bar graph indicator for 1X Ampl is green and that the
Current Value field contains no alarm indication.
- 9-8 -
1X Ampl Over Alert/Alarm 1 setpoint level. Wait for 2 to 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for 1X Ampl
changes color from green to yellow and the Current Value Field indicates an
Alarm.
bar graph indicator for 1X Ampl remains yellow and that the Current Value
Field still indicates an Alarm.
1X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 to 3 seconds after
the alarm time delay expires and verify that the bar graph indicator for 1X
Ampl changes color from yellow to red and the Current Value Field indicates
an Alarm.
bar graph indicator for 1X Ampl remains red and that the Current Value Field
that the bar graph indicator for 1X Ampl changes color to green and that the
Danger/Alarm 2 setpoints by adjusting the function generator amplitude to
exceed the Under Alarm setpoint levels.
9.3.4 1X Phase
the I/O module.
- 9-9 -
Note
If you can not change the phase output, change the phase alarm
setpoints to activate the over and under phase alarms. The
setpoints must be downloaded to the monitor to take effect.
divide setting is one. Adjust the phase to produce a reading that is within the
1X Phase setpoint levels on the 1X Phase bar graph display of the
Verification screen.
4. The 1X Amplitude needs to be a minimum of 42.7 mV to get a valid 1X Phase
reading.
OK LED is on, the bar graph indicator for 1X Phase is green, and the Current
6. Adjust the phase such that the reading just exceeds the 1X Phase Over
Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm time
delay expires and verify that the bar graph indicator for 1X Phase changes
color from green to yellow and the Current Value Field indicates an Alarm.
bar graph indicator for 1X Phase remains yellow and that the Current Value
color from yellow to red and that the Current Value Field indicates an Alarm.
bar graph indicator for 1X Phase remains red and that the Current Value
10. Adjust the phase such that the reading is below the Over Alarm setpoint
levels. If the nonlatching option is configured, observe that the bar graph
indicator for 1X Phase changes color to green and that the Current Value Box
contains no indication of alarms. Press the RESET switch on the Rack
Interface Module (RIM) to reset latching alarms.
Danger/Alarm 2 setpoints by adjusting the phase to exceed the Under Alarm
setpoint levels.
- 9-10 -
Note
the I/O module.
divide setting is two. Adjust the function generator amplitude to produce a
OK LED is on, the bar graph indicator for 2X Ampl is green, and the Current
2X Ampl Over Alert/Alarm 1 setpoint level. Wait 2 or 3 seconds after the
an Alarm.
2X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after
Ampl changes color from yellow to red and that the Current Value Field
indicates an Alarm.
- 9-11 -
9.3.6 2X Phase
the I/O module.
Note
divide setting is two. Adjust the phase to produce a reading that is within the
reading.
delay and verify that the bar graph indicator for 2X Phase changes color from
green to yellow and that the Current Value Field indicates an Alarm.
- 9-12 -
setpoint levels.
9.3.7 Not 1X Amplitude (Not 1X)
Note
the I/O module.
reading that is below the Not 1X setpoint levels on the Not 1X bar graph
OK LED is on, the bar graph indicator for Not 1X is green, and the Current
Not 1X Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
- 9-13 -
alarm time delay expires and verify that the bar graph indicator for Not 1X
an Alarm.
bar graph indicator for Not 1X remains yellow and that the Current Value
Not 1X Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Not 1X
an Alarm.
bar graph indicator for Not 1X remains red and that the Current Value Field
that the bar graph indicator for Not 1X changes color to green and the
9.3.8 S
max
Amplitude
Note
1. Disconnect PWR, COM, and SIG field wiring from the channel pair terminals
on the I/O module.
and Software Setup" on page 9-2. S
max
requires input connections to
both channel 1 and 2 or channel 3 and 4.
- 9-14 -
3. Adjust the function generator amplitude to produce a reading that is below
the S
max
setpoint levels on the S
max
bar graph display of the Verification
screen.
OK LED is on, the bar graph indicator for S
max
is green, and the Current
S
max
Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for S
max
an Alarm.
bar graph indicator for S
max
remains yellow and that the Current Value Field
S
max
Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for S
max
an Alarm.
bar graph indicator for S
max
remains red and that the Current Value Field still
indicates an Alarm.
that the bar graph indicator for S
max
changes color to green and the Current
wiring to the channel pair terminals on the I/O module. Verify that the OK
LED comes on and the OK relay energizes. Press the RESET switch on the
Rack Interface Module (RIM) to reset the OK LED.
9.4 Verify Channel Values
The general approach for testing channel values is to simulate the vibration and
Keyphasor input signal with a function generator. The output values are verified
by varying the input vibration signal level (both peak to peak amplitude and DC
voltage bias) and observing that the correct results are reported in the
Verification screen on the test computer.
- 9-15 -
Note
These parameters have an accuracy specification of 1 %
of full scale for amplitude and 3 degrees for phase.
9.4.1 Direct
the I/O module.
3. Calculate the full-scale voltage according to the equation and examples
shown below. Adjust the amplitude of the function generator to the
calculated voltage.
Application Alert
Use the Transducer Scale Factor displayed in the Scale
Factor Box on the Verification Screen.
Full Scale Voltage = Direct Meter Top Scale Transducer Scale Factor
Example 1:
Direct Meter Top Scale = 10 mil
Transducer Scale Factor = 200 mV/mil
Full Scale = (10 0.200)
= 2.000 Vpp
For Vrms input:
Vrms = (0.707/2) (Vpp), for a sinewave input
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
Direct Meter Top Scale = 200 m
Transducer Scale Factor = 7,874 mV/mm
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
- 9-16 -
For Vrms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
divide setting is one. Verify that the Direct bar graph display and Current
Value Box is reading 1 % of full scale.
5. If the reading does not meet specifications, check that the input signal is
correct. If the monitor still does not meet specifications or fails any other part
of this test, go to "If a Channel Fails a Verification Test" found in the "Monitor
9.4.2 Gap
the I/O module.
3. If Gap is configured to read in volts, adjust the power supply to produce a
voltage equal to -18.00 Vdc on the Gap bar graph display. Verify that the
Gap bar graph display and Current Value Box is reading 1 % of -18.00 Vdc.
4. Adjust the power supply to produce a voltage equal to mid-scale on the Gap
bar graph display. Verify that the Gap bar graph display and Current Value
Box is reading 1 % of the mid-scale value. Go to step 8.
If Gap is configured to read in displacement units, calculate the full-scale and
bottom-scale voltage using the following equation:
Note
Use the Transducer Scale Factor displayed in the
Scale Factor Box on the Verification Screen.
Gap Full-Scale = Gap Zero Position Volts + (Gap Meter Top Scale Transducer
Scale Factor)
Example 1:
Gap = 15-0-15 mil
- 9-17 -
Gap Top Scale = 15 mil
Gap Zero Position Volts = -9.75 Vdc
Gap Full Scale input = -9.75 Vdc + (15 0.200)
= -6.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
Gap Top Scale = 300 m
= -7.3878 Vdc
Gap Bottom-Scale = Gap Zero Position Volts - (Gap Meter Bottom Scale
Transducer Scale Factor)
Example 1:
Gap = 15-0-15 mil
Gap Bottom Scale = 15 mil
Gap Bottom Scale input = -9.75 Vdc - (15 0.200)
= -12.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
Gap Bottom Scale = 300 m
= -12.1122 Vdc
5. Adjust the power supply voltage to match the voltage displayed in the Gap
Zero Position Volts Box. The Gap bar graph display and Current Value Box
should read 0 mil (0 mm) 1 %.
6. Adjust the power supply to produce a voltage equal to top scale (from step 3)
on the Gap bar graph display. Verify that the Gap bar graph display and
Current Value Box is reading 1 % of top scale.
7. Adjust the power supply to produce a voltage equal to bottom scale (from
step 3) on the Gap bar graph display. Verify that the Gap bar graph display
and Current Value Box is reading 1 % of bottom scale.
- 9-18 -
Note
The Keyphasor must be triggering and have a valid
rpm value to check this parameter.
the I/O module.
shown below. Adjust the function generator amplitude to the calculated
voltage.
Note
Full Scale Voltage = 1X Ampl Meter Top Scale X Transducer Scale Factor
Example 1:
1X Ampl Meter Top Scale = 10 mil
Full Scale = (10 0.200)
= 2.000 Vpp
For V rms input:
V rms = (0.707/2) (Vpp), for a sinewave input
= (0.707/2) (2)
= 0.707 Vrms
- 9-19 -
Example 2:
1X Ampl Meter Top Scale = 200 m
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For V rms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
divide setting is one. Verify that the 1X Ampl bar graph display and Current
9.4.4 1X Phase
If the test equipment is not capable of changing the phase output to a known
value, use the following procedure. If your test equipment can change the phase
output to a known value, use the procedure "If the Test Equipment Can Change
the Phase Output (1X Phase)" on page 9-20.
9.4.4.1 If the Test Equipment Cannot Change the Phase Ouput (1X Phase)
the I/O module.
and Software Setup" on page 9-2. Set the Keyphasor multiplier/divider so
that the multiply setting is one and the divide setting is one.
3. Attach one channel of a two channel oscilloscope to the vibration signal
buffered output and attach the other channel to the associated Keyphasor
signal buffered output and observe the two signals simultaneously.

4. Measure the phase. 1X Phase will be measured from the leading edge of the
Keyphasor
pulse to the first positive peak of the vibration signal. See the
example below which illustrates a phase of 45. Observe the 1X Phase bar
graph display and Current Value Box; it should read approximately what was
measured above.
- 9-20 -
Example:
1X = one cycle of vibration signal per shaft revolution
(1) 1X Vibration Signal
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
9.4.4.2 If the Test Equipment Can Change the Phase Output (1X Phase)
If the test equipment has the capability to change the phase output to a known
value, use the following procedures.
the I/O module.
3. Adjust the phase for mid-scale. Verify that the 1X Phase bar graph display
and Current Value Box is reading 1.5 % of mid-scale.
- 9-21 -
4. If the reading does not meet specifications double check the input signal to
ensure it is correct. If the monitor still does not meet specifications or fails
any other part of this test, go to "If a Channel Fails a Verification Test" found
in the "Monitor Verification" section of the manual.
Note
the I/O module.
voltage.
Note
Full Scale Voltage = 2X Ampl Meter Top Scale Transducer Scale Factor
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
For V rms input:
- 9-22 -
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For V rms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
divide setting is two. Verify that the 2X Ampl bar graph display and Current
9.4.6 2X Phase
output to a known value, use the procedure "If the Test Equipment can Change
the Phase Output (2X Phase) on page 9-23.
9.4.6.1 If the Test Equipment Cannot Change the Phase Output (2X Phase)
the I/O module.
and Software Setup on page 9-2. Set the Keyphasor multiplier/divider so that
the multiply setting is one and the divide setting is two.
3. Attach one channel of the two channel oscilloscope to the vibration signal

Keyphasor
- 9-23 -
measured above.
Example:
2X = two cycles of vibration signal per shaft revolution
(1) 0
(2) First Cycle
(3) One shaft revolution
(4) Second cycle
(6) Phase lag = 90
(7) Keyphasor signal
(8) 360
(9) Time
9.4.6.2 If the Test Equipment can Change the Phase Output (2X Phase)
value, use the following procedure.
the I/O module.
- 9-24 -
that the multiply setting is one and the divide setting is two.
4. If the reading does not meet specifications, double check the input signal to
ensure it is correct. If the monitor still does not meet specifications and/or
fails any other part of this test, go to "If a Channel Fails a Verification Test"
found in the "Monitor Verification" section of the manual.
9.4.7 Not 1X Amplitude
Note
the I/O module.
3. Calculate the full-scale voltage according to the equation and example shown
below. Adjust the function generator amplitude to the calculated voltage.
Note
Full-Scale Voltage =Not 1X Ampl Meter Top Scale Transducer Scale Factor
Example 1:
Not 1X Ampl Meter Top Scale = 10 mil
- 9-25 -
Full Scale = (10 0.200)
= 2.000 Vpp
For Vrms input:
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
Not 1X Ampl Meter Top Scale = 200 m
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For V rms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
divide setting is two. Verify that the Not 1X bar graph display and Current
9.4.8 S
max
Amplitude
Note
on the I/O module.
- 9-26 -
and Software Setup" on page 9-2. S
max
requires input connections to
both channel 1 and 2 or channel 3 and 4.
3. Calculate the full-scale voltage using the equation and example shown
below.
Note
Full-Scale Voltage = (S
max
Meter Top Scale Transducer Scale Factor)
1.414
Example 1:
S
max
Meter Top Scale = 10 mil
Full Scale = (10 0.200) 1.414
= 2.828 Vpp
For Vrms input:
= (0.707/2) (2.828)
= 0.999 Vrms
Example 2:
S
max
Meter Top Scale = 200 m
= 7.874 mV/m
Full Scale = (200 .007874) 1.414
= 2.2267 Vpp
For Vrms input:
= (0.707/2) (2.2267)
= 0.7871 Vrms
4. Set the Keyphasor multiplier/divider so that the multiply setting is set to one
and the divide setting is set to one. Adjust the function generator amplitude
for full scale. Verify that the S
max
bar graph display and Current Value Box is
reading 1 % of full scale.
- 9-27 -
9.5 Test OK Limits
The general approach for testing OK limits is to input a DC voltage and adjust it
above the Upper OK limit and below the Lower OK limit. This will cause a
channel not OK condition and the OK Relay to change state (de-energize). The
Upper and Lower OK limits are displayed in the Verification screen on the test
computer.
the I/O module.
3. Bypass all other configured channels.
4. Adjust the power supply voltage to -7.00 Vdc.
monitor OK LED is on and that the Channel OK State line in the Channel
Status box of the Verification screen reads OK.
Note
If the Danger Bypass has been activated, then the BYPASS LED
will be on. All other channels in the rack must be OK or bypassed
for the relay to be energized.
6. Verify that the OK relay on the Rack Interface I/O Module indicates OK
(energized). See 3500/20 Rack Interface Module Operation and
Maintenance Manual, part number 129768-01.
7. Increase the power supply voltage (more negative) until the OK LED just
goes off (upper limit). Verify that the Channel OK State line in the Channel
Status box reads not OK and that the OK Relay indicates not OK. Verify that
the Upper OK limit voltage displayed on the Verification screen is equal to or
more positive than the input voltage.
8. Decrease the power supply voltage (less negative) to -7.00 Vdc.
OK LED comes back on and the OK relay energizes. Verify that the Channel
OK State line in the Channel Status box reads OK.
- 9-28 -
10. Gradually decrease the power supply voltage (less negative) until the OK
LED just goes off (lower limit). Verify that the Channel OK State line in the
Channel Status box reads not OK and that the OK Relay indicates not OK.
Verify that the Lower OK limit voltage displayed on the Verification screen is
equal to or more negative than the input voltage.
11. Increase the power supply voltage (more negative) to -7.00 Vdc.
OK LED comes back on, the OK relay energizes and that the Channel OK
State line in the Channel Status box reads OK.
13. If you can not verify any configured OK limit, go to "If a Channel Fails a
Verification Test" found in the "Monitor Verification" section of the manual.
wiring to the channel terminals on the Monitor I/O Module. Press the RESET
switch on the Rack Interface Module (RIM) and verify that the OK LED comes
on and the OK relay energizes.
16. Return the bypass switch for all configured channels back to their original
setting.
Radial Vibration Default OK Limits Table
Transducer Lower OK Limit
(volts)
Upper OK Limit
(volts)
7200 5&8 mm w/ barriers -2.7 to -2.8 -16.7 to 16.8
7200 5&8 mm w/o barriers -2.7 to -2.8 -16.7 to -16.8
7200 11 mm w/o barriers -3.5 to -3.6 -19.6 to -19.7
3300 5&8 mm w/ barriers -2.7 to -2.8 -16.7 to -16.8
3300 XL 8 mm w/ barriers -2.7 to -2.8 -16.7 to -16.8
3300 XL 8 mm w/o barriers -2.7 to -2.8 -16.7 to -16.8
3000 (-18 V) w/o barriers -2.4 to -2.5 -12.0 to -12.1
3300 RAM w/o barriers -2.4 to -2.5 -12.5 to -12.6
3300 RAM w/ barriers -2.4 to -2.5 -12.1 to -12.2
3300 16 mm HTPS w/o
barriers
-2.7 to -2.8 -16.7 to -16.8
Note: Assume 50 mV accuracy for check tolerance.
Section 10 - Thrust Position General Information
- 10-1 -
10. Thrust Position General Information
Thrust position, a measure of the position or change in position of a rotor in axial
direction with respect to the thrust bearing, lets you monitor the wear of the thrust
collar of a rotor.
In a 3500 Monitoring System, Thrust Position channels are programmed in pairs.
These channels, depending on configuration, typically condition the input signals
into various parameters called proportional values. Alert setpoints can be
- 10-2 -
Blank Page
Section 11 - Thrust Position Configuration
- 11-1 -
11. Thrust Position Configuration
Table of Contents
11.1 Introduction.................................................................................................. 11-2
11.2 Configuration Considerations....................................................................... 11-2
11.3 Configuration Options .................................................................................. 11-3
11.3.1 General Parameters and Buttons.................................................. 11-3
11.3.2 Reference Information .................................................................. 11-4
11.3.3 Enable .......................................................................................... 11-4
11.3.4 OK Mode ...................................................................................... 11-5
11.3.5 Delay ............................................................................................ 11-6
11.3.6 Transducer Selection.................................................................... 11-6
11.3.7 Alarm Mode .................................................................................. 11-9
11.3.8 Barriers....................................................................................... 11-10
11.4 Alarm Setpoints ......................................................................................... 11-10
11.4.1 Available Setpoints ..................................................................... 11-11
- 11-2 -
11.1 Introduction
Configuration Software screens associated with the Thrust Position Channel.
Consider the following items before configuring a Thrust Position Channel:
Internal Barrier I/O Modules are not currently supported with 7200 11 mm or
14 mm, or 3000 Proximitors, or the 3300 16 mm HTPS.
Because an extreme Thrust Position movement can exceed the OK limits of
the transducer, a transducer Not OK event on a Thrust Position channel will
not inhibit alarming on that channel.
The "No Keyphasor" option is automatically selected for this channel type.
No Keyphasors are required.
The Thrust Direct full-scale range is dependent upon the transducer type.
The Zero Position voltage range is dependent upon the direct full-scale range
and the upscale direction.
may be configured as Thrust Position and Channels 3 and 4 may be
configured as Radial Vibration).
mV/mil.
mV/mil.
- 11-3 -
This section describes the options available on the Thrust Position Channel
Transducer Jumper on the I/O Module. For the function of this jumper, refer to
Setting the I/O Jumper in the manual of the monitor that contains this channel.
CP Mod: Selecting the CP Mod button in the Channel Options Dialog Box,
allows a Custom channel configuration to be downloaded to the monitor.
Custom configuration data is stored in a Custom Products Modification File.
Custom Products Modification files follow the naming convention <modification
#.mod>. These files must be located in the \3500\Rackcfg\Mods\ directory.
When a CP Mod file is selected, a window is displayed which describes the
function of the modification. CP Mod files are available through Bently Nevada's
Custom Products Division. Contact your local Bently Nevada Sales
Representative for details.
Zero Position (Direct): Represents the transducer DC voltage corresponding to
the zero indication on the channel's meter scale for the direct proportional value.
The amount of adjustment allowed is dependent upon the Direct Full Scale
Range and the transducer OK limits. For maximum amount of zero adjustment,
gap the transducer as close as possible to the ideal zero position voltage based
on the full-scale range, the transducer scale factor, and the Upscale Direction.
For a mid-scale zero the ideal gap is the center of the range.
- 11-4 -
utility starts that helps you set the direct zero position voltage. Since this utility
Normal Thrust Direction: Towards the active thrust bearing (for example
towards or away from the probe mounting). This field defines whether rotor
movement toward or away from the thrust probe corresponds to a more positive
thrust reading (for example upscale on a bar graph). If this field is set to "Toward
Probe", then as the rotor moves toward the thrust probe the thrust position direct
proportional value will increase and go upscale on a bar graph.
(Standard or TMR).
11.3.3 Enable
Direct: Average position, or change in position, of a rotor in the axial direction
with respect to some fixed reference. This value may be displayed in mils or m.
This proportional value supports both center zero and non-center zero Full Scale
Ranges.
observed surface. The distance is expressed in terms of voltage. Standard
polarity convention dictates that a decreasing gap results in an increasing (less
negative) output signal.
- 11-5 -
Direct Full-scale Ranges by Transducer Type
3300 XL 8 mm
Proximitor
3300 - 5 and 8 mm
Proximitor
7200 - 5 and 8 mm
Proximitor
3300 XL 11mm
Proximitor
7200 - 11 and 14 mm
Proximitor
3300 - 16 mm HTPS
Nonstandard
3000 (-18V)
Proximitor
3000 (-24V)
Proximitor
3300 RAM
Proximitor
25-0-25 mil
30-0-30 mil
40-0-40 mil
0.5 - 0 0.5 mm
1.0 - 0 1.0 mm
Custom
25-0-25 mil
30-0-30 mil
40-0-40 mil
50-0-50 mil
75-0-75 mil
0.5 - 0 - 0.5 mm
1.0 - 0 - 1.0 mm
2.0 - 0 - 2.0 mm
Custom
25-0-25 mil
0.5 - 0 - 0.5 mm
Custom
The Gap Full Scale Ranges are the same for all transducer types.
Gap
-24 Vdc
Custom
proportional value is Bypassed or defeated. The selected value can be between
the minimum and maximum full-scale range values. Only the values available
from the Recorder Outputs, Communication Gateway and Display Interface
Module are clamped to the specified value when the proportional value is invalid.
at the recorder output. If the channel is bypassed, the output will be clamped to
the selected clamp value or to 2 mA (if the 2 mA clamp is selected).
11.3.4 OK Mode
Latching: If a channel is configured for Latching OK, once the channel has gone
not OK the status stays not OK until a reset is issued. Reset a latched not OK by
using one of the following methods:
- 11-6 -
Nonlatching: The OK status of that channel will track the defined OK status of
the transducer.
11.3.5 Delay
Setpoint screen.
The Danger time delay can be set at one second intervals (from 1 through
60).
The Danger time delay can be set for all available proportional values.
Type: The following transducer types are available for the Thrust Position
3300 - 5mm Proximitor
3300 XL 8mm Proximitor
- 11-7 -
3300 RAM Proximitor
3300 - 16mm HTPS
Nonstandard
The following transducer types are available for the Thrust Position Channel
3300 RAM Proximitor
Nonstandard
adjusted.
mV/mil.
- 11-8 -
Scale Factor
Transducer Without
Barriers
With
Bently
Nevada
Internal
Barriers
Standard
I/O with
Barriers
Discrete
TMR I/O
with
Barriers
Bussed
TMR I/O
with
Barriers
3300 XL 8 mm 200 mV/mil 200 mV/mil 192 mV/mil 200 mV/mil 199 mV/mil
3300 5 and 8 mm
7200 5 and 8 mm
3300 XL 11 mm 100 mV/mil 100 mV/mil 96 mV/mil 100 mV/mil 96 mV/mil
7200 11 mm 100 mV/mil * * * *
7200 14 mm 100 mV/mil * * * *
3000 (-18 V) 200 mV/mil * * * *
3000 (-24 V) 285 mV/mil * * * *
3300 RAM 200 mV/mil 200 mV/mil 192 mV/mil 200 mV/mil 199 mV/mil
3300 16 mm HTPS 100 mV/mil * * * *
Note : 15% scale factor adjustment allowed.
* Barriers are not supported with this transdcuer option.
- 11-9 -
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
3300 XL 8 mm -19.04 -18.20 -1.28 -1.10 -10.16 -9.65
3300 XL 11 mm -1.28** -9.74**
3300 8 mm
3300 5 mm
7200 5 mm
7200 8 mm
7200 11 mm -20.39 * -3.55 * -11.97 *
7200 14 mm -18.05 * -1.65 * -9.85 *
3000 (-18 V) -13.14 * -1.16 * -7.15 *
3000 (-24 V) -16.85 * -2.25 * -9.55 *
3300 RAM -13.14 -12.35 -1.16 -1.05
-1.16**
-7.15 -6.7
-6.76**
3300 16 mm
HTPS
-18.05 * -1.65 * -9.85 *
* Barriers are not suppoted with this transducer option.
** BN Internal Barrier I/O Modules.
11.3.7 Alarm Mode
- 11-10 -
11.3.8 Barriers
11.4 Alarm Setpoints
This section specifies the available setpoints for each type of channel. A setpoint
is the level within the full-scale range that determines when an alarm occurs.
The 3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for every
proportional value on each channel. The channel will drive an Alert/Alarm 1
indication if one or more of the channel proportional values exceeds its setpoints.
The 3500 Monitoring System also allows up to four Danger/Alarm 2 setpoints
(two over setpoints and two under setpoints) to be set for up to two of the
proportional values. You may select any two of the available proportional values
for the channel.
Note
The setpoint over and under limits can only be
placed within the OK limits of the specified
transducer.
Alert/Alarm 1 and Danger/Alarm 2 setpoints. This screen will vary depending
upon the type of channel.
- 11-11 -
The following table list the Alert/Alarm 1 and Danger/Alarm 2 setpoints available
for the Thrust Position channel type. The setpoint number is used in the
Setpoint
Number
Thrust Position
1 Over Direct
2 Under Direct
3 Over Gap
4 Under Gap
- 11-12 -
All the Alert/Alarm 1 setpoints are provided first, followed by the configured
danger setpoints.
Example 1:
Radial Vibration with the Danger/Alarm 2 Over 2X Ampl setpoint and the
Danger/Alarm 2 Under 2X Ampl setpoint selected.
Alert/Alarm 1 setpoints: setpoints 1 through 13
Danger/Alarm 2 setpoints: setpoint 14 is Over 2X Ampl (Danger)
setpoint 15 is Under 2X Ampl (Danger)
Example 2:
Thrust Position with the Danger/Alarm 2 Over Gap setpoint and the
Danger/Alarm 2 Under Gap setpoint selected.
Alert/Alarm 1 setpoints: setpoints 1 through 4
Danger/Alarm 2 setpoints: setpoint 5 is Over Gap (Danger)
setpoint 6 is Under Gap (Danger)
Section 12 - Differential Expansion General Information
- 12-1 -
12. Differential Expansion General
Information
Differential expansion, a measure of the axial position of the rotor with respect to
the machine case, lets you monitor the thermal expansion or contraction of a
rotor.
In a 3500 Monitoring System, Differential Expansion channels are programmed
in pairs. These channels, depending on configuration, typically condition the
input signals into various parameters called proportional values. Alert setpoints
can be configured for each active proportional value and Danger setpoints can
be configured for any two of the active proportional values.
- 12-2 -
Blank Page
Section 13 - Differential Expansion Configuration
- 13-1 -
13. Differential Expansion Configuration
Table of Contents
13.1 Introduction.................................................................................................. 13-2
13.3.3 Enable .......................................................................................... 13-4
13.3.4 OK Mode ...................................................................................... 13-5
13.3.5 Timed OK Channel Defeat ............................................................ 13-5
13.3.6 Delay ............................................................................................ 13-5
13.3.8 Alarm Mode .................................................................................. 13-7
13.3.9 Upscale Direction.......................................................................... 13-8
13.4 Alarm Setpoints ........................................................................................... 13-8
13.4.1 Available Setpoints ....................................................................... 13-9
13.4.2 Alarm Hysteresis......................................................................... 13-10
- 13-2 -
13.1 Introduction
Configuration Software screens associated with the Differential Expansion
Channel.
Consider the following items before configuring a Differential Expansion Channel:
None of the differential expansion channel transducers are able to support
discrete Internal Barrier I/O modules.
The Differential Expansion Direct full-scale range is dependent upon the
transducer type.
The Zero Position voltage range is dependent upon the direct full-scale
range.
may be configured as Differential Expansion and Channels 3 and 4 may be
configured as Thrust Position).
The Latching OK Mode and the Timed OK Channel Defeat options are not
compatible.
- 13-3 -
This section describes the options available on the Differential Expansion
Channel configuration screen.
Range and the transducer OK limits. For maximum amount of zero adjustment,
gap the transducer as close as possible to the ideal zero position voltage based
on the full-scale range, the transducer scale factor, and the Upscale Direction.
For a mid-scale zero the ideal gap is the center of the range.
Adjust Button: Adjust the Zero Position voltage. When this button is clicked a
- 13-4 -
(Standard or TMR).
13.3.3 Enable
Direct: Change in position of the shaft due to the thermal growth relative to the
machine casing. This value may be displayed in inches or mm. This
proportional value supports both center zero and noncenter zero Full Scale
Ranges.
Direct Full Scale Ranges by transducer type
25 mm Extended Range
Proximitor
Proximitor
Proximitor
Nonstandard
5-0-5 mm
0-10 mm
0.25 - 0 - 0.25 in
0.0 - 0.5 in
Custom
5-0-5 mm
0-10 mm
10-0-10 mm
0-20 mm
0-25 mm
0.25 - 0 - 0.25 in
0.0 - 0.5 in
0.5 - 0 - 0.5 in
0.0 - 1.0 in
Custom
- 13-5 -
The Gap Full Scale Ranges are the same for all transducer types.
Gap
-24 Vdc
Custom
proportional value is Bypassed or defeated (For example when a problem occurs
maximum full-scale range values. Only the values available from the Recorder
Outputs, Communication Gateway and Display Interface Module are clamped to
the specified value when the proportional value is invalid.
channel full-scale range. An increase in the proportional value that would be
at the recorder output. If the channel is Bypassed, the output will be clamped to
13.3.4 OK Mode
Nonlatching: The OK status of the channel will track the defined OK status of
the transducer.
13.3.5 Timed OK Channel Defeat
An option that prevents a channel from returning to an OK status until that
channel's transducer has remained in an OK state for the specified period of
time. If the option is enabled, the time is set to 10 seconds. The option protects
against false trips caused by intermittent transducers.
13.3.6 Delay
- 13-6 -
Setpoint screen.
Type: The following transducer types are available for the Differential Expansion
Channel:
25mm Extended Range Proximitor
Nonstandard
adjusted.
The Non-standard transducer's scale factor must be between 8.5 and 23
mV/mil.
- 13-7 -
Transducer Without Barriers
25 mm 20 mV/mil
35 mm 20 mV/mil
50 mm 10 mV/mil
Note: 15 % scale factor adjustment allowed.
Transducer Upper
(V)
Lower
(V)
Center Gap
Voltage (V)
25mm -12.55 -1.35 -6.95
35mm -12.55 -1.35 -6.95
50mm -12.55 -1.35 -6.95
Transducer Jumper on the I/O Module. For the function of this jumper refer to
13.3.8 Alarm Mode
Latching: Once an alarm is active, it will remain active even after the
proportional value drops below the configured setpoint level. The channel will
remain in alarm until it is reset using one of the following methods:
- 13-8 -
Nonlatching: When an alarm is active, it will go inactive as soon as the
proportional value drops below the configured setpoint level. Alert should be the
first level alarm that occurs when the transducer signal level exceeds the
selected value. Danger should be the second level alarm that occurs when the
transducer signal level exceeds the selected value. The Alert and Danger values
are set on the Setpoint screen.
13.3.9 Upscale Direction
Towards or away from the probe mounting. This field defines whether rotor
movement toward or away from the differential expansion corresponds to a more
positive differential expansion (for example upscale on a bar graph). If this field
is set to "Toward Probe", then as the rotor moves toward the differential
expansion probe the differential expansion direct proportional value will increase
and go upscale on a bar graph.
for the channel.
Note
- 13-9 -
Alert/Alarm 1 and Danger/Alarm 2 setpoints.
for each channel pair type. The setpoint number is used in the Communication
Gateway and Display Interface Modules.
Setpoint
Number
1 Over Direct
2 Under Direct
3 Over Gap
4 Under Gap
- 13-10 -
When a channel exceeds an alarm setpoint, it must fall back the setpoint less the
hysteresis before it can go out of alarm.
For example, for a channel configuration with a 0 to 10 mil full scale and an
alarm setpoint of 6 mils, the hysteresis = 10 mils/64 = 0.16 mils. The channel
input, therefore, must fall below 6 miles 0.6 mils (5.84 mils) before the channel
is out of alarm.
Section 14 - Thrust Position and Differential Expansion Verification
- 14-1 -
14. Thrust Position and Differential
Expansion Verification
Table of Contents
14.1 Introduction.................................................................................................. 14-2
14.2 Test Equipment and Software Setup............................................................ 14-2
14.2.1 Required Test Equipment ............................................................. 14-2
14.2.2 Test Equipment Setup .................................................................. 14-3
14.2.3 Verification Screen Setup.............................................................. 14-4
14.3 Test Alarms.................................................................................................. 14-4
14.3.1 Direct ............................................................................................ 14-4
14.3.2 Gap............................................................................................... 14-5
14.4.1 Direct ............................................................................................ 14-6
14.4.2 Gap............................................................................................... 14-9
14.5 Test OK Limits ............................................................................................. 14-9
- 14-2 -
14.1 Introduction
limits for channels configured as Thrust Position and Differential Expansion. The
output values and alarm setpoints are verified by varying the input DC voltage
from a power supply and observing that the correct results are reported in the
Thrust Position and Differential Expansion channels can be configured for the
following channel values and alarms:
Alarms Channel
Values
Over Under
Direct X X
Gap X X
The following test equipment and software setup can be used as the initial setup
needed for all the Thrust Position and Differential Expansion channel verification
procedures (Test Alarms, Verify Channels, and Test OK Limits).
14.2.1 Required Test Equipment
The verification procedures in this section require the following test equipment.
Power Supply (single channel)
Multimeter - 4 digits
WARNING!
High voltage present. Contact could cause
shock, burns, or death. Do not touch
exposed wires or terminals.
- 14-3 -
Application Alert
Tests will exceed alarm setpoint levels
causing alarms to activate. This could result
in a relay contact state change.
Application Alert
Disconnecting field wiring will cause a not
OK condition.
Simulate the transducer signal by connecting power supply (output terminals)
and multimeter (input terminals) to COM and SIG of channel 1 with polarity as
shown below.
The Test Equipment outputs should be floating relative to earth ground.
- 14-4 -
14.3 Test Alarms
The general approach for testing alarm setpoints is to simulate the Thrust
Position and Differential Expansion signal with a power supply. The alarm levels
are tested by varying the DC voltage and observing that the correct results are
reported in the Verification screen on the test computer. It is only necessary to
test those alarm parameters that are configured and being used. The general
test procedure to verify current alarm operation will include simulating a
transducer input signal and varying this signal:
to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints.
to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints.
14.3.1 Direct
the I/O module.
3. Adjust the power supply to produce a voltage that is within the Direct setpoint
levels on the Direct bar graph display of the Verification screen.
5. Adjust the power supply voltage such that the signal just exceeds the Direct
time delay expires and verify that the bar graph indicator for Direct changes
Alarm.
7. Adjust the power supply such that the signal just exceeds the Direct Over
delay expires and verify that the bar graph indicator for Direct changes color
- 14-5 -
the bar graph indicator for Direct changes color to green and that the Current
14.3.2 Gap
the I/O module.
levels on the Gap bar graph display.
OK LED is on, the bar graph indicator for Gap is green, and the Current
Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds until the alarm time
from green to yellow and that the Current Value Field indicates an Alarm.
bar graph indicator for Gap remains yellow and that the Current Field still
indicates an Alarm.
indicates an Alarm.
- 14-6 -
The general approach for testing these parameters is to simulate the Thrust
Position and Differential Expansion signal with a power supply. The output
values are verified by varying the input DC voltage and observing that the correct
results are reported in the Verification screen on the test computer.
14.4.1 Direct
1. Disconnect PWR, COM, and SIG field wiring from the channel terminals
on the I/O module.
2. Connect test equipment and run software as described in "Test
Equipment and Software Setup" on page 14-2.
3. Calculate the full-scale and bottom scale values. These values can be
calculated in the following way:
Full-scale Value, Bottom Scale Value = Zero Position Voltage
(Transducer Scale Factor Scale Range)
Note
The Zero Position Voltage is the voltage input that will
cause the reading on the bar graph display and the Current
Value Box to be zero. The Zero Position Volts value is
displayed in the Z.P. Volts box above each channel value
bar graph.
- 14-7 -
Note
If the bottom scale range is zero (for example 0 to 80 mil),
use the Full-scale Value formula.
Note
If Upscale direction (Normal for Thrust, Long for Differential Expansion) is
toward the probe:
Full Scale = (Zero Position Voltage) + (Transducer Scale Factor Top
Meter Scale)
Bottom Scale = (Zero Position Voltage) - (Transducer Scale Factor
ABS (Bottom Meter Scale)
Example 1:
Transducer scale factor = 200 mV/mil
Meter scale range = 25-0-25 mil
Zero Position Voltage = -9.75 Vdc
Full Scale Value = (-9.75) + (0.200 25)
= -4.75 Vdc
Bottom Scale Value = (-9.75) - (0.200 25)
= -14.75 Vdc
Example 2:
Transducer scale factor = 7,874 mV/mm
Meter scale range = 1-0-1 mm
Full Scale Value = (-10.16) + (7.874 1)
= -2.286 Vdc
Bottom Scale Value = (-10.16) - (7.874 1)
= -18.03 Vdc
If Upscale direction (Normal for Thrust, Long for Differential Expansion) is
away from the probe:
- 14-8 -
Full Scale = (Zero Position Voltage) - (Transducer Scale Factor Top
Meter Scale)
Bottom Scale = (Zero Position Voltage) + (Transducer Scale Factor
ABS(Bottom Meter Scale)
Example 1:
Transducer scale factor = 200 mV/mil
Meter scale range = 25-0-25 mil
Full Scale Value = (-9.75) - (0.200 25)
= -14.75 Vdc
Bottom Scale Value = (-9.75) + (0.200 25 )
= -4.75 Vdc
Example 2:
Meter scale range = 1-0-1 mm
Full Scale Value = (-10.16) - (7.874 1)
= -18.03 Vdc
Bottom Scale Value = (-10.16) + (7.874 1)
= -2.286 Vdc
4. Adjust the power supply voltage to match the voltage displayed in the
Z.P. Volts box. The Direct bar graph display and the Current Value Box
5. Adjust the power supply voltage for the calculated full scale. Verify that
the Direct bar graph display and the Current Value Box is reading 1 % of
full scale.
6. Adjust the power supply voltage for the calculated bottom scale. Verify
that the Direct bar graph display and the Current Value Box is reading 1
% of bottom scale.
correct. If the monitor still does not meet specifications or fails any other
part of this test, go to "If a Channel Fails a Verification Test" found in the
"Monitor Verification" section of the manual.
8. Disconnect the test equipment and reconnect the PWR, COM, and SIG
field wiring to the channel terminals on the I/O module. Verify that the OK
LED comes on and the OK relay energizes. Press the RESET switch on
the Rack Interface Module (RIM) to reset the OK LED.
- 14-9 -
14.4.2 Gap
the I/O module.
3. Adjust the power supply to produce a voltage equal to -18.00 Vdc on the Gap
bar graph display. Verify that the Gap bar graph display and the Current
Value Box is reading 1 % of -18.00 Vdc.
bar graph display. Verify that the Gap bar graph and Current Value Box is
reading 1 % of the mid-scale value.
14.5 Test OK Limits
computer.
the I/O module.
- 14-10 -
Note
If the Danger Bypass has been activated, then the
BYPASS LED will be on. All other channels in the rack
must be OK or bypassed for the OK relay to be energized.
OK LED comes back on, the OK relay energizes, and the Channel OK State
line in the Channel Status box reads OK.
16. Return the bypass switch for all configured channels to their original setting.
- 14-11 -
Thrust Position Default OK Limits Table
(volts)
Upper OK Limit
(volts)
3300 XL 8mm, 3300 XL 11mm
3300 5 mm & 3300 8 mm w/o
barriers
-1.23 to -1.33 -18.99 to -19.09
3300 XL 8mm, 3300 XL 11mm
3300 5 mm & 3300 8 mm w/
barriers
-1.05 to -1.15
-1.23 to -1.33 *
-18.15 to -18.25
7200 5 & 8 mm w/ barriers -1.05 to -1.15
-1.23 to -1.33 *
-18.15 to -18.25
7200 5 & 8 mm w/o barriers -1.23 to -1.33 -18.99 to -19.09
3000 (-18V) w/o barriers -1.11 to -1.21 -13.09 to -13.19
3000 (-24V) w/o barriers -2.2 to -2.3 -16.8 to -16.9
3300 RAM w/ barriers -1.0 to -1.1
-1.11 to -1.21 *
-12.3 to -12.4
3300 16mm HTPS w/o barriers -1.6 to -1.7 -18.0 to -18.1
* = BN Internal Barrier I/O Modules.
Differential Expansion Default OK Limits Table
(volts)
Upper OK Limit
(volts)
25 mm w/o barriers -1.30 to -1.40 -12.5 to -12.6
- 14-12 -
Blank Page
Section 15 - Eccentricity General Information
- 15-1 -
15. Eccentricity General Information
The Eccentricity channel type measures the amount of shaft bow. The shaft bow
may be due to: (1) fixed mechanical bow, (2) temporary thermal bow, or (3)
temporary bow due to any sort of sag or bow at rest, sometimes called gravity
bow.
In a 3500 Monitoring System, Eccentricity channels are programmed in pairs.
- 15-2 -
Blank Page
Section 16 - Eccentricity Configuration
- 16-1 -
16. Eccentricity Configuration
Table of Contents
16.1 Introduction.................................................................................................. 16-2
16.3.3 Enable .......................................................................................... 16-4
16.3.4 Delay ............................................................................................ 16-6
16.3.5 Instantaneous Crossover .............................................................. 16-7
16.3.6 Direct Channel Above 600 RPM................................................... 16-7
16.3.8 Alarm Mode .................................................................................. 16-9
16.3.9 Barriers....................................................................................... 16-10
16.3.10 OK Mode ................................................................................ 16-10
16.3.11 Timed OK Channel Defeat ...................................................... 16-10
16.4 Alarm Setpoints ......................................................................................... 16-10
- 16-2 -
16.1 Introduction
Configuration Software screens associated with the Eccentricity Channel.
Consider the following items before configuring an Eccentricity Channel:
Internal Barrier I/O Modules are not currently supported with 7200 11 mm or
14 mm, 3000 Proximitors, 3300 16 mm HTPS, or 3300 RAM.
the rack.
The full-scale options allowed for each proportional value is dependent upon
External barriers are not currently supported with 7200 11 mm, 14 mm, or
3300 16 mm HTPS.
Monitors must be configured in channel pairs (for example Channels 1 and 2
may be configured as Eccentricity and Channels 3 and 4 may be configured
as Thrust Position).
The Peak to Peak proportional value is disabled when "No Keyphasor" is
selected on the Four Channel Monitor screen.
compatible.
- 16-3 -
This section describes the options available on the Eccentricity Channel
Range and the transducer OK limits. To ensure maximum amount of zero
adjustment, gap the probe as close as possible to the center gap voltage
specified in the OK Limit table.
Adjust Button: Adjust the Zero Position voltage. When this button is clicked a
- 16-4 -
Rack Type: Identifies the type of Rack Interface Module installed (Standard or
TMR).
16.3.3 Enable
Peak to Peak: The difference between the positive and the negative extremes of
the rotor bow. The proportional value is only available when a Keyphasor
channel has been selected. This value may be displayed in mils or m.
Direct: The instantaneous eccentricity value. The direct value can be displayed
three ways:
At shaft rotative speeds greater than 600 rpm, the direct value is the average
distance between the probe tip and the shaft and is displayed in a way similar
to a thrust measurement. This direct measurement is displayed only when
Direct Channel Above 600 rpm is enabled.
At shaft rotative speeds between 600 rpm and the rpm setting for
Instantaneous Crossover, the direct measurement consists of two values: a
maximum and minimum value relative to a zero reference. These two direct
values are called Direct Max and Direct Min.
At shaft rotative speeds less than the rpm setting for Instantaneous
Crossover, Direct Max and Direct Min are equal and the direct measurement
consists of an instantaneous measurement relative to a zero reference. This
type of direct measurement is called instantaneous gap.
- 16-5 -
Peak to Peak Full Scale Ranges by transducer type
3300 - 5 and 8 mm Proximitor
3300 16 mm HTPS
Nonstandard
0-5 mil pp
0-10 mil pp
0-20 mil pp
0-30 mil pp
0-100 m pp
0-200 m pp
0-500 m pp
Custom
0-5 mil pp
0-10 mil pp
0-20 mil pp
0-30 mil pp
0-50 mil pp
0-100 m pp
0-200 m pp
0-500 m pp
0-1000 m pp
Custom
3300 16 mm HTPS
Nonstandard
5-0-5 mil
10-0-10 mil
20-0-20 mil
30-0-30 mil
100-0-100 m
200-0-200 m
500-0-500 m
Custom
5-0-5 mil
10-0-10 mil
20-0-20 mil
30-0-30 mil
50-0-50 mil
100-0-100 m
200-0-200 m
500-0-500 m
1000-0-1000 m
Custom
- 16-6 -
The Gap values are the same for all transducer types.
Gap
-24 Vdc
Custom
16.3.4 Delay
Setpoint screen.
the Danger time delay can be set at one second intervals (from 1 to 60).
the Danger time delay can be set for any two available proportional values.
the Danger time delay is set to 100 ms.
the Danger time delay can only be set for the primary proportional value.
- 16-7 -
16.3.5 Instantaneous Crossover
The value for shaft-rotative speed where the direct eccentricity measurement
changes from Direct Max/ Direct Min to instantaneous gap. The value for
Instantaneous Crossover must be between 1 and 10 rpm.
16.3.6 Direct Channel Above 600 RPM
Disabled: Display and alarming of the Direct proportional value will be disabled
when the shaft rotative speed exceeds 600 rpm.
Enabled: Display and alarming of the Direct proportional value will remain active
when shaft rotative speed exceeds 600 rpm.
Type: The following transducer types are available for the Eccentricity Channel
(non-barrier I/O module):
3300 16 mm HTPS
Nonstandard
The following transducer types are available for the Eccentricity Channel (barrier
I/O module):
Nonstandard
adjusted.
- 16-8 -
mV/mil.
Scale Factor
Transducer Without
Barriers
With
Bently
Nevada
Internal
Barriers
Standard
I/O with
Barriers
Discrete
TMR I/O
with
Barriers
Bussed
TMR I/O
with
Barriers
3300 XL 8 mm 200
mV/mil
200
mV/mil
192
mV/mil
200
mV/mil
199
mV/mil
3300 5 and 8 mm
7200 5 and 8 mm
3300 XL 11 mm 100
mV/mil
100
mV/mil
96
mV/mil
100
mV/mil
96 mV/mil
7200 11 mm 100
mV/mil
* * * *
7200 14 mm 100
mV/mil

3300 16 mm
HTPS
100
mV/mil
* * * *
Note : 15% scale factor adjustment allowed.
* Barriers are not supported with this transdcuer option.
- 16-9 -
Transducer Upper Lower Center
Gap
Voltage
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
3300 XL 8 mm -16.75 -16.75 -2.75 -2.75 -9.75 -9.75
3300 XL 11 mm
3300 8 mm
3300 5 mm
7200 5 mm
7200 8 mm
7200 11 mm -19.65 * -3.55 * -11.60 *
7200 14 mm -16.75 * -2.75 * -9.75 *
3300 16 mm
HTPS
-16.75 * -2.75 * -9.75 *
Barriers are not suppoted with this transducer option.
Note: With Barriers includes BN Internal Barrier I./O Modules
Setting the I/O Jumper in the manual for the monitor that contains this channel.
16.3.8 Alarm Mode
proportional value drops below the configured setpoint level. The channel will
remain in alarm until it is reset using one of the following methods:
- 16-10 -
16.3.9 Barriers
16.3.10 OK Mode
Nonlatching: If a channel is configured for Nonlatching OK, the OK status of that
channel will track the defined OK status of the transducer.
time. If the option is enabled, the time is set to 60 seconds. The option protects
against false trips caused by intermittent transducers.
for the channel.
- 16-11 -
Note
- 16-12 -
Setpoint
Number
Eccentricity
1 Over Peak to Peak
2 Over Gap
3 Under Gap
4 Over Direct Max
5 Under Direct Max
6 Over Direct Min
7 Under Direct Min
input, therefore, must fall below 6 mils 0.16 mils (5.84 mils) before the channel
is out of alarm.
Section 17 - Eccentricity Verification
- 17-1 -
17. Eccentricity Verification
Table of Contents
17.1 Introduction.................................................................................................. 17-2
17.3 Test Alarms.................................................................................................. 17-5
17.3.1 Peak to Peak ................................................................................ 17-5
17.3.2 Gap............................................................................................... 17-6
17.3.3 Direct ............................................................................................ 17-7
17.4.1 Peak to Peak ................................................................................ 17-8
17.4.2 Gap............................................................................................. 17-10
17.4.3 Direct .......................................................................................... 17-10
17.5 Test OK Limits ........................................................................................... 17-12
- 17-2 -
17.1 Introduction
limits for channels configured as Eccentricity. The output values and alarm
setpoints are verified by varying the input Eccentricity signal level (both peak to
peak amplitude and DC voltage bias) and observing that the correct results are
Eccentricity channels can be configured for the following channel values and
alarms:
Channel Values Alarms
Over Under
Peak to Peak X
Gap X X
Direct X X
needed for all the Eccentricity channel verification procedures (Test Alarms,
Verify Channels, and Test OK Limits).
WARNING!
High voltage present. Contact could cause
shock, burns, or death. Do not touch exposed
wires or terminals.
Application Alert
Tests will exceed alarm setpoint levels causing
alarms to activate. This could result in a relay
contact state change.
- 17-3 -
Application Alert
Disconnecting field wiring will cause a not OK
condition.
generator and multimeter to COM and SIG of channel 1 with polarity as shown
below. Set the test equipment as specified below:
Power Supply Function Generator
DC Volts: 0 Vdc
Frequency: 5 Hz
Amplitude level: Minimum (Above Zero)
- 17-4 -
Eccentricity Test Setup
Function Generator
I/O Module
Keyphasor Signal
40 k
Keyphasor I/O Module
100 F
- 17-5 -
Note
If the Timed OK Channel Defeat is enabled, the OK LED will not come on
immediately after you connect the test equipment. It will take 60 seconds for
a channel to return to the OK status from not OK. If OK mode is configured
for latching, press the RESET button on the Rack Interface Module (RIM) to
return to the OK status.
17.3 Test Alarms
The general approach for testing alarm setpoints is to simulate the eccentricity
signal with a function generator and power supply. The alarm levels are tested
by varying the output from the test equipment and observing that the correct
results are reported in the Verification screen on the test computer. It is only
necessary to test those alarm parameters that are configured and being used.
The general test procedure to verify current alarm operation will include
simulating a transducer input signal and varying this signal:
to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints.
to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints.
17.3.1 Peak to Peak
the I/O module.
3. Adjust the function generator amplitude such that the signal level does not
exceed any setpoint value for the pp mil bar graph.
OK LED is on, the bar graph indicator for pp is green, and the Current Value
field has no alarm indication.
pp Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm
time delay expires and verify that the bar graph indicator for pp changes color
from green to yellow and that the Current Value Field indicates an Alarm.
bar graph indicator for pp remains yellow and that the Current Value Field still
indicates an Alarm.
pp Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for pp
- 17-6 -
an Alarm.
bar graph indicator for pp remains red and the Current Value Field still
indicates an Alarm.
that the bar graph indicator for pp changes color to green and that the
17.3.2 Gap
the I/O module.
OK LED is on, the bar graph indicator for Gap is green, and the Current
Value still has no alarm indication.
Alarm.
indicates an Alarm.
- 17-7 -
17.3.3 Direct
Note
the I/O module.
3. Adjust the power supply to produce a reading that is within the Direct setpoint
levels on the Direct bar graph display of the Verification screen.
5. Adjust the power supply voltage such that the signal just exceeds the Direct
time delay expires and verify that the bar graph indicator for Direct changes
Alarm.
- 17-8 -
7. Adjust the power supply such that the signal just exceeds the Direct Over
delay expires and verify that the bar graph indicator for Direct changes color
the bar graph indicator for Direct changes color to green and that the Current
The general approach for testing these parameters is to simulate the eccentricity
signal with a function generator and power supply. The output levels are verified
results are reported in the Verification screen on the test computer.
17.4.1 Peak to Peak
Note
Most DMM's are not designed for measuring ac signals
at low frequencies. An oscilloscope is recommended
the I/O module.
- 17-9 -
3. Calculate the full-scale voltage according to the following equation and
examples.
Note
Verification Input Signal = Peak to Peak Meter Full-scale Transducer Scale
Factor
Example 1:
Peak to Peak Meter Top Scale = 10 mil
Full Scale = (10 0.200)
= 2.000 Vpp
For Vrms input:
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
Peak to Peak Meter Top Scale = 200 m
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For Vrms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
4. Adjust the function generator amplitude for the calculated full scale. Verify
that the pp bar graph display and the Current Value Box is reading 1 % of
full scale.
- 17-10 -
17.4.2 Gap
the I/O module.
bar graph display. Verify that the Gap bar graph display and the Current
Value Box is reading 1 % of -18.00 Vdc.
4. Adjust the power supply to produce a voltage equal to the mid-scale on the
Gap bar graph display. Verify that the Gap bar graph display and current
value box is reading 1 % of the mid-scale value.
17.4.3 Direct
Note
the I/O module.
3. Calculate the full-scale and bottom-scale values. These values can be
calculated in the following way:
Full / Bottom Scale Value = Zero Position Voltage (Transducer Scale
Factor Scale Range)
- 17-11 -
Note
The Zero Position Voltage is the voltage input that
will cause the reading on the bar graph display and
the Current Value Box to be zero. The Zero Position
Volts value is displayed in the Z.P. Volts box above
each channel value bar graph.
Note
Full Scale = (Zero Position Voltage) - (Transducer Scale Factor Top Meter
Scale)
Bottom Scale = (Zero Position Voltage) + (Transducer Scale Factor ABS
(Bottom Meter Scale))
Example 1:
Transducer scale factor = 200 mV/millmeter
scale range = 20-0-20 mil
Full-Scale Value = (-9.75) - (0.200 20)
= -13.75 Vdc
Bottom-Scale Value = (-9.75) + (0.200 20)
= -5.75 Vdc
Example 2:
= 7.874 mV/m
Meter scale range = 200-0-200 m
Full-Scale Value = (-9.75) - (0.007874 200)
= -11.3248 Vdc
Bottom-Scale Value = (-9.75) + (0.007874 200)
= -8.1752 Vdc
- 17-12 -
4. Adjust the power supply voltage to match the voltage displayed in the Z.P.
Volts Box. The Direct bar graph display and the Current Value Box should
read 0 mil (0 mm) 1 %.
5. Adjust the power supply voltage for full scale. Verify that the Max value in the
Current Value Box (the value on the left of the divider bar) is reading 1 % of
full scale.
6. Adjust the power supply voltage for bottom scale. Verify that the Min value in
the Current Value Box (the value on the right of the divider bar) is reading
1% of bottom scale.
8. Disconnect the power supply and multimeter and reconnect the PWR, COM,
and SIG field wiring to the channel terminals on the I/O module. Verify that
the OK LED comes on and the OK relay energizes. Press the RESET switch
on the Rack Interface Module (RIM) to reset the OK LED.
17.5 Test OK Limits
computer.
the I/O module.
Note
must be OK or bypassed for the relay to be energized.
- 17-13 -
OK LED comes back on and the OK relay energizes and that the Channel
wiring to the channel 1 terminals on the Monitor I/O Module. Press the
RESET switch on the Rack Interface Module (RIM) and verify that the OK
LED comes on and the OK relay energizes.
setting.
- 17-14 -
Eccentricity Default OK Limits Table
(volts)
Upper OK Limit
(volts)
3300 XL 8mm, 3300 XL 11mm,
3300 5mm & 3300 8 mm w/
barriers
-2.70 to -2.80 -16.70 to -16.80
3300 XL 8mm, 3300 XL 11mm,
3300 5mm & 3300 8 mm w/o
barriers
-2.70 to -2.80 -16.70 to -16.80
7200 5 & 8 mm w/ barriers -2.70 to -2.80 -16.70 to -16.80
7200 5 & 8 mm w/o barriers -2.70 to -2.80 -16.70 to -16.80
3300 16 mm HTPS w/o barriers -2.70 to -2.80 -16.70 to -16.80
Section 18 - REBAM General Information
- 18-1 -
18. REBAM General Information
REBAM stands for rolling element bearing activity monitor. Major features of this
channel type are:
Monitor of the bearing's condition through the use of high pass filter to
implement a "spike" region.
Monitor the loading of the bearing through the use of a band pass filter
centered about the element pass frequency.
Monitor rotor related issues such as balance and alignment through the use
of a lowpass filter setting related to nominal machine speed and by providing
1X amplitude and phase information.
Monitor variable-speed machines by adjusting the filter settings based on the
current machine speed.
In a 3500 Monitoring System, REBAM channels are programmed in pairs. These
channels, depending on configuration, typically condition the input signals into
various parameters called proportional values. These values, along with a
Keyphasor signal provide phase measurements.
The channels also provide setpoints that can be used for alarming. Alert
setpoints can be configured for each active proportional value and Danger
setpoints can be configured for any two of the active proportional values.
- 18-2 -
Blank Page
Section 19 - REBAM Configuration
- 19-1 -
19. REBAM Configuration
Table of Contents
19.1 Introduction.................................................................................................. 19-2
19.3 General Options........................................................................................... 19-3
19.4 Channel Configuration Tab .......................................................................... 19-4
19.4.1 Trip Multiply .................................................................................. 19-4
19.4.2 Transducer Jumper Status (on I/O Module) .................................. 19-4
19.4.3 Enable .......................................................................................... 19-5
19.4.4 Delay ............................................................................................ 19-6
19.4.6 Alarm Mode .................................................................................. 19-9
19.4.7 Transducer Orientation ............................................................... 19-10
19.4.8 Barriers....................................................................................... 19-10
19.5 Bearing Configuration Tab ......................................................................... 19-11
19.5.1 Shaft Speed................................................................................ 19-12
19.5.2 Number of Elements ................................................................... 19-12
19.5.3 Bearing Diameter (D) .................................................................. 19-12
19.5.4 Rolling Element Diameter (d) ...................................................... 19-12
19.5.5 Contact Angle (a) ........................................................................ 19-12
19.5.6 Estimation Factor ........................................................................ 19-12
19.6 Filter Configuration Tab.............................................................................. 19-13
19.6.1 Filter Units................................................................................... 19-13
19.6.2 Bearing Frequencies................................................................... 19-13
19.6.3 Filters.......................................................................................... 19-14
19.6.4 Stepping/Tracking Enabled......................................................... 19-14
19.7 Filter Summary Tab ................................................................................... 19-15
19.8 Alarm Setpoints ......................................................................................... 19-15
- 19-2 -
19.1 Introduction
Configuration Software screens associated with the REBAM Channel.
Consider the following items before configuring a REBAM Channel:
When "No Keyphasor" is selected, the 1X Amplitude (Ampl) and Phase Lag
values cannot be enabled.
When "No Keyphasor" is selected, the filter Stepping/Tracking feature cannot
be enabled.
the rack.
The 1X Phase value can be enabled only if the selected Keyphasor channel
is configured for an events per revolution equal to 1 will.
Setpoints may only be set on proportional values that are enabled.
may be configured as REBAM and Channels 3 and 4 may be configured as
Thrust Position).
Some configurations, typically for the higher speed machines, will allow only
one channel of a channel pair to be enabled. Refer to "Signal Conditioning" in
the "Specifications" section of the manual.
TMR configurations are not supported by the REBAM channel type.
- 19-3 -
19.3 General Options
This section describes the general options available on the REBAM Channel
Type configuration screens.
(Standard or TMR).
Help Assistant: Select this button to turn on the context-sensitive help system.
Select the button again to turn the help system off.
Units: Allows the user to view and configure the channel parameters using either
English or Metric units of measure.
- 19-4 -
details.
19.4 Channel Configuration Tab
This section describes the options available on the Channel Configuration tab.
19.4.1 Trip Multiply
The value selected to temporarily increase the alarm (Alert and Danger) setpoint
values. This value is normally applied by manual (operator) action during startup
to allow a machine to pass through high vibration speed ranges without monitor
alarm indications. Such high vibration speed ranges may include system
resonances and other normal transient vibrations.
19.4.2 Transducer Jumper Status (on I/O Module)
Returns the position of the Transducer Jumper on the I/O Module. Refer to
Setting the I/O Jumper in the "I/O Module Descriptions" section of the manual, if
applicable.
- 19-5 -
19.4.3 Enable
Spike: A high-pass filtered value that contains the high frequency content of the
input signal. This is generally associated with the condition of the bearing.
Element: A band-passed filtered value that contains the signal content of the
Element Pass Frequency (Outer Race). It is generally associated to the loading
of the bearing.
Rotor: A low-pass filtered value that is generally used to monitor rotor related
issues such as misalignment and unbalance.
Direct: Wide-band data that represents the overall peak to peak vibration.
that occurs at the rotor rotative speed frequency.
component that occurs at the rotor rotative speed frequency.
Full Scale Range: All proportional values except Gap provide the ability to set a
full scale value. If the desired full scale value is not in the pull down list, then the
custom selection can be chosen. The full scale range for Gap is always 0 - (-24)
Vdc The values in the following table are the same for all transducer types.
- 19-6 -
Proportional Value Full Scale
Range
(uin pp)
(um pp)
Spike Element Rotor Direct 1X Ampl
0-50
0-1
X X
0-100
0-2
X X X X X
0-200
0-5
X X X X X
0-500
0-10
X X X X X
0-1000
0-20
X X X X X
0-2000
0-50
X X X X
0-3000
0-75
X X X X
1X Phase Lag cannot be selected as a recorder output.
19.4.4 Delay
The time delay is adjustable in one-second increments. The minimum number
allowed is based on the current configuration of the REBAM channel.
- 19-7 -
Setpoint screen. The time delay is adjustable in 0.5 second increments. The
minimum number allowed is based on the current configuration of the REBAM
channel.
??? ms option: The ??? ms option applies to the Danger time delay only. The
value of ??? is based on the current configuration of the REBAM channel and
has the following results:
If the ??? ms option is off ():
The Danger time delay can be set at 0.5 second intervals (up to 400).
Danger setpoints can be set for up to two proportional values.
If the ??? ms option is on ():
The Danger time delay is set to the time displayed.
Danger setpoints can only be set for one proportional value.
Type: The following transducer types are available for the REBAM Channel:
3300 MicroProx 40 mV/um
Nonstandard
adjusted.
mV/mil.
- 19-8 -
Scale Factor
Transducer Without
Barriers
(mV/mil)
With Bently Nevada
Internal Barriers
(mV/mil)
Standard I/O With
External Barriers
(mV/mil)
3300 MicroProx
40 mV/um
1000 1000 960
3300 MicroProx
80 mV/um
2000 2000 1919
7200 MicroProx
80 mV/um
2000 2000 1919
- 19-9 -
Upper Lower
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
3300
MicroProx 40
mV/um
-17.00 -17.00 -1.00 -1.00
3300
MicroProx 80
mV/um
-17.00 -17.00 -1.00 -1.00
7200
MicroProx 80
mV/um
-19.00 -19.00 -3.00 -3.00
Note: OK limits With Barriers includes the Bently Nevada Internal
Barrier I/O Modules
19.4.6 Alarm Mode
- 19-10 -
(1) Shaft
(2) Driver end
(3) Driven end
(4) 0
(5) 90 right
(6) 180
(7) 90 left
19.4.8 Barriers
Select the MTL 796(-) Zener External option if external safety barriers are
connected between the monitor and the transducer. If using an Internal Barrier
I/O Module, select the internal option. These devices are used to restrict the
amount of energy that can flow into a hazardous area.
- 19-11 -
19.5 Bearing Configuration Tab
This section describes the options available on the Channel Configuration tab.
The following table summarizes the required entries for each of the three
methods of entering the bearing configuration. If all the required information is
provided for either Accurate or Estimated, the software will calculate various
bearing frequencies and select appropriate filter settings.
Parameters
Method Shaft
Speed
Number
of
Elements
Bearing
Diamter
Element
Diameter
Contact
Angle
Estimation
Factor
Accurate X X X X X
Estimated X X X
Unknown X
- 19-12 -
19.5.1 Shaft Speed
Enter the nominal speed (in rpm) of the shaft that the bearing is applied to. The
nominal shaft speed applies to the normal operating speed of the shaft.
19.5.2 Number of Elements
If known, enable this field by checking the box on the left, then enter the number
of rolling elements contained in the bearing.
19.5.3 Bearing Diameter (D)
If known, enable this field by checking the box on the left, then enter the pitch
diameter of the bearing. Refer to the diagram for the definition of "pitch
diameter".
19.5.4 Rolling Element Diameter (d)
If known, enable this field by checking the box on the left, then enter the diameter
of the rolling element in the bearing.
19.5.5 Contact Angle (a)
If known, enable this field by checking the box on the left, then enter the contact
angle of the bearing. Refer to the diagram for the definition of "contact angle".
19.5.6 Estimation Factor
Use this field only if either of the diameters or contact angle are not accurately
known. Shaft Speed and Number of Elements must be known and entered in
their appropriate fields. The definition of Estimation Factor is (d/D) cos(a).
Note
If Estimation Factor is enabled, the software will ignore entries for
Bearing Diameter, Rolling Element Diameter and Contact Angle.
- 19-13 -
19.6 Filter Configuration Tab
This section describes the options available on the Filter Configuration tab.
19.6.1 Filter Units
The user can view the bearing frequencies and filter settings in either cycles per
minute (cpm) or Hertz (Hz)
19.6.2 Bearing Frequencies
If the appropriate fields were enabled on the Bearing Configuration tab, the
software will calculate the following frequencies generated by the bearing while
the shaft is running at its nominal operating speed:
Fundamental Train Frequency: Also known as the cage frequency, this is the
frequency at which the bearing cage and the rolling elements as a set make
one revolution.
Element Spin Frequency: The frequency at which a rolling element spins one
revolution about its own spin axis.
Element Pass Frequency, Outer Race (BPFO): The frequency at which a
specific point on the bearing's outer race is passed by the rolling elements.
- 19-14 -
Element Pass Frequency, Inner Race (BPFI): The frequency at which a
specific point on the bearing's inner race is passed by the rolling elements.
19.6.3 Filters
This section displays the current filter selections for the rotor, element pass and
spike regions. These values can be adjusted by changing the nominal values for
each filter region. The "Orders Of" section displays the orders of magnitude
relationship between a region's primary signal of interest and its "Nominal" filter
corner frequency.
Rotor Region Low Pass: The lowpass filter that will be applied to the input
signal for calculating the Rotor proportional value.
Element High Pass Corner and Element Low Pass Corner: The bandpass
filter that will be applied to the input signal for calculating the Element
proportional value.
Spike High Pass: The highpass filter that will be applied to the input signal for
calculating the Spike proportional value.
19.6.4 Stepping/Tracking Enabled
If this box is checked, the filter regions will switch between the Nominal and the
+/- 10% filters as the shaft speed changes by the appropriate amount. A rotor
speed signal is required for this feature.
- 19-15 -
19.7 Filter Summary Tab
This section describes the information available on the Filter Summary tab.
This screen summarizes the filters that will be implemented by the current
configuration. This information will be very useful when verifying the operation of
the monitor. In order to change the information displayed on this screen, the
information on the previous screens will have to be manipulated.
This section lists the available setpoints for the REBAM channel. A setpoint is
the level within the full-scale range that determines when an alarm occurs. The
3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for every
for the channel.
- 19-16 -
Note
- 19-17 -
for each REBAM channel pair. The setpoint number is used in the
Setpoint
Number
Radial Vibration
1 Over Spike
2 Over Element
3 Under Element
4 Over Rotor
5 Over Direct
6 Over Gap
7 Under Gap
8 Over 1X Ampl
9 Under 1X Ampl
of alarm.
- 19-18 -
Blank Page
Section 20 - REBAM Verification
- 20-1 -
20. REBAM Verification
Table of Contents
20.1 Introduction.................................................................................................. 20-2
20.3 Test Alarms.................................................................................................. 20-4
20.3.1 Spike............................................................................................. 20-5
20.3.2 Element ........................................................................................ 20-6
20.3.3 Rotor............................................................................................. 20-7
20.3.4 Direct ............................................................................................ 20-8
20.3.5 Gap............................................................................................... 20-8
20.3.6 1X Amplitude (1X Ampl).............................................................. 20-10
20.3.7 1X Phase.................................................................................... 20-11
20.4 Verify Channel Values ............................................................................... 20-12
20.4.1 Spike........................................................................................... 20-12
20.4.2 Element ...................................................................................... 20-14
20.4.3 Rotor........................................................................................... 20-15
20.4.4 Direct .......................................................................................... 20-16
20.4.5 Gap............................................................................................. 20-17
20.4.7 1X Phase.................................................................................... 20-19
20.5 Test OK Limits ........................................................................................... 20-21
- 20-2 -
20.1 Introduction
limits for channels configured as REBAM. The output values and alarm setpoints
are verified by varying the input vibration signal level (both peak to peak
amplitude and DC voltage bias) and observing that the correct results are
needed for all the REBAM channel verification procedures (Test Alarms, Verify
Channels, and Test OK Limits).
WARNING!
Application Alert
Application Alert
condition.
in the figure below. Set the test equipment as follows:
- 20-3 -
Power
Supply
Multiplier/Divider
DC Volts: 0 Vdc
Frequency: 100 Hz
(above zero)
Divide Switch: 001
The equipment shown in the dashed box is required for 1X Amplitude and
Phase.
Test equipment for REBAM
- 20-4 -
(3) 40 k
(4) 100 F
(9) Mulitmeter
(10) Power supply
Note
Timed OK Channel Defeat is enabled for REBAM
channels. If a channel goes not OK, the length of time it
will be defeated ranges from 15 to 270 seconds before
returning to the OK status. The time is dependent upon
the configured Shaft Speed and Rotor Region Lowpass
Filter. Lower values result in longer times.
20.3 Test Alarms
- 20-5 -
20.3.1 Spike
the I/O module.
divide setting is one. Adjust the function generator frequency to
approximately two times the Spike highpass corner frequency. Adjust the
function generator amplitude to produce a reading that is below the Spike
setpoint levels on the Spike bar graph display of the Verification screen.
OK LED is on, the bar graph indicator for Spike is green, and the Current
Spike Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Spike
an Alarm.
bar graph indicator for Spike remains yellow and that the Current Value Field
Spike Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Spike
an Alarm.
bar graph indicator for Spike remains red and that the Current Value Field still
indicates an Alarm.
that the bar graph indicator for Spike changes color to green and that the
10. If you cannot verify any configured alarm, recheck the configured setpoints.
- 20-6 -
20.3.2 Element
the I/O module.
approximately the mid point between the highpass and lowpass corners of
the bandpass filter. Adjust the function generator amplitude to produce a
reading that is between the Element over and under setpoint levels on the
Element bar graph display of the Verification screen.
OK LED is on, the bar graph indicator for Element is green, and the Current
Element Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Element
an Alarm.
bar graph indicator for Element remains yellow and that the Current Value
Element Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after
the alarm time delay expires and verify that the bar graph indicator for
Element changes color from yellow to red and that the Current Value Field
indicates an Alarm.
bar graph indicator for Element remains red and that the Current Value Field
that the bar graph indicator for Element changes color to green and that the
10. If applicable, perform similar tasks to test the under setpoints.
- 20-7 -
20.3.3 Rotor
the I/O module.
approximately one half the corner frequency of the Rotor Lowpass Filter.
Adjust the function generator amplitude to produce a reading that is below
the Rotor setpoint levels on the Rotor bar graph display of the Verification
screen.
OK LED is on, the bar graph indicator for Rotor is green, and the Current
Rotor Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Rotor
an Alarm.
bar graph indicator for Rotor remains yellow and that the Current Value Field
Rotor Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Rotor
an Alarm.
that the bar graph indicator for Rotor changes color to green and that the
- 20-8 -
20.3.4 Direct
the I/O module.
an Alarm.
an Alarm.
20.3.5 Gap
the I/O module.
- 20-9 -
Alarm.
indicates an Alarm.
- 20-10 -
Note
the I/O module.
Alarm.
an Alarm.
- 20-11 -
20.3.7 1X Phase
the I/O module.
Note
If you cannot change the phase output, change the phase alarm
reading.
- 20-12 -
setpoint levels.
Note
20.4.1 Spike
the I/O module.
3. Adjust the function generator frequency to approximately twice the corner
frequency of the Spike Highpass Filter.
- 20-13 -
calculated voltage.
Application Alert
Full Scale Voltage = Spike Meter Top Scale Transducer Scale Factor
Example 1:
Spike Meter Top Scale = 500 uin pp
Full Scale = (0.500 1.0)
= 0.500 Vpp
For Vrms input:
= (0.707/2) (0.5)
= 0.1768 Vrms
Example 2:
Spike Meter Top Scale = 10 m pp
Transducer Scale Factor = 80 mV/um
Full Scale = (10 0.080)
= 0.800 Vpp
For Vrms input:
= (0.707/2) (0.800)
= 0.2828 Vrms
divide setting is one. Verify that the Spike bar graph display and Current
- 20-14 -
20.4.2 Element
the I/O module.
3. Adjust the function generator frequency to center frequency of the Element
bandpass filter. This is calculated as the square root of the product of the
highpass corner frequency times the lowpass corner frequency.
calculated voltage.
Application Alert
Full Scale Voltage = Element Meter Top Scale Transducer Scale Factor
Example 1:
Element Meter Top Scale = 500 uin pp
Full Scale = (0.500 1.0)
= 0.500 Vpp
For Vrms input:
= (0.707/2) (0.5)
= 0.1768 Vrms
Example 2:
Element Meter Top Scale = 10 m pp
Full Scale = (10 0.080)
= 0.800 Vpp
For Vrms input:
= (0.707/2) (0.800)
= 0.2828 Vrms
- 20-15 -
divide setting is one. Verify that the Element bar graph display and Current
20.4.3 Rotor
the I/O module.
3. Adjust the function generator frequency to approximately one half the corner
frequency of the Rotor lowpass filter.
calculated voltage.
Application Alert
Full Scale Voltage = Rotor Meter Top Scale Transducer Scale Factor
Example 1:
Rotor Meter Top Scale = 500 uin pp
Full Scale = (0.500 1.0)
= 0.500 Vpp
For Vrms input:
= (0.707/2) (0.5)
= 0.1768 Vrms
- 20-16 -
Example 2:
Rotor Meter Top Scale = 10 m pp
Full Scale = (10 0.080)
= 0.800 Vpp
For Vrms input:
= (0.707/2) (0.800)
= 0.2828 Vrms
divide setting is one. Verify that the Rotor bar graph display and Current
20.4.4 Direct
the I/O module.
calculated voltage.
Application Alert
Example 1:
Direct Meter Top Scale = 500 uin pp
- 20-17 -
Full Scale = (0.500 1.0)
= 0.500 Vpp
For Vrms input:
= (0.707/2) (0.5)
= 0.1768 Vrms
Example 2:
Direct Meter Top Scale = 10 m pp
Full Scale = (10 0.080)
= 0.800 Vpp
For Vrms input:
= (0.707/2) (0.800)
= 0.2828 Vrms
20.4.5 Gap
the I/O module.
Box is reading 1 % of -18.00 Vdc.
Box is reading 1 % of the mid-scale value.
- 20-18 -
Note
the I/O module.
voltage.
Note
Example 1:
1X Ampl Meter Top Scale = 500 uin pp
Full Scale = (0.500 1.0)
= 0.500 Vpp
For Vrms input:
= (0.707/2) (0.5)
= 0.1768 Vrms
- 20-19 -
Example 2:
1X Ampl Meter Top Scale = 10 m pp
Full Scale = (10 0.080)
= 0.800 Vpp
For Vrms input:
= (0.707/2) (0.800)
= 0.2828 Vrms
20.4.7 1X Phase
the Phase Output (1X Phase)" on page 20-20.
the I/O module.

Keyphasor
measured above.
- 20-20 -
Example:
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
the I/O module.
- 20-21 -
20.5 Test OK Limits
computer.
the I/O module.
Note
If the Danger Bypass has been activated, then the BYPASS LED
will be on. All other channels in the rack must be OK or bypassed
for the relay to be energized.
- 20-22 -
13. If you cannot verify any configured OK limit, go to "If a Channel Fails a
setting.
REBAM Default OK Limits Table
(volts)
Upper OK Limit
(volts)
3300 MicroProx, 40 mV/um -0.95 to -1.05 -16.95 to 17.05
3300 MicroProx, 80 mV/um -0.95 to -1.05 -16.95 to 17.05
7200 MicroProx, 80 mV/um -2.95 to -3.05 -18.95 to -19.05
Limits are the same if Barriers are used.
Section 21 - Velocity General Information
- 21-1 -
21. Velocity General Information
The velocity measurements from 3500 Velocity channels let you evaluate
machine housing and other structural response characteristics. These channels
can use signals from most seismic or inertial transducers.
The velocity channel type returns a direct measurement of the velocity of the
vibration. Additionally if the monitor is an M series monitor (3500/42M) it is
capable of returning: 1X amplitude, 1X phase, 2X amplitude, and 2X phase.
Although velocity measurements are useful for specific applications, these
measurements have the following limitations:
Electronic integration of a velocity signal yields displacement, but not
position.
Since a casing transducer normally is not able to measure steady state (dc)
position and low frequency motion, the transducer cannot measure the slow
roll bow of a rotor system.
Application Advisory
If housing measurements are being made for overall protection of
the machine, thought should be given to the usefulness of the
measurement for each application. Most common machine
malfunctions (imbalance, misalignment, etc.) originate at the rotor
and cause an increase (or at least a change) in rotor vibration. In
order for any housing measurement alone to be effective for overall
machine protection, a significant amount of rotor vibration must be
faithfully transmitted to the bearing housing or machine casing, or
more specifically, to the mounting location of the transducer.
In addition, care should be exercised in the physical installation of
the transducer. Improper installation can result in a decrease of the
transducer amplitude and frequency response and/or the generation
of signals which do not represent actual machine vibration.
Upon request, Bently Nevada can provide engineering services to
determine the appropriateness of housing measurements for the
machine in question and/or to provide installation assistance.
In a 3500 Monitoring System, Velocity channels are programmed in pairs. These
channels, depending on configuration, typically condition the input signals into
various parameters called proportional values. Alert setpoints can be
There are two different channel types that support the measurement of velocity.
These are Velocity and Velocity II. The Velocity channel type only supports the
direct measurement and works with the 3500/42 and 3500/42M. The Velocity II
- 21-2 -
channel type is an enhanced version of the Velocity channel type. It supports
Direct, 1X Amplitude 1X Phase, 2X Amplitude, and 2X Phase. The Velocity II
channel type is only available on the 3500/42M monitors with revision 2.1
firmware or greater, and requires version 3.2 of the 3500 Configuration software.
Application Alert
When upgrading from using a Velocity to a Velocity II channel type care must
be taken regarding any DCS or PLC programming that utilizes data from the
Communications Gateway. The order and the number of values for the PPL
data and the alarm status data has changed for the Velocity II. This may require
changes to the DCS or PLC programming. If this is undesirable then use the
Velocity channel type.
Section 22 - Velocity Configuration
- 22-1 -
22. Velocity Configuration
Table of Contents
22.1 Introduction.................................................................................................. 22-2
22.3.3 Enable .......................................................................................... 22-4
22.3.4 Corner Frequencies ...................................................................... 22-5
22.3.5 Delay ............................................................................................ 22-5
22.3.7 Alarm Mode .................................................................................. 22-9
22.3.8 Barriers......................................................................................... 22-9
22.3.9 OK Mode .................................................................................... 22-10
22.4 Alarm Setpoints ......................................................................................... 22-10
- 22-2 -
22.1 Introduction
Configuration Software screens associated with the Velocity Channel.
Consider the following items before configuring a Velocity Channel:
The Velocity Direct full-scale range is dependent upon the transducer type.
Seismoprobes are not supported with Prox/Velom I/O modules.
The Velocity Direct full-scale range is dependent upon the transducer type.
When a full-scale range is modified, readjust the setpoints associated with
this proportional value.
may be configured as Velocity and Channels 3 and 4 may be configured as
Thrust Position).
When integration is selected, the available Direct Full-scale Ranges will
change to reflect this.
When band-pass filtering is selected, the high-pass and low-pass filters must
be set a minimum of a decade apart.
The 100ms danger alarm is only available for the Velomitor and High
Temperature Velomitor options.
When a single or dual channel of velocity is activated, the maximum channel
frequency supported is as shown in << Section reference to Signal
Conditioning in the specifications section >>.
compatible.
If the monitor is configured to alarm on high velocity conditions on a
reciprocating machine, it is recommended that you disable the Timed
OK/Channel Defeat option.
- 22-3 -
This section describes the options available on the Velocity Channel
Channel Frequency Support: Supported frequency range of the selected
transducer which depends upon the number of channels selected. See
"Configuration Considerations" on page 22-2.
- 22-4 -
(Standard or TMR).
22.3.3 Enable
Direct: The time rate of change of the displacement. When Integration is
selected it yields a peak to peak measurement of the displacement.
The Direct values are available for all transducer types.
Direct
0-0.5 in/s pk
0-1 in/s pk
0-2 in/s pk
0 - 0.5 in/s rms
0-1 in/s rms
0-2 in/s rms
0-10 mm/s pk
0-20 mm/s pk
0-50 mm/s pk
0-10 mm/s rms
0-20 mm/s rms
0-50 mm/s rms
Custom
Integrate: When Integrate is enabled, the Direct Full-scale Range selections
change to the following:
- 22-5 -
The Direct values (Integrated) are available for all transducer types.
Full-scale Range Direct
0-5 mil pp
0-10 mil pp
0-20 mil pp
0-100 m pp
0-200 m pp
0-500 m pp
Custom
proportional value is bypassed or defeated (for example a problem with the
monitor). The selected value can be between the minimum and maximum full-
scale range values. Only the values available from the Recorder Outputs,
22.3.4 Corner Frequencies
High-pass Filter: A four-pole filter that must be at least a factor of 5.7 times
away from the Low-pass Filter.
HPF = High-pass Filter; LPF = Low-pass Filter
HPF ( LPF / 5.7 )
Low-pass Filter: A four-pole filter that must be at least a factor of 5.7 times
away from the High-pass Filter.
LPF ( HPF * 5.7 )
22.3.5 Delay
The time which a proportional value must remain at or above an alarm level or
outside an acceptance region before an alarm is declared as active.
selected value. The Alert time delay is always set at one second intervals for all
- 22-6 -
exceeds the selected value.
The Danger time delay can be set at one second intervals.
Type: The following transducer types are available for the Velocity Channel
9200 2-wire Seismoprobe (Prox/Seis I/O only)
Nonstandard 2-wire Seismoprobe (Prox/Seis I/O only)
Velomitor
High Temperature Velomitor (Prox/Velom I/O only)
Nonstandard
The following transducer types are available for the Velocity Channel (barrier I/O
module):
Velomitor
High Temperature Velomitor
Nonstandard
adjusted.
mV/in/s.
- 22-7 -
Transducer Without Barriers With BN Internal
Barriers
With Barriers
9200 500 mV/(in/s) * 500 mV/(in/s)
47633 490 mV/(in/s) * 490 mV/(in/s)
86205 477 mV/(in/s) * 477 mV/(in/s)
Nonstandard 2 wire 145 mV/(in/s) * 145 mV/(in/s)
Velomitor 100 mV/(in/s) 100 mV/(in/s) 100 mV/(in/s)
High Temperature
Velomitor
145 mV/(in/s) 145 mV/(in/s) 145 mV/(in/s)
- 22-8 -
Upper Lower Center Gap
Voltage
Transducer
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
9200 -17.95 -17.95 -2.05 -2.05 -10.00 -10.00
47633 -17.95 -17.95 -2.05 -2.05 -10.00 -10.00
86205 -17.95 -17.95 -2.05 -2.05 -10.00 -10.00
NonStandard -17.95 -17.95 -2.05 -2.05 -10.00 -10.00
Velomitor -19.85 -17.95
-19.85
-4.15 -2.05
-4.15
-12.00 -10.00
-12.00
High
Temperature
Velomitor
-21.26 -21.26 -2.74 -2.74 -12.00 -12.00
BN Internal Barrier I/O Modules.

Transducer Jumper on the Proximitor/Seismic I/O Module. For the function of
this jumper, refer to I/O Module Descriptions.
Take Input From Channel A (1 or 3) Transducer: The Channel B (2 or 4)
Velocity channel options screen has an extra control that appears just above the
transducer type list box (see figure below). It is the Take Input from Channel A
Transducer checkbox. When checked (), the channel pair uses Dual Path
Input. That is, input from the first channel (1 or 3) is used for both channels in
the pair. The transducer input, barrier, OK Mode, and Timed OK Channel Defeat
input from channel A will be copied to the second channel (2 or 4) in the channel
pair.
- 22-9 -
Velocity Channel Options Screen for Channel B
22.3.7 Alarm Mode
Alert is the first level alarm that occurs when the transducer signal level exceeds
the selected value. Danger is the second level alarm that occurs when the
value is no longer in alarm. The alarm state will continue until the channel is
reset using one of the following methods:
proportional value is no longer in alarm.
22.3.8 Barriers
For Seismoprobes, select the MTL 764(-) Zener External option if external safety
barriers are connected between the monitor and the transducer. For Velomitor,
- 22-10 -
select the MTL 787(-) Zener External option if external safety barriers are being
used. If using an Internal Barrier I/O Module for Velomitor, select the internal
option. These devices are used to restrict the amount of energy that can flow
into a hazardous area.
22.3.9 OK Mode
not OK, the status stays not OK until a reset is issued using one of the following
methods:
time. If the option is enabled, the time is set to 30 seconds. This option prevents
false trips caused by intermittent transducers.
for the channel.
Note
- 22-11 -
for the Velocity channel type. The setpoint number is used in the
Setpoint
Number
Velocity
1 Over Direct
2 Danger (Over Direct)
3
4
5
6
7
8
9
10
11
- 22-12 -
is out of alarm.
Section 23 - Velocity II Configuration
- 23-1 -
23. Velocity II Configuration
Table of Contents
23.1 Introduction.................................................................................................. 23-2
23.3.3 Enable .......................................................................................... 23-4
23.3.4 Full Scale Ranges......................................................................... 23-5
23.3.6 Delay ............................................................................................ 23-7
23.3.7 Trip Multiply .................................................................................. 23-8
23.3.9 Alarm Mode ................................................................................ 23-10
23.3.10 Barriers................................................................................... 23-11
23.3.11 OK Mode ................................................................................ 23-11
23.4 Alarm Setpoints ......................................................................................... 23-12
23.5 Proportional Value Numbers ...................................................................... 23-14
- 23-2 -
23.1 Introduction
Configuration Software screens associated with the Velocity II Channel Type.
Consider the following items before configuring a Velocity II Channel Type:
2X Amplitude (Ampl) and Phase Lag cannot be selected.
the rack.
Seismoprobes are not supported with Prox/Velom I/O modules.
The Prox/Seismic I/O modules do not support the High Temperature
Velomitor.
may be configured as Velocity and Channels 3 and 4 may be configured as
Thrust Position). Additionally, the same family of transducers must be
selected for both channels in a channel pair; both channels must be either
Velomitors or seismic transducers and not one of each.
When Dual Path operation is selected, transducer 1 is used for channels 1 &
2 and transducer 3 is used for channels 3 & 4.
When using Dual Path both channels must be configured for the same
transducer type.
When integration is selected, the available Full-Scale ranges will change to
integrated units.
When RMS is selected, the available Full-Scale ranges will change to RMS
units.
When a full-scale is modified, readjust the setpoints associated with the
proportional value.
be a minimum of a 5.7 times apart.
The 100ms danger alarm is only available for the Velomitor, High
Temperature Velomitor and Velomitor CT options.
compatible.
volt from the upper and lower OK limits that are selected.
- 23-3 -
The maximum frequency support varies based on transducer type and
measurement units. For all transducers but Velomitor CT the maximum is 3
to 5500 Hz. For Velomitor CT the range is 2 to 5500 HZ. If RMS is selected
the maximum frequency support changes to 10 to 5500 Hz.
This section describes the options available on the Velocity II Channel Type
transducer which depends upon whether RMS is selected. See "Configuration
Considerations" on page 23-2.
- 23-4 -
(Standard or TMR).
23.3.3 Enable
Direct: Direct is data that represents the overall peak measurement of the rate of
change of the displacement. When Integration is selected it yields a peak-to-
peak measurement of the displacement. The signal will be changed if filtering is
selected (High-pass, Low-pass or High-pass and Low-pass selected).
Bias Voltage: The DC voltage used by the system as a bias for the transducer.
Can be used as a diagnostic tool for evaluating system integrity. Bias voltage is
not available when configured for a Velomitor and any I/O other than the
Prox/Seismic I/Os.
This measurement contains no information about the
condition of the machinery being monitored. It has been
provided only for monitoring system diagnostics.
1X Ampl: In a complex vibration signal, 1X ampl is the notation for the amplitude
1X Phase Lag: In a complex vibration signal, 1X Phase Lag is the notation for
the phase lag component that occurs at the rotative speed frequency.
component having a frequency equal to two times the shaft rotative speed.
the phase lag component having a frequency equal to two times the shaft
rotative speed. 2X phase lag is the angular measurement from the leading or
trailing edge of the Keyphasor pulse to the following positive peak of the 2X
vibration signal.
Note
Bias Voltage, 1X Amplitude & Phase, 2X Amplitude &
Phase are only available if the monitor is a 3500/42M.
- 23-5 -
23.3.4 Full Scale Ranges
The full scale ranges are available for all transducer types.
Peak
0-0.5 in/s pk
0-1 in/s pk
0-2 in/s pk
0-10 mm/s pk
0-20 mm/s pk
0-50 mm/s pk
Custom
Integrate: When integration is selected, all of the proportional values for the
channel will be integrated. The following full-scale ranges are available:
Integrated
0-5 mil pp
0-10 mil pp
0-20 mil pp
0-100 m pp
0-200 m pp
0-500 m pp
Custom
- 23-6 -
RMS: When RMS is selected, all of the proportional values for the channel will
be measured as RMS. The following full-scale ranges are available:
RMS
0 0.5 in/s rms
0-1 in/s rms
0-2 in/s rms
0-10 mm/s rms
0-20 mm/s rms
0-50 mm/s rms
Custom
Note
When a full-scale range is modified, readjust the
setpoints associated with this proportional value.
- 23-7 -
The direct value is filtered and the corner of the filter can be adjusted. If no
filtering is selected the monitor will impose filtering at its frequency response
limits. The filter options do not effect the Bias Voltage, 1X or 2X measurements.
High-pass Filter: A four-pole filter that must be at least a factor of 5.7 times
HPF ( LPF / 5.7 )
LPF ( HPF * 5.7 )
23.3.6 Delay
Note
The 100ms danger alarm is only available for the Velomitor,
High Temperature Velomitor and Velomitor CT options.
- 23-8 -
23.3.7 Trip Multiply
The value selected to temporarily increase the alarm (Alert and Danger) setpoint
values. This value is normally applied by manual (operator) action during startup
to allow a machine to pass through high vibration speed ranges without monitor
alarm indications. Such high vibration speed ranges may include system
resonances and other normal transient vibrations.
The increase for the setpoints is handled by defining a multiplier to apply while
the rack is in trip multiply mode. The multiplier can be set from 1 to 3 times in
steps of 0.25x.
Type: The following transducer types are available for the Velocity II Channel
Nonstandard 2-wire Seismoprobe (Prox/Seis I/O only)
Velomitor
High Temperature Velomitor (Prox/Velom I/O only)
Velomitor CT
Nonstandard
The following transducer types are available for the Velocity II Channel (barrier
I/O module):
Velomitor
Velomitor CT
Nonstandard
Note
If a Non-Standard transducer is selected, the setpoint OK limits are
set to 1 volt from the Upper and Lower OK limits that are selected.
- 23-9 -
adjusted.
mV/in/s.
Transducer Without Barriers With BN Internal
Barriers
With Barriers
9200 500 mV/(in/s) * 500 mV/(in/s)
47633 490 mV/(in/s) * 490 mV/(in/s)
86205 477 mV/(in/s) * 477 mV/(in/s)
Nonstandard 2 wire 145 mV/(in/s) * 145 mV/(in/s)
Velomitor 100 mV/(in/s) 100 mV/(in/s) 100 mV/(in/s)
High Temperature
Velomitor
145 mV/(in/s) 145 mV/(in/s) 145 mV/(in/s)
Velomitor CT 100 mV/(in/s) 100 mV/(in/s) 100 mV/(in/s)
- 23-10 -
Upper Lower Bias Voltage
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
9200 -17.95 -17.95 -2.05 -2.05 -10 -10
47633 -17.95 -17.95 -2.05 -2.05 -10 -10
86205 -17.95 -17.95 -2.05 -2.05 -10 -10
NonStandard -17.95 -17.95 -2.05 -2.05 -10 -10
Velomitor -19.85 -17.95
-19.85
-4.15 -2.05
-4.15
-12 -10
-12
High
Temperature
Velomitor
-21.26 -21.26 -2.74 -2.74 -12 -12
Velomitor CT -19.85 -17.95
-19.85
-4.15 -2.05
-4.15
-12 -10
-12

Transducer Jumper on the Proximitor/Seismic and the Proximitor/Velomitor I/O
Modules. For the function of this jumper, refer to I/O Module Description section
of the hardware manual.
Take Input From Channel A (1 or 3) Transducer: The Channel B (2 or 4)
Velocity channel options screen has an extra control that appears just above the
transducer type list box (see figure below). It is the Take Input from Channel A
Transducer checkbox. When checked (), the channel pair uses Dual Path
Input. That is, input from the first channel (1 or 3) is used for both channels in
the pair. The transducer input, barrier, OK Mode, and Timed OK Channel Defeat
input from channel A will be copied to the second channel (2 or 4) in the channel
pair.
23.3.9 Alarm Mode
- 23-11 -
23.3.10 Barriers
For Seismic probes, select the MTL 764(-) Zener External option if external
safety barriers are connected between the monitor and the transducer. For
Velomitors, select the MTL 787(-) Zener External option if external safety barriers
are being used. If using an Internal Barrier I/O Module for Velomitor, select the
internal option. These devices are used to restrict the amount of energy that can
flow into a hazardous area.
23.3.11 OK Mode
methods:
Note
The Latching OK Mode and the Timed OK
Channel Defeat options are not compatible.
- 23-12 -
time. If the option is enabled, the time is set to 30 seconds. This option prevents
false trips caused by intermittent transducers.
for the channel.
Note
- 23-13 -
for the Velocity II channel type. The setpoint number is used in the
Setpoint
Number
Velocity II
1 Over Direct
2 Over 1X Ampl
3 Under 1X Ampl
4 Over 1X Phase Lag
6 Over 2X Ampl
7 Under 2X Ampl
8 Over 2X Phase Lag
10 Reserved
The standard velocity channel type has only two setpoints
and setpoint number 2 was the danger setpoint the
equivalent setpoint is now number 11.
is out of alarm.
- 23-14 -
23.5 Proportional Value Numbers
3500/42M Velocity II Channels
Channel Proportional Value
Number
Proportional
Value Name
1 1 Direct
1 2 Bias Voltage
1 3 1X Amplitude
1 4 1X Phase
1 5 2X Amplitude
1 6 2X Phase
1 7 Reserved
2 8 Direct
2 9 Bias Voltage
2 10 1X Amplitude
2 11 1X Phase
2 12 2X Amplitude
2 13 2X Phase
2 14 Reserved
Section 24 - Velocity Verification
- 24-1 -
24. Velocity Verification
Table of Contents
24.1 Introduction.................................................................................................. 24-2
24.2.1 Test Equipment Setup - Seismoprobe........................................... 24-3
24.2.2 Test Equipment Setup - Velomitor (Proximitor/Seismic I/O) .......... 24-5
24.2.3 Test Equipment Setup - Velomitor (Prox/Velom, Internal Barrier or
TMR I/O) .................................................................................................. 24-7
24.2.4 Test Equipment Setup OK Limits of a Velomitor Sensor with a
Proximitor/Siesmic I/O ........................................................................... 24-8
24.2.5 Test Equipment Setup OK Limits With a Prox/Velom, Internal
Barrier or TMR I/O.................................................................................... 24-9
24.3 Verification Screen Setup............................................................................. 24-9
24.4 Test Alarms................................................................................................ 24-10
24.4.1 Direct .......................................................................................... 24-10
24.4.2 1X Amplitude (1X Amp)............................................................... 24-11
24.4.3 1X Phase.................................................................................... 24-13
24.4.5 2X Phase.................................................................................... 24-15
24.5.1 Direct .......................................................................................... 24-17
24.5.3 1X Phase.................................................................................... 24-19
24.5.5 2X Phase.................................................................................... 24-22
24.6 Verify Filter Corner Frequencies ................................................................ 24-24
24.6.1 Calculating Verification Frequency.............................................. 24-25
24.6.2 Calculating the Input Voltage for Full-scale................................. 24-25
24.6.3 Full Scale Formulas - Integration ................................................ 24-27
24.7 Test OK Limits ........................................................................................... 24-28
24.7.1 For Seismoprobes:...................................................................... 24-28
24.7.2 For Velomitors ............................................................................ 24-29
- 24-2 -
24.1 Introduction
The following sections will describe how to test alarms, verify channels, verify
filter corner frequencies, and test OK limits for channels configured as Velocity or
Velocity II. The output values and alarm setpoints are verified by varying the
input signal level and observing that the correct results are reported in the
The Velocity channels can be configured for the following channel values and
alarms:
Alarms Channel Values
Over Under
Direct X
needed for all the verification procedures (Test Alarms, Verify Channels, Verify
Filter Corner Frequencies, and Test OK Limits).
WARNING!
Application Alert
Application Alert
Disconnecting the field wiring will cause a not OK condition.
- 24-3 -
24.2.1 Test Equipment Setup - Seismoprobe
generator, and multimeter to COM and SIG / A of channel 1 with polarity as
shown below.
Seismoprobe Test
(3) 40 k
(4) 100 F
- 24-4 -
(9) Mulitmeter
(10) DC Power Supply
(11) 2.49 k
Set the test equipment as specified below:
Power Supply Keyphasor
Multiplier / Divider
Function Generator
-6.50 Vdc Multiply Switch: 001
Divide Switch: 001
Waveform: sinewave
DC Volts: 0 Vdc
Frequency: 100 Hz
(above zero)
- 24-5 -
24.2.2 Test Equipment Setup - Velomitor (Proximitor/Seismic I/O)
generator, and multimeter to COM and SIG / A of channel 1 with polarity as
shown below.
Velomitor Test Setup with Proximitor/Siesmic I/O
(3) 40 k
(4) 100 F
- 24-6 -
(9) Mulitmeter
(10) 4 k
(11) 10F
Set the test equipment as specified below.
Keyphasor
Function Generator
Divide Switch: 001
Waveform: sinewave
DC Volts: 0 Vdc
Frequency: 100 Hz
Amplitude level: Minimum (above zero)
- 24-7 -
24.2.3 Test Equipment Setup - Velomitor (Prox/Velom, Internal
Barrier or TMR I/O)
generator, and multimeter to COM / A and SIG / B of channel 1 with polarity as
shown below.
Velomitor Test Setup With Prox/Velom, Internal Barrier or TMR I/O
(3) 40 k
(4) 100 F
(6) I/O Terminals (either External or Internal)
(9) Mulitmeter
(10) 2.74 k
(11) 10F
- 24-8 -
Set the test equipment as specified below.
Keyphasor
Function Generator
Divide Switch: 001
Waveform: sinewave
DC Volts: 0 Vdc
Frequency: 100 Hz
24.2.4 Test Equipment Setup OK Limits of a Velomitor Sensor
with a Proximitor/Siesmic I/O
Test Setup for Verifying the OK Limits of a Velomitor
With Proximitor/Seismic I/O.
- 24-9 -
24.2.5 Test Equipment Setup OK Limits With a Prox/Velom,
Internal Barrier or TMR I/O
Test Setup for Verifying the OK Limits of a Velomitor with a
Prox/Velom, Internal Barrier or TMR I/O
(1) Multimeter
(2) Power Supply
(3) I/O terminals (either External or Internal)
24.3 Verification Screen Setup
Note
If the Timed OK Channel Defeat is enabled, it will take 30
seconds for a channel to return to the OK status from not OK.
If OK MODE is configured for latching, press the RESET button
on the Rack Interface Module (RIM) to return to OK status.
+
-
+ -
PWR
COM/A
SIG/B
- 24-10 -
24.4 Test Alarms
The general approach for testing alarm setpoints is to simulate the Velocity
signal with a function generator and power supply. The alarm levels are tested
results are reported in the Verification screen on the test computer. It is only
necessary to test those alarm parameters that are configured and being used.
The general test procedure to verify current alarm operation will include
simulating a transducer input signal and varying this signal:
to exceed over Alert/Alarm 1 and Danger/Alarm2 Setpoints, and
to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and
24.4.1 Direct
1. Disconnect PWR / B, COM, and SIG / A (PWR, COM / A, and SIG / B for
Proximitor/Velomitor or TMR I/O) field wiring from the channel terminals on
the I/O module.
2. Connect test equipment:
For Seismoprobe: Connect test equipment and run software as described in
"Test Equipment and Software Setup" on page 24-2. Use the setup shown in
"Test Equipment Setup - Seismoprobe".
For Velomitor: Connect test equipment and run software as described in
"Test Equipment Setup - Velomitor (Proximitor/Seismic I/O)"or "Test
Equipment Setup - Velomitor (Prox/Velom, Internal Barrier or TMR I/O)" for
Proximitor/Velomitor and TMR I/O.
3. Calculate the verification frequency using the method in Calculating
Verification Frequency. Adjust the function generator frequency to the
calculated value.
divide setting is one.
the Direct setpoint levels on the Direct bar graph display of the Verification
screen.
Alarm.
- 24-11 -
an Alarm.
13. Disconnect the test equipment and reconnect the PWR / B, COM, and SIG /
A (PWR, COM / A, and SIG / B for Proximitor/Velomitor or TMR I/O) field
24.4.2 1X Amplitude (1X Amp)
Note
the I/O module.
"Test Equipment Setup - Velomitor (Proximitor/Seismic I/O)" or "Test
- 24-12 -
4. Adjust the function generator amplitude to produce a reading that is within the
1X Ampl setpoint levels on the 1X Ampl bar graph display of the Verification
screen.
Alarm.
an Alarm.
- 24-13 -
24.4.3 1X Phase
the I/O module.
Note
If you can not change the phase output, change the phase
alarm setpoints to activate the over and under phase alarms.
The setpoints must be downloaded to the monitor to take effect.
4. Adjust the phase to produce a reading that is within the 1X Phase setpoint
levels on the 1X Phase bar graph display of the Verification screen.
5. Adjust the 1X Amplitude to a minimum of 42.7 mV to get a valid 1X Phase
reading.
- 24-14 -
setpoint levels.
Note
the I/O module.
divide setting is two.
screen.
- 24-15 -
an Alarm.
indicates an Alarm.
24.4.5 2X Phase
the I/O module.
- 24-16 -
Note
5. Adjust the 2X Amplitude to a minimum of 42.7 mV to get a valid 2X Phase
reading.
setpoint levels.
- 24-17 -
The general approach for testing these parameters is to simulate the velocity
signal with a function generator and power supply. The channel values are
verified by varying the output from the test equipment and observing that the
correct results are reported in the Verification screen on the test computer.
Note
These parameters have an accuracy
specification of 1 % of full-scale.
24.5.1 Direct
the I/O module.
3. Calculate the verification frequency using the formulas in Verify Filter Corner
Frequencies. Adjust the function generator frequency to the calculated value.
4. Calculate the full-scale voltage using the procedure in Calculating the Input
Voltage for Full Scale. Adjust the function generator (sinewave) amplitude to
the calculated value.
6. Verify that the Direct bar graph display and the Current Value Box is reading
1 % of full-scale.
- 24-18 -
Note
The Keyphasor must be triggering and have
a valid rpm value to check this parameter.
the I/O module.
3. Calculate the full-scale voltage using the formulas in Calculating the Input
Voltage for Full-scale. Adjust the function generator (sine wave) amplitude to
- 24-19 -
24.5.3 1X Phase
the Phase Output (1X Phase)".
the I/O module.

Keyphasor
measured above. If integration is enabled then add 90 degrees to the
measured value to obtain the correct reading from the monitor.
- 24-20 -
Example:
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
the I/O module.
- 24-21 -
Note
the I/O module.
3. Calculate the full-scale voltage using the formulas in Calculating the Input
Voltage for Full-scale. Adjust the function generator (sine wave) amplitude to
- 24-22 -
24.5.5 2X Phase
the I/O module.

Keyphasor
measured value to obtain the correct reading from the monitor.
- 24-23 -
Example:
(1) 0
(2) First Cycle
(4) Second cycle
(6) Phase lag = 90
(8) 360
(9) Time
the I/O module.
- 24-24 -
24.6 Verify Filter Corner Frequencies
The general approach for testing these parameters is to simulate the Velocity
signal with a function generator and power supply. The corner frequencies are
Note
If the channel units are integrated, change the channel
configuration to a non-integrated scale for this test. When the
test is complete, return the channel to its original configuration.
the I/O module.
3. Calculate the verification frequency using the formulas in "Calculating
Verification Frequency" on page 24-25. Adjust the function generator
frequency to the calculated value.
4. Calculate the full-scale voltage using the procedure in "Calculating the Input
Voltage for Full-scale" on page 24-25. Adjust the function generator
(sinewave) amplitude to the calculated value.
full-scale.
6. Adjust the function generator frequency to the low-pass filter corner
frequency. Verify that the Direct bar graph display and the Current Value Box
is reading between 65 % and 75 % of full-scale.
- 24-25 -
7. Adjust the function generator frequency to the high-pass filter corner
24.6.1 Calculating Verification Frequency
The procedures for verifying channel values and corner frequencies require that
you use the following formulas to calculate the verification frequency:
Find the geometric center of the Band-pass frequency range. Input the
configured High-pass Filter Corner Frequency and the Low-pass Filter Corner
Frequency into the formula below:
LPF * HPF Frequency on Verificati
HPF = High-pass Filter Corner Frequency
LPF = Low-pass Filter Corner Frequency
If no filtering is configured, use a verification frequency of 100 Hz.
If a Low-pass Filter is configured and no High-pass Filter is configured, use
the following to determine the HPF to use in the formula:
If the units are RMS, use a HPF of 10 Hz. For any other configuration, use a
HPF of 3 Hz.
If a High-pass Filter is configured and no Low-pass Filter is configured, use a
LPF of 5,500 Hz.
24.6.2 Calculating the Input Voltage for Full-scale
you use the following formulas to calculate the input voltage for Full-scale. To
find the Full-scale input voltage, use appropriate table or formula for integrated or
non-integrated units.
- 24-26 -
Note
Scale Factor Box on the Verification screen.
Full Scale Formulas - No Integration
Units To Input RMS Volts To Input Peak to Peak
Volts
in/s pk (T.S.F x Full-scale) x 0.707 (T.S.F x Full-scale) x 2
mm/s pk (T.S.F x Full-scale) x 0.707 (T.S.F x Full-scale) x 2
in/s rms (T.S.F x Full-scale) (T.S.F x Full-scale) x 2.82
mm/s rms (T.S.F x Full-scale) (T.S.F x Full-scale) x 2.82
To use the formulas, the T.S.F. should be in volts and the T.S.F and full-scale
values should both be of the same unit system (metric or English). The
transducer Scale Factor will always be specified as volts per inch/second pk or
volts per millimetre/second pk.
Example 1:
Transducer Scale Factor = 500 mV/(in/s)
Full Scale = 0.5 in/s pk
For Peak to Peak input:
(0.500 0.5) 2 = 0.5 Vpp
For Vrms input:
(0.500 0.5) 0.707 = 0.1767 Vrms
Example 2:
Transducer Scale Factor = 19.69 mV/(mm/s)
Full Scale = 20 mm/s pk
(0.01969 20) 2 = 0.7876 Vpp
For RMS input:
(0.01969 20) 0.707 = 0.2784 Vrms
- 24-27 -
24.6.3 Full Scale Formulas - Integration
(For the following units: mil pp and m pp)
07071 . 0 *
Frequency on Verificati /
units) (English Factor Scale
831 . 31
units) (English Scale - Full
rms) (V Voltage Input
]
]
]
,
,
(
(
,
\
,
,
(
j
2 . 0 *
831 . 31
pp) (V Voltage Input
]
]
]
,
,
(
(
,
\
,
,
(
j
To use the formulas, the Velocity Scale Factor should be in volts, and the Full-
scale value and Velocity Scale Factor should be in English units. Use the
following conversion formulas to convert Metric units to English units:
Scale Factor
4 . 25 * (mm/s) Factor Scale Velocity (inch/s) Factor Scale Velocity
Full scale:
4 . 25
) ( Scale - Full
(mil) Scale - Full
Example:
To calculate the input voltage for a channel with the following configuration:
Full Scale = 100 m pp
HPF = 3 Hz
LPF = 3000 Hz
Convert Metric units to English units.
Scale Factor:
mV(in/s) 500 4 . 25 * mV(mm/s) 69 . 19
Full-scale:
mil 9370 . 3
4 . 25
m 100
Calculate the input voltage.

Hz 8683 . 94 Hz 3000 * Hz 3 Frequency on Verificati
rms) (V 4148 . 0 07071 . 0 *
Hz 8683 . 94 /
V/(in/s) 500 0
831 31
mil 9370 . 3
]
]
]
,
,
(
(
,
\
,
,
(
j
.
.
or
- 24-28 -
pp) (V 173 . 1 2 . 0 *
Hz 8683 . 94 /
V/(in/s) 500 0
831 31
mil 9370 . 3
]
]
]
,
,
(
(
,
\
,
,
(
j
.
.
Note
The accuracy of the reading will be affected by frequency values
less than 20 Hz and setting LPF 5.7 times away from the HPF.
24.7 Test OK Limits
Note
must be OK or bypassed for the OK relay to be energized.
24.7.1 For Seismoprobes:
The general approach for testing OK limit is to disconnect the input. This will
cause a not OK condition and the OK Relay to change state (de-energize).
1. Run the Verification Software as described in "Test Equipment and Software
Setup" on page 24-2.
2. Disconnect the SIG / A field wiring from the channel terminals on the
Proximitor / Seismic Monitor I/O Module.
3. Verify that the OK relay changes state (de-energized).
4. Verify that the Channel OK State line on the Verification screen reads not
OK.
5. Reconnect the SIG / A field wiring to the channel terminals on the Monitor I/O
Module. Press the RESET switch on the Rack Interface Module (RIM) and
verify that the OK LED comes on and the OK relay energizes.
6. Verify that the Channel OK State line on the Verification screen reads OK.
- 24-29 -
24.7.2 For Velomitors
There are two methods for testing OK limits if the transducer being used is a
Velomitor. Use method 1 if either following conditions are true, otherwise use
method 2:
The I/O module is a Proximitor/Seismic; or
The Velocity II Channel Type is selected.
24.7.2.1 Method 1
above the Upper OK limit and below the Lower OK limit. This will cause a not
OK condition and the OK Relay to change state (de-energize). The Upper and
Lower OK limits are displayed in the Verification screen on the test computer.
1. Disconnect PWR / B, COM, and SIG / A field wiring from the channel
terminals on the I/O module.
2. Connect test equipment and run software as described "Test Equipment and
Software Setup" on page 24-2.
Status section of the Verification screen reads OK.
(energized). See the 3500/20 Rack Interface Module Operation and
goes off (upper limit). Verify that the Channel OK State line on the
Verification screen reads not OK and that the OK Relay indicates not OK.
Verify that the Upper OK limit voltage displayed on the Verification screen is
equal to or more positive than the input voltage.
OK State line in the Channel Status section reads OK.
Channel Status section reads not OK and that the OK Relay indicates not
OK. Verify that the Lower OK limit voltage displayed on the Verification
screen is equal to or more negative than the input voltage.
line in the Channel Status section reads OK.
- 24-30 -
and SIG field wiring to the channel terminals on the Monitor I/O Module.
Press the RESET switch on the Rack Interface Module (RIM) and verify that
the OK LED comes on and the OK relay energizes.
setting.
24.7.2.2 Method 2
Due to the requirements for increased robustness in the TMR system, the TMR
I/O Module has a Velomitor interface that is different from the Prox/Seis I/O
Module's Velomitor interface. The Proximitor/Velomitor I/O Module shares this
feature with the TMR I/O. The effect of this difference is that the Velomitor signal
input to the I/O Module is 180 degrees out of phase from the correct Velomitor
signal. This inversion is compensated for in the TMR and Proximitor/Velomitor
I/O Module. This means that when you input a test signal using a signal
generator or DC power supply the buffered outputs on the front panel will be
inverted in phase and will have a different DC voltage than the input. This will
not affect the actual vibration readings in the Monitor.
1. Disconnect PWR, COM / A, and SIG / B field wiring from the channel
goes off (lower limit due to the inversion on the I/O Module). Verify that the
Channel OK State line on the Verification screen reads not OK and that the
OK Relay indicates not OK. Verify that the Lower OK limit voltage displayed
on the Verification screen is equal to or more negative than the following
value.
For the TMR I/O Module:
Lower OK limit voltage -20.84 - Vinput
For the Proximitor/Velomitor I/O Module:
- 24-31 -
LED just goes off (upper limit due to the inversion on the I/O Card). Verify
that the Channel OK State line in the Channel Status section reads not OK
and that the OK Relay indicates not OK. Verify that the Upper OK limit
voltage displayed on the Verification screen is equal to or more positive than
the following value.
For the TMR I/O Module:
Upper OK limit voltage -22.02 - Vinput
For the Proximitor/Velomitor I/O Module:
14. Disconnect the power supply and multimeter and reconnect the PWR, COM /
A, and SIG / B field wiring to the channel terminals on the Monitor I/O
setting.
- 24-32 -
Velocity Default OK Limits Table
Transducer Lower Ok Limit
(Volts)
Upper Ok Limit
(Volts)
9200 w/ &w/o barriers -2.0 to -2.1 -17.9 to -18.0
86205 w/ & w/o barriers -2.0 to -2.1 -17.9 to -18.0
47633 w/ & w/o barriers -2.0 to -2.1 -17.9 to -18.0
non std w/ &w/o barriers -2.0 to -2.1 -17.9 to -18.0
Velomitor (standard with
Internal Barrier, Prox/Seis,
or Prox/Velom I/O Module)
-4.1 to -4.2 -19.8 to -19.9
Velomitor (high temp with
Internal Barrier, Prox/Seis,
or Prox/Velom I/O Module)
-2.69 to -2.79 -21.21 to -21.31
Velomitor (standard with
TMR I/O Module)
-4.1 to -4.2 -19.8 to -19.9
Velomitor (high temp with
TMR I/O Module)
-4.1 to -4.2 -19.8 to -19.9
Section 25 - Acceleration General Information
- 25-1 -
25. Acceleration General Information
Acceleration measurements are generally made with an Accelerometer and are
typically used to evaluate high frequency vibration of a machine casing or
bearing housing due to blade passing, gear mesh, cavitation, rolling element
bearing defects, etc.. For harmonic motion, acceleration is often expressed as g
or a. Typical units for acceleration are feet per second per second (ft/s
2
) pk,
meters per second per second (m/s
2
) pk, or more commonly g pk (= acceleration
of gravity = 386.1 in/s
2
= 32.17 ft/s
2
= 9.81 m/s
2
).
Note
Acceleration, as well as velocity, are zero to
peak measurements (Notation = pk).
In a 3500 Monitoring System, Acceleration channels are programmed in pairs.
If housing measurements are being made for overall protection of the
machine, thought should be given to the usefulness of the measurement
for each application. Most common machine malfunctions (imbalance,
misalignment, etc.) originate at the rotor and cause an increase (or at
least a change) in rotor vibration. In order for any housing measurement
alone to be effective for overall machine protection, a significant amount
of rotor vibration must be faithfully transmitted to the bearing housing or
machine casing, or more specifically, to the mounting location of the
transducer.
In addition, care should be exercised in the physical installation of the
transducer. Improper installation can result in a decrease of the
transducer amplitude and frequency response and/or the generation of
signals which do not represent actual machine vibration.
Upon request, Bently Nevada can provide engineering services to
determine the appropriateness of housing measurements for the
machine in question and/or to provide installation assistance.
There are two different channel types that support the measurement of
acceleration. These are Acceleration and Acceleration II. The Acceleration
- 25-2 -
channel type only supports the direct measurement and works with the 3500/42
and 3500/42M. The Acceleration II channel type is an enhanced version of the
Acceleration channel type. It supports Direct, 1X Amplitude 1X Phase, 2X
Amplitude, and 2X Phase. The Acceleration II channel type is only available on
the 3500/42M monitors with revision 2.1 firmware or greater, and requires
version 3.2 of the 3500 Configuration software.
Application Alert
When upgrading from using a Acceleration to a Acceleration II
channel type care must be taken regarding any DCS or PLC
programming that utilizes data from the Communications Gateway.
The order and the number of values for the PPL data and the
alarm status data has changed for the Acceleration II. This may
require changes to the DCS or PLC programming. If this is
undesirable then use the Acceleration channel type.
Section 26 - Acceleration Configuration
- 26-1 -
26. Acceleration Configuration
Table of Contents
26.1 Introduction.................................................................................................. 26-2
26.3.3 Enable .......................................................................................... 26-4
26.3.5 Delay ............................................................................................ 26-7
26.3.7 Alarm Mode ................................................................................ 26-10
26.3.8 Barriers....................................................................................... 26-11
26.3.9 OK Mode .................................................................................... 26-11
26.4 Alarm Setpoints ......................................................................................... 26-11
- 26-2 -
26.1 Introduction
Configuration Software screens associated with the Acceleration Channel.
Consider the following items before configuring an Acceleration Channel:
The Acceleration Direct full-scale range is dependent upon the transducer
type.
may be configured as Acceleration and Channels 3 and 4 may be configured
as Radial Vibration).
When integration is selected, the available Direct Full-scale ranges will
change to reflect this.
be set a minimum of two octaves apart.
When two channels of acceleration are activated, the maximum channel
frequency supported is as shown in << Table reference to Maximum
Channel Frequency when two Acceleration Channels are Activated in
AccelSpecs.doc >>:
When a single channel of acceleration is activated, the maximum channel
frequency supported is as shown in << Table reference to Maximum
Channel Frequency when a single Acceleration Channel is Activated in
AccelSpecs.doc >>:
compatible.
Internal Barrier I/O Modules and External Barriers are not supported with high
frequency accelerometer transducers.
Only 18 high frequency accelerometer transducers can be installed along
with a full rack of standard transducers. This is due to the fact that the rack
can only power 18 high frequency Accelerometer transducers.
- 26-3 -
This section describes the options available on the Acceleration Channel
Timed OK Channel Defeat: An option that prevents a channel from returning to
an OK status until that channel's transducer has remained in an OK state for the
specified period of time. If the option is enabled, the time is set to 30 seconds.
This option prevents false trips caused by intermittent transducers.
- 26-4 -
(Standard or TMR).
transducer depends upon the number of channels selected. See Configuration
Considerations.
26.3.3 Enable
Direct: Machine data using accelerometers for the transducer inputs and
generally used for high frequency measurements. The signal will be changed if
filtering is selected (High-pass, Low-pass or High-pass and Low-pass selected).
- 26-5 -
23733-03 Std Acceleration
Interface Module
24145-02 Hi Freq
Acceleration Interface
Module
330400 Std Integral
Accelerometer
Nonstandard
Interface Module
155023-01 Hi Freq Acceleration
Interface Module
330425 Std
Integral
Accelerometer
0-2 g pk
0-5 g pk
0-10 g pk
0-20 g pk
0-25 g pk (23733-03 and
Nonstandard Only)
0-40 g pk (23733-03 and
Nonstandard Only)
0-45 g pk (23733-03 and
Nonstandard Only)
0-2 g rms
0-5 g rms
0-10 g rms
0-20 g rms (Not 24145-02)
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
0-250 m/s
2
pk (23733-03 and
Nonstandard Only)
0-400 m/s
2
pk (23733-03 and
Nonstandard Only)
0-450 m/s
2
pk (Nonstandard
Only)
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms (Not 24145-02)
Custom
0-20 g pk (49578-01 Only)
0-25 g pk (49578-01 Only)
0-40 g pk (49578-01 Only)
0-50 g pk (49578-01 Only)
0-20 g rms
0-25 g rms
0-40 g rms
0-50 g rms
0-20 m/s
2
rms (49578-01 Only)
0-50 m/s
2
rms (49578-01 Only)
0-100 m/s
2
rms (49578-01 Only)
0-200 m/s
2
rms
0-250 m/s
2
rms
0-400 m/s
2
rms
0-500 m/s
2
rms
0-20 m/s
2
pk (49578-01 Only)
0-50 m/s
2
pk (49578-01 Only)
0-100 m/s
2
pk (49578-01 Only)
0-200 m/s
2
pk (49578-01 Only)
0-250 m/s
2
pk (49578-01 Only)
0-400 m/s
2
pk (49578-01 Only)
0-500 m/s
2
pk (49578-01 Only)
Custom
0-20 g pk
0-25 g pk
0-40 g pk
0-50 g pk
0-20 g rms
0-25 g rms
0-40 g rms
0-50 g rms
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
0-250 m/s
2
pk
0-400 m/s
2
pk
0-500 m/s
2
pk
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms
0-250 m/s
2
rms
0-400 m/s
2
rms
Custom
- 26-6 -
Integrate: When Integrate is enabled, the Direct Full-scale range selections
Direct values (Integrated) by transducer types
Interface Module
Interface Module
330400 Std Integral
Accelerometer
Nonstandard
Interface Module
Interface Module
330425 Std Integral
Accelerometer
0-1 in/s pk
0-2 in/s pk
0-1 in/s rms
0-2 in/s rms
0-25 mm/s pk
0-50 mm/s pk
0-100 mm/s pk (Not 330400)
0-25 mm/s rms
0-50 mm/s rms
Custom
0-2 in/s pk (Not 155023-01)
0-2 in/s rms (Not 155023-01)
0-100 mm/s pk (Not 155023-01)
0-100 mm/s rms
proportional value is bypassed or defeated (for example when a problem occurs
the current proportional to the selected clamp value or to 2 mA (if the 2 mA
clamp is selected).
High-pass Filter: A four-pole filter that must be at least two octaves away from
the Low-pass Filter.
HPF ( LPF / 4 )
- 26-7 -
Low-pass Filter: A four-pole filter that must be at least two octaves away from
the High-pass Filter.
LPF ( HPF * 4 )
26.3.5 Delay
Type: The following transducer types are available for the Acceleration Channel
23733-03 Std Acceleration Interface Module
24145-02 Hi Freq Acceleration Interface Module
330400 Std Integral Accelerometer
Nonstandard
The following transducer types are available for the Acceleration Channel (barrier
I/O module):
- 26-8 -
Nonstandard
adjusted.
The Non-standard transducer's scale factor must be between 21.2 and 115
mV/g.
- 26-9 -
Scale Factor
Transducer Without
Barriers
With Bently
Nevada
Internal
Barriers
Standard
I/O With
Barriers
Discrete
TMR I/O
With
Barriers
Bussed
TMR I/O
With
Barriers
23733-03 100 mV/g 100 mV/g 95.6mV/g 100 mV/g 99.4 mV/g
24145-02 100 mV/g * * * *
330400 100 mV/g 100 mV/g 95.6mV/g 95.6 mV/g 95.6 mV/g
155023-01 25 mV/g * * * *
- 26-10 -
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
23733-03 -15.05 -13.85
-15.05
-2.75 -3.10
-2.75
-8.90 -8.475
-8.90
24145-02 -15.05 * -2.75 * -8.90 *

330400 -15.05 -13.85
-15.05
-2.75 -3.10
-2.75
-8.90 -8.475
-8.90
330425 -11.37 -10.86

-11.37
-5.63 -5.34
-5.63
-8.50 -8.10
-8.50
49578-01 -11.37 -10.86

-11.37
-5.63 -5.34
-5.63
-8.50 -8.10
-8.50
155023-01 -11.37 * -5.63 * -8.50 *


26.3.7 Alarm Mode
proportional value is no longer in alarm. The alarm state will continue until the
channel is reset using one of the following methods:
- 26-11 -
26.3.8 Barriers
26.3.9 OK Mode
not OK the status stays not OK until a reset is issued using one of the following
methods:
for the channel.
Note
- 26-12 -
- 26-13 -
Setpoint
Number
Acceleration
1 Over Direct
2 Danger (Over Direct)
3
4
5
6
7
8
9
10
11
is out of alarm.
- 26-14 -
Blank Page
Section 27 - Acceleration II Configuration
- 27-1 -
27. Acceleration II Configuration
Table of Contents
27.1 Introduction.................................................................................................. 27-2
27.3.3 Enable .......................................................................................... 27-4
27.3.4 Full Scale Ranges by Transducer Type ........................................ 27-5
27.3.6 Delay ............................................................................................ 27-9
27.3.7 Take Input From Channel A (1 or 3) Transducer ........................... 27-9
27.3.9 Alarm Mode ................................................................................ 27-12
27.3.10 Barriers................................................................................... 27-12
27.3.11 OK Mode ................................................................................ 27-12
27.4 Alarm Setpoints ......................................................................................... 27-13
27.5 Proportional Value Numbers ...................................................................... 27-16
- 27-2 -
27.1 Introduction
Configuration Software screens associated with the Acceleration 2 Channel
Type.
Consider the following items before configuring an Acceleration II Channel:
2X Amplitude (Ampl) and Phase Lag cannot be selected.
the rack.
may be configured as Acceleration and Channels 3 and 4 may be configured
as Radial Vibration).
When integration is selected, the available Full-scale ranges will change to
reflect this. Additionally, the frequency support will be limited to 20kHz.
When integration is selected, the high pass filter will be set to 10Hz if it is not
set to a higher frequency and the vector parameters will be inactive below
10Hz.
be set a minimum of two octaves apart.
When RMS is selected, all of the proportional values for the channel will be in
RMS units.
When the Acceleration Dual Path channel type is selected, transducer 1 is
used for channels 1 & 2 and transducer 3 is used for channels 3 & 4.
When using Dual Path both channels must be configured for the same
transducer type.
Internal Barrier I/O Modules and External Barriers are not supported with high
frequency accelerometer transducers.
Only 18 high frequency accelerometer transducers can be installed along
with a full rack of standard transducers. This is due to the fact that the rack
can only power 18 high frequency Accelerometer transducers.
When a full-scale is modified, readjust the setpoints associated with the
proportional value.
- 27-3 -
This section describes the options available on the Acceleration II Channel Type
- 27-4 -
(Standard or TMR).
transducer depends upon whether integration is enabled.
27.3.3 Enable
Direct: Direct is data that represents the overall peak-to-peak vibration. Machine
data using accelerometers for the transducer inputs and generally used for high
frequency measurements. The signal will be changed if filtering is selected
(High-pass, Low-pass or High-pass and Low-pass selected).
Bias Voltage: The DC voltage used by the system as a bias for the transducer.
Can be used as a diagnostic tool for evaluating system integrity.
This measurement contains no information about the
condition of the machinery being monitored. It has been
provided only for monitoring system diagnostics.
the phase lag component that occurs at the rotative speed frequency.
component having a frequency equal to two times the shaft rotative speed.
the phase lag component having a frequency equal to two times the shaft
rotative speed. 2X phase lag is the angular measurement from the leading or
trailing edge of the Keyphasor pulse to the following positive peak of the 2X
vibration signal.
Note
Bias Voltage, 1X Amplitude & Phase, 2X Amplitude &
Phase are only available if the monitor is a 3500/42M.
- 27-5 -
Integrate: Integration applies to all values returned from the monitor. When
integration is selected, the available Full-scale ranges will change to reflect this.
Additionally, the frequency support will be limited to 20kHz.
RMS: When RMS is selected, all of the proportional values for the channel will
be measured as RMS. The following full-scale ranges are available:
27.3.4 Full Scale Ranges by Transducer Type
23733-03 Standard Acceleration Interface Module
Non Integrated
Peak
Non-Integrated
RMS
Integrated Peak Integrated RMS
0-2 g pk
0-5 g pk
0-10 g pk
0-20 g pk
0-25 g pk
0-40 g pk
0-45 g pk
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
0-250 m/s
2
pk
0-400 m/s
2
pk
Custom
0-2 g rms
0-5 g rms
0-10 g rms
0-20 g rms
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms
Custom
0-1 in/s pk
0-2 in/s pk
0-4 in/s pk
0-25 mm/s pk
0-50 mm/s pk
0-100 mm/s pk
Custom
0-1 in/s rms
0-2 in/s rms
0-25 mm/s rms
0-50 mm/s rms
Custom
24145-02 High Frequency Acceleration Interface Module
Non Integrated Peak Non-Integrated RMS Integrated Peak Integrated RMS
0-2 g pk
0-5 g pk
0-10 g pk
0-20 g pk
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
Custom
0-2 g rms
0-5 g rms
0-10 g rms
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
Custom
0-1 in/s pk
0-2 in/s pk
0-4 in/s pk
0-25 mm/s pk
0-50 mm/s pk
0-100 mm/s pk
Custom
0-1 in/s rms
0-2 in/s rms
0-25 mm/s rms
0-50 mm/s rms
Custom
- 27-6 -
330400 Standard Acceleration Interface Module
0-2 g pk
0-5 g pk
0-10 g pk
0-20 g pk
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
Custom
0-2 g rms
0-5 g rms
0-10 g rms
0-20 g rms
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms
Custom
0-1 in/s pk
0-2 in/s pk
0-25 mm/s pk
0-50 mm/s pk
Custom
0-1 in/s rms
0-2 in/s rms
0-25 mm/s rms
0-50 mm/s rms
Custom
49578-01 Standard Acceleration Interface Module
0-20 g pk
0-25 g pk
0-40 g pk
0-50 g pk
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
0-250 m/s
2
pk
0-400 m/s
2
pk
0-500 m/s
2
pk
Custom
0-20 g rms
0-25 g rms
0-40 g rms
0-50 g rms
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms
0-250 m/s
2
rms
0-400 m/s
2
rms
0-500 m/s
2
rms
Custom
0-2 in/s pk
0-4 in/s pk
0-50 mm/s pk
0-100 mm/s pk
Custom
0-2 in/s rms
0-4 in/s rms
0-50 mm/s rms
0-100 mm/s rms
Custom
- 27-7 -
330425 Standard Acceleration Interface Module
0-20 g pk
0-25 g pk
0-40 g pk
0-50 g pk
0-20 m/s
2
pk
0-50 m/s
2
pk
0-100 m/s
2
pk
0-200 m/s
2
pk
0-250 m/s
2
pk
0-400 m/s
2
pk
0-500 m/s
2
pk
Custom
0-20 g rms
0-25 g rms
0-40 g rms
0-50 g rms
0-20 m/s
2
rms
0-50 m/s
2
rms
0-100 m/s
2
rms
0-200 m/s
2
rms
0-250 m/s
2
rms
0-400 m/s
2
rms
Custom
0-2 in/s pk
0-4 in/s pk
0-50 mm/s pk
0-100 mm/s pk
Custom
0-2 in/s rms
0-4 in/s rms
0-50 mm/s rms
0-100 mm/s rms
Custom
155023-01 High Frequency Acceleration Interface Module
N/A 0-20 g rms
0-25 g rms
0-40 g rms
0-50 g rms
0-200 m/s
2
rms
0-250 m/s
2
rms
0-400 m/s
2
rms
0-500 m/s
2
rms
Custom
N/A 0-4 in/s rms
0-100 mm/s rms
Custom
Note
When a full-scale range is modified, the setpoints associated
with this proportional value should be readjusted.
- 27-8 -
Clamp Value: The Clamp value is the value that a proportional value goes to
when that channel or proportional value is bypassed or defeated (For example
when a problem occurs with the transducer). The selected value can be
between the minimum and maximum full-scale range values. (1X and 2X Phase
Lag have available values of 0 to 359 degrees.) Only the values available from
the Recorder Outputs, Communication Gateway and Display Interface Module
are clamped to the specified value when the proportional value is invalid.
Recorder Output: This field selects which proportional value of a channel is sent
to the 4 to 20 mA recorder. The recorder output is proportional to the measured
value over the channel full-scale range. An increase in the proportional value
that would be indicated as upscale on a bar graph display results in an increase
in the current at the recorder output.
with and without Hysteresis. If the channel is bypassed, the output will be
If no filters are selected then the monitor will be configured with a 3Hz HPF and a
30kHz LPF if integration is disabled. If integration is enabled the monitor is
configured with a 10Hz HPF and a 20kHz LPF.
High-pass Filter: A four-pole filter that must be set at least two octaves away
from the Low-pass Filter.
HPF (LPF / 4)
Low-pass Filter: A four-pole filter that must be set at least two octaves away
from the High-pass Filter.
LPF (HPF * 4)
- 27-9 -
Note
When band-pass filtering is selected, the high-pass and low-
pass filters must be set a minimum of two octaves apart.
27.3.6 Delay
The time that a proportional value must remain at or above an alarm level or
27.3.7 Take Input From Channel A (1 or 3) Transducer
The Channel B (2 or 4) Acceleration channel options screen has an extra control
that appears just above the transducer type list box. It is the Take Input From
Channel A Transducer checkbox. When checked (), the channel pair is
configured for a Dual Path mode of operation. That is, the input from the first
transducer (1 or 3) is used for the input for both channels of the pair. The
transducer selection, barrier option, OK mode and Timed OK Channel Defeat
setting from channel A will be copied to the second channel (2 or 4) of the pair.
Type: The following transducer types are available for the Acceleration Channel
- 27-10 -
Nonstandard
The following transducer types are available for the Acceleration Channel (barrier
I/O module):
Nonstandard
adjusted.
mV/g.
- 27-11 -
Scale Factor
Transducer Without
Barriers
With Bently
Nevada
Internal
Barriers
Standard
I/O With
Barriers
Discrete
TMR I/O
With
Barriers
Bussed
TMR I/O
With
Barriers
24145-02 100 mV/g * * * *
155023-01 25 mV/g * * * *
Upper Lower Center Bias Voltage
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
23733-03 -15.05 -13.85
-15.05
-2.75 -3.10
-2.75
-8.90 -8.475
-8.90
24145-02 -15.05 * -2.75 * -8.90 *

330400 -15.05 -13.85
-15.05
-2.75 -3.10
-2.75
-8.90 -8.475
-8.90
330425 -11.37 -10.86

-11.37
-5.63 -5.34
-5.63
-8.50 -8.10
-8.50
49578-01 -11.37 -10.86

-11.37
-5.63 -5.34
-5.63
-8.50 -8.10
-8.50
155023-01 -11.37 * -5.63 * -8.50 *


- 27-12 -
27.3.9 Alarm Mode
proportional value is no longer in alarm. The alarm state will continue until the
channel is reset using one of the following methods:
27.3.10 Barriers
27.3.11 OK Mode
not OK the status stays not OK until a reset is issued using one of the following
methods:
- 27-13 -
Note
The Latching OK Mode and the Timed OK
Channel Defeat options are not compatible.
for the channel.
Note
- 27-14 -
- 27-15 -
Gateway and Display Interface Modules. Bias Voltage is not available as an
alarming parameter.
Setpoint
Number
Acceleration
1 Over Direct
2 Over 1X Ampl
3 Under 1X Ampl
4 Over 1X Phase Lag
6 Over 2X Ampl
7 Under 2X Ampl
8 Over 2X Phase Lag
10 Reserved
The standard velocity channel type has only two
setpoints and setpoint number 2 was the danger
setpoint the equivalent setpoint is now number 11.
- 27-16 -
For example, for a channel configuration with a 0 to 10 g full scale and an alarm
setpoint of 6 g, the hysteresis = 10 g/64 = 0.16 g. The channel input, therefore,
must fall below 6 g 0.6 g (5.84 g) before the channel is out of alarm.
27.5 Proportional Value Numbers
3500/42M Acceleration II Channels
Channel Proportional
Value Number
Proportional
Value Name
1 1 Direct
1 2 Bias Voltage
1 3 1X Amplitude
1 4 1X Phase
1 5 2X Amplitude
1 6 2X Phase
1 7 Reserved
2 8 Direct
2 9 Bias Voltage
2 10 1X Amplitude
2 11 1X Phase
2 12 2X Amplitude
2 13 2X Phase
2 14 Reserved
Section 28 - Acceleration Verification
- 28-1 -
28. Acceleration Verification
Table of Contents
28.1 Introduction.................................................................................................. 28-2
28.3 Test Alarms.................................................................................................. 28-4
28.3.1 Direct ............................................................................................ 28-5
28.3.3 1X Phase...................................................................................... 28-7
28.3.5 2X Phase...................................................................................... 28-9
28.4.1 Direct .......................................................................................... 28-11
28.4.3 1X Phase.................................................................................... 28-12
28.4.5 2X Phase.................................................................................... 28-14
28.5 Test OK Limits ........................................................................................... 28-19
- 28-2 -
28.1 Introduction
filter corner Frequencies, and test OK limits for channels configured as
Acceleration or Acceleration II. The output values and alarm setpoints are
verified by varying the input signal level and observing that the correct results are
Acceleration channels can be configured for the following channel values and
alarms:
Alarms
Direct X
Filter Corner Frequencies, and Test OK limits).
WARNING!
High voltage present. Contact could cause shock, burns, or
death. Do not touch exposed wires or terminals.
Application Alert
Application Alert
- 28-3 -
in the figure below. Set the test equipment as specified below.
Power Supply Function Generator Keyphasor
Multiplier/Divider
DC Volts: 0 Vdc
Frequency: 100 Hz
Amplitude level:
Minimum (above zero)
Divide Switch: 001
The equipment shown in the box is required for 1X Amplitude and Phase, 2X
Amplitude and Phase.
- 28-4 -
Acceleration Test Setup
(3) 40 k
(4) 100 F
(9) Mulitmeter
(10) DC Power Supply
Note
on the Rack Interface Module (RIM) to return to the OK status.
28.3 Test Alarms
The general approach for testing alarm setpoints is to simulate the Acceleration
and Keyphasor signals with a function generator and power supply. The alarm
levels are tested by varying the output from the test equipment and observing
that the correct results are reported in the Verification screen on the test
computer. It is only necessary to test those alarm parameters that are
- 28-5 -
28.3.1 Direct
the I/O module.
3. Calculate the verification frequency using the method in "Calculating
screen.
Alarm.
an Alarm.
that the bar graph indicator for Direct changes color to green. The Current
Value Box should contain no indication of Alarms. Press the RESET switch
- 28-6 -
Note
the I/O module.
screen.
Alarm.
an Alarm.
- 28-7 -
28.3.3 1X Phase
the I/O module.
3. If you can not change the phase output, change the phase alarm setpoints to
activate the over and under phase alarms. The setpoints must be
downloaded to the monitor to take effect.
reading.
- 28-8 -
setpoint levels.
Note
the I/O module.
screen.
an Alarm.
- 28-9 -
indicates an Alarm.
28.3.5 2X Phase
the I/O module.
Note
- 28-10 -
reading.
setpoint levels.
The general approach for testing these parameters is to simulate the
Acceleration and Keyphasor signals with a function generator and power
supply. The channel values are verified by varying the output from the test
equipment and observing that the correct results are reported in the Verification
screen on the test computer.
- 28-11 -
Note
These parameters have an accuracy specification
of 1 % of full scale.
28.4.1 Direct
1. Disconnect PWR / B, COM, and SIG / A field wiring from the channel
4. Calculate the full-scale voltage using the formulas in "Calculating the Input
Voltage for Full-scale" on page 28-17. Adjust the function generator (sine
wave) amplitude to the calculated value.
1 % of full scale.
A field wiring to the channel terminals on the I/O module. Verify that the OK
Note
- 28-12 -
the I/O module.
28.4.3 1X Phase
the I/O module.

Keyphasor
measured value.
- 28-13 -
Example:
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
the I/O module.
- 28-14 -
Note
the I/O module.
28.4.5 2X Phase
- 28-15 -
the I/O module.

Keyphasor
example below, which illustrates a phase of 90. Observe the 2X Phase bar
measured value.
Example:
1. 0
2. First Cycle
3. One shaft revolution
4. Second cycle
5. 2X Vibration Signal
6. Phase lag = 90
7. Keyphasor signal
8. 360
9. Time
- 28-16 -
the I/O module.
you use the following formulas to calculate the verification frequency.
configured high-pass filter corner frequency and the low-pass filter corner
frequency into the formula below:
If a low-pass filter is configured and no high-pass filter is configured, use the
following to determine the HPF to use in the formula:
If the units are integrated or rms, use a HPF of 10 Hz. For any other
configuration, use a HPF of 3 Hz.
If a high-pass filter is configured and no low-pass filter is configured, use the
following to determine the LPF to use in the formula:
If the configuration is with no integration, use a LPF of 30 kHz.
- 28-17 -
If the configuration is with integration, use a LPF of 14.5 kHz.
The procedures for verifying channel values and corner frequencies required that
you use the following formulas to calculate the input voltage for full-scale. To
find the full-scale input voltage, use appropriate table for integrated or non-
integrated units.
Note
Use the transducer scale factor displayed in the
Units To Input RMS Volts To Input Peak to Peak Volts
g peak (T.S.F. x Full-scale) x 0.707 (T.S.F. x Full-scale) x 2
g rms (T.S.F x Full-scale) (T.S.F. x Full-scale) x 2.82
m/s
2
peak (T.S.F. x Full-scale) x 0.707 (T.S.F. x Full-scale) x 2
m/s
2
rms (T.S.F x Full-scale) (T.S.F. x Full-scale) x 2.82
T.S.F = Transducer Scale Factor.
To use the formulas, the T.S.F. should be in volts and the T.S.F. and full-scale
values should both be of the same unit system (metric or English).
The transducer Scale Factor will always be specified as volts per g pk or volts
per m/s
2
pk.
Example 1:
Transducer Scale Factor = 100 mV/g
Full Scale = 2 g peak
(0.100 2) 2 = 0.4 Vpp
For Vrms input:
(0.100 2) 0.707 = 0.1414 Vrms
Example 2:
Transducer Scale Factor = 10.19 mV/( m/s
2
)
Full Scale = 20 m/s
2
pk
- 28-18 -
(0.01019 20) 2 = 0.4076 Vpp
For RMS input:
(0.01019 20) 0.707 = 0.1440 Vrms
(For the Following units: in/s pk, in/s rms, mm/s pk, mm/s rms)
To input rms volts for peak full scale units:
3535 . 0 *
72 . 30
]
]
]
,
,
(
(
,
\
,
,
(
j
To input rms volts for rms full scale units:

5 . 0 *
72 . 30
]
]
]
,
,
(
(
,
\
,
,
(
j
To input peak to peak volts for peak full scale units:

]
]
]
,
,
(
(
,
\
,
,
(
j
72 . 30
To input peak to peak volts for RMS full scale units:
414 . 1 *
72 . 30
]
]
]
,
,
(
(
,
\
,
,
(
j
To use the formulas, the acceleration full-scale value and scale factor should be
in English units. Use the following conversion formulas to convert metric units to
English units:
Scale Factor:
8135 . 9 * ) (mV/(m/ Factor Scale Accel (mV/g) Factor Scale Accel
s
2
Full-scale:
39372 . 0 * s) (in Scale - Full s) (mm Scale - Full / /
Example:
Transducer Scale Factor = 10.19 mV/( m/s
2
)
Full Scale = 25 m/s
2
pk
HPF = 10 Hz
LPF = 8000 Hz
- 28-19 -
1. Convert metric units to English units.
Scale Factor:
(mV/g) 100 8135 . 9 * ) (mV/(m/ 19 . 10
s
2
Full-scale:
s) (in 0 . 1 39372 . 0 * s) (mm 25 / /
2. Calculate the input voltage.
To Input RMS Volts for Peak Units
rms) (V 3254 . 0 3535 . 0 *
Hz 84 . 282 /
(V/g) 1 . 0
72 . 30
s in 0 . 1
]
]
]
,
,
(
(
,
\
,
,
(
j
/
To Input Peak to Peak Volts for Peak Units
pp) (V 9207 . 0
Hz 84 . 282 /
(V/g) 1 . 0
72 . 30
s in 0 . 1
]
]
]
,
,
(
(
,
\
,
,
(
j
/
28.5 Test OK Limits
Note
If the Danger Bypass has been activated, then the BYPASS
LED will be on. All other channels in the rack must be OK or
bypassed for the OK relay to be energized.
above the Upper OK limit and below the Lower OK limit. This should cause a not
OK condition and cause the OK Relay to change state. The Upper and Lower
OK limits are displayed in the Verification screen on the test computer.
the I/O module.
- 28-20 -
Status section of the Verification Display screen reads OK.
(energized). See 3500/20 Rack Interface Module manual, part #129768-01.
goes off (upper limit). Verify that the Channel OK State line on the
Verification screen reads not OK and that the OK Relay indicates not OK.
Verify that the Upper OK limit voltage displayed on the Verification screen is
equal to or more positive than the input voltage.
Channel Status section reads not OK and that the OK Relay indicates not
OK. Verify that the Lower OK limit voltage displayed on the Verification
screen is equal to or more negative than the input voltage.
13. If you cant verify any configured OK limit, go to "If a Channel Fails a
and SIG field wiring to the channel terminals on the I/O Module. Press the
RESET switch on the Rack Interface Module (RIM) and verify that the OK
LED comes on and the OK relay energizes.
setting.
- 28-21 -
Acceleration Default OK Limits Table
(Volts)
Upper Ok Limit
(Volts)
23733-03 w/o barriers -2.7 to -2.8 -15.0 to -15.1
23733-03 w/ barriers -3.05 to -3.15
-2.7 to -2.8 *
-13.8 to -13.9
-15.0 to -15.1 *
49578-01 w/o barriers -5.58 to -5.68 -11.32 to -11.42
49578-01 w/ barriers -5.29 to -5.39
-5.58 to -5.68 *
-10.81 to -10.91
-11.32 to -11.42 *
24145-02 w/o barriers -2.7 to -2.8 -15.0 to -15.1
155023-01 w/o barriers -5.58 to -5.68
330400 w/ barriers -3.05 to -3.15
-2.7 to -2.8 *
-13.8 to -13.9
-15.0 to -15.10 *
330400 w/o barriers -2.7 to -2.8 -15.0 to -15.10
330425 w/ barriers -5.29 to -5.39
-5.58 to -5.68 *
-10.81 to -10.91
-11.32 to -11.42 *
330425 w/o barriers -5.58 to -5.68 -11.32 to -11.42
* = BN Internal Barrier I/O Modules.
- 28-22 -
Blank Page
Section 29 - Shaft Absolute General Information
- 29-1 -
29. Shaft Absolute General Information
Shaft absolute vibration is the vibration of a shaft relative to an inertial (fixed
point in free space) reference frame. A shaft absolute measurement uses two
signals one from a proximity probe and one from velocity transducer. These
transducers operate in groups with a proximity probe and velocity transducer
installed radially at the same point, usually in a common junction box on the
machine bearing.
These two transducers provide the following four separate measurements:
1. shaft relative radial position within the bearing clearance,
2. shaft dynamic motion relative to the bearing,
3. machine casing absolute vibration measured by the velocity transducer, and
4. shaft absolute motion represented by the summation of the velocity signal
integrated to displacement and added to the shaft relative signal.
The 3500 Monitoring System uses one 4-channel monitor for shaft absolute
vibration measurements in both the X and Y planes. These monitors have two
channels configured as Shaft Absolute Radial Vibration and two as Shaft
Absolute Velocity. The channels are configured and verified as channel pairs
one pair as Radial Vibration and the other as Velocity. These channels are then
associated into functional groups with a Radial Vibration and a Velocity channel
in each group. For example, in a 3500 monitor that is measuring shaft absolute
vibration, Group 1 contains channels 1 and 3 and Group 2 contains channels 2
and 4.
- 29-2 -
Blank Page
Section 30 - Shaft Absolute Configuration
- 30-1 -
30. Shaft Absolute Configuration
Table of Contents
30.1 Introduction.................................................................................................. 30-2
30.2 About Shaft Absolute Channel Types........................................................... 30-2
- 30-2 -
30.1 Introduction
This section describes the configuration considerations that apply to all Shaft
Absolute channels.
30.2 About Shaft Absolute Channel Types
In the 3500 Monitoring System, all four channels of a Proximitor/Seismic
monitor are required for shaft absolute measurements. One channel pair must
be configured as Shaft Absolute Radial Vibration and the other as Shaft Absolute
Velocity. This configuration is shown in the following figure.
After they are configured, these channels are associated in two functional
groups. Each group contains a Shaft Absolute Radial Vibration channel and a
Shaft Absolute Velocity channel. Group 1 consists of channels 1 and 3 and
Group 2 of channels 2 and 4. The shaft absolute proportional values are derived
from both channels in a functional group.
The following configuration considerations apply to all Shaft Absolute channels:
The Shaft Absolute Velocity channel type and the Shaft Absolute Radial
Vibration channel type are configured in channel pairs, but the association of
the particular shaft absolute proximity and velocity transducers is according
to Group 1 (channels 1 and 3) and Group 2 (channels 2 and 4).
Section 30 - Shaft Absolute Configuration
- 30-3 -
Monitors must be configured in channel pairs (for example, when channels 1
and 2 are configured as Shaft Absolute Radial Vibration, channels 3 and 4
must be configured as Shaft Absolute Velocity).
The Shaft Absolute Direct proportional value will become invalid when either
of the associated radial vibration or velocity transducers become not-OK.
The Shaft Absolute Direct proportional value is the vector summation the
Shaft Absolute Velocity Direct and the Shaft Absolute Radial Vibration Direct
signals.
The Shaft Absolute Direct proportional value will operate on the combined
Timed OK Channel Defeat options of the radial vibration and velocity
channels.
- 30-4 -
Blank Page
Section 31 - Shaft Absolute Radial Vibration Options
- 31-1 -
31. Shaft Absolute Radial Vibration Options
Table of Contents
31.1 Introduction.................................................................................................. 31-2
31.3.3 Enable .......................................................................................... 31-4
31.3.4 Delay ............................................................................................ 31-6
31.3.5 Direct Frequency Response.......................................................... 31-7
31.3.7 Alarm Mode .................................................................................. 31-8
31.3.8 Transducer Orientation ................................................................. 31-9
31.4 Alarm Setpoints ........................................................................................... 31-9
- 31-2 -
31.1 Introduction
Configuration Software screens associated with the Shaft Absolute Radial
Vibration Channel.
Consider the following items before configuring a Shaft Absolute Radial Vibration
Channel:
can not be selected.
the rack.
The 1X Phase value can be enabled only if the selected Keyphasor channel
- 31-3 -
This section describes the options available on the Shaft Absolute Radial
Vibration Channel configuration screen.
seconds. This feature is always enabled in the Radial Vibration Channels. The
option protects against false trips caused by intermittent transducers.
CP Mod: Selecting the CP Mod button Channel Options Dialog Box allows a
details.
Gap Scale.
- 31-4 -
Channel: The number of the channel being configured (1 or 2).
Group: The association of channels which derive the shaft absolute signal.
Group 1 consists of channels 1 and 3, Group 2 consists of channels 2 and 4.
(Standard or TMR).
31.3.3 Enable
value.
- 31-5 -
Direct
1X Ampl
0-5 mil pp
0-10 mil pp
0-15 mil pp
0-20 mil pp
0-100 m pp
0-150 m pp
0-200 m pp
0-400 m pp
0-500 m pp
Custom
Gap Full Scale Ranges by transducer type
33005 mm Proximitor
33008 mm Proximitor
72005 mm Proximitor
72008 mm Proximitor
Nonstandard
-24 Vdc
15-0-15 mil
25-0-25 mil
300-0-300 m
600-0-600 m
Custom
-24 Vdc
15-0-15 mil
25-0-25 mil
50-0-50 mil
300-0-300 m
600-0-600 m
1000-0-1000 m
Custom
maximum full-scale range values. (1X Phase Lag has available values of 0 to
359 degrees.) Only the values available from the Recorder Outputs,
- 31-6 -
If 1X Phase Lag is selected then the two options available are with and without
Hysteresis. If the channel is Bypassed, the output will be clamped to the
selected clamp value or to 2 mA (if the 2 mA clamp is selected).
31.3.4 Delay
Setpoint screen.
- 31-7 -
31.3.5 Direct Frequency Response
The upper and lower corners for the band-pass filter used with direct vibration
measurements. The available ranges are 240 to 240,000 cpm and 60 to 36,000
cpm.
Type: The following transducer types are available for the Shaft Absolute Radial
Vibration Channel:
Nonstandard
adjusted.
mV/mil.
- 31-8 -
Transducer Scale Factor
3300 5 and 8 mm
3300 XL 8 mm
7200 5 and 8 mm
200 mV/mil
200 mV/mil
200 mV/mil
3300 XL 11 mm
7200 11 mm
100 mV/mil
7200 14 mm 100 mV/mil
Shaft Absolute Radial Vibration OK Limits by Transducer Type
Transducer Upper
(V)
Lower
(V)
Center Gap Voltage
(V)
3300 XL 8 mm
3300 XL 11 mm
3300 8 mm
3300 5 mm
7200 5 mm
7200 8 mm
-16.75
-16.75
-16.75
-16.75
-16.75
-2.75
-2.75
-2.75
-2.75
-2.75
-9.75
-9.75
-9.75
-9.75
-9.75
7200 11 mm -19.65 -3.55 -11.6
7200 14 mm -16.75 -2.75 -9.75
Transducer Jumper Status (on I/O Module): The jumper position on the Shaft
Absolute I/O module applies to the Shaft Absolute Velocity channel pair with
channels 3 and 4. For Shaft Absolute Radial Vibration the jumper status does
not apply. Refer to Setting the I/O Jumper in the manual of the monitor that
contains this channel.
31.3.7 Alarm Mode
- 31-9 -
This drawing is for horizontal shafts.
(1) Shaft
(2) Driver end
(3) Driven end
(4) 0
(5) 90 right
(6) 180
(7) 90 left
This section specifies the available setpoints for Shaft Absolute Radial Vibration
channel type. A setpoint is the level within the full-scale range that determines
when an alarm occurs. The 3500 Monitoring System allows Alert/Alarm 1
setpoints to be set for every proportional value on each channel. The channel
will drive an Alert/Alarm 1 indication if one or more of the channel proportional
values exceeds its setpoints. The 3500 Monitoring System also allows up to four
Danger/Alarm 2 setpoints (two over setpoints and two under setpoints) to be set
- 31-10 -
for up to two of the proportional values. You may select any two of the available
proportional values for the channel.
Note
Use the following screen in the Rack Configuration Software to adjust Alert/Alarm
1 and Danger/Alarm 2 setpoints for the Shaft Absolute Radial Vibration channel
type.
- 31-11 -
The following table lists the Alert/Alarm 1 and Danger/Alarm 2 setpoints available
for the Shaft Absolute Radial Vibration channel type. The setpoint number is
used in the Communication Gateway and Display Interface Modules.
Setpoint
Number
Shaft Absolute Radial
Vibration
1 Over Direct
2 Over Gap
3 Under Gap
4 Over 1X Ampl
5 Under 1X Ampl
6 Over 1X Phase Lag
12
13
14
is out of alarm.
- 31-12 -
Blank Page
Section 32 - Shaft Absolute Radial Vibration Verification
- 32-1 -
32. Shaft Absolute Radial Vibration
Verification
Table of Contents
32.1 Introduction.................................................................................................. 32-2
32.3 Test Alarms.................................................................................................. 32-4
32.3.1 Direct ............................................................................................ 32-4
32.3.2 Gap............................................................................................... 32-6
32.3.4 1X Phase...................................................................................... 32-8
32.4.1 Direct .......................................................................................... 32-10
32.4.2 Gap............................................................................................. 32-11
32.4.4 1X Phase.................................................................................... 32-14
32.5 Test OK Limits ........................................................................................... 32-16
- 32-2 -
32.1 Introduction
limits for channels configured as Shaft Absolute Radial Vibration. The output
values and alarm setpoints are verified by varying the input vibration signal level
(both peak to peak amplitude and DC voltage bias) and observing that the
Shaft Absolute Radial Vibration channels can be configured for the following
channel values and alarms:
Alarms
Direct X
Gap X X
needed for all the Shaft Absolute Radial Vibration channel verification
procedures (Test Alarms, Verify Channels, and Test OK Limits).
WARNING!
Application Alert
Application Alert
- 32-3 -
in the figure below (Shaft Absolute Radial Vibration Test Setup). Set the test
equipment as specified below.
Power
Supply
Multiplier/Divider
DC Volts: 0 Vdc
Frequency: 100 Hz
(above zero)
Divide Switch: 001
Shaft Absolute Radial Vibration Test Setup
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 32-4 -
(3) 4 k
(4) 100 F
(5) Keyphasor Multiplier/Divider
(6) Multimeter
(7) Shaft Absolute I/O Module terminals (either External or Internal)
(8) Function Generator
(9) Power Supply
Note
Timed OK Channel Defeat is enabled for Shaft Absolute
Radial Vibration channels. It will take 30 seconds for a
channel to return to the OK status from a not OK condition.
32.3 Test Alarms
32.3.1 Direct
the I/O module.
- 32-5 -
Note
For testing Alarms on Direct and Gap, there will be
no need for items 1-5 of the Shaft Absolute Radial
Vibration Test Setup.
screen.
an Alarm.
an Alarm.
- 32-6 -
32.3.2 Gap
the I/O module.
Note
For testing Alarms on Direct and Gap, there will be no need for
items 1-5 of the Shaft Absolute Radial Vibration Test Setup.
Alarm.
indicates an Alarm.
- 32-7 -
Note
the I/O module.
Alarm.
an Alarm.
- 32-8 -
32.3.4 1X Phase
the I/O module.
Note
Note
The 1X Amplitude needs to be a minimum of
42.7 mV to get a valid 1X Phase reading.
- 32-9 -
setpoint levels.
- 32-10 -
Note
32.4.1 Direct
the I/O module.
calculated voltage.
Note
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
- 32-11 -
32.4.2 Gap
the I/O module.
If Gap is configured to read in volts, adjust the power supply to produce a
Adjust the power supply to produce a voltage equal to mid-scale on the Gap
If Gap is configured to read in displacement units, calculate the full-scale
and bottom-scale voltage using the following equation:
Note
Gap Full-Scale = Gap Zero Position +Volts + (Gap Meter Top Scale
Example 1:
Gap = 15-0-15 mil
- 32-12 -
= -6.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
= -7.3878 Vdc
Example 1:
Gap = 15-0-15 mil
= -12.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
= -12.1122 Vdc
- 32-13 -
Note
the I/O module.
voltage.
Note
Scale Voltage = 1X Ampl Meter Top Scale Transducer Scale Factor
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
- 32-14 -
= 1.5748 Vpp
32.4.4 1X Phase
Note
If the test equipment is not capable of changing the phase output to
a known value, use the following procedure. If your test equipment
can change the phase output to a known value, use the procedure "If
the Test Equipment Can Change the Phase Output (1X Phase)".
32.4.4.1 If the test equipment cannot change the phase output (1X phase)
the I/O module.

Keyphasor
example below illustrates a phase of 45. Observe the 1X Phase bar graph
display and Current Value Box; it should read approximately what was
measured above.
- 32-15 -
Example:
1X = one cycle of vibration signal per shaft revolution.
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
the I/O module.
- 32-16 -
6. Repeat steps 1 through 5 for all configured channels
32.5 Test OK Limits
computer.
the I/O module.
Note
- 32-17 -
setting.
Shaft Absolute Radial Vibration Default OK Limits Table
(volts)
Upper OK Limit
(volts)
7200 5&8 mm -2.7 to -2.8 -16.7 to -16.8
7200 11 mm -3.5 to -3.6 -19.6 to -19.7
7200 14 mm -2.7 to -2.8 -16.7 to -16.8
3300 5&8 mm -2.7 to -2.8 -16.7 to -16.8
3300XL 8&11 mm -2.7 to -2.8 -16.7 to -16.8
- 32-18 -
Blank Page
Section 33 - Shaft Absolute Velocity Options
- 33-1 -
33. Shaft Absolute Velocity Options
Table of Contents
33.1 Introduction.................................................................................................. 33-2
33.3.3 Enable .......................................................................................... 33-4
33.3.5 Delay ............................................................................................ 33-7
33.3.7 Alarm Mode .................................................................................. 33-9
33.3.8 OK Mode ...................................................................................... 33-9
33.4 Alarm Setpoints ........................................................................................... 33-9
- 33-2 -
33.1 Introduction
Configuration Software screens associated with the Shaft Absolute Velocity
Channel.
Consider the following items before configuring a Shaft Absolute Velocity
Channel:
The Shaft Absolute Direct proportional value is the primary proportional value
used in the Shaft Absolute Velocity channel.
The jumper selection on the I/O modules must match the velocity transducer
selected in the Rack Configuration Software.
can not be selected.
the rack.
The 1X Phase values can be enabled only if the selected Keyphasor channel
When a full-scale range is modified, readjust the setpoints associated with
this proportional value.
When integration is selected, the available Direct Full-scale Ranges will
change to reflect this. 1X Amplitude always displays in displacement units.
The minimum machine speed supported by the 1X vector filtering is 4 Hz.
be set a minimum of a decade apart.
The 100ms danger alarm is only available for the Velomitor and High
Temperature Velomitor options.
The maximum channel frequency supported is 1 Hz to 4000 Hz.
compatible.
- 33-3 -
This section describes the options available on the Shaft Absolute Velocity
Channel configuration screen.
- 33-4 -
Channel: The number of the channel being configured (3 or 4).
Group: The association of channels which derive the shaft absolute signal.
Group 1 consists of channels 1 and 3, Group 2 consists of channels 2 and 4.
(Standard or TMR).
transducer.
33.3.3 Enable
Shaft Absolute Direct: Data which represents the overall peak to peak vibration
of the Shaft Absolute signal. The Shaft Absolute signal is the vector summation
of the corresponding shaft relative proximitor (channel 1 or 2) and the bearing
absolute integrated velocity (channel 3 or 4) signals. All frequencies within the
selected Shaft Absolute Direct Frequency Response are included in this
proportional value.
- 33-5 -
Shaft Absolute Direct
Shaft Absolute 1X Ampl
1X Ampl
0-5 mil pp
0-10 mil pp
0-15 mil pp
0-20 mil pp
0-150 m pp
0-250 m pp
0-400 m pp
0-500 m pp
Custom
Direct (Velocity): The time rate of change of the displacement. When
Integration is selected it yields a peak to peak measurement of the displacement.
The Direct values are available for all transducer types.
Direct
0-0.5 in/s pk
0-1 in/s pk
0-2 in/s pk
0-10 mm/s pk
0-20 mm/s pk
0-50 mm/s pk
Custom
Integrate: When Integrate is enabled, the Direct Full-scale Range selections
The Direct values (Integrated) are available for all transducer types.
- 33-6 -
Full-scale Range Direct
0-5 mil pp
0-10 mil pp
0-20 mil pp
0-100 m pp
0-200 m pp
0-500 m pp
Custom
If 1X Phase Lag is selected then the two options available are with and without
Hysteresis. If the channel is Bypassed, the output will be clamped to the
selected clamp value or to 2 mA (if the 2 mA clamp is selected).
High-pass Filter: A two-pole filter that must be at least a factor of 5.7 times
- 33-7 -
LPF ( LPF / 5.7 )
Recommended high-pass filter setting: A minimum of two octaves below the
typical machine speed. For example: Machine speed = 3600 RPM = 60 Hz
HPF ((60 / 2) /2) = 15 Hz
LPF ( HPF * 5.7 )
33.3.5 Delay
Type: The following transducer types are available for the Shaft Absolute
Velocity Channel:
9200 2-wire Seismoprobe
74712 High Temperature 2-wire Seismoprobe
Nonstandard 2-wire Seismoprobe
Velomitor
Nonstandar
- 33-8 -
adjusted.
mV/in/s.
Transducer Scale Factor
9200 500 mV/(in/s)
74712 500 mV/(in/s)
Nonstandard 2 wire 145 mV/(in/s)
Velomitor 100 mV/(in/s)
High Temperature
Velomitor
145 mV/(in/s)
OK Limits
Transducer Upper Lower Center Gap
Voltage
9200 -17.95 -2.05 -10.00
74712 -17.95 -2.05 -10.00
NonStandard -17.95 -2.05 -10.00
Velomitor -19.85 -4.15 -12.00
High Temperature
Velomitor
-21.26 -2.74 -12.00
- 33-9 -
Transducer Jumper on the Shaft Absolute I/O Module. Refer to Setting the I/O
Jumper in the manual of the monitor that contains this channel for the function of
this jumper.
33.3.7 Alarm Mode
33.3.8 OK Mode
methods:
This section specifies the available setpoints for the Shaft Absolute Velocity
channel type. A setpoint is the level within the full-scale range that determines
when an alarm occurs. The 3500 Monitoring System allows Alert/Alarm 1
setpoints to be set for every proportional value on each channel. The channel
- 33-10 -
will drive an Alert/Alarm 1 indication if one or more of the channel proportional
values exceeds its setpoints. The 3500 Monitoring System also allows up to four
Danger/Alarm 2 setpoints (two over setpoints and two under setpoints) to be set
for up to two of the proportional values. You may select any two of the available
proportional values for the channel.
Note
Use the following screen in the Rack Configuration Software to adjust Alert/Alarm
1 and Danger/Alarm 2 setpoints for a Shaft Absolute Velocity channel.
- 33-11 -
The following table lists the Alert/Alarm 1 and Danger/Alarm 2 setpoints available
for the Shaft Absolute Velocity channel type. The setpoint number is used in the
Setpoint
Number
Shaft Absolute Velocity
1 Over Shaft Absolute Direct
2 Over Shaft Absolute 1X Ampl
3 Under Shaft Absolute 1X Ampl
4 Over Shaft Absolute 1X Phase Lag
5 Under Shaft Absolute 1X Phase Lag
6 Over Direct
7 Over 1X Ampl
8 Under 1X Ampl
9 Over 1X Phase Lag
is out of alarm.
- 33-12 -
Blank Page
Section 34 - Shaft Absolute Velocity Verification
- 34-1 -
34. Shaft Absolute Velocity Verification
Table of Contents
34.1 Introduction.................................................................................................. 34-2
34.2.1 Test Equipment Setup - Seismoprobe........................................... 34-3
34.2.2 Test Equipment Setup - Velomitor (Shaft Absolute I/O)................. 34-3
34.2.3 Verification Screen Setup............................................................ 34-10
34.3 Test Alarms................................................................................................ 34-11
34.3.1 Shaft Absolute Direct (SA DIR) ................................................... 34-11
34.3.2 Shaft Absolute 1X Amplitude (SA 1X) ......................................... 34-12
34.3.3 Shaft Absolute 1X Phase (SA 1X Ph).......................................... 34-13
34.3.4 Direct .......................................................................................... 34-15
34.3.6 1X Phase.................................................................................... 34-17
34.4.1 Shaft Absolute Direct (SA DIR) ................................................... 34-19
34.4.2 Shaft Absolute 1X Amplitude (SA 1X) ......................................... 34-20
34.4.3 Shaft Absolute 1X Phase (SA 1X Ph).......................................... 34-20
34.4.4 Direct .......................................................................................... 34-22
34.4.6 1X Phase.................................................................................... 34-23
34.5 Verify Filter Corner Frequencies ................................................................ 34-24
34.6 Test OK Limits ........................................................................................... 34-28
34.6.1 For Seismoprobes:...................................................................... 34-28
34.6.2 For Velomitors ............................................................................ 34-29
- 34-2 -
34.1 Introduction
filter corner frequencies, and test OK limits for channels configured as Shaft
Absolute Velocity. The output values and alarm setpoints are verified by varying
the input signal level and observing that the correct results are reported in the
Shaft Absolute Velocity channels can be configured for the following channel
values and alarms:
Alarms Channel Values
Over Under
Shaft Absolute Direct X
Shaft Absolute 1X Ampl X X
Shaft Absolute 1X Phase X X
Direct X
1X Amplitude X X
1X Phase X X
Filter Corner Frequencies, and Test OK Limits).
WARNING
Application Alert
- 34-3 -
Application Alert
Disconnecting the field wiring will cause a
not OK condition.
34.2.1 Test Equipment Setup - Seismoprobe
generator, and multimeter to the channel group terminals of channel 3 with
polarity as shown in the corresponding figures for either Alarm Testing, Channel
Verification, or 1X Amplitude and Phase Testing. Set the test equipment as
specified below:
Power Supply Function Generator
DC Volts: 0 Vdc
Frequency: 100 Hz
Amplitude level: Minimum (above
zero)
34.2.2 Test Equipment Setup - Velomitor (Shaft Absolute I/O)
generator, and multimeter to the channel group terminals of channel 3 with
polarity as shown in the corresponding figures for either Alarm Testing, Channel
Verification, 1X Amplitude and Phase Testing, or Velomitor OK Limit Testing.
Set the test equipment as specified below:
Function Generator
Waveform: sinewave
DC Volts: 0 Vdc
Frequency: 100 Hz
- 34-4 -
Seismoprobe Alarm Test Setup
(1) Multimeter
(3) Power Supply
(5) 2.49 k
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-5 -
Seismoprobe Channel Verification Test Setup
(1) Power Supply
(2) Multimeter
(4) Power Supply
(6) 2.49 k
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-6 -
Seismoprobe 1X Amplitude and Phase Test Setup
(3) 40 k
(4) 100 F
(5) Keyphasor Multiplier/Divider
(8) Power Supply
(9) 2.49 k
(10) Multimeter
(11) Power Supply
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-7 -
Velomitor Alarm Test Setuo
(1) Multimeter
(2) Power Supply
(5) 4 k
(6) 10 F
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-8 -
Velomitor Channel Verification Test Setup
(1) Power Supply
(2) Multimeter
(5) 4 k
(6) 10 F
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-9 -
Velomitor 1X Amplitude and Phase Test Setup
(3) 40 k
(4) 100 F
(5) Keyphasor Mutiplier/Divider
(6) Multimeter
(8) Power Supply
(9) 4 k
(10) 10 F
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-10 -
Velomitor OK Limit Test Setup
(1) Multimeter
(2) Power Supply
Note
on the Rack Interface Module (RIM) to return to OK status.
COM
PWR
SIG
SEIS/B
SEIS/A
COM
S ABS
- 34-11 -
34.3 Test Alarms
The general approach for testing alarm setpoints is to simulate the Shaft
Absolute and Velocity signals with a function generator and power supply. The
alarm levels are tested by varying the output from the test equipment and
observing that the correct results are reported in the Verification screen on the
test computer. It is only necessary to test those alarm parameters that are
to exceed over Alert/Alarm 1 and Danger/Alarm2 Setpoints, and
34.3.1 Shaft Absolute Direct (SA DIR)
1. Disconnect PWR, COM, SIG, SIES/B, and SEIS/A field wiring from the
channel group terminals on the I/O module.
and Software Setup" on page 34-2:
For Seismoprobe: Use the setup shown in ""Seismoprobe Alarm Test Setup
on page 34-4.
For Velomitor: Use the setup shown in Velomitor Alarm Test Setup on page
34-7.
frequency to the calculated value..
the Shaft Absolute Direct setpoint levels on the Shaft Absolute Direct bar
graph display of the Verification screen.
Shaft Absolute Direct Over Alert/Alarm 1 setpoint level. Wait for 2 or 3
seconds after the alarm time delay expires and verify that the bar graph
indicator for Shaft Absolute Direct changes color from green to yellow and the
Current Value Field indicates an Alarm.
bar graph indicator for Shaft Absolute Direct remains yellow and that the
Current Value Field still indicates an Alarm.
Shaft Absolute Direct Over Danger/Alarm 2 setpoint level. Wait for 2 or 3
- 34-12 -
indicator for Shaft Absolute Direct changes color from yellow to red and that
the Current Value Field indicates an Alarm.
bar graph indicator for Shaft Absolute Direct remains red and that the Current
Value Field still indicates an Alarm.
that the bar graph indicator for Shaft Absolute Direct changes color to green
and that the Current Value Box contains no indication of alarms. Press the
RESET switch on the Rack Interface Module (RIM) to reset latching alarms.
12. Disconnect the test equipment and reconnect the PWR, COM, SIG, SEIS/A,
and SEIS/B field wiring to the channel group terminals on the I/O module.
Verify that the OK LED comes on and the OK relay energizes. Press the
RESET switch on the Rack Interface Module (RIM) to reset the OK LED.
34.3.2 Shaft Absolute 1X Amplitude (SA 1X)
Note
1. Disconnect PWR, COM, SIG, SEIS/A, and SEIS/B field wiring from the
and Software Setup" on page 34-2. Use the appropriate test setup in either
Seismoprobe 1X amplitude and Phase Test Setup (page 34-6) or Velomitor
1X Amplitude and Phase Test Setup (page 34-9).
reading that is within the Shaft Absolute 1X Ampl setpoint levels on the Shaft
Absolute 1X Ampl bar graph display of the Verification screen.
OK LED is on, the bar graph indicator for Shaft Absolute 1X Ampl is green
and that the Current Value field contains no alarm indication.
Shaft Absolute 1X Ampl Over Alert/Alarm 1 setpoint level. Wait for 2 to 3
- 34-13 -
indicator for Shaft Absolute 1X Ampl changes color from green to yellow and
bar graph indicator for Shaft Absolute 1X Ampl remains yellow and that the
Shaft Absolute 1X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 to 3
indicator for Shaft Absolute 1X Ampl changes color from yellow to red and
bar graph indicator for Shaft Absolute 1X Ampl remains red and that the
that the bar graph indicator for Shaft Absolute 1X Ampl changes color to
green and that the Current Value Box contains no indication of alarms. Press
the RESET switch on the Rack Interface Module (RIM) to reset latching
alarms.
34.3.3 Shaft Absolute 1X Phase (SA 1X Ph)
and Software Setup" on page 34-2. Use the appropriate test setup in
Seismoprobe 1X amplitude and Phase Test Setup (page 34-6) or Velomitor
- 34-14 -
Note
Shaft Absolute 1X Phase setpoint levels on the Shaft Absolute 1X Phase bar
graph display of the Verification screen.
Note
OK LED is on, the bar graph indicator for Shaft Absolute 1X Phase is green,
and the Current Value field contains no alarm indication.
5. Adjust the phase such that the reading just exceeds the Shaft Absolute 1X
Phase Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Shaft
Absolute 1X Phase changes color from green to yellow and the Current
Value Field indicates an Alarm.
bar graph indicator for Shaft Absolute 1X Phase remains yellow and that the
7. Adjust the phase such that the reading just exceeds the Shaft Absolute 1X
Phase Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Shaft
Absolute 1X Phase changes color from yellow to red and that the Current
bar graph indicator for Shaft Absolute 1X Phase remains red and that the
indicator for Shaft Absolute 1X Phase changes color to green and that the
- 34-15 -
setpoint levels.
34.3.4 Direct
For Seismoprobe: Use the setup shown in Seismoprobe Alarm Test Setup
on page 34-4.
For Velomitor: Use the setup shown in Velomitor Alarm Test Setup on page
34-7.
screen.
Alarm.
an Alarm.
- 34-16 -
12. Disconnect the test equipment and reconnect the PWR, COM, SIG, SEIS / A,
Note
Seismoprobe 1X Amplitude and Phase Test Setup (page 34-6) or Velomitor
- 34-17 -
Alarm.
an Alarm.
SEIS/B field wiring to the channel group terminals on the I/O module. Verify
that the OK LED comes on and the OK relay energizes. Press the RESET
switch on the Rack Interface Module (RIM) to reset the OK LED.
34.3.6 1X Phase
1. Disconnect PWR, COM, SIG, SEIS/A, SEIS/B field wiring from the channel
group terminals on the I/O module.
- 34-18 -
Note
Note
- 34-19 -
setpoint levels.
SEIS/B field wiring to the channel group terminals on the I/O module. Verify
that the OK LED comes on and the OK relay energizes. Press the RESET
switch on the Rack Interface Module (RIM) to reset the OK LED.
The general approach for testing these parameters is to simulate the velocity
signal with a function generator and power supply. The Shaft Absolute Radial
Vibration signal (channels 1 or 2) will be zero, making the shaft absolute signal
equal to the integrated velocity signal. The channel values are verified by
varying the output from the test equipment and observing that the correct results
are reported in the Verification screen on the test computer.
34.4.1 Shaft Absolute Direct (SA DIR)
For Seismoprobe: Use the setup shown in Seismoprobe Channel
Verification Test Setup on page 34-5.
For Velomitor: Use the setup shown in Velomitor Channel Verification Test
Setup on page 34-8.
4. Calculate the full-scale voltage using the procedure in "Full Scale Formulas -
Integration" on page 34-27. Adjust the function generator (sinewave)
amplitude to the calculated value.
1 % of full-scale.
- 34-20 -
34.4.2 Shaft Absolute 1X Amplitude (SA 1X)
Note
1. Disconnect PWR, COM, SIG, SEIS / A, and SEIS/B field wiring from the
34.4.3 Shaft Absolute 1X Phase (SA 1X Ph)
1. Disconnect PWR, COM, SIG, SEIS / A, and SEIS/B field wiring from the
- 34-21 -

Keyphasor
pulse to the first positive peak of the vibration signal. Since the
Shaft Absolute 1X signal is determined after integration of the velocity signal,
you must add 90 from the phase measured with the input signal. See the
example below which illustrates a phase of 45. After adding 90, the phase
will be 45 + 90 = 135. Observe the 1X Phase bar graph display and
Current Value Box; it should read approximately what was measured above,
plus 90.
Example:
1. 1X Vibration Signal
2. Keyphasor Signal
3. Time
4. 0
5. One cycle
6. 360
7. Phase lag = 45
- 34-22 -
34.4.4 Direct
Verification Test Setup on page 34-5.
Setup on page 34-8.
1 % of full-scale.
- 34-23 -
6. Verify that the 1X Ampl bar graph display and Current Value Box is reading
1 % of full scale.
34.4.6 1X Phase
channel group terminals on the I/O module

Keyphasor
pulse to the first positive peak of the vibration signal. Since the
Shaft Absolute 1X signal is determined after integration of the velocity signal,
you must add 90 from the phase measured with the input signal. See the
example below which illustrates a phase of 45. After adding 90, the phase
will be 45 + 90 = 135. Observe the 1X Phase bar graph display and
Current Value Box; it should read approximately what was measured above,
plus 90.
- 34-24 -
Example:
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
34.5 Verify Filter Corner Frequencies
The general approach for testing these parameters is to simulate the Velocity
signal with a function generator and power supply. The corner frequencies are
- 34-25 -
Note
If the channel units are integrated, change the channel configuration
to a non-integrated scale for this test. This test cannot be performed
on the Shaft Absolute Direct, Shaft Absolute 1X, or 1X PPLs. When
the test is complete, return the channel to its original configuration.
channel group terminals on the I/O module
Verification Test Setup (page 34-5).
Setup (page 34-8).
3. Calculate the verification frequency using the formulas in "Calculating
full-scale.
6. Adjust the function generator frequency to the low-pass filter corner
7. Adjust the function generator frequency to the high-pass filter corner
- 34-26 -
you use the following formulas to calculate the verification frequency:
configured High-pass Filter Corner Frequency and the Low-pass Filter Corner
Frequency into the formula below:
If a Low-pass Filter is configured and no High-pass Filter is configured, use a
HPF of 1 Hz.
If a High-pass Filter is configured and no Low-pass Filter is configured, use a
LPF of 4,000 Hz.
you use the following formulas to calculate the input voltage for Full-scale. To
find the Full-scale input voltage, use appropriate table or formula for integrated or
non-integrated units.
Note
Units To Input RMS Volts To Input Peak to Peak
Volts
in/s pk (T.S.F x Full-scale) x 0.707 (T.S.F x Full-scale) x 2
mm/s pk (T.S.F x Full-scale) x 0.707 (T.S.F x Full-scale) x 2
To use the formulas, the T.S.F. should be in volts and the T.S.F and full-scale
values should both be of the same unit system (metric or English). The
transducer Scale Factor will always be specified as volts per inch/second pk or
volts per millimetre/second pk.
Example 1:
Transducer Scale Factor = 500 mV/(in/s)
Full Scale = 0.5 in/s pk
- 34-27 -
(0.500 0.5) 2 = 0.5 Vpp
Example 2:
Full Scale = 20 mm/s pk
(0.01969 20) 2 = 0.7876 Vpp
(For the following units: mil pp and m pp)
07071 . 0 *
831 . 31
]
]
]
,
,
(
(
,
\
,
,
(
j
2 . 0 *
831 . 31
]
]
]
,
,
(
(
,
\
,
,
(
j
To use the formulas, the Velocity Scale Factor should be in volts, and the Full-
scale value and Velocity Scale Factor should be in English units. Use the
following conversion formulas to convert Metric units to English units:
Scale Factor
4 . 25 * (mm/s) Factor Scale Velocity (inch/s) Factor Scale Velocity
Full scale:
4 . 25
) ( Scale - Full
(mil) Scale - Full
Example:
To calculate the input voltage for a channel with the following configuration:
Full Scale = 100 m pp
HPF = 3 Hz
LPF = 3000 Hz
1. Convert Metric units to English units.
Scale Factor:
mV(in/s) 500 4 . 25 * mV(mm/s) 69 . 19
Full-scale:
mil 9370 . 3
4 . 25
m 100
2. Calculate the input voltage.

- 34-28 -
rms) (V 4148 . 0 07071 . 0 *
Hz 8683 . 94 /
V/(in/s) 500 0
831 31
mil 9370 . 3
]
]
]
,
,
(
(
,
\
,
,
(
j
.
.
or
pp) (V 173 . 1 2 . 0 *
Hz 8683 . 94 /
V/(in/s) 500 0
831 31
mil 9370 . 3
]
]
]
,
,
(
(
,
\
,
,
(
j
.
.
Note
The accuracy of the reading will be affected by frequency values
less than 20 Hz and setting LPF 5.7 times away from the HPF.
34.6 Test OK Limits
Note
If the Danger Bypass has been activated, then the BYPASS
LED will be on. All other channels in the rack must be OK
or bypassed for the OK relay to be energized.
34.6.1 For Seismoprobes:
The general approach for testing OK limit is to disconnect the input. This will
cause a not OK condition and the OK Relay to change state (de-energize).
1. Disconnect the SIG / A field wiring from the channel terminals on the Shaft
Absolute Monitor I/O Module.
3. Verify that the OK relay changes state (de-energized).
4. Verify that the Channel OK State line on the Verification screen reads not
OK.
- 34-29 -
5. Reconnect the SIG / A field wiring to the channel terminals on the Monitor I/O
6. Verify that the Channel OK State line on the Verification screen reads OK.
34.6.2 For Velomitors
Due to the requirements for increased robustness in the Shaft Absolute system,
the Shaft Absolute I/O Module has a Velomitor interface that is different from the
Prox/Seis I/O Module's Velomitor interface. The effect of this difference is that
the Velomitor signal input to the I/O Module is 180 degrees out of phase from the
correct Velomitor signal. This means that when you input a test signal using a
signal generator or DC power supply the buffered outputs on the front panel will
be inverted in phase and will have a different DC voltage than the input. This will
not affect the actual vibration readings in the Monitor.
1. Disconnect PWR, COM / A, and SIG / B field wiring from the channel
goes off (lower limit due to the inversion on the I/O Module). Verify that the
Channel OK State line on the Verification screen reads not OK and that the
OK Relay indicates not OK. Verify that the Lower OK limit voltage displayed
on the Verification screen is equal to or more negative than the following
value.
- 34-30 -
LED just goes off (upper limit due to the inversion on the I/O Card). Verify
that the Channel OK State line in the Channel Status section reads not OK
and that the OK Relay indicates not OK. Verify that the Upper OK limit
voltage displayed on the Verification screen is equal to or more positive than
the following value.
14. Disconnect the power supply and multimeter and reconnect the PWR, COM /
A, and SIG / B field wiring to the channel terminals on the Monitor I/O
setting.
Velocity Default OK Limits Table
(volts)
Upper Ok Limit
(volts)
9200 -2.0 to -2.1 -17.9 to -18.0
74172 -2.0 to -2.1 -17.9 to -18.0
non std 2-wire Seismoprobe -2.0 to -2.1 -17.9 to -18.0
Velomitor (standard) -4.1 to -4.2 -19.8 to -19.9
Velomitor (high temp) -2.69 to -2.79 -21.21 to -21.31
non std -2.0 to -2.1 -17.9 to -18.0
Section 35 - Circular Acceptance Region General Information
- 35-1 -
35. Circular Acceptance Region General
Information
Radial vibration is the dynamic motion of a shaft or casing in a direction
perpendicular to the shaft axis. 3500 Radial Vibration channels measure this
motion by using input signals from proximity probes. These channels condition
the input signals into various parameters called proportional values. A Radial
Vibration channel typically provides proportional values such as Direct, Gap, 1X
amplitude and phase lag angle (when used in conjunction with a Keyphasor
signal), and 2X amplitude and phase lag angle. Each channel also provides
setpoints that can be used for alarming. Alert setpoints can be configured for
each active proportional value and Danger setpoints can be configured for any
two of the active proportional values.
Setpoints can be used to define an Acceptance Region for the 1X or 2X vibration
vectors. The user typically defines the normal Acceptance Region for each shaft
radial vibration measurement on the machine, based on historical data for the
machine under all normal operating conditions.
With a standard Radial Vibration Channel, alarm setpoints are set independently
for maximum and minimum values of both amplitude and phase. When
represented in polar format, these four setpoints define a pie shaped
acceptance region (see figure below).
Radial Vibration Acceptance Region
Lower Phase Setpoint
Upper Amplitude Setpoint
Lower Amplitude Setpoint
Upper Phase Setpoint
- 35-2 -
Using the Circular Acceptance Region channel type, a circular acceptance region
can be defined. When represented in polar format, the Circular Acceptance
Region is defined by a reference vector (D
sp
,
sp
) from the origin and a radius
(R
sp
) which functions as the alarm setpoint (see figure below).
Circular Acceptance Region
Ysp
Xsp
(sp,Dsp)
Rsp
Section 36 - Circular Acceptance Region Configuration
- 36-1 -
36. Circular Acceptance Region
Configuration
Table of Contents
36.1 Introduction.................................................................................................. 36-2
36.3.3 Enable .......................................................................................... 36-4
36.3.4 Delay ............................................................................................ 36-7
36.3.6 Alarm Mode ................................................................................ 36-10
36.3.7 Transducer Orientation ............................................................... 36-11
36.3.8 Barriers....................................................................................... 36-11
36.4 Alarm Setpoints ......................................................................................... 36-11
- 36-2 -
36.1 Introduction
Configuration Software screens associated with the Circular Acceptance
Channel.
Consider the following items before configuring a Circular Acceptance Region
Channel:
Internal Barrier I/O Modules and External barriers are not currently supported
with 7200 11 mm or 14 mm, or 3000 Proximitors, or the 3300 16 mm HTPS.
2X Amplitude (Ampl) and Phase Lag, 1X Circular Acceptance (CAR), and 2X
Circular Acceptance (CAR) can not be selected.
the rack.
mV/mil.
mV/mil.
may be configured as Radial Vibration and Channels 3 and 4 may be
configured as Circular Acceptance).
- 36-3 -
3000 (-18V), 3000 (-24V), and 3300 RAM Proximitors have limited linear
ranges. Therefore, you should use caution when selecting the Full-scale
range of the Direct, 1X Amplitude (Ampl), 2X Amplitude (Ampl), 1X Circular
Acceptance (CAR) and 2X Circular Acceptance (CAR) PPLs. Full-scale
value x Trip Multiply should not exceed the linear range of the transducer.
This section describes the options available on the Circular Acceptance Channel
seconds. This feature is always enabled in the Circular Acceptance Channels.
The option protects against false trips caused by intermittent transducers.
details.
- 36-4 -
Gap Scale.
Direct Frequency Response: The upper and lower corners for the band-pass
filter used with direct vibration measurements. The available ranges are 240 to
240,000 cpm and 60 to 36,000 cpm.
(Standard or TMR).
36.3.3 Enable
value.
1X CAR: Circular Acceptance Region, where a reference angle and magnitude
are specified and the magnitude of rotative speed frequency vibration component
is reported relative to this reference.
- 36-5 -
having a frequency equal to two times the shaft rotative speed.
component having a frequency equal to two times the shaft rotative speed. 2X
phase lag is the angular measurement from the leading or trailing edge of the
Keyphasor pulse to the following positive peak of the 2X vibration signal.
2X CAR: Circular Acceptance Region, where a reference angle and magnitude
are specified and the magnitude of two times rotative speed frequency vibration
component is reported relative to this reference.
Configure buttons: Used to adjust the Reference Vector for 1X and 2X CAR
calculations. The Reference Vector amplitude must be between 0 and 10 mil.
Also, vector phase must be between 0 and 359 degrees
Direct
1X Ampl
2X Ampl
0-3 mil pp
0-5 mil pp
0-10 mil pp
0-15 mil pp
0-20 mil pp
0-100 m pp
0-150 m pp
0-200 m pp
0-400 m pp
0-500 m pp
Custom
- 36-6 -
Gap Full-scale Ranges by Transducer Type
33005 mm Proximitor
33008 mm Proximitor
72005 mm Proximitor
72008 mm Proximitor
330016 mm HTPS
Nonstandard
3300 RAM Proximitor
-24 Vdc
15-0-15 mil
25-0-25 mil
300-0-300 m
600-0-600 m
Custom
-24 Vdc
15-0-15 mil
25-0-25 mil
50-0-50 mil
300-0-300 m
600-0-600 m
1000-0-1000 m
Custom
-24 Vdc
15-0-15 mil
300-0-300 m
- 36-7 -
36.3.4 Delay
Setpoint screen.
Type: The following transducer types are available for the Circular Acceptance
3300 Transducers
3300 RAM Proximitor
3300 16 mm HTPS
7200 Transducers
3000 Transducers
- 36-8 -
Nonstandard
The following transducer types are available for the Circular Acceptance Channel
3300 Transducers
3300 RAM Proximitor
7200 Transducers
Nonstandard
adjusted.
mV/mil.
- 36-9 -
Scale Factor
Transducer Without
Barriers
With Bently
Nevada
Internal
Barriers
Standard
I/O With
Barriers
Discrete
TMR I/O
With
Barriers
Bussed
TMR I/O
With
Barriers
3300 XL 8 mm
3300 5 and 8 mm
7200 5 and 8 mm
200
mV/mil
200 mV/mil 192 mV/mil 200 mV/mil 199 mV/mil
3300 XL 11 mm 100
mV/mil
7200 11 mm *100
mV/mil
* * * *
7200 14 mm *100
mV/mil
* * * *
3000 (-18 V) *200
mV/mil
* * * *
3000 (-24 V) *285
mV/mil
* * * *
3300 RAM 200
mV/mil
3300 16 mm
HTPS
100
mV/mil
* * * *
- 36-10 -
Transducer Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
Without
Barriers
(V)
With
Barriers
(V)
3300 XL 8 mm
3300 XL 11 mm
3300 5 mm
3300 8 mm
7200 5 mm
7200 8 mm
-16.75 -16.75 -2.75 -2.75 -9.75 -9.75
7200 11 mm -19.65 * -3.55 * -11.6 *
7200 14 mm -16.75 * -2.75 * -9.75 *
3000 (-18 V) -12.05 * -2.45 * -7.25 *
3000 (-24 V) -15.75 * -3.25 * -9.5 *
3300 RAM -12.55 -12.15 -2.45 -2.45 -7.5 -7.3
3300 16 mm
HTPS
-16.75 * -2.75 * -9.75 *
Note: With Barriers includes BN Internal Barrier I/O Modules.
36.3.6 Alarm Mode
- 36-11 -
(1) Shaft
(2) Driver end
(3) Driven end
(4) 0
(5) 90 right
(6) 180
(7) 90 left
36.3.8 Barriers
This section lists the available setpoints for the Circular Acceptance channel. A
setpoint is the level within the full-scale range that determines when an alarm
occurs. The 3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for
every proportional value on each channel. The channel will drive an Alert/Alarm
1 indication if one or more of the channel proportional values exceeds its
setpoints. The 3500 Monitoring System also allows up to four Danger/Alarm 2
setpoints (two over setpoints and two under setpoints) to be set for up to two of
the proportional values. You may select any two of the available proportional
values for the channel.
- 36-12 -
Note
Alert/Alarm 1 and Danger/Alarm 2 setpoints for Circular Acceptance channels.
- 36-13 -
for each Circular Acceptance channel pair. The setpoint number is used in the
Setpoint
Number
Circular Acceptance
1 Over Direct
2 Over Gap
3 Under Gap
4 Over 1X Ampl
5 Under 1X Ampl
6 Over 1X Phase Lag
8 Over 1X Circular Acceptance Radius
9 Over 2X Ampl
10 Under 2X Ampl
13 Over 2X Circular Acceptance Radius
of alarm.
- 36-14 -
Blank Page
Section 37 - Circular Acceptance Region verification
- 37-1 -
37. Circular Acceptance Region Verification
Table of Contents
37.1 Introduction.................................................................................................. 37-2
37.3 Test Alarms.................................................................................................. 37-5
37.3.1 Direct ............................................................................................ 37-5
37.3.2 Gap............................................................................................... 37-6
37.3.4 1X Phase...................................................................................... 37-8
37.3.5 1X Circular Acceptance............................................................... 37-10
37.3.7 2X Phase.................................................................................... 37-13
37.4.1 Direct .......................................................................................... 37-16
37.4.2 Gap............................................................................................. 37-18
37.4.4 1X Phase.................................................................................... 37-21
37.4.7 2X Phase.................................................................................... 37-26
37.4.9 Test OK Limits ............................................................................ 37-30
- 37-2 -
37.1 Introduction
limits for channels configured as Circular Acceptance. The output values and
alarm setpoints are verified by varying the input vibration signal level (both peak
to peak amplitude and DC voltage bias) and observing that the correct results
are reported in the Verification screen on the test computer.
Circular Acceptance channels can be configured for the following channel values
and alarms:
Alarms
Direct X
Gap X X
1X Circular Acceptance X
2X Circular Acceptance X
needed for all the Circular Acceptance channel verification procedures (Test
Alarms, Verify Channels, and Test OK Limits).
WARNING!
High voltage present. Contact could cause shock, burns, or
death. Do not touch exposed wires or terminals.
Application Alert
Tests will exceed alarm setpoint levels causing alarms to activate.
This could result in a relay contact state change.
- 37-3 -
Application Alert
condition.
in the figure below (Circular Acceptance Test Setup). Set the test equipment as
specified below.
Power Supply Function Generator Keyphasor
Multiplier/Divider
DC Volts: 0 Vdc
Frequency: 100 Hz
Amplitude level:
Minimum (above zero)
Divide Switch: 001
- 37-4 -
The equipment shown in the dashed box is required for 1X Amplitude, 1X Phase,
1X Circular Acceptance, 2X Amplitude, 2X Phase, and 2X Circular Acceptance
tests.
Test equipment for Circular Acceptance
(3) 40 k
(4) 100 F
(9) Mulitmeter
(10) Power supply
- 37-5 -
Note
Timed OK Channel Defeat is enabled for Circular Acceptance
channels. It will take 30 seconds for a channel to return to
the OK status from a not OK condition.
37.3 Test Alarms
37.3.1 Direct
the I/O module.
- 37-6 -
an Alarm.
an Alarm.
37.3.2 Gap
the I/O module.
Alarm.
- 37-7 -
indicates an Alarm.
Note
the I/O module.
- 37-8 -
Alarm.
an Alarm.
37.3.4 1X Phase
Note
the I/O module.
- 37-9 -
Note
4. The 1X Amplitude needs to be a minimum of 10 mV to get a valid 1X Phase
reading.
setpoint levels.
- 37-10 -
37.3.5 1X Circular Acceptance
Note
The Keyphasor must be triggering and have a valid rpm
value to check this parameter.
the I/O module.
Note
reading that is below the Not 1X setpoint levels on the Not 1X bar graph
OK LED is on, the bar graph indicator for 1X Circular Acceptance is green,
and the Current Value field has no alarm indication.
1X Circular Acceptance Over Alert/Alarm 1 setpoint level. Wait for 2 or 3
indicator for 1X Circular Acceptance changes color from green to yellow and
that the Current Value Field indicates an Alarm.
bar graph indicator for 1X Circular Acceptance remains yellow and that the
- 37-11 -
1X Circular Acceptance Over Danger/Alarm 2 setpoint level. Wait for 2 or 3
indicator for 1X Circular Acceptance changes color from yellow to red and
bar graph indicator for 1X Circular Acceptance remains red and that the
that the bar graph indicator for 1X Circular Acceptance changes color to
green and the Current Value Box contains no indication of alarms. Press the
10. Adjust the phase such that the reading just exceeds the 1X Circular
Acceptance Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after
Phase changes color from green to yellow and the Current Value Field
indicates an Alarm.
Acceptance Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds
after the alarm time delay expires and verify that the bar graph indicator for
1X Circular Acceptance changes color from yellow to red and that the Current
indicator for 1X Circular Acceptance changes color to green and that the
- 37-12 -
Note
the I/O module.
an Alarm.
indicates an Alarm.
- 37-13 -
37.3.7 2X Phase
Note
the I/O module.
2. Connect test equipment and run software as described in Test Equipment
Setup.
Note
4. The 2X Amplitude needs to be a minimum of 10 mV to get a valid 2X Phase
reading.
- 37-14 -
setpoint levels.
Note
the I/O module.
2. Connect test equipment and run software as described in Test Equipment
Setup.
- 37-15 -
Note
OK LED is on, the bar graph indicator for 2X Circular Acceptance is green,
and the Current Value field has no alarm indication.
2X Circular Acceptance Over Alert/Alarm 1 setpoint level. Wait for 2 or 3
indicator for 2X Circular Acceptance changes color from green to yellow and
2X Circular Acceptance Over Danger/Alarm 2 setpoint level. Wait for 2 or 3
indicator for 2X Circular Acceptance changes color from yellow to red and
that the bar graph indicator for 2X Circular Acceptance changes color to
green and the Current Value Box contains no indication of alarms. Press the
Acceptance Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after
Circular Acceptance changes color from green to yellow and the Current
- 37-16 -
Acceptance Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds
after the alarm time delay expires and verify that the bar graph indicator for
2X Circular Acceptance changes color from yellow to red and that the Current
indicator for 2X Circular Acceptance changes color to green and that the
Note
37.4.1 Direct
the I/O module.
2. Connect test equipment and run software as described in Test Equipment.
- 37-17 -
calculated voltage.
Application Alert
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
For Vrms input:
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For Vrms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
- 37-18 -
37.4.2 Gap
the I/O module.
3. If Gap is configured to read in volts, adjust the power supply to produce a
If Gap is configured to read in displacement units, calculate the full-scale and
bottom-scale voltage using the following equation:
Note
Gap Full-Scale = Gap Zero Position Volts + (Gap Meter Top Scale Transducer
Scale Factor)
Example 1:
Gap = 15-0-15 mil
= -6.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
= -7.3878 Vdc
- 37-19 -
Example 1:
Gap = 15-0-15 mil
= -12.75 Vdc
Example 2:
= 7.874 mV/m
Gap = 300-0-300 m
= -12.1122 Vdc
- 37-20 -
Note
the I/O module.
voltage.
Note
Full Scale Voltage = 1X Ampl Meter Top Scale X Transducer Scale Factor
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
For V rms input:
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
- 37-21 -
For V rms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
37.4.4 1X Phase
the I/O module.

Keyphasor
measured above.
- 37-22 -
Example:
(3) Time
(4) 0
(5) One cycle
(6) 360
(7) Phase lag = 45
the I/O module.
- 37-23 -
Note
the I/O module.

4. Measure the phase. Phase will be measured from the leading edge of the
Keyphasor
example in 1X Phase that illustrates a phase of 45.
Note
If the test equipment is capable of changing the
phase, set output to a known value.
shown in "1X Amplitude (1X Ampl)" on page 37-20. Adjust the function
generator amplitude to the calculated voltage.
6. Calculate the 1X Circular Acceptance Radius according to the equations and
example shown below.
Formulas - Circular Acceptance Radius
X and Y Vibration Components:
- 37-24 -
) ( phase Voltage (Input Cos * (D) Vibration (X) component X
) ( phase Voltage (Input Sin * (D) Vibration (Y) component Y
X and Y Setpoint Components:
) p ( phase Voltage (Input Cos * (Dsp) Vibration (Xsp) component Xsp s
) sp ( phase Voltage (Input Cos * (Dsp) Vibration (Ysp) component Ysp
Radius from Setpoint:
( ) ( )
2 2
(X) component X - (Xsp) component Xsp (X) component X - (Xsp) component Xsp (Rcalc) Radus Calculated +
Example:
Reference Vector Amplitude (Dsp) = 1 mil
Reference Vector Phase (sp) = 45 degrees
Vrms Input = 0.707 Vrms
Input Voltage phase () = 100 degrees
Transducer Scale Factor = 200mV/mill
Calculate Vibration (D):
Vpp = (2/0.707) x (Vrms), for sinewave only
= (2/0.707) x (0.707)
= 2.000 Vpp
Vibration (D) = (Vpp) x (1/Transducer Scale Factor)
= 2.00 x (1/0.2)
= 10 mill
Calculate X and Y Vibration Components:
mil 736 . 1 ) (100 Cos * mil 0 1 (X) component X
Y
X
Ysp
Xsp
(,D)
(sp,Dsp)
Rsp
X + Xsp
Y - Ysp
Rcalc
- 37-25 -
mil 848 . 9 ) (100 Sin * mil 0 1 (Y) component Y
Calculate Xsp and Ysp Reference Vector Components:
mil 707 . 0 ) (45 Cos * mil 1 (Xsp) component Xsp
mil 707 . 0 ) (45 Sin * mil 1 (Ysp) component Ysp
Calculate Circular Acceptance Radius (Rcalc):
Note
The Keyphasor must be triggering and have a valid rpm
value to check this parameter.
the I/O module.
voltage.
Note
( ) ( ) mil 462 . 9 mil 848 . 9 - mi 707 . 0 mil 736 . 1 - mil 707 . 0 (Rcalc) Radus Calculated
2 2
+
- 37-26 -
Example 1:
Full Scale = (10 0.200)
= 2.000 Vpp
For V rms input:
= (0.707/2) (2)
= 0.707 Vrms
Example 2:
= 7.874 mV/m
Full Scale = (200 0.007874)
= 1.5748 Vpp
For V rms input:
= (0.707/2) (1.574)
= 0.5566 Vrms
37.4.7 2X Phase
the I/O module.
- 37-27 -

Keyphasor
example below, which illustrates a phase of 90. Observe the 2X Phase bar
measured above.
Example:
(1) 0
(2) First Cycle
(4) Second cycle
(6) Phase lag = 90
(8) 360
(9) Time
- 37-28 -
the I/O module.
Note
on the I/O module.

4. Measure the phase. Phase will be measured from the leading edge of the
Keyphasor
example in "2X Phase" on page 37-26 that illustrates a phase of 45.
- 37-29 -
Note
If the test equipment is capable of changing the phase,
set output to a known value.
shown in "2X Amplitude (2X Ampl)" on page 37-25. Adjust the function
generator amplitude to the calculated voltage.
6. Calculate the 2X Circular Acceptance Radius according to the equations in
"1X Circular Acceptance" on page 37-23 and example shown below.
Example:
Reference Vector Amplitude (Dsp) = 1 mil
Reference Vector Phase (sp) = 45 degrees
Vrms Input = 0.707 Vrms
Input Voltage phase () = 100 degrees
Transducer Scale Factor = 200mV/mill
For Vibration (D):
Vpp = (2/0.707) x (Vrms), for sinewave only
= (2/0.707) x (0.707)
= 2.000 Vpp
Y
X
Ysp
Xsp
(,D)
(sp,Dsp)
Rsp
X + Xsp
Y - Ysp
Rcalc
- 37-30 -
Vibration (D) = (Vpp) x (1/Transducer Scale Factor)
= 2.00 x (1/0.2)
= 10 mill
Calculate X and Y Vibration Components:
mil 736 . 1 ) (100 Cos * mil 0 1 (X) component X
mil 848 . 9 ) (100 Sin * mil 0 1 (Y) component Y
Calculate Xsp and Ysp Reference Vector Components:
mil 707 . 0 ) (45 Cos * mil 1 (Xsp) component Xsp
mil 707 . 0 ) (45 Sin * mil 1 (Ysp) component Ysp
Calculate Circular Acceptance Radius (Rcalc):
37.4.9 Test OK Limits
computer.
the I/O module.
( ) ( ) mil 462 . 9 mil 848 . 9 - mi 707 . 0 mil 736 . 1 - mil 707 . 0 (Rcalc) Radus Calculated
2 2
+
- 37-31 -
Note
setting.
- 37-32 -
Circular Acceptance Default OK Limits Table
Transducer Lower OK
Limit (volts)
Upper OK Limit
(volts)
7200 5&8 mm w/ barriers -2.7 to -2.8 -16.7 to 16.8
3300 5&8 mm w/ barriers -2.7 to -2.8 -16.7 to -16.8
3300 XL 8 mm w/ barriers -2.7 to -2.8 -16.7 to -16.8
3300 XL 8 mm w/o barriers -2.7 to -2.8 -16.7 to -16.8
3300 RAM w/ barriers -2.4 to -2.5 -12.1 to -12.2
3300 16 mm HTPS w/o barriers -2.7 to -2.8 -16.7 to -16.8
Section 38 - Specifications
- 38-1 -
38. Specifications
Table of Contents
38.1 Inputs........................................................................................................... 38-2
38.2 Outputs........................................................................................................ 38-2
38.3 Signal Conditioning...................................................................................... 38-3
38.3.1 Radial Vibration ............................................................................ 38-3
38.3.2 Thrust and Differential Expansion ................................................. 38-4
38.3.3 Eccentricity ................................................................................... 38-4
38.3.4 Acceleration.................................................................................. 38-4
38.3.5 Velocity......................................................................................... 38-5
38.3.6 Shaft Absolute, Radial Vibration.................................................... 38-6
38.3.7 Shaft Absolute, Velocity ................................................................ 38-6
38.3.8 Circular Acceptance Region:......................................................... 38-7
38.3.9 REBAM: ........................................................................................ 38-7
38.4 Alarms ....................................................................................................... 38-10
38.5 Static Values.............................................................................................. 38-10
38.6 Barrier Parameters..................................................................................... 38-11
38.7 Environmental Limits.................................................................................. 38-12
38.8 CE Mark Directives .................................................................................... 38-12
38.8.1 EMC Directives ........................................................................... 38-12
38.8.2 CE Mark Low Voltage Directives................................................. 38-12
38.9 Hazardous Area Approvals ........................................................................ 38-12
38.10 Physical ................................................................................................ 38-13
- 38-2 -
38.1 Inputs
Signal: Accepts from 1 to 4 proximity, velocity or acceleration transducer signals.
Input Impedance
o Standard I/O: 10 k. (Proximitor and Acceleration Inputs).
o TMR I/O: The effective impedance of three Bussed TMR I/O channels wired
in parallel to one transducer is 50 k.
Power Consumption: 7.7 Watts, typical.
Sensitivity
o Radial Vibration: 3.94 mV/m (100 mV/mil) or 7.87 mV/m (200 mV/mil).
o Thrust: 3.94 mV/m (100 mV/mil) or 7.87 mV/m (200 mV/mil).
o Eccentricity: 3.94 mV/m (100 mV/mil) or 7.87 mV/m (200 mV/mil).
o Differential Expansion: 0.394 mV/m (10 mV/mil) or 0.787 mV/m (20
mV/mil).
o Acceleration & Acceleration II: 10 mV/(m/s2) (100 mV/g).
o Velocity & Velocity II: 20 mV/(mm/s) pk (500 mV/(in/s) pk) or 5.8 mV/(mm/s)
pk (145 mV/(in/s) pk) or 4 mV/(mm/s) pk (100 mV/(in/s) pk).
o Shaft Absolute
Radial Vibration: 3.94 mV/m (100 mV/mil) or 7.87 mV/m (200
mV/mil).
Direct: 3.94 mV/m (100 mV/mil) or 7.87 mV/m (200 mV/mil).
Velocity: 20 mV/(mm/s) pk (500 mV/(in/s) pk) or 5.8 mV/(mm/s) pk
(145 mV/(in/s) pk) or 4 mV/(mm/s) pk (100 mV/(in/s) pk)
o REBAM: 1000 mV/mil (40 mV/um) or 2000 mV/mil (80 mV/um).
o Circular Acceptance Region: see Radial Vibration.
38.2 Outputs
Front Panel LEDs
o OK LED: Indicates when the 3500/42M is operating properly.
o TX/RX LED: Indicates when the 3500/42M is communicating with other
modules in the 3500 rack.
o Bypass LED: Indicates when the 3500/42M is in Bypass Mode.
Buffered Transducer Outputs:
o The front of each monitor has one coaxial connector for each channel. Each
connector is short-circuit protected.
o Output Impedance: 550 .
Transducer Power Supply: -24 Vdc.
Recorder Outputs
- 38-3 -
o +4 to +20 mA:. Values are proportional to monitor full-scale. Individual
recorder values are provided for each channel. Monitor operation is
unaffected by short circuits on recorder outputs.
o Voltage Compliance (current output): 0 to +12 Vdc range across load. Load
resistance is 0 to 600 .
o Resolution: 0.3662 A per bit
o Error: 0.25% error at room temperature 0.7% error over temperature
range.
o Update rate: 100 ms or less.
Shaft Absolute Buffered Outputs
o The Shaft Absolute I/O modules have one output for each channel group.
Each output is short-circuit protected.
o Output Impedance: 300 .
38.3 Signal Conditioning
Specified at +25C (+77 F).
38.3.1 Radial Vibration
Frequency Response
o Direct Filter: User-programmable, 4 Hz to 4000 Hz or 1 Hz to 600 Hz.
o Gap Filter: -3 dB at 0.09 Hz.
o Not 1X Filter: 60 cpm to 15.8 times running speed. Constant Q notch filter.
Minimum rejection in stopband of -34.9 dB.
o Smax: 0.125 to 15.8 times running speed.
o 1X & 2X Vector Filter: Constant Q Filter. Minimum rejection in stopband of -
57.7 dB.
Note
1X & 2X Vector, Not 1X, and Smax parameters are
valid for machine speeds of 60 cpm to 60,000 cpm.
Accuracy
o Direct and Gap: Within 0.33% of full scale typical, 1% maximum.
o 1X & 2X: Within 0.33% of full-scale typical, 1% maximum.
o Smax: Within 5% maximum.
o Not 1X: 3% for machine speeds less than 30,000 cpm. 8.5% for machine
speeds greater than 30,000 cpm.
- 38-4 -
38.3.2 Thrust and Differential Expansion
Frequency Response
o Direct Filter: -3 dB at 1.2 Hz.
Accuracy
o Within 0.33% of full-scale typical, 1% maximum.
38.3.3 Eccentricity
Frequency Response
o Direct Filter: -3 dB at 15.6 Hz.
Accuracy
o Within 0.33% of full-scale typical, 1% maximum.
38.3.4 Acceleration
Frequency Response:
o Bias Voltage: Low-Pass: -3 dB at 0.01 Hz
o 1X & 2X Vector Filter: Constant Q Filter. Minimum rejection in stopband of
51.0 dB.
Note
1X & 2X Vector parameters are valid for
machine speeds of 60 cpm to 60,000 cpm.
o The following table represents the frequency ranges for the 3500/42M under
different options using the Acceleration II Channel Type. Resources used for
processing data are assigned based on channel pairs. It is possible to select
different options for the two channels of a channel pair. However, the
frequency response for both channels will be limited to the worst case
frequency response of the individual channels.
Output Type Non Integrated Integration
RMS 10 Hz to 20 kHz 10 Hz to 20 kHz
Peak 3 Hz to 30 kHz 10 Hz to 20 kHz
The next two tables represent the frequency ranges if the Acceleration
Channel type is selected instead of the Acceleration II. The following table
shows the frequency ranges if both channels of a channel pair are enabled
- 38-5 -
Output Type Without Filter Low Pass Filter,
High Pass Filter
Integration after
filters
RMS 10 Hz to 30 kHz 10 Hz to 9.155 kHz 10 Hz to 9.155 kHz
Peak 3 Hz to 30 kHz 3 Hz to 9.155 kHz 10 Hz to 9.155 kHz
The next table shows the frequency response range if a single channel is
enabled for a channel pair when using the Acceleration channel type.
Output Type Without Filter, Low Pass
Filter, High Pass Filter
With Integration
RMS 10 Hz to 30 kHz 10 Hz to 14.5 kHz
Peak 3 Hz to 30 kHz 10 Hz to 14.5 kHz
Filter Quality
o High-Pass: 4-pole (80 dB per decade, 24 dB per octave).
o Low-Pass: 4-pole (80 dB per decade, 24 dB per octave).
Accuracy
o Within 0.33% of full scale typical, 1% maximum. Exclusive of filters.
38.3.5 Velocity
Frequency Response
o Bias Voltage: Low-Pass: -3 dB at 0.01 Hz
o RMS: 10 to 5,500 Hz, -3 dB.
o Peak or Peak-to-Peak: 3 to 5,500 Hz, -3 dB.
o 1X & 2X Vector Filter: Constant Q Filter. Minimum rejection in stopband of
51.0 dB.
Note
1X & 2X Vector parameters are valid for
machine speeds of 60 cpm to 60,000 cpm.
Filter Quality
- 38-6 -
Accuracy
o Velomitor
Full Scale 0-0.5: 3% Typical
38.3.6 Shaft Absolute, Radial Vibration
Frequency Response
o Direct Filter: User-programmable, 4 Hz to 4000 Hz or 1 Hz to 600 Hz.
o 1X Vector Filter: Constant Q Filter. Minimum rejection in stopband of -57.7
dB.
Note
1X Vector parameters are valid for machine
speeds of 240 cpm to 60,000 cpm.
Accuracy
o Direct and Gap: Within 0.33% of full scale typical, 1% maximum.
o 1X: Within 0.33% of full-scale typical, 1% maximum.
38.3.7 Shaft Absolute, Velocity
Frequency Response:
o Peak or Peak-to-Peak: User-programmable, 1 to 4,000 Hz, -3 dB.
Filter Quality
Accuracy
o Shaft Absolute Buffered Output: 6.0% @ 25 C
- 38-7 -
38.3.8 Circular Acceptance Region:
See Radial Vibration.
38.3.9 REBAM:
Frequency Response
o Spike: Highpass filter that is user programmable from 0.152 to 8678 Hz.
o Element: Bandpass filter that is user programmable for BPFO ranging from
0.139 to 3836 Hz. Highpass corner is 0.8x BPFO. Lowpass corner is 2.2x
BPFO.
o Rotor: Lowpass filter that is user programmable from 0.108 to 2221 Hz.
o Direct: Highpass filter that is programmable from 3.906 to 14.2 Hz. Selection
is determined by Spike and Rotor filters.
o Gap: Lowpass filter that is programmable from 0.002 to 1.0 Hz. Selection is
determined by the Rotor filter.
o 1X Vector Filter: Constant Q Filter. The range of shaft speeds for which the
value is valid is dependent upon the nominal Shaft Speed the channel is
configured for. The following table summarizes the relationship:
Nominal Shaft Speed (Hz) Valid Speed Range (Hz)
10 to <126 0.071 to 160
126 to <252 0.133 to 330
252 to <504 0.25 to 660
504 to <584 0.50 to 750
Note: If the speed input is generated from a multi-event
gear or speed wheel, the resultant input signal has an
upper limitation of approximately 20 KHz.
Filter Quality
o Spike High Pass: 6-pole Elliptic (155 dB per decade, minimum). Corner
frequency is -0.1 dB.
o Element Band Pass: 8-pole Butterworth (155 dB per decade minimum).
Corner frequency is -3 dB.
o Rotor Low Pass: 6-pole Elliptic (155 dB per decade, minimum). Corner
frequency is -0.1 dB.
o Rotor, Direct High Pass: 1-pole Butterworth (18 dB per decade, minimum).
Corner frequency is -3 dB.
o Spike, Direct Low Pass: Corner is -0.3 dB maximum.
o Gap Low Pass: 1-pole Butterworth (18 dB per decade, minimum). Corner
frequency is -3 dB.
- 38-8 -
o 1X Amplitude: Constant Q of 16.67. Stopband frequencies are 0.91 and 1.09
times the running speed. Stopband attenuation is -51 dB minimum.
Accuracy
o Amplitudes: Within 0.33% of full scale typical, 1% maximum when input
signal is at the center frequency of the proportional value's passband.
o Phase: 3 degrees error, maximum.
Channels Enabled
Certain configurations, generally those for higher speed machines, will only allow
one channel of a channel pair to be enabled. The following graphs show, for both
1-channel and 2-channel configurations, the approximate maximum shaft speed
for the Spike, Element and Rotor filters for a bearing with a given number of
rolling elements. The graph assumes that the rotor lowpass filter corner is set at
3.2X the shaft speed and the spike highpass filter corner is set at 4X the element
pass frequency for the outer race (BPFO).
2-Channel Configuration
0
5000
10000
15000
20000
25000
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Number of Elements
M
a
x

R
P
M
Rotor Element Pass Spike
- 38-9 -
Filter Tracking/Stepping
A valid speed signal input is required for this feature. The following summarizes
how the tracking feature works:
o Initial Condition: Nominal filter set used.
o Switch from Nominal to Lower Filter Set: Current shaft speed =< 0.9 x
(Nominal Shaft Speed).
o Switch from Lower to Nominal Filter Set: Current shaft speed >= 0.95 x
o Switch from Nominal to Higher Filter Set: Current shaft speed >= 1.1 x
o Switch from Higher to Nominal Filter Set: Current shaft speed =< 1.05 x
o Shaft Speed Error Condition: Nominal filter set used.
1-Channel Configuration
0
5000
10000
15000
20000
25000
30000
35000
40000
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Number of Elements
M
a
x

R
P
M
Rotor Element Pass Spike
- 38-10 -
38.4 Alarms
Alarm Setpoints: Alert levels can be set for each value measured by the
monitor. In addition, Danger setpoints can be set for any two of the values
measured by the monitor. All alarm setpoints are set using software
configuration. Alarms are adjustable and can normally be set from 0 to 100% of
full-scale for each measured value. The exception is when the full-scale range
exceeds the range of the transducer. In this case, the setpoint will be limited to
the range of the transducer. Accuracy of alarms are to within 0.13% of the
desired value.
Alarm Time Delays: Alarm delays can be programmed using software, and can
be set as follows:
o Radial Vibration, Thrust, Differential Expansion, Eccentricity, Acceleration,
Velocity, Acceleration 2, Velocity 2, Circular Acceptance Regions, Shaft
Absolute Radial Vibration,
Alert: From 1 to 60 seconds in 1 second intervals.
Danger: 0.1 seconds, or from 1 to 60 seconds in 0.5 second intervals.
o Shaft Absolute Velocity
Alert: From 1 to 60 seconds in 1 second intervals.
Danger: From 1 to 60 seconds in 0.5 second intervals.
o REBAM
Alert: From (calculated minimum value) to 400 seconds in 1 second intervals.
Danger: From (calculated minimum value) to 400 seconds in 0.5 second
intervals.
38.5 Static Values
Static values are measurements used to monitor the machine. The Proximitor
Seismic Monitor provides the following static values:
Radial Vibration: Direct, Gap, 1X Amplitude, 1X Phase Lag, 2X Amplitude, 2X
Phase Lag, Not 1X Amplitude, and Smax Amplitude.
Thrust Position: Direct, Gap.
Differential Expansion: Direct, Gap.
Eccentricity: Peak-to-peak, Gap, Direct Minimum, Direct Maximum.
Acceleration: Direct, define as one of the following: RMS Acceleration or, peak
Acceleration or, RMS Velocity or, peak Velocity or, Band-pass peak
Acceleration or, Band-pass peak Velocity.
Acceleration II: Direct, 1X Amplitude, & 2X Amplitude; define as one of the
following: RMS Acceleration or, peak Acceleration or, RMS Velocity or, peak
Velocity or, Band-pass peak Acceleration or, Band-pass peak Velocity.
Additionally, 1X Phase, 2X Phase and Bias Voltage
Velocity: Direct, define as one of the following: RMS Velocity or, peak Velocity,
peak-to-peak Displacement or, Band-pass peak Velocity or, Band-pass or peak-
to-peak Displacement.
- 38-11 -
Velocity II: Direct, 1X Amplitude, & 2X Amplitude: define as one of the following:
RMS Velocity or, peak Velocity, peak-to-peak Displacement or, Band-pass peak
Velocity or, Band-pass or peak-to-peak Displacement. Additionally, 1X Phase,
2X Phase and Bias Voltage
Shaft Absolute Radial Vibration: Direct, Gap, 1X Amplitude, 1X Phase Lag
Shaft Absolute, Velocity: Shaft Absolute Direct, Shaft Absolute 1X Amplitude,
Shaft Absolute 1X Phase Lag, Velocity Direct, Velocity 1X Amplitude, Velocity 1X
Phase Lag
Circular Acceptance Region: Direct, Gap, 1X Amplitude, 1X Phase Lag, 1X
Circular Acceptance Radius, 2X Amplitude, 2X Phase Lag, 2X Circular
Acceptance Radius
REBAM: Spike, Element, Rotor, Direct, Gap, 1X Amplitude, 1X Phase Lag
38.6 Barrier Parameters
The following parameters apply for both CSA-NRTL/C and CENELEC approvals.
Proximitor Barrier
Circuit Parameters
Vmax (PWR) = 26.80 V
(SIG) = 14.05 V
Imax (PWR) = 112.8 mA
(SIG) = 2.82 mA
Rmin (PWR) = 237.6
(SIG) = 4985
Channel Parameters (Entity)
Vmax = 28.0 V
Imax = 115.62 mA
Rmin (PWR) = 237.6
(SIG) = 4985
Seismic Barrier
Circuit Parameters
Vmax (B) = 27.25 V
Imax (B) = 91.8 mA
Rmin (B) = 297
Channel Parameters (Entity)
Vmax = 27.25 V
Imax = 91.8 mA
Rmin = 297
- 38-12 -
38.7 Environmental Limits
Operating Temperature:
o -30C to +65C (-22F to +150F) when used with Internal/External
Termination Proximitor/Seismic I/O Module.
o 0C to +65C (32F to +150F) when used with Proximitor/Seismic Internal
Barrier I/O Module (Internal Termination).
Storage Temperature: -40C to +85C (-40F to +185F).
Humidity: 95%, noncondensing.
38.8 CE Mark Directives
38.8.1 EMC Directives
Certificate of Conformity: 136669
EN50081-2
o Radiated Emissions: EN 55011, Class A
o Conducted Emissions: EN 55011, Class A
EN50082-2
o Electrostatic Discharge: EN 61000-4-2, Criteria B
o Radiated Susceptibility: ENV 50140, Criteria A
o Conducted Susceptibility: ENV 50141, Criteria A
o Electrical Fast Transient: EN 61000-4-4, Criteria B
o Surge Capability: EN 61000-4-5, Criteria B
o Magnetic Field: EN 61000-4-8, Criteria A
o Power Supply Dip: EN 61000-4-11, Criteria A
o Radio Telephone: ENV 50204, Criteria A
38.8.2 CE Mark Low Voltage Directives
Certificate of Conformity: 134036
EN 61010-1: Safety Requirements
38.9 Hazardous Area Approvals
CSA/NRTL/C:
o When used with Internal/External Termination I/O Module: Class I, Division
2, Groups A through D, T4@ Ta=65.
o Certification Number BN26744C-18
o When used with Internal Barrier I/O Module, refer to specification sheet
141495-01 for approvals information.
- 38-13 -
38.10 Physical
Monitor Module
241.3 mm x 24.4 mm x 241.8 mm (9.50 in x 0.96 in x 9.52 in).
Weight: 0.91 kg (2.0 lbs.).
I/O Modules (non-barrier)
Dimensions (Height x Width x Depth)
Weight: 0.20 kg (0.44 lb.).
I/O Modules (barrier)
Dimensions (Height x Width x Depth)
Weight: 0.46 kg (1.01 lbs.).
Rack Space Requirements
Monitor Module: 1 full-height front slot.
I/O Modules: 1 full-height rear slot.
- 38-14 -
Blank Page
Section 39 - Ordering Information
- 39-1 -
39. Ordering Information
Table of Contents
39.1 Ordering Considerations .............................................................................. 39-2
39.1.1 General ......................................................................................... 39-2
39.1.2 Internal Barrier I/O Module............................................................ 39-2
39.1.3 Shaft Absolute .............................................................................. 39-2
39.1.4 Acceleration II ............................................................................... 39-2
39.1.5 Velocity II ...................................................................................... 39-2
39.1.6 Circular Acceptance Regions........................................................ 39-2
39.1.7 REBAM......................................................................................... 39-3
39.2 List of Options and Part Numbers ................................................................ 39-3
39.2.1 Proximitor Seismic Monitor......................................................... 39-3
39.2.2 External Termination Blocks ......................................................... 39-5
39.2.3 3500 Transducer (XDCR) Signal to External Termination (ET) Block
Cable 39-5
39.2.4 3500 Recorder Output to External Termination (ET) Block Cable 39-5
39.2.5 Spares .......................................................................................... 39-6
- 39-2 -
39.1 Ordering Considerations
39.1.1 General
The 3500/42M Module requires the following (or later) firmware, and software
revisions:
o 3500/01 Software Version 2.50
External Termination Blocks cannot be used with Internal Termination I/O
Modules.
When ordering I/O Modules with External Terminations, the External Termination
Blocks and Cables must be ordered separately.
Bussed External Termination Blocks are to be used with TMR I/O Modules only.
39.1.2 Internal Barrier I/O Module
The 3500 Internal Barrier specification sheet (part number 141495-01) should be
consulted if the Internal Barrier Option is selected.
39.1.3 Shaft Absolute
The Shaft Absolute Channel Type requires the following (or later) firmware and
software revisions:
o 3500/42M Module Firmware Revision 2.02
o DM2000 Software - Version 3.10.
Requires the M version of the 3500 Proximitor/Seismic Monitor.
39.1.4 Acceleration II
The Acceleration II Channel Type requires the following (or later) firmware and
software revisions:
o DM2000 Software - Version 3.30
39.1.5 Velocity II
See Acceleration II.
39.1.6 Circular Acceptance Regions
See Acceleration II.
- 39-3 -
39.1.7 REBAM
The REBAM Channel Type requires the following (or later) firmware and
software revisions:
o DM2000 Software - Version 3.40
39.2 List of Options and Part Numbers
39.2.1 Proximitor Seismic Monitor
3500/42-AXX-BXX
A: I/O Module Type
0 1 Prox/Seis I/O Module with Internal Terminations
0 2 Prox/Seis I/O Module with External Terminations
0 3 TMR I/O Module with External Terminations.
0 4 I/O Module with Internal Barriers (4 x prox./accel. ch's) and Internal
Terminations
0 5 I/O Module with Internal Barriers (2 x prox./accl. + 2 x Velomitor
channels) and Internal Terminations
0 6 I/O Module with Internal Barriers (4 x Velomitor channels) and Internal
Terminations
0 7 Shaft Absolute I/O Module with Internal Terminations
0 8 Shaft Absolute I/O Module with External Terminations
0 9 Prox/Velom I/O Module with Internal Terminations
1 0 Prox/Velom I/O Module with External Terminations
Note
1. The following table shows the ordering
option and supported transducer types.
- 39-4 -
Ordering Option Prox/Accel Velom Seismo-probe
A01 & A02 See Note 4 X
A03 X X
A04, A05, & A06 See Note 2
A07 & A08 X X X
A09 & A10 X X
Note
2. The following table shows the ordering
options that are available for Internal
Barriers with this monitor.
Ordering Option Channel 1 & 2 Channel 3 & 4
A04 Prox/Accel Prox/Accel
A05 Prox/Accel Velomitor
A06 Velomitor Velomitor
Note
3. HTVS transducer is supported in A 09
and A 10 I/O module type options.
Note
4. Prox/Accel and Velomitor are supported
with the A01 & A02 options. However,
unless Seismoprobes will be used the
appropriate choice is the A09 and A10
options.
B: Agency Approval Option
0 0 None
- 39-5 -
0 1 CSA/NRTL/C
39.2.2 External Termination Blocks
125808-02: Prox/Seismic External Termination Block (Euro Style connectors).
128015-02: Prox/Seismic External Termination Block (Terminal Strip
connectors).
132242-01: Prox/Seismic Bussed TMR External Termination Block (Euro Style
connectors).
132234-01: Prox Seismic Bussed TMR External Termination Block (Terminal
Strip connectors).
128702-01: Recorder External Termination Block (Euro Style connectors).
128710-01: Recorder External Termination Block (Terminal Strip connectors).
140993-01: Shaft Absolute External Termination Block (Euro Style connectors).
141001-01: Shaft Absolute External Termination Block (Terminal Strip
connectors).
125808-08: Proximitor/Velomitor External Termination Block (Euro Style
connectors).
128015-08: Proximitor/Velomitor External Termination Block (Terminal Strip
connectors).
39.2.3 3500 Transducer (XDCR) Signal to External Termination
(ET) Block Cable
129525 -AXXXX-BXX
A: Cable Length
0 0 0 5 5 feet (1.5 metres)
0 0 0 7 7 feet (2.1 metres)
0 0 1 0 10 feet (3 metres)
0 0 2 5 25 feet (7.5 metres)
0 0 5 0 50 feet (15 metres)
0 1 0 0 100 feet (30.5 metres)
B: Assembly Instructions
0 1 Not Assembled
0 2 Assembled
39.2.4 3500 Recorder Output to External Termination (ET) Block
Cable
129529-AXXXX-BXX
A: Cable Length
- 39-6 -
0 0 0 5 5 feet (1.5 metres)
0 0 0 7 7 feet (2.1 metres)
0 0 1 0 10 feet (3 metres)
0 0 2 5 25 feet (7.5 metres)
0 0 5 0 50 feet (15 metres)
0 1 0 0 100 feet (30.5 metres)
B: Assembly Instructions
0 1 Not Assembled
0 2 Assembled
39.2.5 Spares
140734-02: 3500/42M Proximitor/Seismic Monitor.
128229-01: Prox/Seismic I/O Module with Internal Terminations.
128240-01: Prox/Seismic I/O Module with External Terminations.
126632-01: Prox/Seismic TMR I/O Module with External Terminations.
00530843: 3500/42M Prox/Seismic I/O Module four-pin connector shunt.
143489-01: 3500/42M Monitor Manual.
135489-01: I/O Module with Internal Barriers (Internal terminations) (4 x
Prox/Accel).
Prox/Accel + 2 x Velomitor).
Velomitor).
138708-01: Shaft Absolute I/O Module with Internal Terminations.
138700-01: Shaft Absolute I/O Module with External Terminations.
00517018: 3500/42M Shaft Absolute I/O Module eight-pin connector shunt.
140471-01: Prox/Velom I/O Module with Internal Terminations.
140482-01: Prox/Velom I/O Module with External Terminations.
00561941: 3500/42M Prox/Velom I/O Module ten-pin connector shunt.
00580434: Internal Termination I/O Module connector header, Euro Style, 8 pin.
Used on I/O modules 128229-01 and 138708-01.
00580432: Internal Termination I/O Module connector header, Euro Style, 10 pin.
Used on I/O modules 128229-01, 138708-01.
00502133: Internal Barrier I/O Module connector header, Euro Style, 12 pin
Revision F, May 2001

3500/92
COMMUNICATION
MODULE

OPERATON AND MANTENANCE
MANUAL

3500/92 COMMUNCATON MODULE OPERATON AND MANTENANCE MANUAL
ii

BentIy Nevada Corporation 2001

Data Subject to Change Without Notice
AII Rights Reserved

No part of this pubIication may be reproduced, transmitted, stored in a retrievaI system or transIated into
any human or computer Ianguage, in any form or by any means, eIectronic, mechanicaI, magnetic,
opticaI, chemicaI, manuaI, or otherwise, without the prior written permission of the copyright owner,

Bently Nevada Corporation
1631 Bently Parkway South
Minden, Nevada 89423 USA
Telephone (800) 227-5514 or (775) 782-3611
Fax (775) 782-9259

Copyright infringement is a serious matter under
the United States of America and foreign copyright laws.

Keyphasor and Proximitor are registered trademarks

iii
AdditionaI Information

Notice:
This manuaI does not contain aII the information required to operate and maintain the
3500/92 COMMUNICATION MODULE. Refer to the FoIIowing manuaIs for other
required information.

3500 Monitoring System Rack InstaIIation and Maintenance ManuaI (129766-01)

3500 Monitoring System Rack Configuration and UtiIities Guide (129777-01)
Guidelines for using the 3500 test utilities to verify that the input and output terminals on

3500 Monitoring system Computer Hardware and Software ManuaI (128158-01)

3500 FieId Wiring Diagram Package (130432-01)
iv
Contents

1. Receiving and HandIing Instructions ........................................ 1
1.1 Receiving nspection......................................................................................... 1
1.2 Handling and Storing Considerations ................................................................ 1
1.3 Disposal Statement ........................................................................................... 1
2. GeneraI Information.................................................................... 2
2.1 Communications from 3500/92 to 3500 Configuration Software........................ 3
2.2 Communications from 3500/92 to 3500 Data Acquisition Software ................... 4
2.3 Triple Modular Redundant (TMR) Description ................................................... 5
2.4 Module and Channel Statuses .......................................................................... 5
2.5 LED Descriptions .............................................................................................. 7
3. Configuration Information.......................................................... 8
3.1 Hardware Considerations.................................................................................. 8
3.2 Setting Communication Parameters.................................................................. 9
3.3 Configurable Modbus Registers ...................................................................... 13
3.4 Setting Software Switches............................................................................... 15
4. I/O ModuIe Description............................................................. 17
4.1 Modbus RS-232/422 /O Module Description .................................................. 17
4.1.1 General Response Time .................................................................. 18
4.1.2 Connecting a Modbus RS-232/422 /O Module Port to the Host
(Display or Host Computer) via RS-232....................................................... 18
4.1.3 Connecting a Modbus RS-232/422 /O Module Port to the Honeywell
PLCG via RS-232........................................................................................ 19
4.1.4 Connecting a Modbus RS-232/422 /O Module Port to a Host (Display
or Host Computer) via RS-422..................................................................... 20
4.1.5 Daisy Chaining Modbus RS-232/422 /O Module Ports via RS-422.. 21
4.1.6 Additional nformation for Connecting a Rack nterface /O Module to
a Host Computer in an ntrinsically Safe Application.................................... 22
4.2 Modbus RS-485 /O Module Description ......................................................... 23
4.2.1 General Response Time .................................................................. 24
4.2.2 Four-Wire Connections ................................................................... 24
4.2.3 Two-Wire Connections..................................................................... 25
4.2.4 Termination...................................................................................... 25
4.3 Ethernet/RS-232 /O........................................................................................ 27
4.3.1 Ethernet - port 1............................................................................... 28
4.3.2 RS-232 - port 2 ................................................................................ 28
4.4 Ethernet/RS-485 /O........................................................................................ 29
4.4.1 Ethernet port 1 .............................................................................. 30
4.4.2 RS-485 port 2................................................................................ 30
4.5 Cable Pin Outs................................................................................................ 31
5. ProtocoIs................................................................................... 35
5.1 Modbus ........................................................................................................... 35
5.1.1 Modbus nterface Description........................................................... 35
5.1.2 Scaling the Data............................................................................... 62

v
5.1.3 Modbus Language Description ........................................................ 64
6. Maintenance.............................................................................. 88
6.1 Comm Gateway Port Test Utility..................................................................... 88
6.2 Performing Firmware Upgrades...................................................................... 88
6.2.1 nstallation Procedure...................................................................... 88
7. TroubIeshooting ....................................................................... 92
7.1 Self-test .......................................................................................................... 92
7.2 LED Fault Conditions...................................................................................... 93
7.3 System Event List Messages.......................................................................... 93
7.4 Alarm Event List Messages ............................................................................ 99
8. Ordering Information.............................................................. 100
9. Specifications ......................................................................... 104

vi
Section 1 Receiving and Handling nstructions
1
1. Receiving and HandIing Instructions
Visually inspect the module for obvious shipping damage. f shipping damage is
Corporation.
1.2 HandIing and Storing Considerations
order given.

Application Alert

Communication with the externaI
device (DCS, PLC, remote dispIay,
etc) wiII be Iost when this moduIe
is removed from the rack.

the rack while power is applied to the rack. Refer to the Rack nstallation and
1.3 DisposaI Statement
the end of its use.
2

2. GeneraI Information
The Communication Gateway Module provides serial communications
between the 3500 Monitor System and a plant information system such as a
distributed control system (DCS) or a programmable logic controller (PLC).
The Communication Gateway Module collects static data from the modules in
the rack over a high-speed internal network and sends this data to the
information system upon request.

The Communication Gateway is able to communicate via Ethernet with up to
six hosts. Hosts can be Modbus protocol based or computers with 3500
Rack Configuration and Data Acquisition software. Only one Comm Gateway
module per 3500 rack can be configured to accept Rack Configuration or
Data Acquisition hosts.

Front View Rear View

1) Status LEDs, refer to Section 2.5
2) Comm Gateway Module
3) RS485 /O Module
4) RS232/422 /O Module
5) Ethernet/RS232 /O Module
6) Ethernet/RS485 /O Module

Refer to Section 4 for all /O Module information.

Section 2 General nformation
3
The Communication Gateway Module can support a variety of protocols by using
a different /O module for each protocol. The module also lets you optimize the
communications with external devices using the 3500 Rack Configuration
Software to assign the most important data to contiguous registers in the module.
The main part of this manual contains information about the LED states, the
module and channel statuses, and detailed configuration information for the
Communication Gateway Module. The appendices contain information about
using the different protocols to retrieve data from the rack.
2.1 Communications from 3500/92 to 3500
Configuration Software
You can configure an entire 3500 rack through the Ethernet link on the 3500/92.
This link provides broader access than the serial port on the RM. Establish this
link by selecting "connect in the file pull down menu and then the "network
option.

Connect Password
Connect Password is the same password used for direct communications via the
RM. This Password is set in the RM configuration.

Connect
This button selects the device listed in the "Network Device Name field. Upon
entering this screen, the previous device will be named. Simply click on connect
4
and connection to this device will be established. f this is not the device desired,
select browse, highlight the desired device, and click on connect; or, select
browse and double click on the desired device.

Browse
This button searches for 3500 racks on the local network (within the same
subnet).

Advanced
Settings that will assist in establishing network communications. Set these
parameters with the help of a network administrator.
2.2 Communications from 3500/92 to 3500 Data
Acquisition Software
To establish a link between a 3500/92 and 3500 Data Acquisition software:
1) Select Setup in the Data Acquistion Software. The following screen will
appear.

2) n the Connection Parameters tab, select the network connection type.
3) n the Rack Addresses and Passwords tab, select the appropriate rack
address.

f no rack address appears in the Rack Addresses and Passwords, you can
Browse the network and assign a networked rack to a rack address. f Browse
doesn't work than use the Advanced button and contact a network administrator
for assistance.
5

2.3 TripIe ModuIar Redundant (TMR) Description
The Communication Gateway is considered a "Consumer" of data because it
receives data from other modules, formats it, and sends it on to an external
device. Since the module does not produce data or provide data to other
modules in the 3500 rack, redundant Communication Gateway Modules with
voting options are not required. For applications that require redundant
communication links, two or more Communication Gateway Modules can operate
in parallel in the same rack, provided that only one module is configured to allow
the "Bently Centurion Protocol" (see section 3.2). This configuration can be used
in both standard and TMR rack types.
2.4 ModuIe and ChanneI Statuses
The Communication Gateway Module returns both module and channel statuses.
This section describes the available statuses and where they can be found.

ModuIe Status
OK
ndicates if the Communication Gateway is functioning correctly. A not OK status
is returned under any of the following conditions:
Slot D Failure

f the Module OK status goes not OK, the system OK Relay on the Rack

Configuration FauIt
ndicates if the Communication Gateway Module configuration is invalid.

Bypass
ndicates whether the Communication Gateway Monitor is communicating. An
active module bypass may be caused by the following events:
The Communication Gateway Module has detected a serious internal fault.
The Bypass switch has been set for a channel in the Communication Gateway
Module.

ChanneI Status
OK
ndicates if the associated Communication Gateway Module communication port
has detected some internal fault. f the Communication Gateway Module goes
not OK, then all the channels are not OK.

Bypass
ndicates if the associated Communication Gateway Module communication port
has been bypassed. Channel Bypass can result from an internal fault or switch
setting and causes the Communication Gateway port to stop communicating.
6

Off
ndicates that the associated Communication Gateway Module communication
port has been turned off. The Communication Gateway Module communication
ports may be turned off (inactivated) in the Rack Configuration Software.


Statuses

Communication
Gateway
ModuIe

Rack
Configuration
Software

Operator
DispIay
Software

Module OK

X

X

Module Bypass

X

Module Configuration Fault

X

Channel OK

X

X

Channel Bypass

X

X

Channel Off

X

X

7

The LEDs on the front panel of the Communication Gateway Module indicate the
operating status of the module as shown in the following figure. Refer to Section
7.2 for all the available LED conditions.

1) OK
ndicates that the Communication Gateway Module and the /O
module are operating correctly
2) TX/RX
Flashes at the rate that messages are received from other 3500
modules.

8

3. Configuration Information
Configure a Communication Gateway Module by using the 3500 Rack
Configuration Software to complete the following tasks:
Set the communication parameters for the ports on the Communication
Gateway /O Module.
Assign data from rack modules to reserved addresses (Configurable Modbus
Registers) in the Communication Gateway Module.
Set software switches.
3.1 Hardware Considerations
The slots in the rack are numbered from 0 to 15, counting from left to right. The
power supplies go into slot 0 and the Rack nterface module goes into slot 1.
Slots 2 through 15 are called "monitoring positions. The 3500/92 module can be
installed into any of the monitoring positions. However, if the 3500/20 Rack
nterface Module and Data Manager /O are to be used to interface to DDX,
TDX, or TDXnet, refer to the manual on the 3500/20 for slot restrictions this may
place on your configuration.
Section 3 Configuration nformation
9

3.2 Setting Communication Parameters
The Modbus Protocol Setup screen lets you set the communication parameters
for the HOST and RACK connectors on the Communication Gateway /O
Module.

Reference Information
Slot
The location of the Communication Gateway Module in the 3500 rack.

10
ProtocoI
Selects which /O card is being used. The /O cards are ordered as an option to
the 3500/92.

Option Protocol
Port 1 Port2
-01 Modbus RS-232/422 Modbus RS-232/422
-02 Modbus RS-485 Modbus RS-485
-03 Ethernet TCP/P Modbus RS-232
-04 Ethernet TCP/P Modbus RS-485

The Ethernet TCP/P option allows for both Modbus and Bently Nevada 3500
software protocol. These protocols can run simultaneously on the same port.

ConfigurabIe Modbus Registers
This links into the dialog box that configures the programmable modbus
registers. Configurable Modbus Registers are programmed for both ports
together.

Active
Turns the Communication Port on () or off (). The port must be on to
respond to commands sent by the DCS.

Address
The address used by the Communication Protocol to talk to the Communication
Port. f the Communication Gateway Ports are daisy chained, all the ports in the
chain must have a unique address. The range of addresses is 1 to 255.

Connection
Direct is the only option available for the Modbus protocol.

Word Swapped
Switches the first sixteen bits of a 32-bit number with the last sixteen bits. This
switching applies only to the Modbus data that requires two registers. This
flexibility has been added to accommodate different number formats.

Config AIIowed
Enables a Modbus user to change Monitor Setpoints, Rack Trip Multiply, Rack
Alarm nhibit, software switches, Rack Reset, and Rack Date and Time.

Communication
Parity
Used for error checking.

None
No parity error checking is used.

Odd
Each word has an odd number of 1 bits.
11

Even
Each word has an even number of 1 bits.

Baud Rate
Rate of communication between the Communication Gateway Module and the
DCS. The available values are:
1200, 2400, 4800, 9600, 19.2, and 38.4 kbaud

Stop Bits
Signifies the end of the character. One or two bits can be used.

Byte Timeout
The number of byte periods, which the communication line must be idle before a
communication, is considered complete. One byte period is a function of the
baud rate selected. The available values are 3, 10, 25, or 50 bytes.

FuII ScaIe Data Range
A value between 1 and 65535 that is the maximum value in the full-scale range.
The Current Proportional Values and the Primary Values will be scaled between
0 and the selected value.

For example: f the Full Scale Data Range field is set to 4096, then the Current
Proportional Values and the Primary Values will be scaled between 0 and 4096.

Numeric Format
Hex
Base 16 numbering system used by the Modbus protocol to receive and transmit
values.
12

Network Device Name
Name assigned to the 3500/92. This name is often used to uniquely identify a
3500 rack on a network.

Rack IP Address
P (nternet Protocol) Address is the unique address for an Ethernet network
device. The address is a string of 4 numbers each from 0 to 255. For networks
managed through an nformation Systems department, consult the network
administrator for a valid P address. Note that addresses 0.0.0.0 and
255.255.255.255 are not valid.

Rack Subnet Mask
The Subnet Mask identifies which bits of the P address are address bits for the
physical network. Typically, the Subnet Mask is the same for the LAN (local area
network); however, consult the network administrator for valid settings.

AvaiIabIe Services
Different communication protocols available with the 3500/92. Ethernet networks
allow multiple protocols running at the same time.

Bently Centurion Protocol
Protocol used to communicate between the 3500/92 and a computer running
3500 Configuration and 3500 Data Acquisition software. f multiple 3500/92s
13
are present in a 3500 rack, only one may have Bently Centurion Protocol
enabled.

Modbus over Ethernet
Modbus Application Protocol communicates on Ethernet networks between
3500/92 and PLC's, DCS's, and MM's also running TCP/P.
3.3 ConfigurabIe Modbus Registers
Configurable Modbus Registers is a reserved area of the modbus register map
that consists of 500 registers starting at address 45000. These registers let you
assign important proportional values, statuses, and setpoints to consecutive
registers so that the communication with the 3500 rack is more efficient and the
need for supporting hardware is reduced.

Use the ComGateway92 Configuration screen to assign values to these
registers.

Assign values to registers by either double-clicking or by dragging and dropping.
As you assign values to registers, keep the following guidelines in mind:

To assign all values from a monitor to a set of consecutive registers, double-click
on the monitor or drag and drop the monitor to the appropriate starting register in
the REGSTERS | DATA box.
14
To assign specific values to a register, use the tree in the Monitor Options box.
Dragging and dropping a folder assigns all the data underneath the folder. To
maximize flexibility, folders have been arranged by specific register types,
channels, and a combination of both.
To control how data is assigned to registers, use Fixed or Moveable in the Mode
box. Fixed places the register or block of registers in the selected address and
overwrites any existing data in registers below the selected address. Moveable
places the register or block of registers in the selected address and moves any
existing registers down. Registers over the end of the 500 block will be lost.

Mode
Fixed
Places the register or block of registers from address selected and below, and will
overwrite existing registers.

Moveable
Places the register or block of registers from the address selected and will move the
existing registers down. Registers over the end of the 500 block will be lost.

FIoating Point
Selects the data type that is being displayed either scaled integer or floating point. Both
data types are always available but at different addresses within the memory map. The
memory map for integer registers ranges from 45000 to 45499, and the floating point
registers range from 46000 to 46999. Floating point numbers can be read directly without
any scaling conversions; however, they are represented in two registers and take up twice
the memory space.

Print

Four functions are available with the printing features
of the 3500/92 configuration screens. These
functions are selected through the pop up menu
activated by moving the mouse cursor over the print
button. The print button within the pop up menu will
then execute the selected option.

Modbus Registers
To Screen
This prints the Modbus Register Map to WordPad for editing or document
formatting purposes. Saving this to a file after editing is completed within
WordPad.

To Printer
Simply prints the Modbus Register Map to a printer.

Modbus Cfg file
This feature activates a Save dialog box which will save rack configuration data
to a file. This aids in the configuration of PLC's, DCS's, and/or MM's.

15
Print Form
Prints the active configuration screen to a printer.

3.4 Setting Software Switches
The Communication Gateway Module supports two software switches that let
you temporarily bypass the module and channel functions. Set these switches
on the Software Switches screen under the UtiIities Option on the main screen
of the Rack Configuration Software.


ModuIe Switches
Configuration Mode
A switch that allows the Communication Gateway Module to be configured.
To configure the module, enable () this switch and set the key switch on
the front of the Rack nterface Module in the PROGRAM position. When
downloading a configuration from the Rack Configuration Software, this
switch will automatically be enabled and disabled by the Rack Configuration
Software. f the connection to the rack is lost during the configuration
process, use this switch to remove the module from Configuration Mode.

16
The module switch number is used in the Communication Gateway Module.

Module Switch Number Switch Name

ChanneI Switches
Bypass
Turn the associated Communication Port on the Communication Gateway /O
Module (Modbus) on () or off ().

The channel switch number is used in the Communication Gateway Module.

Channel Switch Number Switch Name
4 Bypass

Section 4 /O Module Description
17
4. I/O ModuIe Description
This section describes the Communication Gateway Modbus RS-232/422,
Modbus RS-485, Ethernet RS-232, and Ethernet RS-485 /O Modules. t also
contains the information needed to use the Communication Gateway /O
Modules and a distributed control system (DCS), display, or host computer to
communicate with a 3500 rack using the Modicon Modbus protocol.
4.1 Modbus RS-232/422 I/O ModuIe Description
The Communication Gateway Modbus RS-232/422 /O Module is used with a
DCS, display, or host computer to collect data from a 3500 rack and change
setpoints or switches using the Modicon Modbus protocol. The Communication
Gateway /O Module must be installed behind the Communication Gateway
Module (in a Rack Mount or a Panel Mount rack) or above the Communication
Gateway Module (in a Bulkhead rack).

1) These connectors are used to connect Ports 1
and 2 of the Communication Gateway Modbus
RS-232/422 /O Module to the host (DCS,
display, or host computer). This connection can
be RS-232 or RS-422. Refer to Sections 4.1.2,
4.1.3, 4.1.4.
2) These connectors are used to connect this
Communication Gateway Modbus RS-232/422
/O Module to the next Communication Gateway
Modbus RS-232/422 /O Module in the chain.
Only RS-422 can be used for this connection.
Refer to Section 4.1.5.
18
4.1.1 GeneraI Response Time
The Communication Gateway Modbus RS-232/422 /O Module has a general
response time of less than 0.5 seconds with a 3 byte time out.
4.1.2 Connecting a Modbus RS-232/422 I/O ModuIe Port to the
Host (DispIay or Host Computer) via RS-232
The communication rate is limited by the baud rate selected between the host
(display or host computer) and the first Communication Gateway Modbus RS-
232/422 /O Module port.

1) Cable 130419-XXXX-XX is available in various lengths up to 30 meters (100 ft).
Refer to Section 8 for the specific options.

19
4.1.3 Connecting a Modbus RS-232/422 I/O ModuIe Port to the
HoneyweII PLCG via RS-232
The communication rate is limited by the baud rate selected between the
Honeywell PLCG and the first Communication Gateway Modbus RS-232/422 /O
Module port.

1) Cable 130420-XXX-XX is available in various lengths up to 30 meters
(100 ft). Refer to Section 8 for the specific options.

20
4.1.4 Connecting a Modbus RS-232/422 I/O ModuIe Port to a
Host (DispIay or Host Computer) via RS-422
The baud rate selected between the host (display or host computer) and the first
Communication Gateway /O Module (Modbus) port limit the communication rate.

1) For lengths of 150 meters (500 ft) or less, use
cable 130530-XXXX-XX (PVC insulation) or
cable 131109-XXXX-XX (Teflon insulation).
For lengths greater than 150 meters (500 ft), use
one cable 130530-XXXX-XX (PVC insulation) or
cable 131109-XXXX-XX (Teflon insulation) along
with as many RS-422 extension cables 130531-XX-
XX (150 meters (500 ft) standard length) to create a
cable up to the maximum 1220 meters (4000 ft).

2) RS-232/422 Converter.
For 110 VAC use part number 02230411. For 220
VAC use part number 02230412. A converter is not
necessary if the host computer is equipped with an
RS422 port.
3) Cable 130119-01 is available in a 3 meter (10 ft)
length.
4) Display or host computer

Refer to Section 8 for the specific options of the
cables listed above.
21
4.1.5 Daisy Chaining Modbus RS-232/422 I/O ModuIe Ports via
RS-422
This section shows how to daisy chain Communication Gateway Modbus RS-
232/422 /O Module ports together.

To host (see
Sections
4.1.2, 4.1.3,
4.1.4).

Take note of the following items when daisy chaining Communication Gateway
Modbus RS-232/422 /O Module ports:
Use the HOST port to connect to the DCS, display or host computer, or the
rack in the daisy chain that is closer to the host.
Use the RACK port to connect to the rack that is farther from the host.
Use the following cables for the connection between the racks in the daisy
chain:
- For lengths of 150 metres (500 ft) or less, use cable 129665-XXXX-
XX (PVC nsulation) or cable 131108-XXXX-XX (Teflon nsulation).

- For lengths greater than 150 metres (500 ft), use one cable 129665-
XXXX-XX (PVC nsulation) or cable 131108-XXXX-XX (Teflon
nsulation) along with as many RS-422 extension cables 130531-XX-
XX (150 metres (500 ft) standard length) to create a cable up to 1220
metres (4000 ft).

22
4.1.6 AdditionaI Information for Connecting an RS-232 I/O
ModuIe to a Host Computer in an IntrinsicaIIy Safe
AppIication
To avoid ground loops, the system must provide a single point ground. n ntrinsically Safe
applications the 3500 Rack is floated and referenced to an intrinsically safe ground instead
of earth ground. RS-232 communications are referenced to earth ground, and therefore to
keep the rack isolated from earth ground, a serial data isolator must be used. RS-485 uses
an isolated ground and hence no additional isolation is required.

1) Host Computer
meters (100 ft).
3) Serial Data solator P/N 02200633

23
4.2 Modbus RS-485 I/O ModuIe Description
The Communication Gateway Modbus RS-485
/O Module is used with a DCS, display, or
host computer to collect data from a 3500 rack
and change setpoints or switches using the
Modicon Modbus protocol. The
Communication Gateway /O Module must be
installed behind the Communication Gateway
Module (in a Rack Mount or a Panel Mount
rack) or above the Communication Gateway
Module (in a Bulkhead rack). The RS-485
interface allows up to 32 devices multi-
dropped on up to 4000 feet of cable.

1) These connectors are used to connect Ports 1 and 2
of the Communication Gateway Modbus RS-485 /O
Module to the host (DCS, display, or host computer).

2) These connectors are used to connect
Communication Gateway Modbus RS-485 /O
Modules together. Refer to Section 4.2.2 and the
drawing in Section 4.2.3.
3) These switches are used for RS-485 line termination.
24
4.2.1 GeneraI Response Time
The Communication Gateway Modbus RS-485 /O Module has a general
response time of less than 0.5 seconds with a 3 byte time out.
4.2.2 Four-Wire Connections
When connecting the Modbus RS-485 /O Module to a host device or to another
/O module, the connections are made per the diagram below. See the following
table for connector designations.

Signal

Name

Host Connector
(15 Pin) Pin #

Rack Connector
(9 pin) Pin #

GND
TXB
TXA
RXB
RXA

Ground
Transmit Positive
Transmit Negative
Receive Positive
Receive Negative

8
7
15
13
6

5
3
9
4
6

1) Distributed Control System
2) Remote Display or Host Computer
3) Terminate these devices
4) For lengths of 150 metres (500 ft) or less, use cable 129665-XXXX-
XX (PVC nsulation) or cable 131108-XXXX-XX (Teflon nsulation).

For lengths greater than 150 metres (500 ft), use one cable 129665-
XXXX-XX (PVC nsulation) or cable 131108-XXXX-XX (Teflon
25
nsulation) along with as many RS-422/RS-485 extension cables
130531-XX-XX (150 metres (500 ft) standard length) to create a total
RS-485 cable run up to 1220 metres (4000 ft).

5) Terminate these devices

4.2.3 Two-Wire Connections
Bently Nevada Corporation recommends using 4 wire communications when
possible. n order to use 2 wire communications the devices in the 485 chain
must meet the following conditions:
All devices must automatically tri-state the line
At least one device must have proper biasing to ensure the line remains in a
known state during idle conditions (see section 4.2.4)
The master device in the Modbus chain must have a configurable delay
between the time it receives its response and when it requests data again.
This delay must give sufficient time for every device in the chain to transition
into tri-state mode. 10ms delay is recommended.
f these conditions cannot be met 4 wire must be used to ensure a reliable
connection.
When using the Modbus RS-485 /O Module in a 2-wire configuration, the wiring
between the host device and the /O module is shown below.

4.2.4 Termination
Proper termination is critical for reliable communications. mproper termination
can result in a loss of communication. n normal 4 wire applications the last
device of each end of the chain should be terminated. The transmitting pair
should use a standard termination and the receiving pair should use a bias
termination (also called a fail-safe termination or a power termination). Biasing
prevents the appearance of a false bit being received at a device when
communications are idle. n normal 2 wire applications the Modbus master
26
should have a bias termination and the farthest device should have a standard
termination. f the Modbus master does not provide a bias termination another
device in the chain must provide the bias. With long distances or in noisy
environments it may be necessary to provide a bias at additional devices
regardless of termination. The /O provides 4 switches that allow configuration of
a termination scheme.

1) This switch provides a 120-ohm termination across the transmitting lines
2) This switch provides a 120-ohm termination across the receiving lines
3&4) These switches add bias to the receiving lines and when used with switch 2
provide a bias termination across the receiving lines.
Suggested switch settings (X indicates switch depressed)
1 2 3&4
Standard 4 Wire
installation
X X X
Standard 2 Wire
installation
X
2 wire with
master not
providing bias
X X
Unterminated
Unterminated
with biasing
X

Older RS485 /O's use a single "Term/Unterm" switch that provides a normal 4 wire
termination. For these older /O's in a 2 wire installation, use a discrete120 ohm resistor
between RX+ and RX- to terminate; always leave the switch in the "UNTERM" position.
27

4.3 Ethernet/RS-232 I/O
This /O provides for Ethernet network communications and PLC/DCS network
communications at the same time.

1) Port 1 Ethernet

2) Port 2 RS-232

28
4.3.1 Ethernet - port 1
This port connects to networks running TCP/P. The connector, RJ45, is a single-
drop connector and is standard in most applications. For multi-drop applications a
network hub is required. This port allows for communication to six devices
running either 3500 software or Modbus Application Protocol (MBAP). Cable
number 138131-xxx connects to this port
4.3.2 RS-232 - port 2
RS-232 port is a 9 pin sub D connector. The standard pins are listed below:

Signal

Name

Connector (9-pin) Pin #

GND
TXD
RXB

Ground
Transmit
Receive

5
3
2

Additional pins are provided for the Modbus Master devices with this capability:

Signal

Name

Connector (9-pin) Pin #

GND
DTR
DSR
RTS
CTS
CD

Ground
Data Transmit Ready
Data Send Ready
Ready To Send
Clear To Send
Carrier Detect

1
4
6
7
8
9

Standard 9 pin RS-232 cabling will work with this port.
For information about using this /O in an intrinsically safe environment see
section 4.1.6
Note, the RS-232 port is not intended to be connected to a multiple device
network. nstead, the RS-485 with a "Y cable is a better solution (see below).
29

4.4 Ethernet/RS-485 I/O
This /O is used for Ethernet network communications and PLC/DCS network
communications.

1) Port 1 Ethernet

2) Port 2 RS-485
30

4.4.1 Ethernet - port 1
This port connects to networks running TCP/P. The connector, RJ45, is a
single-drop connector and is standard in most applications. For multi-drop
applications a network hub is required. This port allows for communication to six
devices running either 3500 software or Modbus Application Protocol (MBAP).
Cable number 138131-xxx connects to this port

4.4.2 RS-485 - port 2
RS-485 port is a 9-pin sub-D connector with the following pin outs

Signal

Name

Connector (9 pin) Pin #

GND
TXB
TXA
RXB
RXA

Ground
Transmit Positive
Transmit Negative
Receive Positive
Receive Negative

5
3
9
4
6

RS485 is preferred for a multiple device network. The multi-drop connection
allows devices on the chain to continue to communicate when other devices are
not operating. A "Y connection provides multi-drop capability.
Use cable number 139036-01 for the "Y connection.
Cable number 131179-AAAA-BB-CC connects to this port.
See sections 4.2.3 and 4.2.4 for important information regarding installation and
termination for this /O.
31

4.5 CabIe Pin Outs

Cable Number 129665-XXXX-XX (PVC nsulation)
Cable Number 131108-XXXX-XX (Teflon nsulation)
RS-422/RS-485 - 3500/92 to 3500/92 Cable

Host Computer to RS-232/422 Converter Cable

32

RS-232 Host Computer to 3500/92 Cable

33

RS-232 Honeywell PLCG to 3500/92 Cable

Cable Number 130530-XXXX-XX (PVC nsulation)
Cable Number 131109-XXXX-XX (Teflon nsulation)
RS-232/422 Converter to 3500/92 Cable RS-422

34

RS-422 Extension Cable - 3500/92

RS-485 "Y Cable - 3500/92

Section 5 -- Protocols
35
5. ProtocoIs
5.1 Modbus
5.1.1 Modbus Interface Description
This section describes the Modbus nterface and shows how it relates to the
Communication Gateway Module. Before you begin programming, use the
following document to become familiar with the basics of the Modbus protocol:
AEG Modicon Modbus Protocol Reference Guide, Publication P-MBUS-300
Rev E - March 1993
This section does not tell you how to program your DCS computer to access the
Communication Gateway Module nor how to configure the interface database.
You must refer to the DCS computer or controller manuals for this information.
5.1.1.1 Register Map
This section describes the function codes, addressing notation, and registers
supported by the Communication Gateway Module.
5.1.1.1.1 Supported Function Codes

Modbus Function Code

Communication Gateway ModuIe
Data

Code

Meaning

02

Read nput Status

Rack, Module, and Channel Statuses

03

Read Holding Registers

Setpoint Configuration, Switch Settings,
Configuration Lock, Alarm Event List,
System Event List, Rack Date and Time,
Rack Reset, Rack Trip Multiply -
Software,
Rack Trip Multiply - Hardware,
Rack Alarm nhibit - Software,
Rack Alarm nhibit - Hardware,
Last Command Success,
Full-scale Data Range, Port Number,
Data Ready,
Repeated Read nput Status Data,
Repeated Read nput Register Data and
Configurable Registers

04

Read nput Registers

Current Proportional Values, Last Read
Proportional Time Stamp

06
and
16

Preset Single Register
And
Preset Multiple

Setpoint Configuration, Switch Settings,
Configuration Lock, Alarm Event List,
System Event List, Rack Date and Time,
36

Modbus Function Code

Communication Gateway ModuIe
Data

Code

Meaning

Registers Rack Reset, Rack Trip Multiply -
Software,
Rack Alarm nhibit Software,

08

Loopback/Maintenance
Diagnostic Codes:
0

2

10

11

12

13

18

Query Data

Diagnostic Register

Clear Counters

Message Count

Communication Error Count

Exception Count

Character Overrun Count

17

Report Slave D

Family D and current revision number of
the Communication Gateway Module's
firmware

5.1.1.1.2 DCS and Modbus Addressing Notation
The following table shows the notation used to refer to the function code
addresses in the DCS computer database and in the Modbus queries.

Data Type

Modbus ProgrammabIe
ControIIer Register
(1-based)

Query Address
(zero-based)

Format

Range

Format

Range

nput Status

1XXXX

10001-19999

XXXX

0000-9998

Holding Registers

4XXXX

40001-49999

XXXX

0000-9998

nput Registers

3XXXX

30001-39999

XXXX

0000-9998


4XXXX

40001-49999

XXXX

0000-9998

Preset Multiple
Registers

4XXXX

44001-49999

XXXX

0000-9998

37

Note
Addresses are listed in this section using 2 formats: the Modbus
Programmable Controller format (1-based) and the query address format
(zero-based). Use whichever format is appropriate for your host.

5.1.1.1.3 GeneraI Register Layout
The Communication Gateway Module uses fixed protocol addresses for the
starting locations of data in the rack. The data addresses are used in the
protocol messages to access data that is available from the module and are not
the physical data addresses in the Communication Gateway Module. The
protocol starting addresses and Modicon PC Registers are as follows:

Data Type

Function
Code

Address Ranges

Query
Address
Format
(zero-based)

Modbus
ProgrammabIe
ControIIer
Format
(1-based)

Not Used
Current Proportional Values
Last Read Proportional Time Stamp

Module Statuses (nput Status Format)
Channel Statuses
Rack Status

Setpoint Configuration
Switch Settings
Configuration Lock

Alarm Event List
System Event List
Rack Date and Time

Rack Reset
Trip Multiply Group
Rack Trip Multiply Software

Rack Trip Multiply - Hardware
Rack Alarm nhibit - Software
Rack Alarm nhibit Hardware

Last Command Success
Full-scale Data Range

-
4
4

2
2
2

3, 6
3, 6
3, 6

3, 6
3, 6
3, 6

3, 6
3, 6
3, 6

3
3, 6
3

3
3

0-447
500-947
950-956

0-95
100-3683
3684-3692

0-5
6-10
11

12-29
30-63
80-93

94
95
96

97
98
99

100-112
113

30001-30448
30501-30948
30951-30957

10001-10096
10101-13684
13685-13693

40001-40006
40007-40011
40012

40013-40030
40031-40064
40081-40094

40095
40096
40097

40098
40099
40100

40101-40113
40114
38

Data Type

Function
Code

Address Ranges

Query
Address
Format
(zero-based)

Modbus
ProgrammabIe
ControIIer
Format
(1-based)
Port D

Data Ready
*Unused
*Repeated Current Proportional Values

*Repeated Last Read Time Stamp
*Repeated Module Statuses
*Repeated Channel Statuses

*Repeated Rack Status
*Repeated Current Proportional Values
Floating Point
*Repeated Setpoint Configuration
Floating Point

Setpoints
Otherwise
Configurable Registers Floating Point
Setpoints
Otherwise
3

3
-
3

3
3
3

3

3

3,6, or 16

3,6, or 16
3

3,6, or 16
3
114

115
1000-1447
1500-1947

1950-1956
2000-2005
2006-2229

2230

2500-3395

4000-4007

5000-5499

6000-6999
40115

40116
41001-41448
41501-41948

41951-41957
42001-42006
42007-42230

42231

42501-43396

44001-44008

45001-45500

46001-47000

*The repeated data registers contain duplicated data in different registers for
some Modbus devices that only support the 4XXXX series registers. Status data
is bit packed in the 4XXXX registers such that the least significant bit (bit 0) of
register 42001 corresponds to register 10001 and the most significant bit (bit 15)
of register 42001 corresponds to register 10016.
39

For more information about these data types, refer to the following pages:

Data Type

Page Number

Primary Values

40

Current Proportional Values

40

Last Read Proportional Time Stamp

42

Module Statuses (nput Status Format)

42

Channel Statuses

46
Rack Status 47


47

Switch Settings

52

Configuration Lock

53

Alarm Event List

54

System Event List

55

Rack Date and Time 57

Rack Reset

57

Rack Trip Multiply - Software

58

Rack Trip Multiply - Hardware

59

Rack Alarm nhibit - Software

59

Rack Alarm nhibit - Hardware

59


60
60
Port Number
61
Data Ready
61

5.1.1.2 Data Type DetaiIs
This section describes each data type in detail and describes what each register
is used for.

40
Primary VaIues
The primary values are not used in the 3500/92. nstead, the configurable
registers were added to accomplish this (see page 61). Because of this
difference, the 3500/92 is not completely compatible with the 3500/90. Users will
need to reconfigure their DCS or PLC with the addresses of the configurable
registers. n addition the configurable registers will need to be mapped using the
3500 Configuration software. All proportional values can be configured,
expanding the scope and adding flexibility to the contiguous register set.

Current ProportionaI VaIues
The current proportional values include monitor values such as direct (overall
vibration amplitude), probe gap, and 1X and 2X amplitude and phase lag. These
values are different for each channel pair type. Page 78, lists the proportional
values for each module. Use the READ NPUT REGSTERS command (function
code 4) to read the Current Proportional Values. Current proportional values
have space available for 32 values per monitor slot. Each slot can return from 0
to 32 channels and 0 to 8 values per channel, but not more than 32 values total
per slot. Each value is sent high byte to low byte. The value returned is scaled
to the value set for Full Scale Data Range in the Rack Configuration Software
(see Section 3.3). The Current Proportional Values are fixed with 32 addresses
for each slot. f a full-height monitor does not use all 32 proportional values, then
the addresses are filled with zeros.

Starting Addresses for Current ProportionaI VaIues

3500 Rack
SIot Number

Starting Address

FuII Height ModuIe or
Upper HaIf-height ModuIe

Lower HaIf-height ModuIe

Modbus PC
Format

Query
Format

Modbus PC
Format

Query
Format

2
3
4
5
6
7
8
9
10
11
12
13
14
15

30501
30533
30565
30597
30629
30661
30693
30725
30757
30789
30821
30853
30885
30917

500
532
564
596
628
660
692
724
756
788
820
852
884
916

30517
30549
30581
30613
30645
30677
30709
30741
30773
30805
30837
30869
30901
30933

516
548
580
612
644
676
708
740
772
804
836
868
900
932

41
For example, for a 3500/40 Proximitor Monitor installed in slot 3 with channel 1
and 2 optioned as Thrust Position and channel 3 and 4 optioned as Radial
Vibration, the proportional values for this monitor will be setup as follows:

Addresses for SampIe 3500/40 Proximitor Monitor

ProportionaI VaIue

Address

Number

Name

Query
Format
(zero-based)

Modbus
ProgrammabIe
ControIIer Format
(1-based)

1
2
3
4

5
6
7
8

9
10
11
12

13
14
15
16

Direct
Gap
Direct
Gap

Direct
Gap
1X Amplitude
1X Phase Lag

2X Amplitude
2X Phase Lag
Not 1X Amplitude
Smax Amplitude

Direct
Gap
1X Amplitude
1X Phase Lag

532
533
534
535

536
537
538
539

540
541
542
543

544
545
546
547

30533
30534
30535
30536

30537
30538
30539
30540

30541
30542
30543
30544

30545
30546
30547
30548

17
18
19
20

21
22
23
24

25
26
27
28

29
30
31
32

2X Amplitude
2X Phase Lag
Not 1X Amplitude
Smax Amplitude

0
0
0
0

0
0
0
0

0
0
0
0

548
549
550
551

552
553
554
555

556
557
558
559

560
561
562
563

30549
30550
30551
30552

30553
30554
30555
30556

30557
30558
30559
30560

30561
30562
30563
30564

42
f half-height modules are installed, then each module is fixed with 16 addresses.
Similar to a full-height module, a half-height module will fill unused addresses
with zeros. n addition, the topmost half-height module will send the entire 16
proportional values, including zeros, before the bottom module sends its block of
16 proportional values, including zeros.

Last Read ProportionaI Time Stamp
This set of registers is a time stamp of when the last read proportional value was
last updated. All the proportional values in one channel are updated at the same
time and therefore have the same time stamp. When a proportional value is
read, the time stamp for that proportional value is put into the Last Read
Proportional Time Stamp Registers. To find the time that proportional values
were obtained, first read a single proportional value or multiple proportional
values in the same channel by following the directions for Current Proportional
Values or Primary Values, then use the READ NPUT REGSTERS command
(function code 4) to read the time stamp at the addresses shown in the table
below. f a single read command requests proportional values from more than
one channel, then the time stamp data will be the time stamp of the last
requested register. The format for the Last Read Proportional Time Stamp
Registers is shown in the table below.

Last Read ProportionaI VaIue
or Status Time Stamp Address

FieId Name

Code
Range

Notes

Query Format

Modbus PC
Format

950
951
952
953
954
955
956

30951
30952
30953
30954
30955
30956
30957

Year
Month
Day
Hour
Minute
Second
1/100 Second

00 99*
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
0 - 99

Months are in
sequential order
(e.g. 1 = Jan)

24-hour clock: 12
= Noon and 00 =
Midnight
* Year = 00 implies the year 2000

ModuIe Statuses (Input Status Format)
The Module Statuses have a value of "1" for true and "0" for false. Each half-slot
module has three status bits associated with it, Alert/Alarm 1, Danger/Alarm 2,
and not OK. (Full-height modules will not use the Lower Slot statuses.) For
relay modules, the Alert/Alarm 1 status bit indicates that a relay has tripped. The
Alert/Alarm 1 and Danger/Alarm 2 status bits have no meaning for Keyphasor
Modules and Communication Gateway Modules and so are always false (status
bit equals "0"). The Power Supplies and Rack nterface Module only use the not
OK status so the other statuses are not used. f the Power Supply is faulted or
not installed, then the status for that power supply will be not OK ("1"). f the
Rack nterface Module is not OK then the not OK status will be set to "1". f the
state of the Module Status is unknown then it will be defaulted to "0" for false.
43
Use the READ NPUT STATUS command (Function code 2) to read the Module
Statuses. A simple formula to compute the starting address in zero-based format
for any slot status is:

Upper Slot Starting Address = 6 * slot number
Lower Slot Starting Address = (6 * slot number) + 3

ModuIe Status Addresses

SIot

ModuIe Status

Address

Query
Format

Modbus
PC Format

0 Upper
0 Upper
0 Upper

Rack OK Relay (0=ok, 1=not ok)
(not used)
Power Supply 1 not OK

0
1
2

10001
10002
10003

0 Lower
0 Lower
0 Lower

(not used)
(not used)
Power Supply 2 not OK

3
4
5

10004
10005
10006

1 Upper
1 Upper
1 Upper

(not used)
(not used)
RM not OK

6
7
8

10007
10008
10009

1 Lower
1 Lower
1 Lower

(not used)
(not used)
(not used)

9
10
11

10010
10011
10012

2 Upper
2 Upper
2 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

12
13
14

10013
10014
10015

2 Lower
2 Lower
2 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

15
16
17

10016
10017
10018

3 Upper
3 Upper
3 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

18
19
20

10019
10020
10021

3 Lower
3 Lower
3 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

21
22
23

10022
10023
10024

4 Upper
4 Upper
4 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

24
25
26

10025
10026
10027

4 Lower
4 Lower
4 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

27
28
29

10028
10029
10030
44

SIot

ModuIe Status

Address

Query
Format

Modbus
PC Format

5 Upper
5 Upper
5 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

30
31
32

10031
10032
10033

5 Lower
5 Lower
5 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

33
34
35

10034
10035
10036

6 Upper
6 Upper
6 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

36
37
38

10037
10038
10039

6 Lower
6 Lower
6 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

39
40
41

10040
10041
10042

7 Upper
7 Upper
7 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

42
43
44

10043
10044
10045

7 Lower
7 Lower
7 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

45
46
47

10046
10047
10048

8 Upper
8 Upper
8 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

48
49
50

10049
10050
10051

8 Lower
8 Lower
8 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

51
52
53

10052
10053
10054

9 Upper
9 Upper
9 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

54
55
56

10055
10056
10057

9 Lower
9 Lower
9 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

57
58
59

10058
10059
10060

10 Upper
10 Upper
10 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

60
61
62

10061
10062
10063

10 Lower
10 Lower
10 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

63
64
65

10064
10065
10066
45

SIot

ModuIe Status

Address

Query
Format

Modbus
PC Format

11 Upper
11 Upper
11 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

66
67
68

10067
10068
10069

11 Lower
11 Lower
11 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

69
70
71

10070
10071
10072

12 Upper
12 Upper
12 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

72
73
74

10073
10074
10075

12 Lower
12 Lower
12 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

75
76
77

10076
10077
10078

13 Upper
13 Upper
13 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

78
79
80

10079
10080
10081

13 Lower
13 Lower
13 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

81
82
83

10082
10083
10084

14 Upper
14 Upper
14 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

84
85
86

10085
10086
10087

14 Lower
14 Lower
14 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

87
88
89

10088
10089
10090

15 Upper
15 Upper
15 Upper

Alert/Alarm 1
Danger/Alarm 2
not OK

90
91
92

10091
10092
10093

15 Lower
15 Lower
15 Lower

Alert/Alarm 1
Danger/Alarm 2
not OK

93
94
95

10094
10095
10096

46
ChanneI Statuses
Channel statuses are only available for slot 2 through slot 15. The
Communication Gateway stores a true or false value for the channel statuses for
each channel. A "0" indicates false and a "1" indicates true. Each slot is fixed
with 32 channels. f a full-height monitor does not have all 32 channels, then the
Channel Status bits for the unused channels will be zero. Use the READ NPUT
STATUS command (Function Code 2) to access the Channel Status values for
the Rack. Refer the specific module's Operation and Maintenance Manual to
determine what channel statuses it returns. (Half-height modules can only have
up to 16 channels with 8 status values each.) The status bits for each channel is
in the following order:

Bit

ChanneI Statuses

0
1
2
3
4
5
6
7

Channel not OK
Channel Alert / Alarm 1
Channel Danger / Alarm 2
Channel n Bypass Mode
Channel Off
Channel Trip Multiply Mode
Channel Special Alarm nhibit
Channel Not Communicating

Starting Addresses for ChanneI Statuses

3500 Rack SIot
Number

Starting Address

FuII Height ModuIe or
Upper HaIf-height ModuIe

Lower HaIf-height ModuIe

Modbus PC
Format

Query Format

Modbus
PC
Format

Query Format

2
3
4
5
6
7
8
9
10
11
12
13
14
15

10101
10357
10613
10869
11125
11381
11637
11893
12149
12405
12661
12917
13173
13429

100
356
612
868
1124
1380
1636
1892
2148
2404
2660
2916
3172
3428

10229
10485
10741
10997
11253
11509
11765
12021
12277
12533
12789
13045
13301
13557

228
484
740
996
1252
1508
1764
2020
2276
2532
2788
3044
3300
3556

47
The equation for the upper not OK address is the following:
address for upper not OK = 100 + ( (slot # - 2) * 256 ) + ( (channel # - 1) * 8 )
For example: calculate the address for not OK of upper slot 3, channel 1 as
follows:
address = 100 + ( (3 - 2) * 256 ) + ( (1 - 1) * 8 )
address = 356

The equation for the lower not OK address is the following:
address for lower not OK = 228 + ( (slot # - 2) * 256 ) + ( (channel # - 1) * 8 )
For example: calculate the address for not OK of lower slot 2, channel 1 as
follows:
address = 228 + ((2 - 2) * 256 ) + ( (1 - 1) * 8 )
address = 228

Rack Status
The rack status is a range of registers that summarize the channel status
registers for all modules. Register 3684 corresponds to channel status bit 0
(channel not OK) and register 3692 corresponds to channel status bit 7 (channel
not communicating). Registers between 3684 and 3692 are used similarly for
the remaining channel statuses. f any module in the rack sets a channel status
bit, the corresponding rack status register will also be set.
The repeated rack status register (address 2230) is a single register with 8 bits.
Each bit summarizes the channel status registers for all modules in the rack.
The least significant bit (LSB) corresponds to channel status bit 0 (channel not
OK) and the remaining bits are used similarly for the remaining channel statuses.
f any module in the rack sets a channel status bit, the corresponding repeated
rack status bit will also be set.

Monitor setpoints may be either read or written. The setpoints are acquired one
at a time. The following information is required to read or write setpoints:

Setpoint Information

Refer to...

Setpoint types

Page 76 of this manual

Setpoint number

Operation and maintenance manual
for the monitor

Proportional value full-scale range

Channel Option screens in the Rack

Take the following precautions when you use the Communication Gateway
Module to adjust setpoints:
48
Adjust setpoints so that the over setpoint is greater than the under setpoint.
Refer to page 49 for additional information about 1X and 2X phase setpoints.
Since the Communication Gateway requires that you adjust one setpoint at a
time, turn channel bypass on before you change setpoints for proportional
values that have over and under setpoints.
Check that adjusted setpoints are within the linear range of the transducer.

To read a setpoint:
1. Use the PRESET MULTPLE REGSTERS command (function code 16) or
PRESET SNGLE REGSTER command (function code 6) to write to the Slot
Number, Channel Number, and Setpoint Number Registers at addresses 0,
1, and 2 (Modicon PC Registers 40001 to 40003) to specify which setpoint is
desired. Once these registers have been written, the Setpoint Value,
Setpoint Type, and Setpoint Enabled will be loaded into addresses 3, 4, and
5 (Modicon PC Registers 40004 to 40006).
2. Use the READ HOLDNG REGSTERS command (function code 3) to read
addresses 0 to 5 (Modicon PC Registers 40001 to 40006). Reading those
addresses before they have been updated will yield the previous setpoint
value from the previous setpoint request.
To write a new setpoint value:
1. Acquire Configuration Lock - Write a "1" to the Configuration Lock Register
using a function code 6 or 16 to request the Configuration Lock.
2. Verify Configuration Lock is granted - Read the Configuration Lock
Register using function code 3. A "0" means the Configuration Lock is
granted to another port and a "1" means the Configuration Lock is granted

Note
The Configuration Lock will not be granted and setpoint values can not be
changed if any other port has the Configuration Lock. Also, if the
Communication Gateway is configured to not allow changing configuration,
then writing to the Configuration Lock Register will cause an illegal address
response. For details, refer to page 53 (Configuration Lock).

49

3. Write new setpoint vaIue - Use the PRESET MULTPLE REGSTERS
command (function code 16) or PRESET SNGLE REGSTER command
(function code 6) to write to the Slot Number, Channel Number, Setpoint
Number, and Setpoint Value Registers at addresses 0 to 3 (Modicon PC
Registers 40001 to 40004) to specify which setpoint is to be changed and the
new value it is to be changed to. You may change multiple setpoints in the
same slot by repeating step 3.

Application Alert

The Communication Gateway ModuIe aIIows the Under
setpoint to be set above the Over Setpoint. Reversing
the Over and Under setpoints resuIts in different
acceptance regions as shown in the foIIowing 4
scenarios.

50

Scenarios 1 through 4

1) Acceptance Region
2) Over Setpoint for Scenarios 1 through 4
3) Under Setpoint for Scenarios 1 through 4

Note
Phase acceptance regions define the areas for a nonalarm state. The
endpoints (setpoints) are included in the nonalarm state.

For 1X and 2X Phase Lag, the Over Setpoint does not have to be greater
than the Under Setpoint.

The acceptance region is always from the Under Setpoint to the Over
Setpoint in a counter-clockwise direction.

f the Under Setpoint equals the Over Setpoint, then there is full
acceptance (no alarms).

4. Verify new setpoint vaIue - f you did not receive an error code when the
setpoint was written, you can verify the new setpoint value by either following
the read setpoint steps to read back the setpoint value (the value read back
may be slightly different from what was written due to scaling), or read the
Last Command Success registers (see page 60).
5. ReIinquish the Configuration Lock - Write a "0" to the Configuration Lock
Register using a function code 6 or 16 to relinquish the Configuration Lock.
51
52

Setpoint
Configuration

Query
Address

Modicon PC
Register

FIoating
Point
Registers

Read or
Write

Data Range
(DecimaI)

Slot Number
Channel Number
Setpoint Number
Setpoint Value

Setpoint Type
Setpoint Enabled

0
1
2
3

4
5

40001
40002
40003
40004

40005
40006

44001
44002
44003
44004
44005
44006
44007

Read/Write
Read/Write
Read/Write
Read/Write

Read Only
Read Only

2 - 15
1 - 32
1 - 20
0 65535

0 - 255
0 = FALSE
1 = TRUE

Switch Settings
Use the Switch Setting to read or write channel settings. Setup which Switch
Setting is desired by writing to the Slot Number, Upper/Lower, Channel Number,
and Switch Number registers. Refer to the switch section of the module
operation and maintenance manual for the switch numbers.

To read Channel Settings:
1. Use the PRESET MULTPLE REGSTERS command (function code 16) or
PRESET SNGLE REGSTER command (function code 6) to write to the Slot
Number, Upper/Lower, Channel Number, and Switch Number registers to
specify which Switch Setting is desired. Once these registers have been
written, the Channel Setting information will be loaded into the Switch Value
register.
2. Use the READ HOLDNG REGSTERS command (function code 3) to read
the Slot Number, Upper/Lower, Channel Number, Switch Number, and
Switch Value. Reading those addresses before they have been updated will
yield the previous Channel Settings from the previous Switch Setting request.

To write a new Switch Setting value:
1. Acquire Configuration Lock - Requisition the configuration lock by writing a
"1" to the Configuration Lock Register using a function code 6 or 16.
2. Verify that the Configuration Lock is granted - Read the Configuration
Lock Register using function code 3. A "0" means the Configuration Lock is
not granted and a "1" means the Configuration Lock is granted.

Note
The Configuration Lock will not be granted and switch values can not be
changed if any other port has the Configuration Lock. Also, if the
Communication Gateway is configured to not allow changing configuration,
then writing to the Configuration Lock Register will cause an illegal address
response. For details, see page 53 (Configuration Lock).

53
3. Write the new ChanneI Setting - Use the PRESET MULTPLE REGSTERS
command (function code 16) or PRESET SNGLE REGSTER command
(function code 6) to write to the Slot Number, Upper/Lower, Channel Number,
Switch Number, and Switch Setting Registers to specify which Channel
Setting is to be changed and the new value it is to be changed to. (To
change the module switches, then specify Channel 0.) You may change
Switch Settings on different channels in the same slot by repeating step 3.
4. Verify new Switch Setting - f you did not receive an error code when the
switch was written, you can verify the new switch value by either following the
read Switch Setting steps to read back the switch value or read the Last
Command Success registers (see page 60).
5. ReIinquish the Configuration Lock - Relinquish the Configuration Lock by
writing a "0" to the Configuration Lock Register using a function code 6 or 16.

Switch Setting

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(DecimaI)

Slot Number
Upper/Lower

Channel Number
Switch Number
Switch Value

6
7

8
9
10

40007
40008

40009
40010
40011

Read/Write
Read/Write

Read/Write
Read/Write
Read/Write

0 - 15
0 = UPPER
1 = LOWER
0 - 32
1 - 16
0 = OFF
1 = ON

Configuration Lock
The Configuration Lock allows only one device to configure the 3500 rack at a
time. To acquire the Configuration Lock, write a "1" to the Configuration Lock
Register using the PRESET SNGLE REGSTER command (function code 6) or
the PRESET MULTPLE REGSTERS command (function code 16).
To see if the Configuration Lock has been granted, read the Configuration Lock
Register using the READ HOLDNG REGSTERS command (function code 3).
A "0" means that the Configuration Lock is granted to another port and a "1"
means the Configuration Lock is granted.
To relinquish the Configuration Lock, write a "0" to the Configuration Lock
Register using the PRESET SNGLE REGSTER command (function code 6) or
the PRESET MULTPLE REGSTERS command (function code 16). To verify
that the Configuration Lock was relinquished, you can read the Last Command
Success registers (see page 60).
The Configuration Lock will not be granted if the following conditions are true:
Another port in the rack has the lock
The Config Allowed box on the Modbus Protocol Setup screen of the Rack
Configuration Software is cleared ()
Writing to the Configuration Lock Register when one of these conditions is true
will cause an illegal address response.
54

Register

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(DecimaI)

Configuration Lock

11

40012

Read/Write

0 - 1

AIarm Event List
The Alarm Event List contains the latest 1000 Alarm Events. Each Alarm Event
is identified with a unique 32 bit sequence number. The Last Posted Alarm
Event Register contains the sequence number of the latest Alarm Event. To
request an Alarm Event, first write the desired sequence number to the
Requested Alarm Event Registers using the PRESET SNGLE REGSTER
command (function code 6) or the PRESET MULTPLE REGSTERS command
(function code 16). The specified event can then be read using the READ
HOLDNG REGSTERS command (Function code 3).
f you read the holding register before the registers are updated, the last
requested event will be returned. f the event requested is more than 999 events
older than the last posted alarm event sequence number, then the exception
code "LLEGAL DATA VALUE" will be returned.
55

AIarm Event List
Description

Query
Address

Modicon
PC
Register

Data Range
(decimaI)

Read or
Write

Requested Alarm Event
Sequence Number

12 - 13

40013 -
40014

0 - 4,294,967,245

Read/Write

Last Posted Alarm Event
Sequence Number

14 - 15

40015 -
40016

0 - 4,294,967,245

Read Only

Alarm Event Sequence No.

Slot Number
Upper/Lower

Channel
Alarm Type

Alarm Direction

Year
Month
Day
Hour
Minute
Second
1/100 Second

16 - 17

18
19

20
21

22

23
24
25
26
27
28
29

40017 -
40018
40019
40020

40021
40022

40023

40024
40025
40026
40027
40028
40029
40030

0 - 4,294,967,245

0 - 15
0 = UPPER
1 = LOWER
0 - 32
0 = Alert
1 = Danger
2 = not OK
3 = Relay Trip
0 = Entered Alarm
1 = Exit Alarm
00 99*
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
0 - 99

Read Only

Read Only
Read Only

Read Only
Read Only

Read Only

Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only

System Event List
The System Event List contains the latest 500 System Events. Each System
Event is identified with a unique 32 bit sequence number. The Last Posted
System Event Register contains the sequence number of the latest System
Event. To request a System Event, first write the desired sequence number to
the Requested System Event Registers using the PRESET SNGLE REGSTER
command (function code 6) or the PRESET MULTPLE REGSTERS command
(function code 16). The specified event can then be read using the READ
HOLDNG REGSTERS command (Function code 3).
f you read the holding registers before the registers are updated, the last
requested event will be returned. f the event requested is 499 events older than
the last posted alarm event sequence number, then the exception code
"LLEGAL DATA VALUE" will be returned.
56

System Event List
Description

Query
Address

Modicon
PC
Register

Data Range
(DecimaI)

Read or
Write

Requested System
Event Sequence
Number

30 - 31

40031 -
40032

0 - 4,294,967,295

Read/Write

Last Posted System
Event Sequence
Number

32 - 33

40033 -
40034

0 - 4,294,967,295

Read Only

Sequence Number

Event Classification

System Event Number
Source Slot
Upper/Lower

Destination Slot*
Upper/Lower*

Year
Month
Day
Hour
Minute
Second
1/100 Second
Event Specific String

Event String

34 - 35

36

37
38
39

40
41

42
43
44
45
46
47
48
49 - 51

52 - 63

40035 -
40036
40037

40038
40039
40040

40041
40042

40043
40044
40045
40046
40047
40048
40049
40050 -
40052
40053 -
40064

0 - 4,294,967,295

0= Severe/Fatal
Event
1 = Potential
Problem Event
2 = Typical logged
Event
3 = Reserved
0 - 65535
0 - 15
0 = Upper Slot
1 = Lower Slot
0 - 15
0 = Upper Slot
1 = Lower Slot
00 - 99*
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
0 - 99
ASC text

ASC text

Read Only

Read Only

Read Only
Read Only
Read Only

Read Only
Read Only

Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only

Read Only

Refer to the module's operation and maintenance manual for the System Event
List Messages. The Source Slot number is the module that caused the action
(for example if the Communication Gateway Module changed the module's
setpoint the Communication Gateway Module would be listed as the source slot).
* Refer to the operation and maintenance manual for the module installed in this
slot (upper or lower).
57
Rack Date and Time
The rack date and time can be either read or written. To read the actual rack
date and time, use READ HOLDNG REGSTER command (function code 3) and
the Actual Rack Date and Time Registers shown in the table below.
To write a new rack date and time, write the desired time using PRESET
SNGLE REGSTERS command (function code 6) or PRESET MULTPLE
REGSTERS command (function code 16) to the Write and Verify Rack Date and
Time Registers shown in the table below. The Write and Verify Rack Date and
Time Registers can be read back to verify what you entered. You can preload
the date and time except for the 1/100 second register. When the 1/100 second
register is written to, the new rack date and time will be stored.
To verify the new rack date and time, you can either read the rack date and time
using the Actual Rack Date and Time Registers, or you can read the Last

Rack
Date/Time
Address

Modicon
PC
Register

FieId
Name

Code
Range

Notes

Read or Write

Actual Rack Date and Time Registers

80
81
82
83
84
85
86

40081
40082
40083
40084
40085
40086
40087

Year
Month
Day
Hour
Minute
Second
1/100
Second

00 - 99*
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
0 - 99

Months are in sequential order
(e.g. 1 = Jan)

24-hour clock: 12 = Noon and
00 = Midnight

Read Only
Read Only
Read Only
Read Only
Read Only
Read Only
Read Only

Write and Verify Rack Date and Time Registers

87
88
89
90
91
92
93

40088
40089
40090
40091
40092
40093
40094

Year
Month
Day
Hour
Minute
Second
1/100
Second

00 - 99*
1 - 12
1 - 31
0 - 23
0 - 59
0 - 59
0 99

Months are in sequential order
(e.g. 1 = Jan)

24-hour clock: 12 = Noon and
00 = Midnight
(Writing to the 1/100 Second
register causes the time stored in
the Write/Verify Rack date and
Time Registers to be written to
the Actual Rack Date and Time
Registers)

Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write

Rack Reset
Before you perform this command, use the 3500 Rack Configuration Software to
verify that the Config Allowed box on the Modbus Protocol Setup screen is
checked (). f you attempt to write a "1" to the software Rack Reset software
address when the Config Allowed box is cleared (), an LLEGAL DATA
ADDRESS will be returned. To enable the software Rack Reset for that group
with the Modbus protocol, write a the group number of the monitor or 255 for all
monitors to software Rack Reset address using the PRESET MULTPLE
58
REGSTERS command (function code 16) or PRESET SNGLE REGSTER
(function code 6).
To verify that the software Rack Reset was enabled, you can read the Last

Register

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(decimaI)

Rack Reset

94

40095

Read/Write

1 - 16 or 255

Rack Group
This register controls the group referred in the software Rack Trip Multiply
register. Groups are set in the RM. The default value, 255, means all groups; in
other words the entire rack.

Register

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(decimaI)

Rack Group

95

40096

Read/Write

1 16 or 255

Rack Trip MuItipIy (Software)
checked (). f you attempt to write a "1" to the software Rack Trip Multiply
software address when the Config Allowed box is cleared (), an LLEGAL
DATA ADDRESS will be returned. First, set the Rack Group Register. To
enable the software Rack Trip Multiply for that group with the Modbus protocol,
write a "1" to software Rack Trip Multiply address using the PRESET MULTPLE
(function code 6).
To disable the software Rack Trip Multiply with the Modbus protocol, write a "0"
to the Rack Trip Multiply using the PRESET MULTPLE REGSTERS command
(function code 16) or PRESET SNGLE REGSTER (function code 6).
To verify that the software Rack Trip Multiply was either enabled or disabled, you
can read back the software Rack Trip Multiply register using the READ
HOLDNG REGSTERS command (function code 3) or read the Last Command
Success registers (see page 60).

Register

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(decimaI)

Rack Trip Multiply
(Software)

96

40097

Read/Write

0 - 1

59
Rack Trip MuItipIy (Hardware)
To see if the Rack Trip Multiply contact on the Rack nterface /O Module is
enabled or disabled, read the hardware Rack Trip Multiply register using the
READ HOLDNG REGSTERS command (function code 3). f the value in the
register is a "1" then the hardware Rack Trip Multiply is enabled. f the value in
the register is a "0", the hardware Rack Trip Multiply is disabled.

Register

Query
Address

Modicon PC
Register

Read
or
Write

Data Range
(decimaI)

Rack Trip Multiply
(Hardware)

97

40098

Read
Only

0 - 1

Rack AIarm Inhibit (Software)
checked (). To enable the software Rack Alarm nhibit with the Modbus
protocol, write a "1" to the software Rack Alarm nhibit register using the
PRESET MULTPLE REGSTERS command (function code 16) or PRESET
SNGLE REGSTER (function code 6).
To disable the software Rack Alarm nhibit with the Modbus protocol, write a "0"
to the software Rack Alarm nhibit register using the PRESET MULTPLE
(function code 6).
To verify that the software Rack Alarm nhibit was either enabled or disabled,
read back the software Rack Alarm nhibit register using the READ HOLDNG
REGSTERS command (function code 3) or read the Last Command Success
registers (see page 60).

Register

Query
Address

Modicon
PC
Register

Read or
Write

Data Range
(decimaI)

Rack Alarm nhibit
(Software)

98

40099

Read/Write

0 - 1

Rack AIarm Inhibit (Hardware)
To see if the Rack Alarm nhibit contact on the Rack nterface /O Module is
enabled or disabled, read the hardware Rack Alarm nhibit register using the
READ HOLDNG REGSTERS command (function code 3). f the value in the
register is a "1", then the hardware Rack Alarm nhibit is enabled. f the value is
a "0", the hardware Rack Alarm nhibit is disabled.
60

Register

Query
Address

Modicon PC
Register

Read or
Write

Data Range
(decimaI)

Rack Alarm nhibit
(Hardware)

99

40100

Read Only

0 - 1

The Last Command Success Error Code indicates if
the last command was executed successfully
the last command was not completed
an error was detected

The Last Command Success String contains a message that
explains the error
states if the command was successful or unsuccessful
indicates if the register is busy

Register

Query
Address

Modicon PC
Register

Data Range
(decimaI)

Error Code
Status String

100
101 - 112

40101
40102 - 40113

0 - 65535
text

FuII-scaIe Data Range
The Full-scale Data Range register indicates the maximum size for values that
are returned from the port. Typical values for this register are 12 bits (4095), 16
bits (65535), etc.

Register

Query
Address

Modicon PC
Register

Data Range
(decimaI)

Read/Write

Full-scale
Data Range

113

40114

1 - 65535

Read Only

Data is scaled between zero and the number entered for the Full-scale Data
Range in the Rack Configuration Software. The Full-scale Data Range value is
equivalent to 100% of full-scale.
Refer to Page 62(Scaling the Data) for examples.

61
Port Number
The port number will return which of the two comm ports that you are connected
to and talking on.

Register

Query
Address

Modicon PC
Register

Read
or
Write

Data Range
(decimaI)

Port Number

114

40115

Read
Only

0 - 1

Data Ready
The data ready register indicates whether or not a request for any of the multiple
registers (setpoints, switch settings, events, or date/time) have completed
fetching the information from the rim. This register can be set manually if the
transition from zero to one is desired to be seen or it will toggle automatically
upon request for the information.

Register

Query
Address

Modicon PC
Register

Read
or
Write

Data Range
(decimaI)

Data Ready

115

40116

Read/
Write

0 - 1

5.1.1.3 ConfigurabIe Registers
Configurable registers are user selected proportional values, channel status,
module status, and setpoints. This data is a subset of what is available in the
rack. Selecting only the important registers and packing them together allows a
faster, more efficient map. Two register maps, each capable of storing 500,
values are duplicated for the configurable registers: integer mapped from 45001
to 45500; floating point mapped from 46001 to 47000 if needed. Floating point
(EEE 32 bit standard) values span across 2 registers. n the case of a setpoint
both registers can be written to at once because both registers make up one
value.
ChanneI Status
Bits 0-7 are described in "Channel Statuses page 46.
Bits 8-15 are specific to the monitor. Details can be reviewed from the printed
register map in the 3500 Config Software.
ModuIe Status
This is specific to the monitor. Details can be reviewed from the printed register
map in the 3500 Config Software.
PPL Status
62
This is specific to the monitor. Details can be reviewed from the printed register
map in the 3500 Config Software.
ProportionaI VaIues
All proportional values are available to be configured and are described
throughout this document. Specific proportional values for each monitor are
listed on page 78
Setpoints
Setpoints can be read (function code 3) or written (function code 6,16). n a
Modbus command only one setpoint can be set at a time.
5.1.2 ScaIing the Data
To scale the data, you must do one of the following:
set the full-scale range for the proportional value or the setpoint in the Rack
know the full-scale range for the proportional value or the setpoint
63

5.1.2.1 ProportionaI VaIue ExampIe
Use the following equation to convert the output of the ports on a Communication
Gateway /O Module to engineering units:

For example, for a monitor channel that is operating as shown in the following
table...

Parameter

VaIue

Direct Full-scale range
Measured value

0 - 10 mil
39321
65535

...calculate the output as follows:

5.1.2.2 Setpoint ExampIe
Calculate the setpoint value to send to the Communication Gate Module using
the following equation:

For example, for a monitor channel that is operating as shown in the following
table...

Parameter

VaIue

Direct Full-scale range
Desired Setpoint Value

25-0-25 mil
8.2 mil
65535

Scaled Value
(engineering
units)
Proportional Value
Gateway Full-Scale Value
Upper
Monitor
Range
Lower
Monitor
Range
=
+
Lower
Monitor
Range
( )
Scaled Value
(engineering units)
39321
65535
10 - 0 6 mil = + =
Scaled
setpoint value
Desired
setpoint value
Lower
Monitor Range
Gateway
Full - scale
Upper
Monitor Range
Lower
Monitor Range
=

64

...calculate the setpoint to input to the Communication Gateway Module as
follows:

f 43515 is successfully sent to the Communication Gateway Module, the data
read back may be a few counts off because of scale differences.
5.1.3 Modbus Language Description
The Modbus interface complies with EA standard RS-232C, interface type D.
The communications transactions are carried out in a half-duplex mode. A
transaction consists of a master sending a command and a slave device
returning a response. The commands and responses are communicated
asynchronously via a bit serial protocol. By design, Modbus can support multiple
stations with one master and up to 255 responder stations. The Communication
Gateway /O Module (Modbus) supports 255 daisy chained Communication
Gateway /O Module (Modbus) stations when using any available baud rate.
Assign each responder a unique fixed device address in the range of 1 to 255 by
setting the address in the Rack Configuration Software.
n Communication Gateway /O Module (Modbus) connections, the
Communication Gateway /O Module (Modbus) will behave as a slave on the
communication link. A separate interfacing device, called a gateway, will serve
as the master on this connection and usually as a protocol converter between
Modbus protocol and a higher level Data Highway system. This section is
concerned only with the Modbus communication link and does not discuss any
special features or requirements of the gateway or the data highway.
5.1.3.1 Message Definition
When the word status or point is used in the Modbus context, it means alarm
status or control bit status. This status is discrete data, which usually is
represented as a single bit in a 16-bit word. When the word register is used in
Modbus, it represents a 16-bit word of memory.
5.1.3.2 Byte Layout of Modbus Commands (RTU Framing)
Each Modbus transaction consists of the transmission of a query and response
frame. These frame types are all similar and are subdivided into four fields:
slave address, function code, information, and error check.

SLAVE ADDRESS

FUNCTON CODE

NFORMATON

CRC
Last
First
Order of Transmission
( ) ( )
( )
Scaled
setpoint value
8.2- -25 65535
25 - -25
43515 =
=
65

The length of each field is an integral multiple of 8-bit bytes. The slave address
field is sent first and the other fields follow in the order shown.
SIave Address
The slave address field of both the query and the response frames contain the
slave address of the affected responder station. Since there is only one initiator
station, the initiator is not addressed explicitly.
The slave address field is one byte long and is defined for the values 0 to 255 as
follows:
0 Signifies Broadcast frame, all stations are selected. Communication
Gateway /O Module (Modbus) lets you set the time for all the 3500
racks in a daisy chain with this message. No response will be given.

1 to 255 Selects the corresponding Communication Gateway /O Module
(Modbus).

Function Code
A one-byte long portion of the command that identifies the command type. The
Communication Gateway /O Module (Modbus) supports the following values:

Code

Function

2
3
4
6
8
16
17

Read nput Status
Read Holding Register
Read nput Register
Loopback/Maintenance
Preset Multiple Registers
Report Slave D

Information FieId
Contains all other information necessary to specify a required function or its
response.
CRC Error Check FieId
A field that is appended to the frame to detect transmission errors between the
sending and receiving stations. The field contains no application information.
The error check field is cyclic redundancy check (CRC-16) and is 2-bytes long.
ts value is a function of the preceding data in the frame. The transmitter uses
the following method to calculate the CRC value:
1. Load the 16-bit CRC register with FFFF hex (all 1s).
2. Exclusive OR the first 8-bit byte of the message with the low-order byte of the
16-bit CRC register and place the result in the CRC register.
3. Shift the CRC register one bit to the right (toward the LSD) and insert a zero
in the MSB.
66
4. Extract and examine the LSB:
f LSB = 0: repeat Step 3
f LSB = 1: exclusive OR the CRC register with the polynomial value A001
hex (1010 0000 0000 0001).
5. Repeat steps 3 and 4 until 8 shifts have been performed. When this is done,
a complete 8-bit byte will have been processed.
6. Repeat steps 2 through 5 for the next 8-bit byte of the message. Continue
doing this until all bytes have been processed.

The final contents of the CRC register is the CRC value. As each additional byte
is transmitted, it is included in the value in the register the same way. The
receiver also calculates the CRC value and compares it to the received CRC
value to verify the accuracy of the data received.
5.1.3.3 Read Input Status Command
Use this command (function code 02) to obtain the discrete (True or False)
Module Statuses and Channel Statuses from the Communication Gateway /O
Module (Modbus). The query frame is shown below:

Slave
Address
01

Function
Code
02

Start Addr
High Byte

Start Addr
Low Byte

No. of Points
High Byte

No. of Points
Low Byte

CRC
High Byte
XX

CRC
Low Byte
XX

The data fields and their meanings are described in the following paragraphs.
The slave address and the CRC Check have the same format and meaning as
described in earlier sections.
Start Address
Start Address is the Modbus address of the first input status in the group to be
read. Note that each discrete input is allocated a Modbus Status Address. The
higher order byte is transmitted first followed by the lower order byte. The
allowed ranges are 0 to 3683 (Zero referenced). Any address outside this range
for which a status is requested will result in the exception response "LLEGAL
ADDRESS". See Section 5.1.1.1 for the mapping of the Modicon PC Registers
to the Communication Gateway /O Module (Modbus) data.

Number of Points
This 16-bit field contains the discrete points beginning at the "Start Address".
The Communication Gateway /O Module (Modbus) has a limit of 2000 readable
discrete points at one time. The maximum number of discrete inputs may also
be limited by the DCS controller. Refer to the appropriate DCS controller manual
for more information.

67
ExampIe

Slave
Address

01

Function
Code

02

Start Addr
High Byte

00

Start Addr
Low Byte

00

No. of
Points
High Byte
00

No. of
Points
Low Byte
60

CRC
High
Byte
78

CRC
Low
Byte
22
The above example shows a Read nput Status Command (the byte values are
in Hex) that retrieves 96 Module Statuses starting at address zero.
5.1.3.4 Read Input Status Response
The format of the Read nput Status response is shown below. The response
includes the slave address, function code, number of bytes of packed discrete
points being sent and the CRC check. The discrete points are packed into bytes
with 1 bit for each status ("1" = True/ON "0" = False/OFF). The lower order bit of
the first byte of data contains the first addressed input (point) and the remainder
follows. For input quantities not a multiple of eight, the last byte will be filled with
zeros in the high order bit positions.

Slave
Address
01

Function
Code
02

Byte
Count

First 8
Points

Next
8 Points

...

Last
8 Points

CRC
High
Byte
XX

CRC
Low
Byte
XX

Queries containing requests for data from outside the valid ranges 0 to 3683
(Zero referenced) will result in an "LLEGAL ADDRESS" exception response.
5.1.3.5 Read HoIding Registers Command
Use this command (function code 03) to obtain the following data from the
Communication Gateway /O Module:

Setpoint Configuration Switch Settings
Configuration Lock Alarm Event List
System Event List Rack Date and Time
Rack Reset Rack Trip Multiply - Software

Rack Trip Multiply - Hardware Rack Alarm nhibit - Software
Rack Alarm nhibit - Hardware Last Command Success
Full-scale Data Range Repeated 3XXXX and 1XXXX Data
The data for each register is a 16-bit word. The query frame is shown below:

68

Slave
Address
01

Function
Code
03

Start
Address
High Byte

Start
Address
Low Byte

No. of
Registers
High Byte

No. of
Registers
Low Byte

CRC
High
Byte
XX

CRC
Low
Byte
XX

The slave address and the CRC check have the same format and meaning as

Start Address
Start Address is the 16-bit Modbus holding register address corresponding to the
starting value. The higher order byte is transmitted first followed by the lower
order byte. The allowed ranges are 0 to 6999 (Zero referenced). Any address
outside this range will result in the exception response "LLEGAL ADDRESS".
See page 35 for the mapping of the Modicon PC Registers to the Communication
Gateway /O Module (Modbus) data.

Number of Registers
This 16-bit field is the number of values to be obtained beginning at the "Start
Address". The maximum number of input registers read in a single query is
limited to 114 registers by the Communication Gateway /O Module (Modbus)
and may be limited by the DCS controller. Refer to the appropriate DCS
controller manual for more information.
ExampIe

Slave
Address

01

Function
Code

03

Start
Address
High Byte
00

Start
Address
Low Byte
06

No. of
Registers
High Byte
00

No. of
Registers
Low Byte
05

CRC
High Byte

65

CRC
Low Byte

C8

The above example shows a Read Holding Registers Command (the byte values
are in Hex) that retrieves five values starting at address six.
5.1.3.6 Read HoIding Registers Response
The format of the response to Read Holding Registers is shown below. The
response includes the slave address, function code, number of bytes of data
being sent, and the CRC check. The contents of the registers requested are two
bytes each: the first byte is the high order and the second byte is the lower order.
Note that the Byte Count is the number of bytes in the data portion of the
response or two times the number of registers.

Slave
Address
01

Function
Code
03

Byte
Count

Data
Reg. 1
High | Low

.....

Data
Reg. N
High | Low

CRC
High Byte
XX

CRC
Low Byte
XX

Queries containing requests for data from outside the valid range will result in an
"LLEGAL ADDRESS" exception response.
69
5.1.3.7 Read Input Registers Command
Use this command (function code 04) to obtain the following data from the
Communication Gateway /O Module (Modbus): the Primary Values, Current
Proportional Values, and the Last Read Proportional Time Stamp. The data for
each register is a 16-bit word. The query frame is shown below:

Slave
Address
01

Function
Code
04

Start
Address
High Byte

Start
Address
Low Byte

No. of
Registers
High Byte

No. of
Registers
Low Byte

CRC
High
Byte

CRC
Low
Byte

Start Address
Start address is the 16-bit Modbus input data register address corresponding to
the first register. The higher order byte is transmitted first followed by the lower
order byte. The allowed ranges are 0 to 956 (Zero referenced). Any address
Number of Registers
Address". The maximum number of input registers read in a single query is
limited to 125 registers by the Communication Gateway /O Module and may be
limited by the DCS controller. Refer to the appropriate DCS controller manual for
more information.
ExampIe

Slave
Address

01

Function
Code

04

Start
Address
High Byte
02

Start
Address
Low Byte
01

No. of
Registers
High Byte
00

No. of
Registers
Low Byte
06

CRC
High
Byte
20

CRC
Low
Byte
70

The above example shows a Read nput Register Command (the byte values are
in Hex) that retrieves six values starting at address 513.
5.1.3.8 Read Input Registers Response
The format of the response to Read nput Register is shown below. The
response includes the slave address, function code, number of bytes of data
being sent, and the CRC check. The contents of the registers requested are two
bytes each: the first byte is the high order and the second byte is the lower order.
Note that the Byte count is the number of bytes in the data portion of the
response or two times the number of registers.

70

Slave
Address
01

Function
Code
04

Byte
Count

Data
Reg. 1
High | Low

........

Data
Reg. N
High | Low

CRC
High
Byte
XX

CRC
Low
Byte
XX

Queries containing requests for data from addresses outside the valid range 0 to
956 will result in an "LLEGAL ADDRESS" exception response.
5.1.3.9 Preset SingIe Register Command
Use this command (function code 06) to preset a value in the Setpoint
Configuration, Switch Settings, Configuration Lock, Alarm Event List, System
Event List, Rack Date and Time, Rack Reset, Rack Trip Multiply - Software and
Rack Alarm nhibit - Software. The data for each register is a 16-bit word. The
query frame is shown below:

Slave
Address
01

Function
Code
06

Address
High Byte

Address
Low Byte

Data
High Byte

Data
Low Byte

CRC
High Byte
XX

CRC
Low Byte
XX

The data fields and their meaning are described in the following paragraph. The
slave address and the CRC check have the same format and meaning as

Address
Address is the 16-bit Modbus address corresponding to the register. The higher
order byte is transmitted first followed by the lower order byte. The allowed
ranges are 0 -3, 6 -13, 30 - 31, 87 - 96, and 98 (Zero referenced). Any address
Data
Data is the 16-bit word that will be written to the address.
ExampIe

Slave
Address
01

Function
Code
06

Address
High Byte
00

Address
Low Byte
62

Data
High Byte
00

Data
Low Byte
01

CRC
High Byte
E9

CRC
Low Byte
D4

The above example shows a Preset Single Register Command (the byte values
are in Hex) that sets the address 98 to one.
71

5.1.3.10 Preset SingIe Register Response
The format of the response to Preset Single Register is shown below. The
response includes the slave address, function code, the address, the preset
value and the CRC check.

Slave
Address
01

Function
Code
06

Address
High Byte
00

Address
Low Byte
62

Data
High Byte
00

Data
Low Byte
01

CRC
High Byte
E9

CRC
Low Byte
D4

Queries containing addresses outside the valid ranges will result in an "LLEGAL
ADDRESS" exception response. The valid ranges are as follows: 0 -3, 6 -13, 30
- 31, 87 - 96, and 98 (Zero referenced).

5.1.3.11 Preset MuItipIe Registers Command
Use this command (function code 16 [10 Hex]) to preset a value in the Setpoint
Configuration, Switch Settings, Configuration Lock, Alarm Event List, System
Event List, Rack Date and Time, Rack Reset, Rack Trip Multiply - Software and
Rack Alarm nhibit - Software. The data for each register is a 16-bit word. The
query frame is shown below:

Slave
Address
01

Function
Code
10

Start
Address
High Byte

Start Address
Low Byte

No. of
Registers
High Byte

No. of
Registers
Low Byte

Byte
Count
8 bits

(continued)

Data Reg. 1
High Byte

Data Reg. 1
Low Byte

.....

Data Reg.
N
High Byte

Data Reg. N
Low Byte

CRC
High Byte
XX

CRC
Low Byte
XX

Start Address
Start Address is the 16-bit Modbus address corresponding to the starting value.
The higher order byte is transmitted first followed by the lower order byte. The
allowed ranges are 4000 4003, 5000 5500, and 6000 - 6999 (Zero
referenced). Any address outside this range will result in the exception response
"LLEGAL ADDRESS". See page 35 for the mapping of the Modicon PC
Registers to the Communication Gateway /O Module (Modbus) data.

Number of Registers
Address". The maximum number of registers preset in a single query is limited
72
to the number of continuous write registers by the Communication Gateway /O
Module (Modbus) and may be limited by the DCS controller. Refer to the
appropriate DCS controller manual for more information.
ExampIe

Slave
Address
01

Function
Code
10

Start Address
High Byte
00

Start Address
Low Byte
57

No. of Registers
High Byte
00

No. of Registers
Low Byte
07

(continued)

Byte Count

0E

Data Reg. 1
High Byte
00

Data Reg. 1
Low Byte
5F

Data Reg. 2
High Byte
00

Data Reg. 2
Low Byte
05

(continued)

Data Reg. 3
High Byte
00

Data Reg. 3
Low Byte
12

Data Reg. 4
High Byte
00

Data Reg. 4
Low Byte
16

Data Reg. 5
High Byte
00

Data Reg. 5
Low Byte
09

(continued)

Data Reg. 6
High Byte
00

Data Reg. 6
Low Byte
02

Data Reg. 7
High Byte
00

Data Reg. 7
Low Byte
5E

CRC
High Byte
XX

CRC
Low Byte
XX

The above example shows a Preset Multiple Registers Command (the byte
values are in Hex) that preset seven values starting at the address 87.
5.1.3.12 Preset MuItipIe Registers Response
The format of the response to Preset Multiple Registers is shown below. The
response includes the slave address, function code, starting address, and the
number of registers.

Slave
Address
01

Function
Code
10

Start
Address
High Byte

Start
Address
Low Byte

No. of
Registers
High Byte

No. of
Registers
Low Byte

CRC
High Byte
XX

CRC
Low Byte
XX

Queries containing addresses outside the valid ranges 4000-4003, 5000-5500,
and 6000-6999 will result in an "LLEGAL ADDRESS" exception response.
5.1.3.13 Loopback/Maintenance Function Code 8
A Diagnostic function code causes the slave to echo the data regardless of the
status of the associated device. The code also restarts or interrogates the
communication option in the slave without affecting the associated slave device.
The query frame format is shown below:
73

Slave
Address
01

Function
Code
08

Diagnostic
Code
High Byte

Diagnostic
Code
Low Byte

Data 1
Byte

Data 2
Byte

CRC
High Byte

CRC
Low Byte

Response
The same as the query except that the DATA field depends on the Diagnostic
code.

The following table lists the Diagnostic codes.

Code

Meaning

DATA

0

Return query register

Data 1 = echoes query data
Data 2 = echoes query data

2

Return diagnostic register

**

10*

Clear counters and diagnostics
registers

16-bit response (This echoes the
query data.)

11

Return message count

16-bit count response

12

Return communication error count


13

Return exception count


18

Return char overrun count


* Only power-up or diagnostic code 10 clears counters and diagnostic registers.
All counters count modulo 65536.

** The following bit pattern will be returned in the response.

74

Address
01

Function
08

Diagnostic Code
00 | 02

Data 1
00

Data 2
XX

CRC
?? | ??

Bit Pattern

7

6

5 4

3

2 1 0

D
A
T
A

C
O
M
M
U
N
C
A
T
O
N

C
O
M
M
U
N
C
A
T
O
N

G
A
T
E
W
A
Y

/
O

M
O
D
U
L
E

S
L
O
T

D
E
N
T
C
A
T
O
N

C
O
N
F
G

N
O
D
E

V
O
L
T
A
G
E

F
L
A
S
H

R
O
M

R
A
M

A logic "1" in the bit pattern represents a FALURE in the respective area.
5.1.3.14 Exception Conditions
f the addressed Communication Gateway /O Module (Modbus) receives a query
frame without a communications error and if some condition stops the
Communication Gateway /O Module (Modbus) from responding, the interface
returns an exception response containing the appropriate error code to the
master.
The high order bit (Hex 80) of the function code field is set to "0" in a query or
normal response frame and "1" in an exception response. And regardless of the
function code, the information field of all exception response frames is one byte
long. This byte contains the exception code, defined below.

Code

Exception Condition

1

2

3

6

llegal function. The function code received in the query is not
supported.

llegal data address in the information field.

llegal data value in the information field.

Slave Device Busy

The Communication Gateway /O Module (Modbus) implements exception codes
1, 2, 3, and 6.
75
5.1.3.15 Report SIave ID Function Code 17
Use function code 17 to obtain device dependent status and configuration
information from the Communication Gateway /O Module (Modbus).
Query:

Address
01

Function
11

CRC
C0 | 2C

Response:

Address
01

Function
11

Byte Count
6

Family D
MSB

Family D
LSB

(continued)

Communication Gateway /O
Module (Modbus)
Major Revision Number

Communication Gateway /O
Module (Modbus)
Minor Revision Number

CRC

High Byte

CRC

Low Byte

FamiIy ID MSB
Most significant byte of the 3500 monitoring system in HEX (0D).

FamiIy ID LSB
Least significant byte of the 3500 monitoring system in HEX (AC).

Major Rev Number
Changed when a major firmware revision occurs.

Minor Rev Number
Changed when a minor firmware revision occurs.
5.1.3.16 Modbus AppIication ProtocoI (MBAP)
MBAP is the implementation of the Modbus protocol on TCP/P Ethernet
network. MBAP is the same as the Modbus protocol with a few minor
exceptions. These exceptions are necessary to properly operate on a non-
deterministic network.

MBAP supports function code 2,3, 4, 6, and 16. All data can be read through
function codes 2, 3, and 4. All data can be written through function codes 6 and
16; however, only one value can be changed per command. Using function code
16 to write two registers is only valid for floating point values. All other writes are
for single registers.
76
5.1.3.17 Monitor Setpoints
When writing to the query registers, you will send the slot number (2 to 15), the
channel number (1 to 32) and the setpoint number. Refer to the setpoint section
of the operation and maintenance manuals of the monitor for the setpoint
numbers and values.

The setpoint types are structured in an 8-bit (byte) format. Each bit in the byte
has a specified meaning. The byte is broken down as shown below.
Setpoint Types
MSB LSB
WW X YYYYY where WW is alarm type
X is alarm level
YYYYY is type of proportional value

Meaning of the Bits in the Setpoint Byte

DecimaI
VaIue

Meaning

WW
0
1
2
3

Over / From
Under / To
Differential
Unused

X
0
1

Alert / Alarm 1
Danger / Alarm 2
77

DecimaI
VaIue

Meaning

YYYYY
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

No Type
Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Max Value
Min Value
Peak To Peak
Speed
Prime Spike
Power
Peak Torque
Peak Speed
Peak Power
Seismic
Acceleration
Composite
nX Amplitude
nX Phase
Shaft Absolute - 1X Ampl
Shaft Absolute - 1X Phase
Not 1X Amplitude
Smax Amplitude
Bandpass
Shaft Absolute - Direct
Num Reverse Rotations
Zero Speed
Speed Band
Position
Differential

78
5.1.3.18 ModuIe ProportionaI VaIues
The following tables list the order of the proportional values for each module.
Refer to section 5.1.1.2 for a detailed explanation of the proportional value
addressing scheme.

3500/25 Keyphasor ModuIe

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Rpm
Rpm
0
0
0
0
0
0
0
0
0
0
0
0
0
0

3500/40(M) RadiaI Vibration ChanneIs

3500/40(M) Eccentricity ChanneIs
ChanneI

ProportionaI
VaIue Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
S
max
Amplitude
Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
S
max
Amplitude

1
1
1
1
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Peak to Peak
Gap
Direct Max
Direct Min
Peak to Peak
Gap
Direct Max
Direct Min
0
0
0
0
0
0
0
0

Applies to monitors with or without the "M".


79

3500/40(M) Thrust Position
ChanneIs

3500/40(M) DifferentiaI Expansion
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0



3500/42 VeIocity ChanneIs

3500/42M VeIocity ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
0
0
0
0
0
0
0
0
0
0
0
0
0
0

1
1
1
1
1
1
1
2
2
2
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
0
0

80

3500/42(M) Eccentricity
ChanneIs

3500/42(M) RadiaI Vibration
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1
1
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Peak to Peak
Gap
Direct Max
Direct Min
Peak to Peak
Gap
Direct Max
Direct Min
0
0
0
0
0
0
0
0

1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
S
max
Amplitude
Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
S
max
Amplitude



3500/42 AcceIeration ChanneIs

3500/42M AcceIeration II ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
0
0
0
0
0
0
0
0
0
0
0
0
0
0

1
1
1
1
1
1
1
2
2
2
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
Direct
Gap
1X Amplitude
1X Phase
2X Amplitude
2X Phase
Not 1x Amplitude
0
0

81

3500/42(M) Thrust Position
ChanneIs

3500/42(M) DifferentiaI Expansion
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0



3500/42M Shaft AbsoIute, RadiaI
Vibration ChanneIs

3500/42M Shaft AbsoIute, VeIocity
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI VaIue
Name

1
1
1
1
2
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

RV Direct
RV Gap
RV 1X Amplitude
RV 1X Phase
RV Direct
RV Gap
RV 1X Amplitude
RV 1X Phase
0
0
0
0
0
0
0
0

3
3
3
3
3
3
4
4
4
4
4
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Shaft Abs Direct
Shaft Abs 1X Amplitude
Shaft Abs 1X Phase
Velocity Direct
Velocity 1X Amplitude
Velocity 1X Phase
Shaft Abs Direct
Shaft Abs 1X Amplitude
Shaft Abs 1X Phase
Velocity Direct
Velocity 1X Amplitude
Velocity 1X Phase
0
0
0
0

82

3500/44(M) Aeroderiviative
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
1X Amplitude
Band-pass
Direct
1X Amplitude
Band-pass
0
0
0
0
0
0
0
0
0
0


3500/45 Thrust Position
ChanneIs

3500/45 DifferentiaI Expansion
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0

1
1
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Gap
Direct
Gap
0
0
0
0
0
0
0
0
0
0
0
0

83

3500/45 Ramp DifferentiaI
Expansion ChanneIs

3500/45 CompIementary Input
ChanneIs

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Composite
Direct
Gap
Composite
Direct
Gap
0
0
0
0
0
0
0
0
0
0

1
1
1
2
2
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Composite
Direct
Gap
Composite
Direct
Gap
0
0
0
0
0
0
0
0
0
0

3500/45 Case Expansion - Paired

3500/45 Case Expansion - SingIe

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

3
3
3
4
4
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Composite
Position
Direct
Composite
Position
0
0
0
0
0
0
0
0
0
0

3
3
4
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Position
Direct
Position
0
0
0
0
0
0
0
0
0
0
0
0

84

3500/45 VaIve Position

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
2
2
3
3
4
4

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Position
Direct
Position
Direct
Position
Direct
Position
0
0
0
0
0
0
0
0

3500/50 Rotor AcceIeration
ChanneI

3500/50 Zero Speed ChanneI

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Rotor Accel
Speed
Peak Speed
0
0
0
0
0
0
0
0
0
0
0
0
0

1
1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Zero Speed
Speed
Peak Speed
0
0
0
0
0
0
0
0
0
0
0
0
0

85

3500/50 Rotor Speed ChanneI

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Speed
Speed Band
Peak Band
0
0
0
0
0
0
0
0
0
0
0
0
0

3500/53 Overspeed ChanneI

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Speed
Peak Speed
0
0
0
0
0
0
0
0
0
0
0
0
0
0

86

3500/60 Temperature ChanneIs


ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
Direct
Direct
Direct
Direct
0
0
0
0
0
0
0
0
0
0

1
1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Composite
Differential
0
0
0
0
0
0
0
0
0
0
0
0
0

Applies if Composite or Differential are
enabled.



ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
Direct
Direct
Direct
Direct
0
0
0
0
0
0
0
0
0
0

1
1
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Composite
Differential
0
0
0
0
0
0
0
0
0
0
0
0
0

Applies if Composite or Differential are
enabled.

87

3500/62 Process VariabIe

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2
3
4
5
6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
Direct
Direct
Direct
Direct
0
0
0
0
0
0
0
0
0
0

3500/64M Dynamic Pressure

ChanneI

ProportionaI
VaIue
Number

ProportionaI
VaIue Name

1
2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Direct
Direct
0
0
0
0
0
0
0
0
0
0
0
0
0
0

88
6. Maintenance

rack while power is applied to the rack. Refer to the Rack nstallation and

This section shows how to verify that the Communication Gateway Module is
6.1 Comm Gateway Port Test UtiIity
Use the Communication (Comm.) Gateway Port Test Utility to verify that the Port
1 HOST connector and the Port 2 HOST connector on the Communication
Gateway RS-232/422 /O Module are operating properly. Before running the
Communication Gateway Port Test Utility, connect cable 130419-01 (RS-232
Host to 3500/92) between the HOST connector on the Communication Gateway
/O Module and the computer that has the utility installed.
Refer to the 3500 Monitoring System Rack Configuration and Utilities Guide (part
number 129777-01) for more information about this utility.

with the 3500/92 Communication Gateway Module. The following instructions
describe how to remove the existing firmware and replace it with upgrade
firmware. The Monitor will need to be reconfigured using the 3500 Rack
Configuration software after having its firmware upgraded.
The following items will be required to perform a firmware upgrade to the
Communications Gateway:
Small Flathead Screwdriver
Upgrade Firmware Cs.*
*Refer to Section 8(Ordering nformation) for part numbers. Users may use their
own grounding wrist strap or C removal tool.
6.2.1 InstaIIation Procedure
The following steps will need to be followed to complete the Communication
Gateway Module firmware upgrade:
Section 6 -- Maintenance
89
Ensure that the Module's configuration is saved using the 3500 Rack
Remove the two original firmware Cs from the monitor PWA.
nstall the two upgrade firmware Cs into the sockets on the monitor PWA.

Top ShieId RemovaI

1) Top Shield.
2) Standoff.
3) Screwdriver.

Step 1. Place the large flathead screwdriver under the top shield and on the
ridge of the rear standoffs and lift upward on the screwdriver to pop the cover
loose from the rear standoffs.

standoffs.
90


Step 1. nsert the small flathead screwdriver under the lip of either end of U5 or
the ODD word C which is situated above the other firmware C. The diagram
shows the approximate location of the chip to be removed, but not necessarily its
orientation.

Step 2. Slightly lift the one end of the chip by gently prying with the screwdriver.
Move to the other end of the chip and repeat. Continue this process until the chip
comes loose from the socket.
Step 3 Repeat the first two steps for U6, or the EVEN word C, which is situated
below the other firmware C.
Section 6 -- Maintenance
91


InstaII the upgrade firmware ICs into the PWA.
Step 1. nstall the U5 upgrade. Place part number 137495-01 into the top socket
on the PWA. Be sure that the notched end of the C is matched to the notched
end of the socket. Ensure that the C is firmly seated in the socket.
Step 2. nstall the U6 upgrade. Place part number 137494-01 into the bottom
socket on the PWA. Be sure that the notched end of the C is matched to the
notched end of the socket. Ensure that the C is firmly seated in the socket.

Top ShieId RepIacement
the top left corner of the module as shown in the diagram under "Top Shield

92
7. TroubIeshooting
This section describes how to troubleshoot a problem with the Communication
Gateway Module or the /O module by using the information provided by the self-
test, the LEDs, the System Event List, and the Alarm Event.
7.1 SeIf-test
To perform the Communication Gateway Module self-test:
Connect a computer running the Rack Configuration Software to the 3500 rack (if
needed).
Select UtiIities from the main screen of the Rack Configuration Software.
Select System Events/ModuIe SeIf-test from the Utilities menu.
Press the ModuIe SeIf-test button on the System Events screen.

Application Alert

Communication wiII be
Iost whiIe the seIf-test is
being performed.

Select the slot that contains the Communication Gateway Module and press the
OK button. The Communication Gateway Module will perform a full self-test
and the System Events screen will be displayed. The list will not contain the
results of the self-test.
Wait 30 seconds for the module to run a full self-test.
Press the Latest Events button. The System Events screen will be updated to
include the results of the self-test.
Verify that the Communication Gateway Module passed the self-test. f the
module failed the self-test, refer to Section 7.3
Section 7 -- Troubleshooting
93
7.2 LED FauIt Conditions
problems.

OK
LED

TX/RX

Condition

SoIution

1 HZ

1HZ

Communication Gateway Module
is not configured.

Reconfigure the
Communication
Gateway Module.

5 HZ

is Not OK.

Check the System
Event List.

ON

Flashing

is operating correctly.

No action required.

OFF

is not operating correctly.

Check the System
Event List.

Not
Flashing

is not communicating correctly or
there are no monitors in the rack.

Check the System
Event List.


Communication Gateway Module and gives an example of one.
Example of a System Event List Message:

Sequence
Number

Event
nformation

Event
Number

Class

Event Date
DDMMYY

Event
Time

Event
Specific

Slot

0000000123

Device Not
Communicating

32

1

02/01/90

12:24:31:99

5L

example 123).

Event nformation: The name of the event (for example Device Not
Communicating).

Event Number: dentifies a specific event.

94
Class: Used to display the severity of the event. The following
classes are available:

CIass VaIue

CIassification

0
1
2
3

Severe /Fatal Event
Reserved

this field.
Slot: dentifies the module that the event is associated with.
f a half-height module is installed in the upper slot or a
f a half-height module is installed in the lower slot,
then the field will be 0L to 15L. For example, a module
installed in the lower position of slot 5 would be 5L.
The following System Event List Messages are associated with the
Communication Gateway Module and are listed in numerical order. f an event
marked with a star (*) occurs, both ports on the Communication Gateway /O
Module will stop communicating. f you are unable to solve any problems,
contact your nearest Bently Nevada Corporation office.
FIash Memory FaiIure
Event Number: 11
Action: Replace the Communication Gateway Module as soon as
possible.

InternaI Network FaiIure
Event Number: 30
Action: Replace the Communication Gateway Module immediately.

Event Number: 32
the Communication Gateway Module
the rack backplane

95
Event Number: 33
the rack backplane

I/O ModuIe Mismatch
Event Number: 62
Action; Verify that the type of /O module installed matches the
protocol selected in the software. f the correct
Communication Gateway /O Module is installed, there may be
a fault with the Communication Gateway Module or the
Communication Gateway /O Module.

Event Number: 100

Event Number: 101

Event Number: 102

Event Number: 103

96
* FaiI Main Board +5V-AB (Fail Main Board +5V - upper and lower Power
Supplies)
Event Number: 104

Supplies)
Event Number: 105
Action Verify that noise from the power source is not causing the

Event Number: 106

Event Number: 107

Event Number: 108

97
Event Number: 109

FaiI Main Board +15V-AB (Fail Main Board +15V - upper and lower Power
Supplies)
Event Number: 110

Pass Main Board +15V-AB (Pass Main Board +15V - upper and Power
Power Supplies)
Event Number: 111

Device Configured
Event Number: 300

Event Number: 301
Action: Download a new configuration to the Communication Gateway
Module. f the problem still exists, replace the Communication
Gateway Module immediately.

ModuIe Entered Cfg Mode (Module Entered Configuration Mode)
Event Number: 302

98
Event Number: 305
Action: Download the software switches to the Communication
Gateway Module. f the software switches are not correct,
replace the Communication Gateway Module.

ModuIe Reboot
Event Number: 320

ModuIe Removed from Rack
Event Number: 325

ModuIe Inserted in Rack
Event Number: 326

Device Events Lost
Event Number: 355

ModuIe AIarms Lost
Event Number: 356

I/O ModuIe Detect FauIt
Event Number: 399
Action: Verify that the Communication Gateway Module and the
Communication Gateway /O Module are plugged into the
3500 rack correctly. f that does not solve the problem, check
to see if one of the following components is faulty:
Communication Gateway /O Module

Pass ModuIe SeIf-test
Event Number: 410

EnabIed Ch Bypass (Enabled Channel Bypass)
Event Number: 416
The specified channel has been bypassed.
99

DisabIed Ch Bypass (Disabled Channel Bypass)
Event Number: 417
The specified channel has been taken out of bypass.

FaiI SIot Id Test
Event Number: 461
Action: Verify that the Communication Gateway Module is fully
inserted in the rack. f the Communication Gateway Module is
installed correctly, check to see if one of the following
the rack backplane

Pass SIot Id Test
Event Number: 462
Action: Verify that the Communication Gateway Module is fully
inserted in the rack. f the Communication Gateway Module is
installed correctly, check to see if one of the following
the rack backplane

FIash Contents Corrupted
Event Number: 666
Action: Replace the Communication Gateway Module as soon as
possible.
7.4 AIarm Event List Messages
The following Alarm Event List Messages are returned by the Communication
Gateway Module.

Alarm Event List Message

When the message will occur

Entered not OK

Left not OK

module went not OK


100
8. Ordering Information

A B C
Part number 3500/92 - - -

A I/O ModuIe Type
01 MODBUS RS-232/422 /O Module
02 MODBUS RS-485 /O Module
03 Ethernet/MODBUS RS-232
04 Ethernet/MODBUS RS-485

B Memory Option
00 Not Available
01 Low Memory

C Agency ApprovaI Option
00 None
01 CSA-NRTL/C

Note
f the 3500/92 Communications Gateway Module is added to an existing 3500 Monitoring
System, the following (or later) hardware and software versions are required:
3500 Rack Configuration Software Version 2.3
3500/20 Main PWA Revision N (if using a 3500/92 Ethernet option)
TMR 3500/20 Main PWA Revision P (if using a 3500/92 Ethernet option)

Spares
Communication Gateway Module 136180-01
MODBUS /O Module RS-232/422 125736-01
MODBUS RS-485 /O Module 133323-01
Ethernet/MODBUS RS-232 /O Module 136188-01
Ethernet/MODBUS RS-485 /O Module 136188-02
Communication Gateway Module Manual 138629-01
Firmware C (ODD) 137495-01*
Firmware C (EVEN) 137494-01*

*Note: The firmware Cs must be ordered and installed as a set when performing a firmware
upgrade.

CabIes
Host Computer to RS-232/422 Converter Cable RS-232 130119-01
RS-485 "Y 139036-01

Section 8 -- Ordering nformation
101

Ethernet RJ45 CabIe
A
Part number 138131 -
A CabIe Length
006 6 feet (1.8 metres)
010 10 feet (3 metres)
100 100 feet (30.5 metres)
120 120 feet (36.6 metres)
150 150 feet (45.8 metres)
250 250 feet (76.3 metres)
320 320 feet (97.5 metres)

Fiber Optic CabIe
A
Part number 130419 -
A CabIe Length
0XXX 10 ft - 500 ft. (3 metres to 152.4 metres) in 10 ft (3
metere) increments only
XX00 500 ft - 6500 ft. (152.4 metres to 1981.2 metres) in 100
ft (30.5 metere) increments only

Host to 3500/92 CabIe RS-232
A B
Part number 130419 - -
A CabIe Length
0100 100 feet (30.5 metres)

B AssembIy Instructions
01 Not Assembled
02 Assembled

102
RS-232/422 Converter to 3500/92 CabIe RS-422 PVC InsuIated
A B
A CabIe Length
0100 100 feet (30.5 metres)
0500 500 feet (152 metres)

01 Not Assembled
02 Assembled

RS-232/422 Converter to 3500/92 CabIe RS-422 TefIon InsuIated
A B
A CabIe Length
0100 100 feet (30.5 metres)
0500 500 feet (152 metres)

01 Not Assembled
02 Assembled

HoneyweII PLCG to 3500/92 RS-232
A B
A CabIe Length
0100 100 feet (30.5 metres)

01 Not Assembled
02 Assembled

Section 8 -- Ordering nformation
103
3500/92 to 3500/92 CabIe RS-422/RS-485 PVC InsuIated
A B
A CabIe Length
0100 100 feet (30.5 metres)
0500 500 feet (152 metres)

01 Not Assembled
02 Assembled

3500/92 to 3500/92 CabIe RS-422/RS-485 TefIon InsuIated
A B
A CabIe Length
0100 100 feet (30.5 metres)
0500 500 feet (152 metres)

00 Not Assembled
01 Assembled

Extension CabIe RS-422/RS-485 (Used with Cables 129665, 131108,
130530, and 131109 for lengths greater
than 152 metres (500 feet))
A B
Part number 130531- -

A AssembIy Instructions
01 Not Assembled
02 Assembled

B InsuIation
01 PVC nsulated
02 Teflon nsulated

104

9. Specifications
INPUTS
Power Consumption: 5 watts Typical

Data: Collects data, such as current values and
current alarm statuses, via a high speed
internal network.

OUTPUTS
Front Panel LEDs:
OK LED:

ndicates when the 3500/92 is operating
properly.

TX/RX LED: ndicates when the 3500/92 is communicating
with other modules in the 3500 rack.

Protocols:
Modbus:

3500 Software:

Based on AEG P-MBUS-300 Rev. E
Reference Manual

Bently Nevada Proprietary Protocol for 3500
Configuration and Data Acquisition


Temperature:

-30 C to 65 C (-22 F to 149 F) operating
-40 C to 85 C (-40 F to 185 F) storage


CE MARK DIRECTIVES:

EMC Directives:

EN50081-2:

EN50082-2:

105




HAZARDOUS AREA APPROVALS
CSA-NRTL/C Class , Division 2, Groups A through D

PHYSICAL
Main Board:
Dimensions (Height x
Width x Depth)

241 mm x 24.4 mm x 242 mm
(9.50 in x 0.96 in x 9.52 in)


/O Module (Modbus RS-232/422 and Modbus RS-485):
Dimensions (Height x
Width x Depth)
241 mm x 24.4 mm x 99.1 mm
(9.50 in x 0.96 in x 3.90 in)


Main Board: 1 full-height front slot
/O Modules: 1 full-height rear slot

Part Number 141078-01
Revision E, July 2003
3300 XL 8mm Proximity
Transducer System
Manual
3300 XL 8mm Proximity Transducer System Manual
Copyright 2003 Bently Nevada, LLC
The following are trademarks or registered trademarks of Bently Nevada, LLC in the United States
and Other Countries:
ACM, Actionable Information
, Actionable Information
to the Right People at the Right Time
, ADRE, , Asset
Condition Management, Asset Condition Monitoring,
Bently ALIGN, Bently BALANCE
, Bently
DOCUVIEW, Bently LUBE, Bently Nevada,
Bently PERFORMANCE, Bently RELIABILITY,
CableLoc, ClickLoc, Data Manager, Decision
Support
SM
, DemoNet, Dynamic Data Manager, Engineer
Assist, FieldMonitor, flexiTIM, FluidLoc, Helping
You Protect and Manage All Your Machinery,
HydroScan, HydroView, Key C, Keyphasor,
Machine Condition Manager 2000,
MachineLibrary, Machine Manager, MicroPROX,
Move Data, Not People, Move Information, Not Data,
NSv, Prime Spike, PROXPAC, Proximitor,
REBAM, RuleDesk, SE, Seismoprobe, Smart
Monitor, Snapshot, System 1, System Extender,
TDXnet, TDIXconnX, The Plant Asset Management
Company
SM
, TipLoc, TorXimitor, Transient Data
Manager, Trendmaster, TrimLoc, Velomitor
Bently Nevadas orbit logo and other logos associated
with the trademarks in bold above, are also all
trademarks or registered trademarks of Bently Nevada
in the United States and other countries.
The following ways of contacting Bently Nevada are provided for those times when you cannot
contact your local Bently Nevada representative:
Minden, NV 89423
USA
Telephone 1 775 782 3611
1 800 227 5514
Fax 1 775 215 2876
ii
Related Documents
The following documents contain additional information that you may find
helpful when you install the transducer.
Installing the Transducer
Best Practices Document - Proximity Probes and Related Accessories: The
Installation and Application of Eddy Current Proximity Transducers (AN028).
Guidelines for Grounding (Earthing) Bently Nevada Rotating Machinery
Information Systems (AN013).
Installation of Electrical Equipment in Hazardous Areas (AN015).
Considerations when using Eddy Current Proximity Probes for Overspeed
Protection Applications (AN085)
Transducer Installation Accessories
31000/32000 Proximity Probe Housing Manual (124200-01).
31000/32000 Proximity Probe Housing Data Sheet (141610-01)
3300 XL Proximitor Housing Data Sheet (141195-01)
3300 XL Monitor and Transducer Verification Kits Data Sheet (141196-01)
Electrical and Mechanical Runout
Glitch: Definition of and Methods for Correction, Including Shaft Burnishing
to Remove Electrical Runout (AN002).
API 670, Fourth Edition, Sections 6.1.1 (Location and Orientation Radial Shaft
Vibration Probes) and 6.1.2 (Location and Orientation Axial Position Probes.
Available from the American Petroleum Institute, Publications and Distribution,
1220 L Street NW, Washington DC, 20005, USA.
Reference
Performance Specifications for the 3300 XL 8 mm Transducer System (159484).
Bently Nevada Glossary (133055-01).
Symbols
Procedures in this manual use the following symbols:
Connect Disconnect Observe Record
Value
iii
European CE mark for the Bently Nevada 3300 XL
Transducer System
In this Document
is a list of the 3300 XL Transducer Assemblies that have the CE mark, applicable
standards used for certification, and installation instructions required for
compliance.
Proximity Transducer Systems
are electronic devices typically used in industrial applications. The 3300 XL
Transducer System has been certified using the same Technical Construction File
(TCF) and Declaration of Conformity as the 3300 8mm Transducer System
because they are similar in design and application. The 3300 XL Proximity
Transducer System consists of a Proximitor Sensor, Proximity Probe, and
Extension Cable.
TCF through TUV Rheinland of North America
A Technical Construction File has been prepared through TUV Rheinland of
North America (TUV Rheinland File Number: P9472350.07). The Certificate of
Compliance is for Directive 89/336/EEC (EMC Directive). The applicable
Generic Norms are: EN50081-2 and EN50082-2.
Installation Instructions
These instructions are an addition to the Installation Instructions in Section 2.
Proximity Probes
All probe cases must have a solid connection to earth ground.
Compliant Systems and Component Part Numbers
# Model Model Numbers
1 3300 XL 330180, 330101*, 330102*, 330103*, 330104*, 330105*, 330106*,
330140, 330141, 330145, 330171, 330172, 330173, 330174, 330191,
330192, 330193, 330194, 330195, 330196, 330197, 330198, 330255,
330130, and 330190**
Includes all options and all approval versions of the base model numbers listed
*--Pre XL probes and cables may be used as part of a CE XL system.
**--any proximity probe, or extension cable which works correctly with the
listed module.
iv
Testing and Test Levels
Title EN
55011
Emission
EN
61000-4-2
ESD
ENV
50140
(EN
61000-4-3)
Rad. RFI
ENV
50204
Rad. RFI
EN
61000-4-4
EFT
ENV
50142
(EN
61000-4-5)
Surge
ENV
50141
(61000-4-
6)
Cond. RFI
EN
61000-4-8
Mag.
Fields
Test
Levels
Emission
Class A
4kV; 8kV
10V/m 10V/m 2kV 0.5kV 10V 30A/m,
50Hz
Criteria N/A A A A B A B A
These notes listed below apply only to the table Testing and Test Levels
discharge method: Contact; Air
80-1000 MHz sweep with 80% 1 kHz sine wave amplitude modulation
900 MHz dwell with 100% 200 Hz square wave modulation
lines tested: I/O
150 kHz-80 MHz sweep with 80% 1 kHz sine wave amplitude modulation
For the purposes of the 5/8mm 3300 XL System CE certification, the
following criteria are defined as follows:
- Criteria A: Transducer system will output less than one third of a
3mil p-p meter scale (less than 1 mil p-p) and will return to steady
state after test completion.
- Criteria B: Transducer system may react in any manner during test,
but must self recover after test completion.
- Criteria C: N/A
v
Contents
Related Documents ...........................................................................................................................iii
European CE mark for the Bently Nevada 3300 XL Transducer System......................................... iv
Section 1 System Description ......................................................... 1
Transducer System............................................................................................................................. 1
Proximitor Sensor ........................................................................................................................... 1
Proximity Probe and Extension Cable ............................................................................................... 1
Connectors ......................................................................................................................................... 2
Extended Temperature Range Applications....................................................................................... 2
Receiving, Inspecting, Handling and Disposing of the System......................................................... 3
Customer Service ............................................................................................................................... 3
Section 2 Installation........................................................................ 5
Installing the Probe ............................................................................................................................ 5
Mounting the Proximitor Sensor..................................................................................................... 7
Interchangeable Mounting Feet.......................................................................................................... 8
Mounting the Proximitor Sensor with DIN Mount Part.................................................................. 9
Removing the Proximitor Sensor from the DIN Rail.................................................................... 10
Termination of Field Wiring in the Terminal Block........................................................................ 10
Routing the Extension Cable and Field Wiring ............................................................................... 11
Section 3 Maintenance and Troubleshooting .............................. 13
Scale Factor Verification.................................................................................................................. 14
Troubleshooting ............................................................................................................................... 17
Fault Type 1: V
XDCR
> -17.5 Vdc or V
XDCR
< -26 Vdc.................................................................... 19
Fault Type 2: V
SIG
= O Vdc ............................................................................................................ 20
Fault Type 3: -1 Vdc < V
SIG
< 0 Vdc .............................................................................................. 20
Fault Type 4: V
XDCR
<V
SIG
< V
XDCR
+ 2.5 Vdc............................................................................... 23
Fault Type 5: V
SIG
= V
XDCR
............................................................................................................. 23
Section 4 3300 XL Proximitor Housing ...................................... 25
Mounting Options ............................................................................................................................ 25
Environmental Certifications ........................................................................................................... 25
Removable gland plates ................................................................................................................... 25
Dimensional Drawings..................................................................................................................... 26
Panel Mount Orientation.............................................................................................................. 27
DIN Mount Orientation................................................................................................................ 28
Section 5 System Specifications................................................... 29
Electrical .......................................................................................................................................... 29
Electrical Classification: .............................................................................................................. 32
Mechanical ....................................................................................................................................... 33
Environmental Limits ...................................................................................................................... 34
Section 6 System Ordering Information....................................... 37
3300 XL 8 mm Proximity Probes: ................................................................................................... 37
3300 XL 8 mm Proximity Probes, Metric:....................................................................................... 38
3300 XL 8 mm Reverse Mount Probes............................................................................................ 38
3300 XL 8 mm Proximity Probes, Smooth Case: ............................................................................ 39
3300 XL 8 mm Extended Temperature Range (ETR) Proximity Probes: ....................................... 40
3300 XL 8 mm Extended Temperature Range (ETR) Proximity Probes, Metric: ........................... 40
3300 XL 8 mm Extended Temperature Range (ETR) Reverse Mount Probes ................................ 41
vi
3300 XL 8 mm Extended Temperature Range (ETR) Proximity Probes, Smooth Case: ................ 41
3300 XL Proximitor Sensor .......................................................................................................... 42
3300 XL Extension Cable................................................................................................................ 42
3300 XL Extended Temperature Range (ETR) Extension Cable .................................................... 43
Accessories ...................................................................................................................................... 43
Section 7 3300 XL 8mm System Graphs and Dimensional
Drawings ............................................................................................. 47
Section 8 Micrometer Specifications and Ordering Information 65
Mechanical ....................................................................................................................................... 65
Ordering Information ....................................................................................................................... 66
3300 XL Precision Micrometer.................................................................................................... 66
3300 XL Shaft Micrometer .......................................................................................................... 66
Accessories .................................................................................................................................. 66
Dimensional Drawings..................................................................................................................... 67
Section 9 Housing Specifications and Ordering Information..... 69
Mechanical ....................................................................................................................................... 69
Ordering Information ....................................................................................................................... 69
3300 XL Proximitor Housing ................................................................................................... 69
Accessories .................................................................................................................................. 71
vii
viii
Section 1 System Description
Transducer System
The 3300 XL 8 mm Proximity Transducer System consists of:
- a 3300 XL 8 mm probe
- a 3300 XL extension cable
- a 3300 XL Proximitor Sensor
1
The system provides an output voltage directly proportional to the distance
between the probe tip and the observed conductive surface. It is capable of both
static (position) and dynamic (vibration) measurements, and is primarily used for
vibration and position measurement applications on fluid-film bearing machines,
as well as Keyphasor and speed measurement applications
2
.
The 3300 XL 8 mm system represents our most advanced performance in an
eddy current proximity transducer system. The standard 3300 XL 8 mm system
is also 100% compliant with the American Petroleum Institutes (API) 670
Standard (4
th
Edition) for such transducers. All 3300 XL 8 mm Proximity
Transducer Systems achieve this level of performance while allowing complete
interchangeability of probe, extension cable, and Proximitor Sensor without the
need for individual component matching or bench calibration.
Each component of the 3300 XL 8 mm Transducer System is backward
compatible and interchangeable
3
with other non-XL 3300 series 5 and 8 mm
transducer system components
4
. This includes the 3300 5 mm probe, which is
used when an 8 mm probe is too large for the available mounting space
5,6
.
Proximitor Sensor
The 3300 XL Proximitor Sensor incorporates numerous improvements over
previous designs. Its physical packaging permits high-density DIN-rail
installation. It can also be mounted in a traditional panel mount configuration,
where it shares an identical footprint to older 4-hole mounted 3300
Proximitor Sensor. The mounting base for either option provides electrical
isolation, eliminating the need for separate isolator plates. The 3300 XL
Proximitor Sensor is highly immune to radio frequency interference, allowing
installation in fiberglass housings without adverse effects from nearby radio
frequency signals. Improved RFI/EMI immunity allows the 3300 XL
Proximitor Sensor to achieve European CE mark approvals without requiring
special shielded conduit or metallic housings, resulting in lower installation costs
and complexity.
The 3300 XLs SpringLoc terminal strips require no special installation tools and
facilitate faster, more robust field wiring connections by eliminating screw-type
clamping mechanisms that can loosen.
Proximity Probe and Extension Cable
The 3300 XL probe and extension cable also reflect improvements over previous
designs. A patented TipLoc molding method provides a more robust bond
between the probe tip and the probe body. The probes cable is more securely
1
attached as well, incorporating a patented CableLoc design that provides 330
N (75 lbf) pull strength where the probe cable attaches to the probe tip.
3300 XL 8 mm Probes and Extension Cables can also be ordered with an
optional FluidLoc cable option. This option prevents oil and other liquids from
leaking out of the machine through the cables interior.
Connectors
The 3300 XL probe, extension cable, and Proximitor Sensor have corrosion-
resistant, gold-plated ClickLoc connectors. These connectors require only
finger-tight torque (connectors will "click"), and the specially engineered locking
mechanism prevents the connectors from loosening. They do not require any
special tools for installation or removal.
3300 XL 8 mm Probes and Extension Cables can also be ordered with connector
protectors already installed. Connector protectors can also be supplied separately
for installation in the field (such as when the cable must be run through
restrictive conduit). Connector protectors are recommended for all installations
and provide increased environmental protection
7
.
Extended Temperature Range Applications
An Extended Temperature Range (ETR) Probe and Extension Cable are available
for applications where either the probe lead or extension cable may exceed the
177 C (350 F) temperature specification. The Extended Temperature Range
Probe has an extended temperature rating for up to 260 C (500 F) for the probe
lead and connector. The probe tip must remain below 177 C (350 F). The
Extended Temperature Range Extension Cable is also rated for up to 260 C (500
F). Both the ETR probe and cable are compatible with standard temperature
probes and cables. For example, you can utilize an ETR probe with the 330130
extension cable. The ETR system uses the standard 3300 XL Proximitor
Sensor.
When using any ETR component as part of your system, the accuracy is limited
to the accuracy of the ETR system.
Notes:
1. Proximitor Sensors are supplied by default from the factory calibrated to
AISI 4140 steel. Calibration to other target materials is available upon
request.
2. Consult Bently Nevada Applications Note AN085 when considering this
transducer system for tachometer or overspeed measurements.
3. 3300 XL 8 mm components are both electrically and physically
interchangeable with non-XL 3300 5 and 8 mm components. Although the
packaging of the 3300 XL Proximitor Sensor differs from its predecessor,
it is designed to fit in the same 4-hole mounting pattern when used with the
4-hole mounting base, and will fit within the same mounting space
specifications (when minimum permissible cable bend radius is observed).
4. When XL and non-XL 3300-series 5 and 8 mm system components are
mixed, system performance is limited to the specifications for the non-XL
3300 5 and 8 mm Transducer System.
2
5. The 3300-series 5 mm probe (refer to Specifications and Ordering
Information p/n 141605-01) uses smaller physical packaging, but does not
permit reduced sideview clearances or tip-to-tip spacing requirements
compared to an 8 mm probe. It is used when physical (not electrical)
constraints preclude the use of an 8 mm probe. When narrow sideview
probes are required, use the 3300 NSv Proximity Transducer System
(refer to Specifications and Ordering Information p/n 147385-01).
6. 8 mm probes provide a thicker encapsulation of the probe coil in the molded
PPS plastic probe tip. This results in a more rugged probe. The larger
diameter of the probe body also provides a stronger, more robust case.
Bently Nevada recommends the use of 8 mm probes when possible to
provide optimal robustness against physical abuse.
7. Silicone tape is also provided with each 3300 XL extension cable and can be
used instead of connector protectors. Silicone tape is not recommended in
applications where the probe-to-extension cable connection will be exposed
to turbine oil.
Receiving, Inspecting, Handling and Disposing of
the System
The probe, extension cable and Proximitor Sensor are shipped as separate units
and must be interconnected at the installation site by the user. Carefully remove
all equipment from the shipping containers and inspect the equipment for
shipping damage. If shipping damage is apparent, file a claim with the carrier
and submit a copy to the nearest Bently Nevada office. Include part numbers and
serial numbers on all correspondence. If no damage is apparent and the
equipment is not going to be used immediately, return the equipment to the
shipping containers and reseal until ready for use.
Store the equipment in an environment free from potentially damaging
conditions such as high temperature or a corrosive atmosphere. See
Environmental Limits on page 34 for environmental specifications.
Customers and third parties who are in control of the product at the end of its life
or at the end of its use are solely responsible for the proper disposal of the
product. No person, firm, corporation, association or agency that is in control of
product shall dispose of it in a manner that is in violation of United States state
laws, United States federal laws, or any applicable international law. Bently
Nevada LLC is not responsible for the disposal of the product at the end of its
life or at the end of its use.
Customer Service
Bently Nevada maintains numerous Sales and Service offices worldwide. To
locate the office nearest you, visit our website http://www.bently.com. Here, you
can also find specifications on all standard product offerings.
Support for products and services should be directed to one of these departments:
3
For product quotations, product applications, product ordering, scheduling on-
site Services, and questions regarding existing orders, please contact your nearby
Bently Nevada Sales and Service Office.
For general product pricing, delivery, or other ordering information, contact your
local BNC office or contact Customer Service Department, Minden, Nevada,
USA Phone: 1-775-215-1011 Fax: 1-775-215-2873.
For technical questions or problems regarding installed BNC products, contact
our Technical Support Staff at:
techsupport@bently.com
or at the following locations:
Technical Support (North America)
Phone: 1-775-782-1818 Fax: 1-775-215-2890
Technical Support (UK)
Phone: (44) 1925 818504 Fax: (44) 1925 817819
4
Section 2 Installation
This section contains a checklist of items that you must consider when you install
a 3300 XL Transducer system.
Installing the Probe
The following figures show the probe sizes and the minimum values for probe
separation, side clearance and target configuration. Refer to Probe Case Torque
on page 33, for proper torque and the dimensions of the thread.
Description 8 mm probe 5 mm probe
Probe tip 8 mm 5 mm
Thread types M10x1, 3/8-24,
or unthreaded
M8x1 or -28
Wrench Flats 8 mm or 5/16 in 7 mm or 7/32 in
Lock nut 17 mm or 9/16 in
Hex
13 mm or 7/16
Hex
5
76.2 mm
(3.00 in)
Min *
15.2 mm
(0.60 in)
Min
50.8 mm
(2.00 in)
Min **
6.4 mm
(0.25 in)
Min
17.8 mm
(0.70 in)
Min
16.0 mm
(0.63 in)
Min
16.0 mm
(0.63 in)
Min
40.6 mm
(1.60 in)
Min
8.9 mm
(0.35 in)
Min
8.9 mm
(0.35 in)
Min
5 mm and 8 mm Probe
Mounting Dimensions
5 mm and 8 mm Probe-to-Probe
Separation Due to Cross Talk
5 mm and 8 mm Probe
Target Sizes
Notes:
* At or below 76.2 mm (3.00 in), an increase in scale factor as the
target size is reduced will occur per performance specification 159484.
See application alert below.
** At or below 50.8 mm (2.00 in), a small vibration signal will occur per
performance specifications 159484, due to cross talk
Application Alert: Mounting dimensions and target size affect the
scale factor of proximity transducer systems. The minimum
recommended dimensions above were chosen to minimize error yet
retain flexibility for different mounting situations. Consult performance
specification 159484 to determine the effect of each of the above
factors for your particular installation.
6
Adjust the distance between the probe tip and the shaft using one of the methods
shown in the following figure. The electrical method for setting the probe gap is
preferred.
M A D E I N U . S . A .
Voltage at the center of
the linear range (typically
-9 Vdc)
-24 V 1
-9 V
Spacer
Mechanical Method Electrical Method
Voltmeter Power Source
OUT
COM
Vt
10 kohm, 1%
1270 um
(50 mil)
Mounting the Proximitor Sensor
Mount the Proximitor Sensor in a location that is compatible with its
environmental specifications (see Environmental Limits on page 34). Consider
the local electrical codes and the presence of hazardous or explosive gas at the
installation site. (Refer to document AN015.)
MADE IN U.S.A.
28.7 mm
(1.13 in)
31.8 mm
(1.25 in)
35 mm DIN rail
88.6 mm
(3.49 in)
70.9 mm
(2.79 in)
7
MADE IN U.S.A.
50.8 mm
(2.00 in)
61.0 mm
(2.40 in)
50.8 mm
(2.00 in)
80.3 mm
(3.16 in)
63.2 mm
(2.49 in)
4.0 mm (0.158 in)
for M3.5 or #6 screw
Interchangeable Mounting Feet
The mounting feet for the 3300 XL Proximitor Sensor are interchangeable. If a
Proximitor Sensor is purchased with one mounting option, either the DIN
mount option or the panel mount option, the mounting hardware can be changed
simply by removing the mounting foot that is currently on the Proximitor
Sensor and replacing it with the other type mounting foot.
(1) DIN Mount Part (part number 138493-01)
(2) 3300 XL Proximitor Sensor
(3) Panel Mount Part (part number 138492-01)
8
Mounting the Proximitor Sensor with DIN Mount
Part
To mount the 3300 XL Proximitor Sensor with a DIN Mount Part on a DIN
rail:
8. Install the Proximitor Sensor into the DIN Mount Part (if not already
installed).
9. Examine the underneath side of the DIN Mount Part. There is a spring-
loaded clip on one side and two protrusions that will catch the edge of the
DIN rail on the other side. The side with the two protrusions will need to be
installed so that the edge of the DIN rail fits into the gap.
(1) Spring-leaded clip
(2) DIN rail
(3) Edge of DIN rail must fit into this gap
10. Push down on the Proximitor Sensor until the unit snaps into place. The
unit is now installed.
9
Removing the Proximitor Sensor from the DIN Rail
Remove the Proximitor Sensor from the DIN rail by using a regular
screwdriver to unclip the unit from the rail.
Install a regular screwdriver into the rear of the spring-loaded clip and push the
top of the screwdriver towards the Proximitor Sensor to pry the spring-loaded
clip back so that the Proximitor Sensor can be removed from the DIN rail.
Termination of Field Wiring in the Terminal Block
1. Strip the insulation from the field wiring to be installed into the terminal
block. The recommended strip length is 10 mm (0.4 in.).
10
2. If ferrules will not be used on the stripped conductor and a stranded wire is
being used, then the strands of the conductor must be twisted together before
installing the field wire into the terminal block.
The terminal block can accommodate field wiring conductor sizes of 0.2
1.5 mm
2
(16 24 AWG). The terminal block can also accommodate field
wiring with ferrules ranging in size from 0.25 0.75 mm
2
(18 23 AWG).
3. Using a small regular screwdriver push down on the orange lever
corresponding to the position in the terminal block where the field wire will
be installed and insert the field wire.
(1) Small screwdriver
(2) Field wiring
Removal of the field wire is accomplished by pushing down on the orange lever
and pulling on the field wire to remove it from the terminal block. If a stranded
wire is used for the field wiring and a strand is broken off inside the terminal
block, turn the Proximitor Sensor upside down while pushing down the orange
lever to remove the strand from the terminal block.
Routing the Extension Cable and Field Wiring
Route the extension cable using the following guidelines.
- Check that the sum of the extension cable and probe lead length equal
the Proximitor Sensor system length. (For example, a 9 metre
Proximitor Sensor will work with an 8 metre extension cable and a 1
metre probe.)
11
- Check component compatibility by verifying system color identification
on all system components.
- Secure the extension cable to supporting surfaces by using mounting
clips or similar devices.
- Identify the probe and both ends of the extension cable by inserting
labels under the clear Teflon sleeves and applying heat to shrink the
tubing.
- Join the coax connectors between the Proximitor Sensor, extension
cable and probe lead. Tighten connectors as follows:
Connector Type Tightening Instruction
Two 3300 XL gold ClickLoc' connectors Finger tight
Two non-XL stainless steel connectors
(non-ClickLoc') or one non-XL connector
and one 3300 XL connector
Finger tight plus 1/8 turn using pliers
- Use either a connector protector or self-fusing silicone tape to insulate
the connection between the probe lead and the extension cable. Do not
use self-fusing silicone tape to insulate a connection made inside of a
machine.
- If the probe is in a part of the machine that is under pressure or vacuum,
seal the hole where the extension cable leaves the machine by using
appropriate cable seals and terminal boxes.
Use the following wiring diagrams to connect the field wiring between the
Proximitor Sensor and the monitoring instruments. (Refer to documents
AN013 and AN015.)
OUT
COM
Vt
Vt
COM
OUT
Transducer Power
Common (ground)
Input Signal
Transducer Power
Common (ground)
Input Signal
Monitor
Terminal
Strip
Cable
Shield
Connector
Protector
Probe
Cable
Shield
Connector
Protector
Probe
Cable
Shield
Monitor
Terminal
Strip
External
Barrier
External Barriers
No Barriers or 3300/3500
Internal Barriers
Proximitor Sensor
Proximitor Sensor
12
Section 3 Maintenance and Troubleshooting
Section 3 Maintenance and
Troubleshooting
This section shows how to verify that the system is operating properly and
identify parts of the system that are not working properly.
The 3300 XL Transducer System (probe, cable and Proximitor Sensor), when
correctly installed and verified, does not need calibration or verification at
regular intervals. If the monitor OK light (green) indicates a NOTOK condition
(light is not illuminated), either a fault has occurred in the field wiring/transducer
system/power source and/or probe is too close to target or detecting other
material than target.
Bently Nevada recommends the following practices to assure continued
satisfactory operation. Verify operation by using the scale factor verification
method on the following page, if:
- Any of the system components (probe, cable or Proximitor Sensor) are
replaced.
- Any of the components are removed and reinstalled or moved and
remounted.
- Any of the components appear to be damaged.
- Whenever the machine being monitored is over-hauled.
Please note that a step change in the output of the transducer system, or other
output that is not consistent with the associated machinerys trended data is, in
most instances, not a transducer problem but a machinery problem. Verification
of the transducer system under these conditions can be done at the users
discretion.
Under harsh operating conditions some users prefer to verify all transducers at a
regular interval. As noted above, this is not required with the 3300 XL
Transducer System. Users who wish to verify the system on a regular interval
should use an interval consistent with their own practices and procedures, which
may or may not be based upon ISO 10012-1 Quality Assurance Requirements
for Measuring Equipment (section 4.11).
For target materials other than AISI 4140 steel and for other special applications,
contact your local Bently Nevada office.
Note:
Hazardous Locations: Area must be free of hazardous material
before any maintenance or troubleshooting can be performed.
The scale factor verification requires the following instruments and equipment:
- Digital multimeter
- Spindle micrometer
- Fixed resistor, 10 kO
- Power supply (-24 Vdc 1)
The scale factor verification uses the test setup as shown in the following figure:
13
Multimeter
Power Supply
-24 Vdc
Vdc
Vin
Com
10 kohm
+ -
Proximitor Sensor
Probe, Target, and Spindle
Micrometer
OUT
COM
Vt
Scale Factor Verification
1. Compensate for mechanical backlash and adjust the spindle micrometer for
electrical zero.
2. Adjust the gap to electrical zero by moving the probe.
14
3. Compensate for mechanical backlash in the micrometer and adjust to the
start of the linear range.
4. Record voltages in the following table and calculate incremental scale factors
and average scale factor using the equations.
15
Adjust Micrometer to Record Voltages Calculate Scale Factor N
mm
n
mil
n
Vdc
n
ISF
n
(Incremental
Scale Factor)
Vdiff
n
(Difference
Voltage)
1 0.25 10 >> >>
2 0.50 20 >> >> >>
3 0.75 30 >> >> >>
4 1.00 40 >> >> >>
5 1.25 50 >> >> >>
6 1.50 60 >> >> >>
7 1.75 70 >> >> >>
8 2.00 80 >> >> >>
9 2.25 90 >> >> >>
ASF
(Average Scale
Factor)
>> = Enter values into these cells
>>
0.25
Vdc Vdc
ISF
n 1 - n
(V/mm) n

=
2
Vdc Vdc
ASF
mm 2.25 mm 0.25
(V/mm)

=
ISF
Vdc Vdc
0.01
n (mV / mil)
n - 1 n
=

ASF
Vdc Vdc
0.08
(mV / mil)
10 mil 90 mil
=

16
Vdiff ) 2 . 0 ( Vdc n n n - + mil = ) 87 . 7 ( Vdc Vdiff n n n - + mm =
5. Use the following formula to determine maximum Deviation from Straight
Line (DSL):
mm
Vdif Vdif
DSL ______
15.74
(min) (max)
(mm) = =

mil
0.4
Vdif Vdif
DSL ______
(min) (max)
(mil) = =

If the ISF or DSL of the system is out of tolerance, contact Bently Nevada,
LLC for further information on possible calibration problems.
The preceding pages indicate scale factor verification using a TK-3. This is
suitable for rough verification. For API 670 system verification a more precise
micrometer and target must be used. There are two different 3300 XL
Micrometer Kits that can be used to verify the calibration of our transducer
systems or to check the scale factor of specific shafts. Both micrometer kits will
work with Bently Nevada eddy current transducers ranging in size from the 3300
XL NSv and 3300 RAM Transducer Systems up to the 3300 XL 11 mm and
the 7200 14 mm Transducer Systems. Both micrometers also have options for
either a metric or English micrometer.
The 3300 XL Precision Micrometer (part number 330185) is a highly accurate
verification device. It should be used when performing acceptance testing on our
transducer systems. All of our transducer systems have a specified linear range
and average scale factor (ASF). The transducer systems also have a maximum
deviation from straight line (DSL) and ISF tolerances for ambient and extended
temperatures. The 3300 XL Precision Micrometer comes with a high precision
4140 steel target and is used to make precise measurements and verify whether
the transducer system is working properly and within published specifications.
The 3300 XL Shaft Micrometer (part number 330186) is used to check the
scale factor of the transducer system directly on your shaft. You can compare
the scale factor of your transducer system with that of a Bently Nevada supplied
4140 steel target to check whether errors in the measurement are due to runout,
target material or a problem in the transducer system.
Troubleshooting
This section shows how to interpret a fault indication and isolate faults in an
installed transducer system. Before beginning this procedure, be sure the system
has been installed correctly and all connectors have been secured properly in the
correct locations.
When a malfunction occurs, locate the appropriate fault, check the probable
causes for the fault indication and follow the procedure to isolate and correct the
fault. Use a digital voltmeter to measure voltage. If you find faulty transducers,
contact your local Bently Nevada, LLC office for assistance.
The troubleshooting procedures use measured voltages as shown in the following
figure and tables:
17
-
M A D E I N U . S . A .
Vps
Vsig
Vxdcr
Table 3-1. Symbols for Measured Voltages
Symbol Meaning Voltage measured
between...
V
SIG
Signal voltage from the transducer OUT and COM
V
PS
Power supply voltage Power Source and Common
V
XDCR
Supply voltage at transducer -V
T
and COM
Note: V
SIG
, V
PS
, and V
XDCR
are all negative voltage values.
Table 3-2 Definitions
Symbol Definition Example
A > B
A < B
A = B
"A" value is more positive than "B"
"A" value is more negative than "B"
"A" same value (or very close) to
"B"
-21 > -23
-12 < -5
-24.1 = -24.0
18
Fault Type 1: V
XDCR
> -17.5 Vdc or V
XDCR
< -26 Vdc
Possible causes:
- Faulty power source
- Faulty field wiring
- Faulty Proximitor Sensor
M A D E I N U . S . A .
Vps
Measure V
PS
: Is V
PS
> -23 Vdc or V
PS
< -26 Vdc?
Yes: Faulty power supply.
No: Go to next step.
M A D E I N U . S . A .
Vxdcr
Measure V
XDCR
: Is V
XDCR
> -23 Vdc or V
XDCR
< -26 Vdc?
Yes: Faulty Field wiring.
No: Faulty Proximitor Sensor.
19
Fault Type 2: V
SIG
= O Vdc
Possible causes:
- Incorrect power source voltage
- Short circuit in field wiring
- Short circuit at Proximitor Sensor terminal connection
Does fault condition type 1 exist?
Yes: Use the procedure for fault type 1
No: Go to the next step
M A D E I N U . S . A .
Vsig
Measure V
SIG
: Is V
SIG
= 0 Vdc?
No: Incorrect power source voltage or short in field wiring or short at
Proximitor sensor terminal connection.
Yes: Faulty Proximitor Sensor.
Fault Type 3: -1 Vdc < V
SIG
< 0 Vdc
Possible causes:
- Probe is incorrectly gapped (too close to target)
- Probe is detecting other material than target (counterbore or machine
case)
- Short or open circuit in a connector (dirty or wet) or loose connectors
- Short or open circuit in the probe
- Short or open circuit in extension cable
20
Is the probe gapped correctly? Are counterbore dimensions correct? (See
Installing the Probe on page 5.)
No: Regap the probe or check counterbore. Retest system.
Yes Go to the next step.
MADE IN U. S.A.
Original probe/
extension cable
Known good probe
with correct length
cable (open gap with
probe held away from
conductive material)
Vsig
Step 2
Measure V
SIG
: Is V
SIG
< V
XDCR
+ 1 Vdc?
No: Faulty Proximitor Sensor
Yes: Go to next step
Inspect for clean connection: Is the connection dirty, rusty, or a poor connection?
Yes: Clean the connector using isopropyl alcohol or electronic terminal cleaner,
reassemble and retest the system.
21
No: Go to the next step.
Measure resistance R
TOTAL
: Is R
TOTAL
within specifications?
5 m system: 8.75 0.70 O
9 m System: 9.87 0.90 O
Yes: Retest original system
Measure resistance, R
PROBE
: Is R
PROBE
with specifications (see Probe dc resistance
(nominal) (R
PROBE
table on page 29)?
No: Faulty probe.
Yes: Go to next step.
22
Measure the resistance, R
JACKET
and R
CORE
: Is the resistance within specifications
(see Extension cable dc resistance [nominal] table on 29)?
No: Faulty extension cable
Yes: Retest the original system
Fault Type 4: V
XDCR
<V
SIG
< V
XDCR
+ 2.5 Vdc
Possible causes:
- Probe is incorrectly gapped (too far from target)
M A D E I N U . S . A .
Measure V
SIG
: Is 1.2 < V
SIG
< -0.3 Vdc?
No: Faulty Proximitor sensor
Yes: Reconnect the system. Regap the probe. Retest the system.
Fault Type 5: V
SIG
= V
XDCR
Possible causes:
- Faulty field wiring (between Out and V
T
)
23
M A D E I N U . S . A .
Vsig
Measure V
SIG
: Is V
SIG
= V
XDCR
?
Yes: Faulty Proximitor Sensor
No: Faulty field wiring (short between Out and V
T
)
Bently Nevada performs failure analysis on all returned transducers that are in
warranty. The information gained during analysis of failed products is used to
improve our current and future products. If you encounter a part that has failed,
return the part with a brief description of the product application and symptoms
observed to our corporate headquarters in Minden, Nevada for analysis:
Bently Nevada, LLC
Attn: Product Repair Department
1631 Bently Parkway South
Minden, Nevada 89423 USA
24
Section 4 3300 XL Proximitor Housing
Section 4 3300 XL Proximitor
Housing
The 3300 XL Proximitor Housing allows you to protect Proximitor Sensors,
interface modules and electrical terminal blocks in areas that would otherwise be
subjected to possible damage from moisture or other adverse environmental
conditions.
Mounting Options
The 3300 XL Proximitor Housing is designed to accommodate both DIN-rail
and panel mounted Proximitor Sensors. The housing holds up to eight DIN-rail
3300 XL Proximitor Sensors or six panel-mounted Proximitor Sensors.
Environmental Certifications
The 3300 XL Proximitor Housing has been tested and certified to meet
stringent IP66 and Type 4X environmental ratings for protecting enclosed
electronic equipment in harsh conditions. The 304L stainless steel construction
resists moisture, corrosion and impacts in virtually all installations. The Housing
may be hosed down for cleaning when necessary. The 3300 XL Proximitor
Housing can be used for North American Division 1 and 2 and European Zone 0,
1, and 2 hazardous area applications when used with approved fittings. However,
it is not an explosion-proof housing.
Removable gland plates
The 3300 XL Proximitor Housing is our only housing with removable gland
plates. This feature makes it easy to remove the side plates or bottom gland plate
for drilling or punching conduit holes. In addition, the door can be easily
unlatched and removed due to its stainless steel slip hinge.
The gland plates have four thickness options to suit various conduit installation
requirements. If you want a threaded conduit hole, a gland plate thickness of 3.05
mm (0.120 in) or greater is required in order to properly drill and tap the holes.
The conduit fittings come with a lock nut and O-ring to firmly tighten and seal
the conduit fitting into both tapped and untapped holes. Fittings are available in
stainless steel, brass, aluminum or chrome-plated zinc.
25
Dimensional Drawings
Figure 4-1 3300 XL Housing Outline Drawing
(1) Stainless steel slip hinge. Allows cover to be removed from housing
(2) M10 x 1.5 6 g ground stud, stainless steel
(3) M6 slotted hex head captive fastener, stainless steel
(4) Approval/ identification label
(5) M6 x 16 mm hex head bolt, stainless steel
26
Section 4 3300 XL Proximitor Housing
(6) | 8.33 [0.328] padlock hasp
(7) Removable gland plate, 3 places
Panel Mount Orientation
The following illustration shows the correct orientation for six panel mounted
3300 XL Proximitor Sensors in the 3300 XL Proximitor Housing:
MAD E IN U. S.A.
MAD E IN U. S.A.
MAD E IN U. S.A.
MADE IN U .S.A.
MADE I N U .S.A.
MADE IN U .S.A.
(1) Mounting plate, 3300 XL Proximitor Housing
27
DIN Mount Orientation
The following illustration shows the correct installation for eight DIN-mounted
3300 XL Proximitor Sensors in a 3300 XL Proximitor Housing:
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U. S . A.
MADE IN U.S .A.
(1) Mounting plate, 3300 XL Proximitor Housing
(2) DIN rail end cap
28
Section 5 System Specifications
Unless otherwise noted, the following specifications are for a 3300 XL 8 mm
Proximitor Sensor, extension cable and 8 mm probe between +18 C and +27
C (+64 F to +80 F), with a -24 Vdc power supply, a 10 kilo O load, an AISI
4140 steel target, and a probe gapped at 1.27 mm (50 mils). Performance
characteristics are applicable for systems that consist solely of 3300 XL 8 mm
components. The system accuracy and interchangeability specifications do not
apply when using a transducer system calibrated to any target other than a Bently
Nevada AISI 4140 steel target.
Electrical
Proximitor Sensor Input:
Accepts one noncontacting 3300-series 5 mm, 3300 8
mm or 3300 XL 8 mm Proximity Probe and Extension
Cable.
Power:
Requires -17.5 Vdc to -26 Vdc without barriers at 12 mA
maximum consumption, -23 Vdc to -26 Vdc with barriers.
Operation at a more positive voltage than -23.5 Vdc can
result in reduced linear range.
Supply Sensitivity:
Less than 2 mV change in output voltage per volt
change in input voltage.
Output resistance:
50 O
Probe dc resistance (nominal) (R
PROBE
) table:
Probe Length Resistance from the Center Conductor
to the Outer Conductor (R
PROBE
) (ohms)
0.5 7.45 0.50
1.0 7.59 0.50
1.5 7.73 0.50
2.0 7.88 0.50
5.0 8.73 0.70
9.0 9.87 0.90
Extension cable dc resistance (nominal):
Length of Extension
Cable
Resistance from Center
Conductor to Center
Conductor (R
CORE)
(ohms)
Resistance from Outer
Conductor to Outer
Conductor (R
JACKET
)
(ohms)
3.0 0.66 0.10 0.20 0.04
3.5 0.77 0.12 0.23 0.05
4.0 0.88 0.13 0.26 0.05
4.5 0.99 0.15 0.30 0.06
7.0 1.54 0.23 0.46 0.09
7.5 1.65 0.25 0.49 0.10
8.0 1.76 0.26 0.53 0.11
8.5 1.87 0.28 0.56 0.11
29
Extension cable capacitance:
69.9 pF/m (21.3 pF/ft) typical
Field wiring:
0.2 to 1.5 mm
2
(16 to 24 AWG) [0.25 to 0.75 mm
2
(18 to
23 AWG) with ferrules]. Recommend using three-
conductor shielded triad cable. Maximum length of 305
metres (1,000 feet) between the 3300 XL Proximitor
Sensor and the monitor. See the frequency response
graphs Figure 7-10 Frequency Response, typical 3300
XL 8 mm 5 m System with varying lengths of field wiring
attached, no barriers, Figure 7-11 Phase Response,
typical 3300 XL 8 mm 5 m System with varying lengths
of field wiring attached, no barriers, Figure 7-12
Frequency Response, typical 3300 XL 8 mm 9 m
System with varying lengths of field wiring attached, no
barriers, and Figure 7-13 Phase Response, typical 3300
XL 8 mm 9 m System with varying lengths of field wiring
attached, no barriers for signal rolloff at high frequencies
when using longer field wiring lengths.
Linear Range:
2 mm (80 mils). Linear range begins at approximately
0.25 mm (10 mils) from target and is from 0.25 to 2.3
mm (10 to 90 mils) (approximately 1 to 17 Vdc).
Recommended Gap Setting:
1.27 mm (50 mils)
Incremental Scale Factor (ISF)
Standard 5 metre
system:
7.87 V/mm (200 mV/mil) 5% including
interchangeability error when measured in increments of
0.25 mm (10 mils) over the 80 mil linear range from 0 to
+45 C (+32 F to +113 F).
Standard 9 metre
system:
7.87 V/mm (200 mV/mil) 6.5% including
+45 C (+32 F to +113 F).
Extended
Temperature Range
(ETR) 5 and 9 metre
systems:
7.87 V/mm (200 mV/mil) 6.5% including
+45 C (+32 F to +113 F).
Deviation from best fit straight line (DSL)
Standard 5 metre
system:
Less than 0.025mm (1 mil) with components at 0 C
to +45 C (+32 F to +113 F).
30
Standard 9 metre
system:
Less than 0.038mm (1.5 mil) with components at 0 C
to +45 C (+32 F to +113 F).
Extended
Temperature Range 5
and 9 metre systems:
Less than 0.038mm (1.5 mil) with components at 0 C
to +45 C (+32 F to +113 F).
Standard 5 metre system performance over extended
temperatures:
Over a probe temperature range of 35 C to +120 C (-
31 F to +248 F) with the Proximitor Sensor and
extension cable between 0 C to +45C (+32 F to +113
F), the ISF remains within 10% of 7.87 V/mm (200
mV/mil) and the DSL remains within 0.076 mm (3
mils).
Over a Proximitor Sensor and extension cable
temperature range of 35 C to +65 C (-31 F to +149
F) with the probe between 0 C to +45 C (+32 F to
+113 F), the ISF remains within 10% of 7.87 V/mm
(200 mV/mil) and the DSL remains within 0.076 mm
(3 mils).
Standard 9 metre system performance over extended
temperatures:
Over a probe temperature range of 35 C to +120 C (-
31 F to +248 F) with the Proximitor Sensor and
extension cable between 0 C to +45C (+32 F to +113
F), the ISF remains within 18% of 7.87 V/mm (200
mV/mil) and the DSL remains within 0.152 mm (6
mils).
Over a Proximitor Sensor and extension cable
temperature range of 35 C to +65 C (-31 F to +149
F) with the probe between 0 C to +45 C (+32 F to
(6 mils).
Extended Temperature Range system performance over
extended temperatures:
Over a probe and extension cable temperature range of
35 C to + 260 C (-31 F to +500 F) with the
Proximitor Sensor between 0 C to +45C (+32 F to
(6 mils).
Frequency Response:
0 to 10 kHz: +0, -3 dB, with up to 305 metres (1000 feet)
of field wiring.
Minimum Target Size:
15.2 mm (0.6 in) diameter (flat target)
Shaft Diameter
31
Minimum:
50.8 mm (2 in)
Recommended
minimum:
76.2 mm (3 in)
Measurements on shaft diameters smaller than 50 mm
(2 in) usually require close spacing of radial vibration or
axial position transducers with the potential for their
electromagnetic emitted fields to interact with one
another (cross-talk), resulting in erroneous readings.
Care should be taken to maintain minimum separation of
transducer tips, generally at least 40 mm (1.6 in) for
axial position measurements or 38 mm (1.5 in) for radial
vibration measurements. Radial vibration or position
measurements on shaft diameters smaller than 76.2 mm
(3 in) will generally result in a change in scale factor.
Consult Performance Specification 159484 for additional
information.
Effects of 60 Hz Magnetic Fields Up to 300 Gauss:
Output voltage in mil pp/gauss:
Gap 5 metre
Proximitor
Sensor
9 metre
Proximitor
Sensor
Probe Ext. Cable
10 mil 0.0119 0.0247 0.0004 0.0004
50 mil 0.0131 0.0323 0.0014 0.0014
90 mil 0.0133 0.0348 0.0045 0.0045
Electrical Classification:
Complies with the European CE mark.
Hazardous Area Approvals
Note: Multiple approvals for hazardous areas certified by Canadian
Standards Association (CSA/NRTL/C) in North America and by Baseefa
(2001) in Europe.
North America:
Ex ia IIC T5; Class I Zone 0 or Exia IIC T5 for Class 1
Division 1; Groups A, B, C, and D, when installed with
intrinsically safe zener barriers per drawing 141092 or
when installed with galvanic isolators.
ExnA IIC T5 ClassI Zone 2 or ExnA IIC T5 for Class I,
Division 2, Groups A, B, C, and D when installed without
barriers per drawing 140979.
T
5
@ T
a
= -35 C to +85 C.
Europe:
EExia IIC T5 for Zones 0, 1 and 2, Group IIC, EC
certificate number BAS99ATEX1101, when installed with
intrinsically safe zener barriers or galvanic isolators,
T5 @ Ta= -35 C to +85 C.
32
EEx nA for Zone 2, Group IIC, EC certificate number
BAS99ATEX3100U.
Mechanical
Probe Tip Material:
Polyphenylene sulfide (PPS).
Probe Case Material:
AISI 304 stainless steel (SST) for forward mount and
smooth case probes; AISI 303 SST for reverse mount
probes.
Probe Cable Specifications:
Standard cable:
75 O triaxial, fluoroethylene propylene (FEP) insulated
probe cable in the following total probe lengths: 0.5, 1,
1.5, 2, 5, or 9 metres.
Extended
Temperature Range
cable:
75 O triaxial, perfluoroalkoxy (PFA) insulated probe
cable in the following total probe lengths: 0.5, 1, 1.5, 2,
5, or 9 metres.
Extension Cable Material:
75 O triaxial, fluoroethylene propylene (FEP) insulated.
Extended Temperature Range (ETR) Extension Cable Material:
75 O triaxial, perfluoroalkoxy (PFA) insulated.
Proximitor Sensor Material:
A308 aluminum
System Length:
5 or 9 metres including extension cable
Standard Probe and Extension Cable Armor (optional):
Flexible AISI 302 or 304 SST with FEP outer jacket.
Extended Temperature Range Probe and Extension Cable
Armor (optional):
Flexible AISI 302 or 304 SST with PFA outer jacket.
Tensile Strength (maximum rated):
330 N (75 lbf) probe case to probe lead. 270 N (60 lbf) at
probe lead to extension cable connectors.
Connector material:
Gold-plated brass or gold-plated beryllium copper.
Probe case torque: Maximum Rated Recommended
Standard forward-mounted
probes
33.9 N-m
(300 in-lbf)
11.2 N-m
(100 in-lbf)
Standard forward-mount
probes - first three threads
22.6 N-m
(200 in-lbf)
7.5 N-m
(66 in-lbf)
Reverse mount probes 22.6 N-m
(200 in-lbf)
7.5 N-m
(66 in-lbf)
33
Connector-to-connector torque
Recommended torque:
see table:
Connector Type Tightening Instructions
Two 3300 XL gold "click" type connectors Finger tight
One non-XL stainless steel connector and
one
3300 XL connector
Finger tight plus 1/8 turn using pliers
Maximum torque:
0.565 N-m (5 in-lbf)
Minimum Bend Radius:
25.4 mm (1.0 in)
Total System Mass (typical):
0.7 kg (1.5 lbm)
Probe:
323 g (11.38 oz)
Extension Cable:
34 g/m (0.4 oz/ft)
Armored Extension
cable:
103 g/m (1.5 oz/ft)
Proximitor Sensor:
246 g (8.7 oz)
Environmental Limits
Probe Temperature Range
Operating and Storage Temperature:
Standard probe:
-51 C to +177 C (-60 F to +351 F)
Extended
Temperature Range
probe:
-51 C to +177 C (-60 F to +351 F) for the probe tip; -
51 C to +260 C (-60 F to +500 F) for the probe cable
and connector.
Note: Exposing the probe to temperatures below 34 C (-30 F) may
cause premature failure of the pressure seal.
Extension Cable Temperature Range
Operating and Storage Temperature:
Standard cable:
-51 C to +177 C (-60 F to +351 F)
34
Extended
Temperature Range
cable:
-51 C to +260 C (-60 F to +500 F)
Proximitor Sensor Temperature Range
Operating
Temperature:
-35 C to +85 C (-31 F to +185 F)
Storage Temperature:
-51 C to +100 C (-60 F to +212 F)
Relative Humidity:
100% condensing, non-submersible when connectors
are protected.
Probe Pressure:
3300 XL 8 mm probes are designed to seal differential
pressure between the probe tip and case. The probe
sealing material consists of a Viton O-ring. Probes are
not pressure tested prior to shipment. Contact our
custom design department if you require a test of the
pressure seal for your application.
Note: It is the responsibility of the customer or user to ensure that all
liquids and gases are contained and safely controlled should leakage
occur from a proximity probe. In addition, solutions with high or low pH
values may erode the tip assembly of the probe causing media leakage
into surrounding areas. Bently Nevada, LLC will not be held
responsible for any damages resulting from leaking 3300 XL 8 mm
proximity probes. In addition, 3300 XL 8 mm proximity probes will not
be replaced under the service plan due to probe leakage.
Patents:
5,016,343;
5,126,664;
5,351,388, and
5,685,884.
Components or procedures described in these patents apply to this product.
35
36
Section 6 System Ordering Information
3300 XL 8 mm Proximity Probes:
330101 3300 XL 8 mm Probe, 3/8-24 UNF thread, without armor
3
330102 3300 XL 8 mm Probe, 3/8-24 UNF thread, with armor
3
Part Number-AXX-BXX-CXX-DXX-EXX
Option Descriptions
A: Unthreaded Length Option
Note: Unthreaded length must be at least 0.8 inches less than the case
length.
Order in increments of 0.1 in
Length configurations:
Maximum unthreaded length: 8.8 in
Minimum unthreaded length: 0.0 in
Example: 0 4 = 0.4 in
B: Overall Case Length Option
Threaded length configurations:
Maximum case length: 9.6 in
Minimum case length: 0.8 in
C: Total Length Option
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
1 5 1.5 metre (4.9 feet)
2 0 2.0 metres (6.6 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
D: Connector and Cable-Type Option
0 0 Connector provided but not installed, standard cable
0 1 Miniature coaxial ClickLoc
TM
connector with connector protector,
standard cable
TM
connector, standard cable
1 0 Connector provided but not installed, FluidLoc cable
TM
FluidLoccable
TM
connector, FluidLoc cable
E: Agency Approval Option
0 0 Not required
0 5 Multiple Approvals
37
3300 XL 8 mm Proximity Probes, Metric:
330103 3300 XL 8 mm Probe, M10 x 1 thread, without armor
3
330104 3300 XL 8 mm Probe, M10 x 1 thread, with armor
3
Part Number-AXX-BXX-CXX-DXX-EXX
Option Descriptions
Note: Unthreaded length must be at least 20 mm less than the case
length.
Order in increments of 10 mm.
Length configuration:
Maximum unthreaded length: 230 mm
Minimum unthreaded length: 0 mm
Example: 0 6 = 60 mm
Metric thread configurations:
Maximum length: 250 mm
Minimum length: 20 mm
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
D: Connector and Cable-Type Option
TM
standard cable
TM
TM
FluidLoc cable
1 2 Miniature coaxial ClickLoc connector, FluidLoc cable
0 0 Not required
3300 XL 8 mm Reverse Mount Probes
330105-02-12-CXX-DXX-EXX, 3/8-24 UNF threads
3
330106-05-30-CXX-DXX-EXX, M10 x 1 threads
3
Option Descriptions
38
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
1 5 1.5 metre (4.9 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
D: Connector Option
0 0 Connector provided but not installed
0 2 Miniature ClickLoc
TM
coaxial connector
0 0 Not required
3300 XL 8 mm Proximity Probes, Smooth Case:
330140 3300 XL 8 mm Probe without armor
2
330141 3300 XL 8 mm Probe with armor
2
Part Number-AXX-BXX-CXX-DXX
Option Descriptions
A: Overall Case Length Option
Maximum length: 9.6 in
Minimum length: 0.8 in
B: Total Length Option
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
C: Connector and Cable-Type Option
TM
standard cable
TM
TM
FluidLoc cable
TM
connector, FluidLoc cable
D: Agency Approval Option
0 0 Not required
39
3300 XL 8 mm Extended Temperature Range (ETR)
Proximity Probes:
330191 3300 XL 8 mm ETR Probe, 3/8-24 UNF thread, without armor
330192 3300 XL 8 mm ETR Probe, 3/8-24 UNF thread, with armor
Option Descriptions
Note: Unthreaded length must be at least 1.0 inches less than the case
length.
Maximum unthreaded length: 8.5 in
Minimum unthreaded length: 0.0 in
Threaded length configurations:
Maximum case length: 9.5 in
Minimum case length: 1.0 in
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
1 5 1.5 metre (4.9 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
0 0 Not required
Proximity Probes, Metric:
330193 3300 XL 8 mm Probe, M10 x 1 thread, without armor
330194 3300 XL 8 mm Probe, M10 x 1 thread, with armor
Option Descriptions
Note: Unthreaded length must be at least 20 mm less than the case
length.
Length configuration:
Maximum unthreaded length: 230 mm
40
Minimum unthreaded length: 0 mm
Metric thread configurations:
Maximum length: 250 mm
Minimum length: 20 mm
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
0 0 Not required
Reverse Mount Probes
330195-02-12-CXX-DXX, 3/8-24 UNF threads
330196-05-30-CXX-DXX, M10 x 1 threads
Option Descriptions
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
1 5 1.5 metre (4.9 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
0 0 Not required
Proximity Probes, Smooth Case:
330197 3300 XL 8 mm Probe without armor
2
330198 3300 XL 8 mm Probe with armor
2
Part Number-AXX-BXX-CXX
Option Descriptions
A: Overall Case Length Option
41
Maximum length: 9.5 in
Minimum length: 1.0 in
B: Total Length Option
0 5 0.5 metre (1.6 feet)
1 0 1.0 metre (3.3 feet)
5 0 5.0 metres (16.4 feet)
1
9 0 9.0 metres (29.5 feet)
C: Agency Approval Option
0 0 Not required
3300 XL Proximitor Sensor
330180-AXX-BXX
Option Descriptions
A: Total Length and Mounting Option
5 0 5.0 metre (16.4 feet) system length, panel mount
5 1 5.0 metre (16.4 feet) system length, DIN mount
5 2 5.0 metre (16.4 feet) system length, no mounting hardware
9 0 9.0 metres (29.5 feet) system length, panel mount
9 1 9.0 metres (29.5 feet) system length, DIN mount
9 2 9.0 metres (29.5 feet) system length, no mounting hardware
B: Agency Approval Option
0 0 Not required
0 5 Multiple approvals
3300 XL Extension Cable
330130-AXXX-BXX-CXX
Note: Make sure that the extension cable length and the probe length,
when added together, equal the Proximitor Sensor total length.
Option Descriptions
A: Cable Length Option
0 3 0 3.0 metres (9.8 feet)
0 3 5 3.5 metres (11.5 feet)
0 4 0 4.0 metres (13.1 feet)
0 4 5 4.5 metres (14.8 feet)
0 7 0 7.0 metres (22.9 feet)
0 7 5 7.5 metres (24.6 feet)
0 8 0 8.0 metres (26.2 feet)
42
0 8 5 8.5 metres (27.9 feet)
B: Connector Protector and Cable Option
0 0 Standard cable
0 1 Armored cable
0 2 Standard cable with connector protectors
0 3 Armored cable with connector protectors
1 0 FluidLoc cable
1 1 Armored FluidLoc cable
1 2 FluidLoc cable with connector protectors
1 3 Armored FluidLoc cable with connector protectors
0 0 Not required
3300 XL Extended Temperature Range (ETR)
Extension Cable
330190-AXXX-BXX-CXX
Note: Make sure that the extension cable length and the probe length,
when added together, equal the Proximitor Sensor total length.
Option Descriptions
A: Cable Length Option
0 3 0 3.0 metres (9.8 feet)
0 3 5 3.5 metres (11.5 feet)
0 4 0 4.0 metres (13.1 feet)
0 4 5 4.5 metres (14.8 feet)
0 7 0 7.0 metres (22.9 feet)
0 7 5 7.5 metres (24.6 feet)
0 8 0 8.0 metres (26.2 feet)
0 8 5 8.5 metres (27.9 feet)
B: Cable Option
0 0 Standard cable
0 1 Armored cable
0 0 Not required
Accessories
141078-01
Manual
159484
Performance Specification 3300 XL Proximity
Transducer System
43
162735
Performance Specification 3300 XL ETR probes and
extension cables
02120015
Bulk field wire. 1.0 mm
2
(18 AWG), 3 conductor,
twisted, shielded cable with drain wire. Specify length in
feet.
137491-AXX
Aluminum probe clamp bracket
2
Option Descriptions
A: Mounting screw option
0 1 10-24 UNC-2A mounting screws
0 2 M5 x 0.8-6g mounting screws
The aluminum clamp bracket is an unthreaded mounting bracket designed to use
with the smooth case probes (330140, 330141, 330197 and 330198). After
gapping the probe, tighten the clamp bracket by tightening the screws. The
mounting screws have pre-drilled holes for safety wire.
137492-AXX
Aluminum probe threaded mounting bracket
Option Descriptions
A: Thread size
0 1 3/8-24
0 4 M10 x 1
The aluminum probe threaded mounting bracket is the standard mounting bracket
for most 3300 and 3300 XL probe installations. The -01 option is supplied with
two 10-24 UNC-2A mounting screws. The -04 option is supplied with two M5 x
0.8-6g mounting screws. The mounting screws have pre-drilled holes for safety
wire.
27474-AXX
Phenolic threaded probe mounting bracket
Option Descriptions
A: Thread size
0 1 3/8-24
0 4 M10 x 1
The phenolic threaded mounting bracket is recommended if additional electric
isolation from the mounting location is required (as in some generator and
electrical motor bearing locations). The -01 option is supplied with two 10-24
UNC-2A mounting screws. The -04 option is supplied with two M5 x 0.8-6g
mounting screws. The mounting screws have pre-drilled holes for safety wire.
138492-01
Replacement panel-mount mounting pad
138493-01
Replacement DIN-mount mounting pad
148722-01
3300 XL Test Plug. The 3300 XL Test Plug is contains
three small test pins attached to three color-coded wires
1 metre in length, each terminated in a banana plug.
The three-pin adapter plugs into the test pin holes on
3300 XL-style Proximitor Sensors. It is used to check
the performance of the Proximitor Sensor from the test
44
pin holes in the terminal strip without requiring the
removal of the field wiring.
04310310
3300 XL Proximitor Sensor Panel-mount Screws.
Package includes four 6-32 UNC thread forming
mounting screws. (Supplied standard with Proximitor
Housings [3300 XL panel-mount option] ).
03200006
Silicone self-fusing tape. A 9.1 metre (10 yard) roll of
silicone tape to protect connectors. It is easy to install
and provides excellent electrical isolation and protection
from the environment. It is not recommended for use
inside the casing of the machine.
40113-02
Connector Protector Kit. Connector Protector Kit for
3300 XL 8 mm probes and extension cables, including
connector protectors and installation tools.
136536-01
Connector Protector Adapter. Allows connector
protector installation tools manufactured prior to 1998 to
be used with 75 O ClickLoc connectors.
40180-02
Connector Protectors. Package contains 10 pairs of
connector protectors for 3300 XL 8 mm probes and 3300
XL 5 and 8 mm extension cables.
03839410
75 ohm Triaxial Male Connector Protector. Male
connector protectors are installed onto the extension
cable and attach to the female connector protector on
the probe, providing environmental protection of
connectors.
03839420
75 ohm Triaxial Female Connector Protector.
Female connector protectors are installed onto the probe
lead and attach to the male connector protector on the
extension cable, providing environmental protection of
connectors. Also placed on the extension cable to slide
over the connection to the Proximitor Sensor and
protect it from the environment.
04301007
3/8-24 Probe Lock Nut with safety wire holes. Single
probe lock nut with two holes drilled through the nut in
order to secure the lock nut in place with safety wire.
04301008
M10 x 1 Probe Lock Nut with safety wire holes.
Single probe lock nut with two holes drilled through the
nut in order to secure the lock nut in place with safety
wire.
330153-01
3300 XL Connector Kit. Used on 3300 XL 8 mm
probes and extension cables. Contains one pair of male
and female ClickLoc
TM
connectors, two color-coded
sleeves, two pieces of slit FEP tubing, and one strip of
silicone tape.
45
163356
Connector Crimp Tool Kit. Includes one set of
multiconnector inserts and connector installation
instructions. Compatible only with 330153 connector
kits or with probes shipped in 2003 or later with
ClickLoc connectors uninstalled. Supplied with
carrying case.
Notes:
1. Five metre probes are designed for use with the five metre Proximitor
Sensor only.
2. Mounting clamps must be ordered separately for 330140, 330141, 330197,
and 330198.
3. For a shorter delivery time, order commonly stocked probes. Currently,
stocked probes consist of the following part numbers:
330101-00-08-05-02-00, 330101-00-08-05-02-05, 330101-00-08-10-02-00,
330101-00-08-10-02-05, 330101-00-12-10-02-00, 330101-00-12-10-02-05,
330101-00-16-10-02-00, 330101-00-16-10-02-05, 330101-00-20-05-02-00,
330101-00-20-10-02-00, 330101-00-20-10-02-05, 330101-00-30-10-02-00,
330101-00-30-10-02-05, 330101-00-40-05-02-00, 330101-00-40-10-02-00,
330101-00-40-10-02-05, 330101-00-60-10-02-00, 330101-00-60-10-02-05,
330102-00-20-10-02-00, 330103-00-02-10-02-05, 330103-00-03-10-02-05,
330103-00-04-10-02-00, 330103-00-04-50-02-00, 330103-00-05-10-02-00,
330103-00-06-10-02-00, 330104-00-06-10-02-00, 330104-01-05-50-02-00,
330105-02-12-05-02-00, 330105-02-12-05-02-05, 330105-02-12-10-02-00,
330105-02-12-10-02-05, 330106-05-30-05-02-00, 330106-05-30-05-02-05,
330106-05-30-10-02-00 and 330106-05-30-10-02-05.
46
Section 7 3300 XL 8mm System Graphs and Dimensional Drawings
Section 7 3300 XL 8mm System
Graphs and Dimensional Drawings
-4
-2
0
2
4
D
S
L

E
r
r
o
r

(
m
i
l
s
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7

V
/
m
m

(
2
0
0
m
V
/
m
i
l
)
-0.10
-0.05
0.00
0.05
0.10
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
Gap (mm)
D
S
L

E
r
r
o
r

(
m
m
)
-10
-5
0
5
10
I
S
F

E
r
r
o
r

(
%
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7

V
/
m
m

(
2
0
0

m
V
/
m
i
l
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
5m @25 C (77 F) 5m @ 45 C (113 F) 5m @ 0 C (32 F)
Figure 7-1 Typical 3300 XL 8 mm 5 m System over API 670 Testing Range
47
-6
-4
-2
0
2
4
6
D
S
L

E
r
r
o
r

(
m
i
l
s
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7

V
/
m
m

(
2
0
0
m
V
/
m
i
l
)
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
Gap (mm)
D
S
L

E
r
r
o
r

(
m
m
)
-10
-5
0
5
10
I
S
F

E
r
r
o
r

(
%
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7

V
/
m
m

(
2
0
0

m
V
/
m
i
l
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
9m @25 C (77 F) 9m @ 45 C (113 F) 9m @ 0 C (32 F)
Figure 7-2 Typical 3300 XL 8 mm 9 m System over API 670 Testing Range
48
-6
-4
-2
0
2
4
6
D
S
L

E
r
r
o
r

(
m
i
l
s
)
R
e
f
e
r
e
n
c
e
d

t
o
7
.
8
7

V
/
m
m
(
2
0
0
m
V
/
m
i
l
)
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 Gap (mm)
D
S
L

E
r
r
o
r
(
m
m
)
-10
-5
0
5
10
I
S
F

E
r
r
o
r

(
%
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7
V
/
m
m

(
2
0
0

m
V
/
m
i
l
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
1m Probe @25 C (77 F) 1m Probe @ -35 C (-31F)
1m Probe @120 C (248 F)
Figure 7-3 Typical 3300 XL 8 mm Probe over API 670 Operating Range
49
-6
-4
-2
0
2
4
6
D
S
L

E
r
r
o
r
(
m
i
l
s
)
R
e
f
e
r
e
n
c
e
d

t
o
7
.
8
7

V
/
m
m
(
2
0
0
m
V
/
m
i
l
)
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
Gap (mm)
D
S
L

E
r
r
o
r
(
m
m
)
-10
-5
0
5
10
I
S
F

E
r
r
o
r
(
%
)
R
e
f
e
r
e
n
c
e
d

t
o

7
.
8
7
V
/
m
m

(
2
0
0
m
V
/
m
i
l
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
TC=25 C (77 F) Tc=-34 C (-30 F) Tc=-51C (-60 F)
Figure 7-4 Typical 3300 XL 8 mm 5 m Proximitor Sensor with 4 m of
Extension Cable @ Tc (Probe is at 25 C)
50
-8
-6
-4
-2
0
2
4
6
8
D
S
L

E
r
r
o
r

(
m
i
l
s
)
R
e
f
e
r
e
n
c
e
d

t
o
2
0
0
(
m
V
/
m
i
l
)
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 Gap (mm)
D
S
L

E
r
r
o
r

(
m
m
)
-15
-10
-5
0
5
10
15
I
S
F

E
r
r
o
r

(
%
)
R
e
f
e
r
e
n
c
e
d

t
o
2
0
0
(
m
V
/
m
i
l
)
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100 Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
25 C (77 F) 65 C (149 F) 85 C (185 F) 100 C (212 F)
Figure 7-5 Typical 3300 XL 8 mm 5 m Proximitor Sensor with 4 m
Extension Cable @ Th (Probe is at 25C)
51
-8
-6
-4
-2
0
2
4
6
8
D
S
L

E
r
r
o
r
(
m
i
l
s
)
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
Gap (mm)
D
S
L

E
r
r
o
r
(
m
m
)
-15
-10
-5
0
5
10
15
I
S
F

E
r
r
o
r

(
%
)
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
Tc=+25 C (+77 F) Tc=-34 C (-30 F) Tc=-51C (-60 F)
Extension Cable @ Tc (Probe is at 25 C)
52
-8
-6
-4
-2
0
2
4
6
8
D
S
L

E
r
r
o
r
(
m
i
l
s
)
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50
Gap (mm)
D
S
L

E
r
r
o
r

(
m
m
)
-15
-10
-5
0
5
10
15
I
S
F

E
r
r
o
r

(
%
)
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100
Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
Th=+25 C (+77 F) Th=+65 C (+149 F)
Th=+85 C (+185 F) Th=+100 C (+212 F)
Extension Cable @ Th (Probe is at 25 C)
53
-10
-8
-6
-4
-2
0
2
4
6
8
10
D
S
L

E
r
r
o
r

(
m
i
l
s
)
-0.25
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.25
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 Gap (mm)
D
S
L

E
r
r
o
r

(
m
m
)
-15
-10
-5
0
5
10
15
I
S
F

E
r
r
o
r
(
%
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100 Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
Th=+25 C (+77 F) Th =+260 C (+500 F)
Figure 7-8 Typical 3300 XL Extended Temperature Range Probe and 4
metres of Extended Temperature Range Extension Cable @ Th (Proximitor
Sensor and probe tip with 1 foot of cable are at +25 C)

54
-10
-8
-6
-4
-2
0
2
4
6
8
10
D
S
L

E
r
r
o
r
(
m
i
l
s
)
-0.25
-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
0.25
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 Gap (mm)
D
S
L

E
r
r
o
r
(
m
m
)
-15
-10
-5
0
5
10
15
I
S
F

E
r
r
o
r

(
%
)
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
0 10 20 30 40 50 60 70 80 90 100 Gap (mils)
O
u
t
p
u
t

(
V
o
l
t
s
)
Th=+25 C (+77 F) Th=+260 C (+500 F)
Figure 7-9 Typical 3300 XL Extended Temperature Range Probe and 8
metres of Extended Temperature Range Extension Cable @ Th (Proximitor
Sensor and probe tip with 1 foot of cable are at +25 C)

55
Frequency Response to Different Field Wiring Lengths
without Barriers (5 m System)
-5
-4
-3
-2
-1
0
1
100 1,000 10,000 100,000
Frequency (Hz)
M
a
g
n
i
t
u
d
e

(
d
B
)
No field wiring 1000' wiring 2000' wiring
5000' wiring 12,000' wiring
Figure 7-10 Frequency Response, typical 3300 XL 8 mm 5 m System with
varying lengths of field wiring attached, no barriers
Phase Response with Different Field Wiring Lengths, No
Barriers (5 m System)
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
100 1,000 10,000 100,000
Frequency (Hz)
P
h
a
s
e

A
n
g
l
e
(
d
e
g
r
e
e
s
)
No field wiring 1000' wiring 2000' wiring
5000' wiring 12,000' wiring
Figure 7-11 Phase Response, typical 3300 XL 8 mm 5 m System with
56
Frequency Response to Different Field Wiring Lengths without
Barriers (9 mSystem)
-5
-4
-3
-2
-1
0
1
100 1,000 10,000 100,000
Frequency (Hz)
M
a
g
n
i
t
u
d
e

(
d
B
)
No field wiring 1000' field wiring 2000' field wiring
5000' field wiring 12,000' field wiring
Figure 7-12 Frequency Response, typical 3300 XL 8 mm 9 m System with
Phase Response with Different Field Wiring Lengths, No
Barriers (9 m System)
-100.00
-90.00
-80.00
-70.00
-60.00
-50.00
-40.00
-30.00
-20.00
-10.00
0.00
100 1,000 10,000 100,000
Frequency (Hz)
P
h
a
s
e

A
n
g
l
e

(
d
e
g
r
e
e
s
)
No field wiring 1000' field wiring 2000' field wiring
5000' field wiring 12,000' field wiring
Figure 7-13 Phase Response, typical 3300 XL 8 mm 9 m System with
57
17.0 (0.67) for M10 threads
14.3 (9/16) for 3/8-24 threads
8 (5/16) Wrench Flats, 4 each
(0.31)
6.0 (0.235) Max.
Case Length "B"
8.0
Probe Tip
Total Length "C", +30%, -0%
Thread
Case
3.7 (0.15) Max. Outside Dia.
75 ohm Cable
Coaxial Connector
Miniature Male
7.23 (0.285) Outside
Dia. Maximum "D"
7.6 (0.30) Outside Dia. of Armor
Unthreaded Length
"A"
2.5 (0.10)
Dia.
2
2
3
R
9.0 (0.35) Max Dia. of Armor Ferrule
Figure 7-14 3300 XL 8 mm Proximity probes, Standard Mount
330101 and 330191, 3/8-24 UNF-2A, without armor
7
330102 and 330192, 3/8-24 UNF-2A, with armor
6
330103 and 330193, M10X1 thread, without armor
7
330104 and 330194, M10X1 thread, with armor
6
Figure 7-15 stalled Connector Protectors
58
Figure 7-16 00 XL 8 mm Proximity Probes, Reverse Mount
4, 7
330105 and 330195, 3/8-24 UNF-2A threads
330106 and 330196, M10X1 threads
With Armor, outside Dia. is 8.0 (0.315)
3.68 (0.145) Dia. Max.
Max. Dia.
8 (0.31)
Dia. Tip
6.0 (0.235) Max.
2.54 (0.100)
Case Length "A"
9.6 (0.38)
4 each
7.9 (0.31)
Wrench Flats
7.23 (0.285) Dia. Max.
349.25 (13.750) Max.
Cable Length
Male (Plug) Connector
75 Ohm Cable
3.9 (0.16) Max. Dia. for FluidLoc Cable
3
R
Figure 7-17 00 XL 8 mm Proximity Probes, Smooth Case
330140 and 330197, without armor
7
330141 and 330198, with armor
6
59
Coaxial Connector
Miniature Female
Triaxial Cable
FEP or PFA Insulated
8.4 (0.33) Dia.
Stainless Steel Ferrules
Cable Length +20%, -0%
7.2 (0.285)
300 (11.8)
Armor Length:
(3.30)
83.8
Coaxial Connector
Miniature Male
Max. Dia.
7.2 (0.285)
less than cable length
(3.30)
83.8
(3.30)
83.8 83.8
(3.30)
3.7 (0.15) max. O.D.
3.9 (0.16) Max. Dia. for FluidLoc cable
7.6 (0.30) Max. O.D. of Armor
75 ohm cable
Max. Dia.
Coated Armor
FEP or PFA
6
R
Figure 7-18 0130, 3300 XL Extension Cable (FEP armor and insulation)
30190, 3300 XL ETR Extension Cable (PFA armor and insulation)
Mounting Option
"A" Options -50 or -90
63.5 (2.50)
50.8
(2.00)
81.3
(3.20)
50.8
(2.00)
61.2
(2.41)
5.1
(0.20)
Figure 7-19 nel Mount 3300 XL Proximitor Sensor
60
Figure 7-20 N Mount 3300 XL Proximitor Sensor
61
50
25.4
(1.95)
50.8
(2.00)
60.2
(2.37)
50.8
(2.00)
79.4
(3.125)
(1.00)
R
86
(3.4)
Mounting Option
"A" Options -50 or -90
63.5
50.8
(2.00)
81.3
(3.20)
50.8
(2.00)
61.2
(2.41)
5.1
(0.20)
(2.50)
(3.2)
81
Figure 7-21 ysical mounting characteristics showing interchangeability of
3300 and 3300 XL Proximitor Sensors when 4-hole mounting option is
used
8
Notes:
1. All dimensions on figures are in millimetres (inches) unless otherwise noted.
2. Standard mount 8 mm probes supplied with 17 mm or 9/16 inch lock nut.
3. Probes ordered with 5 or 9 metre integral cables have a length tolerance of
+20%, -0%.
4. Reverse mount probes not available with armor or connector protector
options.
5. Letters inside quotation marks on figures refer to probe ordering options.
6. Stainless steel armor is supplied with FEP outer jacket for standard probes,
PFA outer jacket for ETR probes.
62
7. FEP jacket is standard non-armored portion of the cable for standard probes,
PFA jacket on non-armored portion for ETR probes.
8. Use M3.5 or #6 screws for panel-mount Proximitor Sensors (screws
provided when purchasing Bently Nevada housings).
63
64
Section 8 Micrometer Specifications and Ordering Information
Section 8 Micrometer Specifications
and Ordering Information
Mechanical
Target Buttons:
AISI 4140 Alloy Steel, 30.5 mm (1.20 in) diameter flat
target
Note: Contact your nearest Bently Nevada Sales Professional for
details on special target materials.
Casing Material:
3300 XL Precision
Micrometer:
Fiberglass and Plastic.
3300 XL Shaft
Micrometer:
ABS Plastic.
Micrometer specifications:
Table 8-1 3300 XL Precision Micrometer:
Part number Resolution Accuracy Range
330185-01 0.000020 in 0.000015 in 0-1 in
330185-02 0.0005 mm 0.0004 mm 0-25 mm
Table 8-2 3300 XL Shaft Micrometer
Part number Resolution Accuracy Range
330186-01 0.001 in 0.0001 in 0-1 in
300186-02 0.01 mm 0.003 mm 0-25 mm
Size
3300 XL Precision Micrometer (case dimensions)
Height:
226 mm (8.9 in)
Width:
274 mm (10.8 in)
Length:
356 mm (14.0 in)
3300 XL Shaft Micrometer (case dimensions)
Height:
65
152 mm (6.0 in)
Width:
246 mm (9.7 in)
Length:
356 mm (14.0 in)
Total System Mass
3300 XL Precision
Micrometer:
6.8 kg (14.5 lbm)
3300 XL Shaft
Micrometer:
2.8 kg (6.2 lbm)
Ordering Information
3300 XL Precision Micrometer
330185-AXX
Option Descriptions
A: Scale Units
0 1 Micrometer in English units (0-1 in)
0 2 Micrometer in metric units (0-25 mm)
3300 XL Shaft Micrometer
330186- AXX
Option Descriptions
A: Scale Units
0 1 Micrometer in English units (0-1 in)
0 2 Micrometer in metric units (0-25 mm)
Note: The 3300 shaft micrometer and precision micrometer come with
probe mounting adapters for inch,
3
/
8
inch, inch,
5
/
8
inch, M8, M10,
M14 and M16 probe thread sizes.
Accessories
Part Number Description
138751-01 3300 XL Precision Micrometer Instruction Sheet
140273-01 3300 XL Shaft Micrometer Instruction Sheet
27505-01 Target button: A replacement 4140 target button that comes
standard with the 3300 XL shaft micrometer. There can be a
variation of up to 5% in the average scale factor (ASF) between
each target button.
136534-01 High Precision target button: A replacement 4140 target button
that comes standard with the 3300 XL precision micrometer.
There can be a variation of up to 0.6% in the Average Scale
Factor (ASF) between each target button.
02200218 Shaft Micrometer Strap: A replacement strap for the 3300 XL
Shaft Micrometer.
66
Section 8 Micrometer Specifications and Ordering Information
Part Number Description
49478-01 Probe mounting adapter, M5 threads.
49478-02 Probe mounting adapter, 1/4 inch threads.
Dimensional Drawings
280 (11) Typical
203 (8.0)
89 (3.5)
1 24
6 4
0 9
1 0
8
0 0
2
8
2
0
2
4 6
8
0
165 (6.5)
0
2
3
1
0
23
22
24
22
23
3
2
152 (6.0)
89 (3.5)
Figure 8-1 3300 XL Precision Micrometer
(1) Collets to fit both metric and English 5mm, 8mm, 11mm, and 14mm
probes.
(2) Removeable AISI 4140 target
67
160.0 (6.30) max.
150.9 (5.94) min.
59.2
(2.33)
105.4
(4.15)
4 3 2 1 2
4
2
3
2
2
2
1
3
2
1
0
Figure 8-2 - 3300 XL Shaft Micrometer
Note: Dimensions for figures are in millimetres (inches)
68
Section 9 Housing Specifications and Ordering Information
Section 9 Housing Specifications and
Mechanical
Housing Rating:
For North America, the Canadian Standards Association
(CSA) tested and certified the housing to a Type 4X
waterproof and corrosion-resistant rating. For Europe,
the Canadian Standards Association (CSA) also tested
and certified the housing to meet the IP66 waterproof
and dust-proof rating along with the 7 joule high impact
mechanical risk test required by CENELEC standard
EN50 014. Verified by Baseefa (2001) certificate number
Ex85122 for use in ExN applications and by certificate
number BAS99ATEX3102 for EEx n applications.
Housing Material:
304L stainless steel.
Gland Plate Gasket Material:
Neoprene.
Cover Gasket Material:
Poron.
Total System Mass:
6.4 kg (14.0 lbm) with standard gland plates but without
conduit fittings installed; 8.0 kg (17.5 lbm) with standard
gland plates and conduit fittings installed.
3300 XL Proximitor Housing
330181 -AXX - BXX - CXX DXX
The 3300 XL Proximitor Housing is rated for IP66 and Type 4X environmental
conditions. It can accommodate up to eight 3300 XL Proximitor Sensors in the
DIN-mount configuration or six panel-mount Proximitor Sensors. It has three
removable gland plates, making it easier to install conduit fittings and cable
gland seals.
Option Descriptions
A: Transducer Type Option
0 0 No mounting hardware
0 1 3300 XL Proximitor Sensors (DIN mount), DIN-rail terminal blocks
0 3 3300 XL Proximitor Sensors (panel mount)
0 4 3300 Proximitor Sensors
0 5 3000 or 7200 Proximitor Sensors, VDCs, and Interface Modules
69
Note: Proximitor Sensors, Interface Modules, and Velocity-to-
Displacement Converters are not included and must be ordered
separately.
Application Advisory: Care must be taken during system length
selection to avoid having excess cable length coiled up inside of the
housing. Excess cable coiled up in the housing may cause chafing and
premature failure of the cables. Additional conduit boxes, armored
cable or special provisions are recommended for long lengths of cable
that must be coiled in the 330181 housing.
B: Conduit Fitting Option
0 0 Without fittings.
0 1 One brass M32 cable gland seal outlet, six brass M25 cable gland
seal inlets.
0 2 One brass M32 cable gland seal outlet, eight brass M25 cable gland
seal inlets.
0 3 One aluminum 1 -11 NPT conduit outlet, six aluminum -14
NPT conduit inlets, six aluminum -14 to -14 NPT reducers.
0 4 One aluminum 1-11 NPT conduit outlet, eight aluminum -14
NPT conduit inlets, eight aluminum -14 to -14 NPT reducers.
0 5 One 316 stainless steel 1 -11 NPT conduit outlet, six 316
stainless steel -14 NPT conduit inlets, six 303 stainless steel -
14 to -14 NPT reducers.
0 6 One 316 stainless steel 1 -11 NPT conduit outlet, eight 316
stainless steel -14 NPT conduit inlets, eight 303 stainless steel -
14 to -14 NPT reducers.
0 7 One chrome-plated zinc 1 -11 NPT conduit outlet, six chrome-
plated zinc -14 NPT conduit inlets, six 303 stainless steel -14 to
-14 NPT reducers.
0 8 One chrome-plated zinc 1 -11 NPT conduit outlet, eight chrome-
plated zinc -14 NPT conduit inlets, eight 303 stainless steel -14
NPT to -14 NPT reducers.
C: Gland Plate Thickness
0 1 Standard 2.34 mm (0.092 in)
0 2 3.05 mm (0.120 in)
0 3 4.76 mm (0.188 in)
0 4 6.35 mm (0.250 in)
D: Terminal Mounting Block Option
0 0 No terminal blocks
0 1 4 DIN rail terminal blocks
2 1 1 terminal block
70
Section 9 Housing Specifications and Ordering Information
2 2 2 terminal blocks
Note: Each DIN rail terminal block accepts only one wire. The
standard terminal blocks each accept four wires. Thus, four DIN rail
terminal blocks equal one standard terminal block.
Accessories
Part number Description
137936-01 Brass cable gland seal, M32
137937-01 Brass cable gland seal, M25
03818111 Nickel-plated brass conduit fitting, PG21 x M20
03839130 Aluminum conduit fitting, -14 NPT
03839132 Aluminum conduit fitting, 1 -11 NPT
03850021 Aluminum reducer, -14 to -14 NPT
03813103 Chrome-plated zinc conduit fitting, -14 NPT
03813105 Chrome-plated zinc conduit fitting, 1-11 NPT
03813106 Chrome-plated zinc conduit fitting, 1 -11 NPT
03818099 AISI 316 stainless steel conduit fitting, 1 -11 NPT
03818100 AISI 316 stainless steel conduit fitting, -14NPT
26650-01 AISI 303 stainless steel reducer, -14 to -14 NPT
26650-03 AISI 303 stainless steel reducer, 1 -11 to 1-11 NPT
03818102 AISI 316 stainless steel conduit fitting, PG21 x M20
03818103 AISI 316 stainless steel conduit fitting, PG21 x PG11
03818104 AISI 303 stainless steel conduit seal, PG11
03818105 AISI 316 stainless steel conduit seal, M20
103537-01 Terminal Mounting Block This 4-wire terminal mounting block
includes screws and is easily installed. Terminal mounting blocks are
used to connect transducer cables to field wiring that is routed back to
the monitoring system. These blocks are used with the PROXPAC
Transducer Assembly, integral 25 mm and 50 mm DE transducers,
temperature sensors, Velomitor Sensors, and seismic transducers.
01691029 DIN-rail Terminal Strip
01691028 DIN-rail Terminal Strip Cover The DIN-rail terminal strip with cover is
a single wire terminal strip that snaps onto a 35 mm DIN rail.
04490104 Conduit Seal Punch Tool A punch tool set is used when installing
conduit seals. The conduit seals come with a rubber insert, with
markings for where to "punch" holes. Use the punch tool set to punch
the number of holes you need for the cables going through each
conduit seal.
Sealtite Flexible
Conduit Assembly
14847-XX -14 NPT Threads
14848-XX -14 NPT Threads
Option Descriptions
A: Length Option
Order in increments of 1 foot (300 mm)
Minimum length: 1 foot = 0 1
71
Maximum length: 99 feet = 9 9
72
5 18 269
Designation:
1.050.124
1 1 5 18 269 _ 110
2 1 5 18 269 _ 120
3 1 5 18 269 _ 130
4 1 5 18 269 _ 140
5 1 5 18 269 _ 150
6 1 5 18 269 _ 160
7 0 5 18 269 _ 220
8 1 5 18 269 _ 300
9 2 5 18 269 _ 460
10 0 5 18 269 _ 700
11 0 5 18 269 _ 825
Issue:
Equipment List
Document to Quality
Project: Hindustan Zinc Prep.: Walther Check: J acobs 05.12.2006
Drwg./Doc.No
Data Sheets (Local Panel +J unction Boxes)
Cable Plan
Terminal List
Layouts
Wiring Diagram
Cable List
com.UIL
Hindustan Zinc, Chanderiya, India
Customer
SO2 Blower - SFO11
ACC job no.:
KK&K Job No.:
com.UIL
Pos. No.
ACC
AVICOMP CONTROLS GMBH
Poetenweg 49 04155 Leipzig
Tel.: +49 (341) 217 87 0 Fax.: +49 (341) 217 87 15
Email: service@avicompcontrols.de http: www.avicompcontrols.de
Documentation
Description Rev. No. Note Drwg./Doc.No.
com.UIL
com.UIL
first issue
com.UIL
com.UIL
as built
after FAT FAT report
Manual
Modbus Data Exchange List com.UIL
first issue
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
Kuehnl e, Kopp & Kausch
AviComp Controls GmbH
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Modi f y
Dat e
Dat e Name KKK No. : 1050124
PHASE II
Cover Sheet
sheet 0
of 108

+LCP
=
1
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
Hesshei mer strasse 2
D- 67227 F rankenthal
J ob- Nr . Pos. - Nr . :
AviComp
Controls GmbH
TYPE: SFO11
HI NDUSTAN ZI NC, CHANDERI YA, I NDI A
SO BLOWER
2
Pl ant :
HI NDUSTAN ZI NC PHASE I I
CHANDERI YA, I NDI A
Pr oj ect : PHASE I I
1050124
5 18 269
SO2 BLOWER Phase I I
P oetenweg 49
D- 04155 Lei pzi g
KKK J ob No: 1. 050. 124
5 18 269- 110
ELEKTRO PROJ ECT LCP
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ El pr o\ 518269WD
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
i n si t u desi gnat i on
r esour ce desi gnat i on
f unct i on desi gnat i on
i n si t u desi gnat i on
+LCP Local Cont r ol Panel
= Tag No.
+J B1 J unct i on box
vi br at i on and
axi al moni t or i ng
Resour ce Desi gnat i on
Ener gi zat i on:
230 V 50 Hz
3 x 415 V 50Hz auxi l ar y dr i ve
cabi net cl i ma cont r ol
Cont r ol vol t age
+LCP, i nt er nal 24 V DC +J B4 J unct i on box bear i ng t emper at ur es
Wi r e Col or
on gear box
bear i ng t emper at ur es +J B5 J unct i on box
on pedest al
on oi l uni t
di gi t al si gnal s wi t h 24 VDC
anal og si gnal s
di gi t al si gnal s wi t h 24 VDC
anal og si gnal s
ci r cui t s wi t h ext er nal power Yel l ow ( YE)
Power ci r cui t Bl ack ( BK)
Gr oundi ng ci r cui t Gr een/ Yel l ow l i ne
Low ener gy ci r cui t Bl ue ( BU)
r esour ce desi gnat i on
- sheet no. r esour ce number
+LCP- 42K1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Legend
sheet 1
of 108
=
0
5 18 269- 110
3
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
518269WD W: \ Pr oj ect s\ 518269_HZL_I I \ 518269WD
cont r ol power 110 V 50 Hz UPS
cabi net l i ght
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Sheet Document No. : Ti t l e Sheet Ti t l e Document No. : Rev. Rev.
Dr awi ng l i st
Contents from
5 18 269- 110
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ For mul ar e\ I nhal t ver z
01 com. UI L 06. 09. 06 J ac
01
30. 05. 2006
000 01 Cover Sheet 5 18 269- 110
001 01 Legend 5 18 269- 110
003 01 Drawing list 5 18 269- 110
007 01 Cover Sheet wiring diagram 5 18 269- 110
040 01 P ower supply 415 V AC 5 18 269- 110
041 01 P ower Suppl y 230 V/ 50 Hz 5 18 269- 110
042 01 Control P ower Supply 5 18 269- 110
043 01 Cubicle Lamp, Socket Heat Exchanger 5 18 269- 110
045 01 spare 5 18 269- 110
047 01 Ground Distribution 5 18 269- 110
048 01 Control Voltage 1, 2 5 18 269- 110
049 01 Control Vol tage 3, 4 5 18 269- 110
050 01 Controlling, Main Switch, Heat Exch. 5 18 269- 110
051 01 Control Equipments Operator P anel 5 18 269- 110
053 01 P LC General View 5 18 269- 110
054 01 Analogue I nputs, P LC Address 256 5 18 269- 110
057 01 Analogue Outputs, PLC Address 304 5 18 269- 110
059 01 Digital I nputs, P LC Address 0 5 18 269- 110
060 01 Digital I nputs, P LC Address 4 5 18 269- 110
061 01 Digital Outputs, P LC Address 0 5 18 269- 110
063 01 Control Equipments 5 18 269- 110
068 01 Emergency Stop 5 18 269- 110
069 01 Motor Current Main Motor 5 18 269- 110
071 01 Vibration Monitors, General View 5 18 269- 110
072 01 Vibration Monitor Rack I nterface 5 18 269- 110
073 01 Vibration Monitor 1, Vibrations 5 18 269- 110
074 01 Vi brati on Monitor 2 Axial Disp. 5 18 269- 110
075 01 Seismic Monitor Vibrations Motor Bear. 5 18 269- 110
076 01 Vibration Monitors, Relais Module 5 18 269- 110
077 01 Bearing Temperature Gear Box 5 18 269- 110
080 01 Bearing Temperature Compressor 5 18 269- 110
081 01 Bearing Temperature Compressor 5 18 269- 110
082 01 Temperature Compressor Bearing DS 5 18 269- 110
084 01 TE P 202 Suction Temperature 5 18 269- 110
085 01 TE P 204/P T P 208 Oil Temp./P ress. 5 18 269- 110
086 01 P SL/P SLL P 209-211 Oil P ressure 5 18 269- 110
087 01 P DI SH P 203 Oil Filter Diff.P ress. 5 18 269- 110
088 01 LSL/LSLL P 242 Oil Level Tank 5 18 269- 110
089 01 TSLH P 244 Oil Heater Control 5 18 269- 110
090 01 SPARE 5 18 269- 110
091 01 PDSH P201 Anti Surge 5 18 269- 110
092 01 I nlet Guide Vane 5 18 269- 110
094 01 Oi l Heater no Error/ Running 5 18 269- 110
095 01 Oil Heater ON 5 18 269- 110
096 01 Main Motor no Error/Running 5 18 269- 110
097 01 Emerg. Oil P ump no Error/Running 5 18 269- 110
098 01 Aux./Emerg.Oil P ump Start 5 18 269- 110
099 01 Main Motor Bearing/Winding Temp. 5 18 269- 110
100 01 Main Motor no Error/Running 5 18 269- 110
101 01 Main Motor P ermissive/Start 5 18 269- 110
102 01 SPARE 5 18 269- 110
103 01 SPARE 5 18 269- 110
105 01 Modbus to DCS Remote Set Point I GV 5 18 269- 110
106 01 Remote Signals DCS 5 18 269- 110
107 01 I GV Closed to DCS 5 18 269- 110
108 01 CABLE PROFIBUS CABLE MODBUS 5 18 269- 110
sheet 3
of 108
1
7
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Modi f y
Dat e
PHASE II sheet 7
of 108

+LCP
=
40
5 18 269- 110
TYPE: SFO11
SO BLOWER
2
Pl ant :
KKK J ob No: 1. 050. 124
3
Cover Sheet
wi r i ng di agr am
Wi r i ng Di agr am
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
415L2
415L3
415L1
Compr essor
common ear t h
f or pot ent i al bondi ng pr ef use 10 A
3 x 415 V, 50 Hz
2
1
4
3
6
5
- 40Q1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Modi f y
Dat e
PHASE II
Power suppl y
415 V AC
sheet 40
of 108

+LCP
=
7
41
5 18 269- 110
6mm bl ack
6mm bl ack
max. 90mm max. 90mm
Power Suppl y, by owner
PE N L2 L3 L1
- X01
PE
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
/ 92. 1
+LCP- 92Q1: 1
/ 92. 1
+LCP- 92Q1: 3
/ 92. 1
+LCP- 92Q1: 5
8
7
10
9
- 40Q1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
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e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Power Suppl y
230 V/ 50 Hz
sheet 41
of 108

+LCP
=
40
42
5 18 269- 110
N
max. 35mm
PE
pr ef use 10 A
power suppl y, by owner
240 V 50 Hz
L
- X02
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
4mm bl ack
J acobs
Servi ce
6 A
- 41F2
Heat Exchanger
33
34
43
44
6 A
- 41F1
2
4
0
N
2
4
0
L
/
4
3
.
1
+
L
C
P
-
4
3
B
1
:
/
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3
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1
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4
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/
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4
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2
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/
4
3
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L
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4
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1
2
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L
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/
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3
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1
+
L
C
P
-
4
3
H
1
:
2
busbar
PE
+LCP
- XB
PE PE PE PE PE PE PE PE PE PE
10 A
- 42F1
Bentl y Vi brati on
Moni tor
Control Vol tage
24 V DC
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
r
e

l
i
a
b
l
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t
o
Modi f y
Dat e
PHASE II
Cont r ol Power Suppl y
sheet 42
of 108

+LCP
=
41
43
5 18 269- 110
max. 35mm
PE
For I nst r ument s & PLC,
by owner
L
- X03
N
UPS Cont r ol Power
110V AC, 50 Hz
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
P
E
P
E
1
1
0
L
1
1
0
L
1
1
0
N
1
1
0
N
P
E
P
E
P
E
P
E
P
E
P
E
P
E
P
E
P
E
4 mm Bl ack
4 mm Bl ack
6 A
- 42F2
6 A
- 42F3
/
7
1
.
1
+
L
C
P
-
7
1
A
1
/
2
:
N
/
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8
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P
-
4
8
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4
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H
1
:
P
E
J acobs
cubi cl e l amp
1 2 PE
- 43H1
P
E
M
A1
A2
240L
240N
Heat Exchanger
- 43B1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Cubi cl e Lamp, Socket
Heat Exchanger
sheet 43
of 108

+LCP
=
42
45
5 18 269- 110
pi pe for water connecti on di a. : 0, 39 " (10mm)
cooling water supply
cool i ng f l ui d: cl ean wat er
oper at i ng pr essur e: nor m. 2, 5bar
oper at i ng pr essur e: max. 10bar
( ai r t emp. di f f er ence i nsi de/ out si de of panel 10K)
( ai r t emp. di f f er ence i nsi de/ out si de of panel 10K)
f l ow r ange: 70 . . . 800 l / h
f l ow: 200 l / h = 1380Wcool i ng power
f l ow: 400 l / h = 1500Wcool i ng power
Mat er i al of const r uct i on on si de and
i sol at i on val ves by owner
I n t he case of f r ost danger
t he wat er shoul d be dr ai ned compl et el y i n or der
t o avoi d damages!
f or detai l ed i nf ormati ons: see data sheets of heat exchanger
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PE
PE
240L1
200V AC, 50 Hz
socket onl y f or
PLC pr ogr ammer
1 2 3
- 43XB1
/ 41. 3
+LCP- 41F1:
/ 41. 3
+LCP- 41F1:
/ 42. 3
+LCP- XB: PE
/ 42. 6
+LCP- XB: PE
J acobs
240N1
/ 41. 5
+LCP- 41F2:
/ 41. 5
+LCP- 41F2:
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II sheet 45
of 108

+LCP
=
43
47
5 18 269- 110
spar e
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
1
- X31
1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13
-
C
P
U
-
O
P
14 14
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
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l
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a
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t
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Modi f y
Dat e
PHASE II
Gr ound Di st r i but i on
sheet 47
of 108

+LCP
=
45
48
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PE
M
MM
M M
M
MM
M
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MM
MMMMMMM
MMMMMMMM
M
/ 42. 3
+LCP- XB: PE
/
5
3
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1
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
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t
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Modi f y
Dat e
PHASE II
Cont r ol Vol t age 1, 2
sheet 48
of 108

+LCP
=
47
49
5 18 269- 110
24 V DC
( - ) ( - )
N L
( +) ( +)
PE
DC ok
13
14
- 48G1
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
110L
110N
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4 A
24 V Out put s
- 49F1
24 V Out put s
33
34
- 49F1
2 A
24 V ext er nal
- 49F2
14
- X32
14 15 15 16 16 17 17 18 18 19 19 20 20
+24 V
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0 1 2 3 4 5
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b
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d
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Cont r ol Vol t age 3, 4
sheet 49
of 108

+LCP
=
48
50
5 18 269- 110
33
34
43
44
13
14
23
24
24 V ext er nal
13
14
- 49F2
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+
2
4
.
4
+
2
4
.
4
+
2
4
.
4
+
2
4
.
4
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4
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4
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4
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2
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4
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2
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+
2
4
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4
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+
2
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.
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4
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3
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2
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.
3
+
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3
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.
3
+
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4
.
3
+
2
4
.
3
+
2
4
.
3
+
2
4
.
3
/ 48. 8
+LCP- 48F2: 1
/ 48. 2
+LCP- X32: 4
/
1
0
5
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1
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:
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/
4
9
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2
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4
9
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6
/ 49. 6
di gi t al i nput
24 V Out put s ok
25
I 6. 3
- 60A1
/ 60. 3
di gi t al i nput
24 V ext er nal ok.
26
I 6. 4
- 60A1
/ 60. 3
J acobs
13
14
- 40Q1
32
- X33
33
- X33
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

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l
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a
b
l
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t
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Modi f y
Dat e
PHASE II
Cont r ol l i ng,
Mai n Swi t ch, Heat Exch.
sheet 50
of 108

+LCP
=
49
51
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 2
+24. 2
33
34
- 41F1
/ 48. 3
+LCP- X32: 4
/ 48. 3
+LCP- X32: 5
/ 41. 3
/ 40. 1
di gi t al i nput
mai n swi t ch on
6
I 4. 4
- 60A1
/ 60. 3
di gi t al i nput
Heat Exchanger Fan MCB
ok
7
I 4. 5
- 60A1
/ 60. 3
J acobs
I F2
9- pol . mal e
- OP
+OP
6AV6574- 2AC00- 2AA0
.
CF- Car d 16MB
MPI BUS
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
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.

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f
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Modi f y
Dat e
PHASE II
Cont r ol Equi pment s
Oper at or Panel
sheet 51
of 108

+LCP
=
50
53
5 18 269- 110
SI EMENS SI MATI C 24VDC
max. 0.9A
USB
Et her net
I F1A
I F1B
RS232
9 Pol .
RS422/ 485
MPI / PB
10/ 100 Mbi t
RS 232/ TTY
15- pol . mal e
MP270
Mul t i panel
( +) ( - ) PE
MPI
RS232
RJ 45
USB
RS232
- 51A1
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PE
/ 42. 4
+LCP- XB: PE
/ 47. 2
+LCP- X31: 2
/ 48. 1
+LCP- X32: 1
/ 53. 0
J acobs
X2 DP
X1 MP1
S7 315
- 2DP
C
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n
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P
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X1: out
X2: i n
X2: out
- 53A1
S7-
SM 331
A
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P
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T

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O
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- 54A1
S7-
SM 331
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- 55A1
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SM 331
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- 56A1
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- 57A1
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- 59A1
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- 60A1
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SM 322
- 61A1
ON
OFF
dp adr . : 2
Modbus RS- 485
PROFI BUS DP
- CPU
+CPU
RJ 45
f
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X1
M
+
2
4
V
- 53A2
0 1 2 3 4 5 6 7 8 9
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nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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t
o
Modi f y
Dat e
PHASE II
PLC Gener al Vi ew
sheet 53
of 108

+LCP
=
51
54
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PE
M
MPI BUS
+24. 1
Modb 1
/ 42. 4
+LCP- XB: PE
/ 47. 1
+LCP- X31: 1
/ 47. 2
+LCP- X31: 1
/ 48. 1
+LCP- X32: 1
/ 48. 2
+LCP- X32: 3
/ 51. 8
/ 105. 1
+LCP- 105A2: X1
/ 71. 1
+LCP- 71A1/ 10: Modb 1
J acobs
X X X X
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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f
f
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a
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a
b
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t
o
Modi f y
Dat e
PHASE II sheet 54
of 108

+LCP
=
53
55
5 18 269- 110
Anal ogue I nput s,
PLC Addr ess 256
C : act i ve i nput f r om4 wi r e t r ansmi t t er
modul e channel gr oup set t i ngs
D : passi ve i nput f r om2 wi r e t r ansmi t t er
wi t h l oop power suppl y f or t he t r ansmi t t er
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
+24. 2
/ 47. 2
+LCP- X31: 1
/ 48. 3
+LCP- X32: 4
A
B
C
D
1 2 3 4
modul
ANALOG INPUTS SM331
FOR SIMATIC S7 SYSTEMS
gear box bear i ng HS NDS
AD 01 TT - P235
gear box axi al bear i ng HS NDS
AD 01 TT - P236
gear box bear i ng HS DS
AD01 TT - P238
gear box bear i ng axi al HS DS
AD 01 TT - P239
gear box bear i ng LS NDS
AD 01 TT - P229
gear box bear i ng axi al LS NDS
AD 01 TT - P230
gear box bear i ng LS DS
AD 01 TT - P231
gear box bear i ng axi al LS DS
AD 01 TT - P233
2 I W256
3
4 I W258
5
6 I W260
7
8 I W262
9
12 I W264
13
14 I W266
15
16 I W268
17
18 I W270
19
1
L
+
1
0
C
o
m
p
+
1
1
M
a
n
a
2
0
M
- 54A1
/ 77. 2
/ 77. 6
/ 78. 2
/ 78. 6
/ 79. 2
/ 79. 6
/ 80. 2
/ 80. 6
J acobs
X X X
X
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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t
o
Modi f y
Dat e
PHASE II sheet 55
of 108

+LCP
=
54
56
5 18 269- 110
Anal ogue I nput s,
PLC Addr ess 272
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
M
+24. 2
/ 47. 2
+LCP- X31: 2
/ 47. 2
/ 47. 2
/ 48. 3
+LCP- X32: 5
A
B
C
D
1 2 3 4
modul
ANALOG INPUTS SM331
compr essor bear i ng NDS
AD 01 TT - P221
compr essor bear i ng axi al DS
AD 01 TT - P227
compr essor bear i ng DS
AD 01 TT - P225
suct i on t emper at ur e
AD 01 TT - P202
oi l t emper at ur e
AD 01 TT - P204
oi l pr essur e
AD 01 PT - P208
I GV posi t i on
KW- 01 GI C - P012
I GV posi t i on r ead out
KW- 01 GI C - P012
2 I W272
3
4 I W274
5
6 I W276
7
8 I W278
9
12 I W280
13
14 I W282
15
16 I W284
17
18 I W286
19
1
L
+
1
0
C
o
m
p
+
1
1
M
a
n
a
2
0
M
- 55A1
/ 81. 2
/ 81. 6
/ 82. 2
/ 84. 3
/ 85. 2
/ 85. 5
/ 92. 6
/ 92. 8
J acobs
X X X X
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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Modi f y
Dat e
PHASE II sheet 56
of 108
+LCP
=
55
57
5 18 269- 110
Anal ogue I nput s,
PLC Addr ess 304
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
+24. 2
/ 47. 3
+LCP- X31: 3
/ 48. 3
+LCP- X32: 5
A
B
C
D
1 2 3 4
modul
ANALOG INPUTS SM331
mai n mot or cur r ent
r emot e set poi nt I GV
2 I W288
3
4 I W290
5
6 I W292
7
8 I W294
9
12 I W296
13
14 I W298
15
16 I W300
17
18 I W302
19
1
L
+
1
0
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m
p
+
1
1
M
a
n
a
2
0
M
- 56A1
/ 69. 7
/ 105. 4
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
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A
C
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.

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Modi f y
Dat e
PHASE II sheet 57
of 108
+LCP
=
56
59
5 18 269- 110
Anal ogue Out put s,
PLC Addr ess 304
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
+24. 3
/ 47. 3
+LCP- X31: 4
/ 49. 2
+LCP- X32: 14
ANALOG OUTPUTS SM332
I GV set poi nt
GC P012
I GV f eedback t o DCS
3
OW256
6
7
OW258
10
1
L
+
2
0
M
- 57A1
/ 92. 6
/ 107. 6
J acobs
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0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

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r
e

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i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II sheet 59
of 108
+LCP
=
57
60
5 18 269- 110
Di gi t al I nput s,
PLC Addr ess 0
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 2
/ 47. 3
+LCP- X31: 4
/ 47. 3
+LCP- X31: 5
/ 48. 4
+LCP- X32: 6
DIGITAL INPUTS SM321
oi l pr essur e swi t ch L
AD 01 PSL - P209
AD 01 PSL - P210
oi l pr essur e swi t ch LL
AD 01 PSLL - P211
oi l f i l t er di f f . pr essur e
AD 01 PDSH - P203
I GV cl osed
KW- 01 GSL P012 CL
ant i sur ge
AD 01 PDSH - P212
oi l l evel L
LSL P242
oi l l evel LL
AD 01 LSLL - P242
oi l t emper at ur e l i mi t er
TSH P244
oi l t emper at ur e cont r ol
TSL P244
Mot or l ube oi l syst emAl ar m
Mot or l ube oi l syst emf aul t
emer gency st opp cont act or
EMERG STOPP
Push But t on Bl ower St ar t
PB START
Push But t on Bl ower St opp
PB STOPP
Local
LOCAL
Of f / Ser vi ce
SERVI CE
Remot e
REMOTE
Reset
PB RESET
Lampt est / Buzzer of f
TEST/ BUZZER
Push But t on Aux. Oi l Pump on
PB AUX. OI L PUMP O
Push But t on Aux. Oi l Pump of f
PB AUX. OI L PUMP O
Push But t on Oi l Heat er On
PB OI L HEATER ON
Push But t on Oi l Heat er Of f
PB OI L HEATER OFF
I l . Push But t on I nl et Gui de Vane O
I PB I GV OPEN
I l . Push But t on I nl et Gui de Vane C
I PB I GV CLOSE
Push But t on Emer g. Oi l Pump on
PB EMERG. OI L PUMP
Push But t on Emer g. Oi l Pump of f
PB EMERG. OI L PUMP
2 I 0. 0
3 I 0. 1
4 I 0. 2
5 I 0. 3
6 I 0. 4
7 I 0. 5
8 I 0. 6
9 I 0. 7
12 I 1. 0
13 I 1. 1
14 I 1. 2
15 I 1. 3
16 I 1. 4
17 I 1. 5
18 I 1. 6
19 I 1. 7
22 I 2. 0
23 I 2. 1
24 I 2. 2
25 I 2. 3
26 I 2. 4
27 I 2. 5
28 I 2. 6
29 I 2. 7
32 I 3. 0
33 I 3. 1
34 I 3. 2
35 I 3. 3
36 I 3. 4
37 I 3. 5
38 I 3. 6
39 I 3. 7
1
L
+
2
0
M
4
0
M
- 59A1
/ 86. 2
/ 86. 4
/ 86. 7
/ 87. 4
/ 92. 3
/ 91. 3
/ 88. 3
/ 88. 5
/ 89. 7
/ 89. 4
/ 102. 6
/ 103. 6
/ 68. 5
/ 63. 2
/ 63. 4
/ 67. 6
/ 67. 8
/ 67. 4
/ 68. 8
/ 67. 2
/ 64. 2
/ 64. 4
/ 65. 2
/ 65. 4
/ 65. 6
/ 65. 8
/ 64. 6
/ 64. 8
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
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r
s

a
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e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II sheet 60
of 108
+LCP
=
59
61
5 18 269- 110
Di gi t al I nput s,
PLC Addr ess 4
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 2
/ 47. 4
+LCP- X31: 5
/ 47. 4
+LCP- X31: 6
/ 48. 4
+LCP- X32: 6
DIGITAL INPUTS SM321
Remot e St ar t
Remot e St op
no pr ocess i nt er l ock i n l ocal mod
vi br at i on moni t or ok.
mai n swi t ch on
Heat Exchanger Fan MCB ok
mai n mot or r unni ng
mai n mot or f aul t
aux. oi l pump r unni ng
aux. oi l pump f aul t
oi l heat er on
oi l heat er f aul t
emer g. oi l pump r unni ng
emer g. oi l pump f aul t
spar e
spar e
I GV MCB ok.
24 V Out put s ok
24 V ext er nal ok.
wi ndi ng t emper at ur e ok.
mot or bear i ng t emper at ur e ok.
vi br at i on al ar m
vi br at i on t r i p
axi al di spl acement al ar m
axi al di spl acement t r i p
2 I 4. 0
3 I 4. 1
4 I 4. 2
5 I 4. 3
6 I 4. 4
7 I 4. 5
8 I 4. 6
9 I 4. 7
12 I 5. 0
13 I 5. 1
14 I 5. 2
15 I 5. 3
16 I 5. 4
17 I 5. 5
18 I 5. 6
19 I 5. 7
22 I 6. 0
23 I 6. 1
24 I 6. 2
25 I 6. 3
26 I 6. 4
27 I 6. 5
28 I 6. 6
29 I 6. 7
32 I 7. 0
33 I 7. 1
34 I 7. 2
35 I 7. 3
36 I 7. 4
37 I 7. 5
38 I 7. 6
39 I 7. 7
1
L
+
2
0
M
4
0
M
- 60A1
/ 106. 3
/ 106. 5
/ 106. 7
/ 72. 3
/ 50. 2
/ 50. 4
/ 100. 6
/ 100. 3
/ 96. 6
/ 96. 3
/ 94. 5
/ 94. 3
/ 97. 6
/ 97. 3
/ 92. 5
/ 49. 2
/ 49. 6
/ 99. 6
/ 99. 3
/ 76. 2
/ 76. 4
/ 76. 6
/ 76. 8
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II sheet 61
of 108
+LCP
=
60
63
5 18 269- 110
Di gi t al Out put s,
PLC Addr ess 0
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
M
M
+24. 2
+24. 2
+24. 3
+24. 3
/ 47. 4
+LCP- X31: 6
/ 47. 5
+LCP- X31: 7
/ 47. 5
+LCP- X31: 7
/ 47. 5
+LCP- X31: 8
/ 48. 4
+LCP- X32: 7
/ 48. 4
+LCP- X32: 7
/ 49. 2
+LCP- X32: 15
/ 49. 3
+LCP- X32: 15
DIGITAL OUTPUTS SM322
I ndi cat or Li ght Bl ower Runni ng
I L RUNNI NG
I ndi cat or Li ght Bl ower Ready t o S
I L READY TO START
I ndi cat or Li ght Al ar m
I L ALARM
I ndi cat or Li ght Auxi l i ar y Oi l Pum
I L AUX. OI L PUMP
I ndi cat or Li ght Oi l Heat er
I L OI L HEATER
I ndi cat or Li ght I GV open
I L I GV OPEN
I ndi cat or Li ght I GV cl osed
I L I GV CLOSED
Buzzer Al ar m
BUZZER
I ndi cat or Li ght Emer g. Oi l Pump on
I L EMERG. OI L PUMP
aux. oi l pump st ar t
mai n mot or per mi ssi ve
PERM
mai n mot or st ar t
START
spar e
oi l heat er ON
I GV cl osed t o DCS
emer g. oi l pump st ar t
Spar e
Spar e
vi br at i on moni t or syst emr eset
SYS RESET
vi br at i on moni t or t r i p mul t i pl y
2 O0. 0
3 O0. 1
4 O0. 2
5 O0. 3
6 O0. 4
7 O0. 5
8 O0. 6
9 O0. 7
12 O1. 0
13 O1. 1
14 O1. 2
15 O1. 3
16 O1. 4
17 O1. 5
18 O1. 6
19 O1. 7
22 O2. 0
23 O2. 1
24 O2. 2
25 O2. 3
26 O2. 4
27 O2. 5
28 O2. 6
29 O2. 7
32 O3. 0
33 O3. 1
34 O3. 2
35 O3. 3
36 O3. 4
37 O3. 5
38 O3. 6
39 O3. 7
1
1
L
+
1
0
1
M
1
1
2
L
+
2
0
2
M
2
1
3
L
+
3
0
3
M
3
1
4
L
+
4
0
4
M
- 61A1
/ 63. 2
/ 63. 6
/ 63. 8
/ 64. 2
/ 65. 2
/ 65. 6
/ 65. 8
/ 67. 2
/ 64. 6
/ 98. 2
/ 101. 2
/ 101. 6
/ 95. 2
/ 107. 2
/ 98. 6
/ 102. 2
/ 103. 2
/ 72. 8
/ 72. 6
J acobs
1
- X33
3
- X33
4 6
21
- X33
22 23
2
- X33
GN
<B1>
READY
TO START
X1
X2
- 63H3
5
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
pr ep.
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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Modi f y
Dat e
PHASE II
sheet 63
of 108

+LCP
=
61
64
5 18 269- 110
13
14
23
24
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+2101
M2101
+24. 2
RESET
<C2>
YE
13
14
- 63S4
MAI N DI VE
OFF
RD
<A3>
21
22
- 63S2
GN MAI N DRI VE
ON
gr uen
13
14
- 63S1
MAI N DRI VE
<A1>
GN
X1
X2
- 63H1
RD ALARM
<C1>
X1
X2
- 63H4
A1
A2
- 63K1
/ 47. 2
+LCP- X31: 2
/ 47. 2
+LCP- X31: 3
/ 48. 8
+LCP- X32: 13
/ 64. 1
+LCP- 64S1: 13
/ 64. 1
+LCP- 64H1: X2
/
6
8
.
2
/
6
8
.
8 di gi t al i nput
Push But t on Bl ower
St ar t
PB START
22
I 2. 0
- 59A1
/ 59. 2
di gi t al i nput
Push But t on Bl ower
St opp
PB STOPP
23
I 2. 1
- 59A1
/ 59. 2
di gi t al out put
I ndi cat or Li ght Bl ower
Runni ng
I L RUNNI NG
2
O0. 0
- 61A1
/ 61. 2
di gi t al out put
I ndi cat or Li ght Al ar m
I L ALARM
4
O0. 2
- 61A1
/ 61. 2
di gi t al out put
I ndi cat or Li ght Bl ower
Ready t o St ar t
I L READY TO START
3
O0. 1
- 61A1
/ 61. 2
J acobs
7
- X33
8 9 10
24
- X33
25
AUX. OI L
PUMP ON
<D2>
GN
13
14
- 64S1
AUX. OI L
PUMP OFF
<D3>
RD
21
22
- 64S2
<E2>
EMERG. OI L
PUMP ON
GN
13
14
- 64S3
EMERG. OI L
PUMP OFF
<E3>
RD
21
22
- 64S4
GN
<E1>
EMERG. OI L
PUMP
X1
X2
- 64H3
GN
<D1>
AUX. OI L
PUMP
X1
X2
- 64H1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
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b
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t
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Modi f y
Dat e
PHASE II
sheet 64
of 108

+LCP
=
63
65
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M2101
+2101 +2101
M2101
/ 63. 9
+LCP- 63S4: 13
/ 63. 9
+LCP- 63H4: X2
/ 65. 1
+LCP- 65H1: X2
/ 65. 1
+LCP- 65S1: 13
di gi t al i nput
Push But t on Aux. Oi l
Pump on
PB AUX. OI L PUMP ON
32
I 3. 0
- 59A1
/ 59. 2
di gi t al i nput
Push But t on Aux. Oi l
Pump of f
PB AUX. OI L PUMP OFF
33
I 3. 1
- 59A1
/ 59. 2
di gi t al i nput
Push But t on Emer g. Oi l
Pump on
PB EMERG. OI L PUMP
38
I 3. 6
- 59A1
/ 59. 2
di gi t al i nput
Push But t on Emer g. Oi l
Pump of f
PB EMERG. OI L PUMP
39
I 3. 7
- 59A1
/ 59. 2
di gi t al out put
I ndi cat or Li ght
Auxi l i ar y Oi l Pump
I L AUX. OI L PUMP
5
O0. 3
- 61A1
/ 61. 2
di gi t al out put
I ndi cat or Li ght
Emer g. Oi l Pump on
I L EMERG. OI L PUMP
12
O1. 0
- 61A1
/ 61. 2
J acobs
11
- X33
12 13 14
26
- X33
27 28
GN OI L HEATER
ON
<F2>
13
14
- 65S1
RD
<F3>
OI L HEATER
OFF
21
22
- 65S2
<G1>
I NLET GUI DE VANE
OPEN
13
14
- 65S3
<G2>
I NLET GUI DE VANE
CLOSED
13
14
- 65S4
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
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f
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n
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r
s

a
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b
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e

t
o
Modi f y
Dat e
PHASE II
sheet 65
of 108

+LCP
=
64
67
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M2101 M2101
+2101 +2101
/ 64. 9
+LCP- 64H3: X2
/ 64. 9
+LCP- 64S4: 21
/ 67. 1
+LCP- 67S1: 13
/ 67. 1
+LCP- 67H1:
di gi t al i nput
Push But t on Oi l Heat er
On
PB OI L HEATER ON
34
I 3. 2
- 59A1
/ 59. 2
di gi t al i nput
Push But t on Oi l Heat er
Of f
PB OI L HEATER OFF
35
I 3. 3
- 59A1
/ 59. 2
di gi t al i nput
I l . Push But t on I nl et
Gui de Vane Open
I PB I GV OPEN
36
I 3. 4
- 59A1
/ 59. 2
di gi t al i nput
I l . Push But t on I nl et
Gui de Vane Cl ose
I PB I GV CLOSE
37
I 3. 5
- 59A1
/ 59. 2
di gi t al out put
I ndi cat or Li ght Oi l
Heat er
I L OI L HEATER
6
O0. 4
- 61A1
/ 61. 2
di gi t al out put
I ndi cat or Li ght I GV
open
I L I GV OPEN
7
O0. 5
- 61A1
/ 61. 2
di gi t al out put
I ndi cat or Li ght I GV
cl osed
I L I GV CLOSED
8
O0. 6
- 61A1
/ 61. 2
J acobs
GN
<F1>
OI L HEATER
X1
X2
- 65H1
I GV opened
<G1>
X1
X2
- 65H3
<G2>
I GV cl osed
X1
X2
- 65H3
15
- X33
16 17 18
29
- X33
LAMPTEST
BUZZER OFF
BK
<H2>
13
14
- 67S1
ALARM
<H1>
- 67H1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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f
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s

a
r
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l
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a
b
l
e

t
o
Modi f y
Dat e
PHASE II
sheet 67
of 108

+LCP
=
65
68
5 18 269- 110
13/ 14 21/ 22 31/ 32 43/ 44
I
O
I I
I - O-I I
<B3>
I - REMOTE
0- LOCAL
I I - SERVI CE
13
14 22
21 31 43
32 44
- 67S2
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M2101
+2101
/ 65. 9
+LCP- 65S4: 13
/ 65. 8
+LCP- 65H3: X2
di gi t al i nput
Lampt est / Buzzer of f
TEST/ BUZZER
29
I 2. 7
- 59A1
/ 59. 2
di gi t al i nput
Remot e
REMOTE
27
I 2. 5
- 59A1
/ 59. 2
di gi t al i nput
Local
LOCAL
25
I 2. 3
- 59A1
/ 59. 2
di gi t al i nput
Of f / Ser vi ce
SERVI CE
26
I 2. 4
- 59A1
/ 59. 2
di gi t al out put
Buzzer Al ar m
BUZZER
9
O0. 7
- 61A1
/ 61. 2
J acobs
PNOZ X2. 8P
A1 S11S12S21S52
A2 S11S12 S22S34
- 68K1
<H1>
EMERGENCY
21
22
- 68S1
13
14
- 63K1
41
42
- 68K1
23
24
- 63K1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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a
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b
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t
o
Modi f y
Dat e
PHASE II
Emer gency St op
sheet 68
of 108

+LCP
=
67
69
5 18 269- 110
14
34
42
13
41
33
24 23
23
24
t o MJ B
Emer gency st op r el eased
cont act cl osed means none ESD
cont act open means ESD
19
- X33
20
- X33
42 41
- X90
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
+24. 4
+24. 2
+24. 2
/ 47. 3
+LCP- X31: 3
/ 48. 3
+LCP- X32: 5
/ 48. 4
+LCP- X32: 6
/ 49. 7
+LCP- X32: 18
/ 63. 8
/ 68. 2 / 63. 8
/ 101. 3
/ 68. 5
/ 68. 4
di gi t al i nput
emer gency st opp
cont act or
EMERG STOPP
19
I 1. 7
- 59A1
/ 59. 2
di gi t al i nput
Reset
PB RESET
28
I 2. 6
- 59A1
/ 59. 2
J acobs
A
MAI N MOTOR
CURRENT
0. . . 200 A
Range: 4. . 20mA
( - )
( +)
- 69P1
4. . . 20 mA
Range: 0. . . 200 A
I n= 171 A
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
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nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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a
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t
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Modi f y
Dat e
PHASE II
Mot or Cur r ent
Mai n Mot or
sheet 69
of 108

+LCP
=
68
71
5 18 269- 110
30
- X33
31
40 SH
2 1
- X
39
- X90
+MJ B_211
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
+24. 3
UB+
UB-
Input +
I I
I
+ +
4 6
9 7
10
11
1 3
- 69A1
/ 47. 5
+LCP- X31: 8
/ 49. 2
+LCP- X32: 15
M-
anal og i nput
MI +
mai n mot or cur r ent
2
I W288
3
- 56A1 / 56. 2
J acobs
N
1L
N
1L
- 71A1/ 2
N
1L
N
1L
- 71A1/ 1
.
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3
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0
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2
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0
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- 71A1/ 3
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5
0
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1
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4

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b
i
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d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
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l
i
a
b
l
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t
o
Modi f y
Dat e
PHASE II
Vi br at i on Moni t or s,
Gener al Vi ew
sheet 71
of 108
+LCP
=
69
72
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
110L
110N
Modb 1
/ 42. 5
+LCP- 42F2:
/ 53. 8
+LCP- 53A2: ???
/ 72. 1 / 74. 1 / 73. 1 / 75. 1 / 76. 1
/ 76. 3
/ 76. 6
/ 76. 8
J acobs
Rack Interface Module
3500/20
HOST Rack SYSTEM CONTACTS OK Rel ay Conf i g. Por t
RS- 232
1 2 34 5 6 7 8 9
N
C
A
R
M
N
O
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
C
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- 71A1/ 3
t r i p mul t i pl y
13
14
- 72K1
syst emr eset
13
14
- 72K2
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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f
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e

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b
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o
Modi f y
Dat e
PHASE II
Vi br at i on Moni t or
Rack I nt er f ace
sheet 72
of 108

+LCP
=
71
73
5 18 269- 110
13
14
13
14
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 2
t r i p mul t i pl y
A1
A2
- 72K1
syst emr eset
vi br at i on moni t or i ng
A1
A2
- 72K2
/ 47. 3
+LCP- X31: 4
/ 47. 3
+LCP- X31: 4
/ 48. 4
+LCP- X32: 6
/ 72. 6 / 72. 8
/
7
2
.
7
/
7
2
.
6
/ 71. 2
di gi t al i nput
vi br at i on moni t or ok.
5
I 4. 3
- 60A1
/ 60. 3
di gi t al out put
vi br at i on moni t or t r i p
mul t i pl y
33
O3. 1
- 61A1
/ 61. 2
di gi t al out put
vi br at i on moni t or
syst emr eset
SYS RESET
32
O3. 0
- 61A1
/ 61. 2
J acobs
3500/40
Vibration Monitor
P
W
R
/
B
C
O
M
S
I
G
/
A
C
h
1
S
I
G
/
A
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h
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P
W
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/
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D
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/
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h
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/
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O
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h
3
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H
L
D
+LCP
- 71A1/ 4
AD 01
XE P219
AD 01
XE P220
AD 01
XE P222
AD 01
XE P224
+J B1
2 3 5 6 7 8 9 10 11 12
1
- X40
2 3 4 5 6 7 8 9 10 11 12
1WH 12x3x0, 5 mm BU
- W_J B1
RD BU 2WHRD BU 3WHRD BU 4WHRD BU
1
+LCP
- X40
4
SH SH SH SH
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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r
s

a
r
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b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Vi br at i on Moni t or 1,
Vi br at i ons
sheet 73
of 108

=
72
74
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PROXIMITOR
Pos. 64. 4
-
V
O
U
T
C
O
M
AD 01
XT P224
PROXIMITOR
Pos. 64. 3
-
V
O
U
T
C
O
M
AD 01
XT P222
PROXIMITOR
Pos. 64. 2
-
V
O
U
T
C
O
M
AD 01
XT P220
PROXIMITOR
Pos. 64. 1
-
V
O
U
T
C
O
M
AD 01
XT P219
/ 71. 3
J acobs
3500/40
Vibration Monitor
P
W
R
/
B
C
O
M
S
I
G
/
A
C
h
1
S
I
G
/
A
C
h
2
C
O
M
P
W
R
/
B
S
H
L
D
S
H
L
D
P
W
R
/
B
C
O
M
S
I
G
/
A
C
h
4
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H
L
D
P
W
R
/
B
C
O
M
S
I
G
/
A
C
h
3
S
H
L
D
+LCP
- 71A1/ 5
AD 01
YE P223
AD 01
YE P226
+J B1
20 21 22 23 24 25 26 27 28
20 21 22 23 24 25 26 27 28
RD BU 6WHRD BU 5WH 12x3x0, 5 mm BU
- W_J B1
19
+LCP
- X40
19
- X40
SH SH SH
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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d
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Vi br at i on Moni t or 2
Axi al Di sp.
sheet 74
of 108

=
73
75
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
PROXIMITOR
axi al di spl acement
compr essor shaf t
Pos. 65. 2
-
V
O
U
T
C
O
M
AD 01
YT P226
PROXIMITOR
compr essor shaf t
Pos. 65. 1
-
V
O
U
T
C
O
M
AD 01
YT P223
/ 71. 3
J acobs
+J B1
W
H
B
N
G
N
W
H
B
N
G
N
13
+LCP
- X40
14 15 16 17 18
SH SH
13
- X40
14 15 16 17 18
WH 12x3x0, 5 mm BU
- W_J B1
BU LBU WH BU LBU
W
H
B
K
W
H
B
K
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II sheet 75
of 108

=
74
76
5 18 269- 110
3500/42
Vibration/ Seismic Monitor
P
W
R
S
I
G
/
A
S
I
G
/
B
C
h
1
S
I
G
/
B
C
h
2
S
I
G
/
A
P
W
R
S
H
L
D
S
H
L
D
P
W
R
S
I
G
/
A
S
I
G
/
B
C
h
4
S
H
L
D
P
W
R
S
I
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/
A
S
I
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/
B
C
h
3
S
H
L
D
+LCP
- 71A1/ 6
Sei smi c Moni t or
Vi br at i ons Mot or Bear .
Pr obe 1 Pr obe 2
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
VELOMITOR
Pos. 64. 6
mot or bear i ng DE Pr obe 2
AB
300500
AD 01
XT P241
VELOMITOR
Pos. 64. 5
mot or bear i ng DE Pr obe 1
AB
300500
AD 01
XT P240
/ 71. 4
J acobs
Channel 1
Rel ay Mode NE
N
C
C
O
M
N
O
r el ai s modul
4 channel s
- 71A1/ 8
Channel 2
Rel ay Mode NE
N
C
C
O
M
N
O
r el ai s modul
4 channel s
- 71A1/ 8
Channel 3
Rel ay Mode NE
N
C
C
O
M
N
O
r el ai s modul
4 channel s
- 71A1/ 8
Channel 4
Rel ay Mode NE
N
C
C
O
M
N
O
r el ai s modul
4 channel s
- 71A1/ 8
Rel ay Mode NE Rel ay Mode NE Rel ay Mode NE Rel ay Mode NE
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
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t
o
Modi f y
Dat e
PHASE II
Vi br at i on Moni t or s,
Rel ai s Modul e
sheet 76
of 108

+LCP
=
75
77
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 2
/ 48. 5
+LCP- X32: 8
/ 71. 5 / 71. 5 / 71. 5 / 71. 5
di gi t al i nput
vi br at i on al ar m
36
I 7. 4
- 60A1
/ 60. 3
di gi t al i nput
vi br at i on t r i p
37
I 7. 5
- 60A1
/ 60. 3
di gi t al i nput
al ar m
38
I 7. 6
- 60A1
/ 60. 3
di gi t al i nput
axi al di spl acement t r i p
39
I 7. 7
- 60A1
/ 60. 3
J acobs
gear box axi al HS NDS
Pos. 53. 3. 2
RD RD
TE P236
BN BN
gear box
+J B4
+J B2
1
- X11
2 3 4 5
- X11
6 7 8
1
+J B4
- X
2 3 4
101102103104
5 6 7 8
105106107108
gear box HS NDS
Pos. 53. 3. 1
RD RD
TE P235
BN BN
2 3 4 5 6 1
25x0, 75mm
- W- 53. 3- 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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n
d
e
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s

a
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e

l
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a
b
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t
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Bear i ng Temper at ur e
Gear Box
sheet 77
of 108

=
76
78
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M-
anal og i nput
MI +
AD 01 TT - P235
2
I W256
3
- 54A1 / 54. 2
M-
anal og i nput
MI +
gear box axi al bear i ng
HS NDS
AD 01 TT - P236
4
I W258
5
- 54A1 / 54. 2
J acobs
2 3 4
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P235
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P236
1
+LCP
- X10 2 3
+LCP
- X10
4
SH SH
1 25x0, 75mm
- W_J B2
2 3 4
1
- X10
gear box HS DS
Pos. 53. 3. 3
RD RD
TE P238
BN BN
gear box axi al HS DS
Pos. 53. 3. 4
RD RD
TE P239
BN BN
+J B4
gear box
+J B2
9
- X11
10 11 12 13
- X11
14 15 16
9
+J B4
- X
10 11 12
109110111112
13 14 15 16
113114115116
8 9 10 11 12 7 25x0, 75mm
- W- 53. 3- 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
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t
y

b
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A
C
C
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b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Gear Box
sheet 78
of 108

=
77
79
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M-
anal og i nput
MI +
AD01 TT - P238
6
I W260
7
- 54A1 / 54. 2
M-
anal og i nput
MI +
gear box bear i ng axi al
HS DS
AD 01 TT - P239
8
I W262
9
- 54A1 / 54. 2
J acobs
5
+LCP
- X10
6 7
+LCP
- X10 8
SH SH
5
25x0, 75mm
- W_J B2
6 7 8
6 7 8
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P238
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P239
5
- X10
gear box LS NDS
Pos. 53. 3. 5
RD RD
TE P229
BN BN
gear box axi al LS NDS
Pos. 53. 3. 6
RD RD
TE P230
BN BN
gear box
+J B4
+J B2
17
- X11
18 19 20 21
- X11
22 23 24
17
+J B4
- X
18 19 20
117118119120
21 22 23 24
121122123124
14 15 16 17 18 13 25x0, 75mm
- W- 53. 3- 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
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A
C
C
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f
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b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Gear Box
sheet 79
of 108

=
78
80
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M-
anal og i nput
MI +
AD 01 TT - P229
12
I W264
13
- 54A1 / 54. 2
M-
anal og i nput
MI +
LS NDS
AD 01 TT - P230
14
I W266
15
- 54A1 / 54. 2
J acobs
9
+LCP
- X10
10 11
+LCP
- X10
12
SH SH
9 25x0, 75mm
- W_J B2
10 11 12
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P229
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P230
10 11 12 9
- X10
BN BN
gear box axi al LS DS
Pos. 53. 3. 8
RD RD
TE P233
BN BN
gear box
+J B4
+J B2
25
- X11
26 27 28 29
- X11
30 31 32
25
+J B4
- X
26 27 28
125126127128
29 30 31 32
129130131132
gear box LS DS
Pos. 53. 3. 7
RD RD
TE P231
19 25x0, 75mm
- W- 53. 3- 1
20 21 22 23 24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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f
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b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Compr essor
sheet 80
of 108

=
79
81
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M-
anal og i nput
MI +
LS DS
AD 01 TT - P233
18
I W270
19
- 54A1 / 54. 2
M-
anal og i nput
MI +
AD 01 TT - P231
16
I W268
17
- 54A1 / 54. 2
J acobs
13
+LCP
- X10
14 15
+LCP
- X10 16
SH SH
13 25x0, 75mm
- W_J B2
14 15 16
14 15 16
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P231
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P233
13
- X10
Pos. 53. 1. 1
RD RD WH
TE P221
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Pos. 53. 1. 3
RD RD WH
TE P227
RD RD WH
+J B5
+J B2
+J B5
33
- X11
34 35 36 37 38 39 40
1
- X
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A R B C T D E V F G X H
1 25x0, 75mm
- W- 53. 1
2 3 4 5 6
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
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s
s

a
u
t
h
o
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t
y

b
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A
C
C
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Compr essor
sheet 81
of 108

=
80
82
5 18 269- 110
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
17
+LCP
- X10
18 19
+LCP
- X10
20
SH
17 25x0, 75mm
- W_J B2
18 19 20
SH
M-
anal og i nput
MI +
AD 01 TT - P221
2
I W272
3
- 55A1 / 55. 2
M-
anal og i nput
MI +
compr essor bear i ng
axi al DS
AD 01 TT - P227
4
I W274
5
- 55A1 / 55. 2
18 19 20
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P221
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P227
17
- X10
Pos. 53. 1. 5
RD RD WH
TE P225
RD RD WH
WH
+J B5 +J B5
+J B2
41
- X11
42 43 44
17
+J B5
- X
18 19 20 21 22 23 24 SH
J Z K L N M
7 25x0, 75mm
- W- 53. 1
8 9
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
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s
s

a
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b
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Temper at ur e Com-
pr essor Bear i ng DS
sheet 82
of 108

=
5 18 269- 110
81
84
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
21
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- X10
22
SH
21
25x0, 75mm
- W_J B2
22
M-
anal og i nput
MI +
AD 01 TT - P225
6
I W276
7
- 55A1 / 55. 2
22
4. . . 20 mA
Pt 100
0. . . 150 C
(
+
)
(
-
)
2341
AD 01
TT P225
21
- X10
Pos. 53. 2
TE P202
+J B2
45
- X11
46 47 48
2 2 2
1 4x1, 5mm
- W- 53. 2
2 3
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
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s
s

a
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b
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
TE P202
Suct i on Temper at ur e
sheet 84
of 108

=
5 18 269- 110
82
85
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
23
+LCP
- X10
24
23
25x0, 75mm
- W_J B2
24
SH
M-
anal og i nput
MI +
AD 01 TT - P202
8
I W278
9
- 55A1 / 55. 2
24
4. . . 20 mA
Pt 100
0. . . 150 C
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+
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(
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2341
AD 01
TT P202
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26
27
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28
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1 5x0, 75mm
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2 3 4
46
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47 48 50
1
5x1, 5mm
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2 3 4 PE
PE PE
41
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Pos. 41. 1
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PT P208
49
1
5x1, 5mm
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2 3 4 PE
42 43 44 45 SH SH
Range
0...+150 C
Range
0...3 bar
0 1 2 3 4 5 6 7 8 9
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b
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d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
TE P204/ PT P208
Oi l Temp. / Pr ess.
sheet 85
of 108

=
5 18 269- 110
84
86
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
Pos. 51. 2
TE/ TT P204
M-
anal og i nput
MI +
AD 01 TT - P204
12
I W280
13
- 55A1 / 55. 2
M-
anal og i nput
MI +
oi l pr essur e
AD 01 PT - P208
14
I W282
15
- 55A1 / 55. 2
J acobs
P
oi l pr essur e l ow
Pos. 41. 2
N
C
C
O
M
N
O
PSL P209
P
Pos. 41. 3
N
C
C
O
M
N
O
PSL P210
P
Pos. 41. 4
N
C
C
O
M
N
O
PSLL P211
Setting Value
<1,2 kg/cm
Setting Value
<0,8 kg/cm
PE
+J B3
PE PE
Setting Value
>2,0 kg/cm
1
+LCP
- X20
2 3 4 5 6
SH
1
25x0, 75mm
- W_J B3- 2
2 3 4 5 6
6
- X1
8 7 9 10 12 11 13 14 16 15 17
1 4x1, 5mm
- W2
3 2 PE 1 4x1, 5mm
- W3
3 2 PE PE 1 4x1, 5mm
- W4
2 3
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
PSL/ PSLL P209- 211
Oi l Pr essur e
sheet 86
of 108

=
5 18 269- 110
85
87
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4 +24. 4
/ 49. 6
+LCP- X32: 17
/ 87. 1
+LCP- X20: 7
di gi t al i nput
AD 01 PSL - P209
2
I 0. 0
- 59A1
/ 59. 2
di gi t al i nput
AD 01 PSL - P210
3
I 0. 1
- 59A1
/ 59. 2
di gi t al i nput
oi l pr essur e swi t ch LL
AD 01 PSLL - P211
4
I 0. 2
- 59A1
/ 59. 2
J acobs
+J B3
G
N
D .
3 2 4 1 5x0, 75mm
- W5
22 21
PE
8 9 7 25x0, 75mm
- W_J B3- 2
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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n
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s

a
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e

l
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a
b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II sheet 87
of 108

=
5 18 269- 110
86
88
PDI SH P203
Oi l Fi l t er Di f f . Pr ess.
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
7
+LCP
- X20
8 9
SH
20 18
- X1
19
PE
PD
oi l f i l t er di f f . pr essur e hi gh
Pos. 42. 1
N
C
C
O
M
N
O
PDI SH P203
+24. 4 +24. 4
/ 47. 3
+LCP- X31: 5
/ 86. 9
+LCP- X20: 5
/ 88. 1
+LCP- X20: 10
di gi t al i nput
oi l f i l t er
di f f . pr essur e
AD 01 PDSH - P203
5
I 0. 3
- 59A1
/ 59. 2
J acobs
+J B3
PE
L
oi l l evel l ow
Pos. 59
YE GN BN
LSL P242
L
oi l l evel l ow l ow
Pos. 59
YE WH RT
LSLL P242
5 7x1, 5mm
- W6
4 6 3 2 1 PE
27
- X1
26 28 25
- X1
24 23 29
10
+LCP
- X20
12
SH
10 25x0, 75mm
- W_J B3- 2
12
11
11
13
13
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
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b
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e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
LSL/ LSLL P242
Oi l Level Tank
sheet 88
of 108

=
5 18 269- 110
87
89
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4 +24. 4
/ 87. 9
+LCP- X20: 7
/ 89. 1
+LCP- X20: 14
di gi t al i nput
oi l l evel L
LSL P242
9
I 0. 7
- 59A1
/ 59. 2
di gi t al i nput
oi l l evel LL
AD 01 LSLL - P242
12
I 1. 0
- 59A1
/ 59. 2
J acobs
Oi l Heat er
Setting Value
>60 C
Pos. 51. 1
3 4
TSL P244
Pos. 51. 1
1 2
TSH P244
SH
+J B3
3
- X1
4 1 2 5
PE
4 1 2 PE 3
5x1, 5mm
- W1
14
+LCP
- X20
15 16 17
17 16 15 14 25x0, 75mm
- W_J B3- 2
13
14
+LCP
- 89K1
A1
A2
+LCP
- 89K2
13
14
+LCP
- 89K2
Setting Value
<20 C
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
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a
b
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II sheet 89
of 108

=
5 18 269- 110
88
90
13
14
23
24
A1
A2
- 89K1
13
14
TSLH P244
Oi l Heat er Cont r ol
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 4 +24. 4
+24. 2
+24. 2
/ 47. 4
+LCP- X31: 5
/ 47. 4
+LCP- X31: 6
/ 48. 5
+LCP- X32: 8
/ 48. 5
+LCP- X32: 9
/ 88. 9
+LCP- X20: 12
/ 91. 1
+LCP- X20: 18
/ 89. 4 / 89. 7
/
8
9
.
7
/
9
5
.
3
/
8
9
.
4
di gi t al i nput
TSL P244
14
I 1. 2
- 59A1
/ 59. 2
di gi t al i nput
TSH P244
13
I 1. 1
- 59A1
/ 59. 2
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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n
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chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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f
f
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s

a
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e

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b
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t
o
Modi f y
Dat e
PHASE II
SPARE
sheet 90
of 108

+LCP
=
5 18 269- 110
89
91
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
2
SH
1
2x1, 5mm
- W- 12
18
+LCP
- X20
19
>80 mbar
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
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i
t
y

b
y

A
C
C
.

O
f
f
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s

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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II sheet 91
of 108

=
5 18 269- 110
90
92
PDSH P201
Ant i Sur ge
Pos. 12
dP
Ant i Sur ge
3 4
PDSH P201
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4 +24. 4
/ 89. 9
+LCP- X20: 16
/ 92. 1
+LCP- X20: 20
di gi t al i nput
ant i sur ge
AD 01 PDSH - P212
8
I 0. 6
- 59A1
/ 59. 2
J acobs
I >I >I >
0, 9- 1, 25 A
1, 0 A
1 3 5
2 4 6
+LCP
- 92Q1
13
14
+LCP
- 92Q1
415L1
415L2
415L3
4. . 20 mA
U
set poi nt
Pos. 61. 1
( +)
2
( - )
3
GC P012
4. . 20 mA
U
posi t i on
( +)
24
( - )
23
GC P012
3
M
I nl et Gui de Vane
Pos. 6. 2
U V W PE
KW- 01
1 4x2, 5mm
- W- 6. 2
2 3 PE
+LCP
- X05
PE 20
+LCP
- X20
21
( +)
29
+LCP
- X10
30 31 32
SH
SH
11 12
1
2x1, 5mm
- W- 60. 1
2 BU 5x0, 75mm
- W- 61. 1
WH BU WH
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
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r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
I nl et Gui de Vane
sheet 92
of 108

=
5 18 269- 110
91
94
13
14
23
24
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
L
I GV cl osed
Pos. 60. 1
GSL P012
+24. 4
M
+24. 2
/ 40. 9
+LCP- 40Q1: 2
/ 40. 9
+LCP- 40Q1: 4
/ 40. 9
+LCP- 40Q1: 6
/ 47. 4
+LCP- X31: 6
/ 48. 4
+LCP- X32: 7
/ 91. 9
+LCP- X20: 18
/ 92. 1
/
9
2
.
5
di gi t al i nput
I GV cl osed
KW- 01 GSL P012 CLOSE
7
I 0. 5
- 59A1
/ 59. 2
di gi t al i nput
I GV MCB ok.
24
I 6. 2
- 60A1
/ 60. 3
M-
anal og i nput
MI +
I GV posi t i on
KW- 01 GI C - P012
16
I W284
17
- 55A1 / 55. 2
M-
anal og i nput
MI +
I GV posi t i on r ead out
KW- 01 GI C - P012
18
I W286
19
- 55A1
/ 55. 2
QI MANA
anal og out put
I GV set poi nt
GC P012
3
OW256
6
- 57A1
/ 57. 3
J acobs
13
14
- 94K1
A1
A2
- 94K1
13
14
- 94K2
A1
A2
- 94K2
630 mA
1
- X90
13
100 mA 2
14
cl osed = on
oi l heat er
r unni ng
3
- X
4 5 6
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Oi l Heat er
no Er r or / Runni ng
sheet 94
of 108

+LCP
=
5 18 269- 110
92
95
13
14
13
14
cl osed = heal t hy
+MJ B_211
oi l heat er
MCB Faul t
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 4 +24. 4
+24. 2
+24. 2
/ 47. 5
+LCP- X31: 7
/ 47. 5
+LCP- X31: 7
/ 48. 5
+LCP- X32: 9
/ 48. 6
+LCP- X32: 10
/ 49. 7
+LCP- X32: 18
/ 96. 1
+LCP- X90: 3
/ 94. 3 / 94. 5
/
9
4
.
3
/
9
4
.
5
di gi t al i nput
oi l heat er on
16
I 5. 4
- 60A1
/ 60. 3
di gi t al i nput
oi l heat er f aul t
17
I 5. 5
- 60A1
/ 60. 3
J acobs
A1
A2
- 95K1
oi l heat er ON
13
14
- 95K1
oi l heat er
ON ( St ar t )
23
24
- 89K2
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Oi l Heat er ON
sheet 95
of 108

+LCP
=
5 18 269- 110
94
96
13
14
110VAC
1, 5mm or ange
110VAC !
7
- X
8
2
630 mA 1
- X91
+MJ B_211
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
/ 47. 5
+LCP- X31: 8
/ 95. 2
/ 89. 7
/
9
5
.
3
di gi t al out put
oi l heat er ON
17
O1. 5
- 61A1
/ 61. 2
J acobs
13
14
- 96K1
13
14
- 96K2
100 mA
3
- X90
15
100 mA 4
- X90
16
cl osed = r un
aux. oi l pump
r unni ng
9
- X
10 11 12
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Mai n Mot or
sheet 96
of 108

+LCP
=
5 18 269- 110
95
97
A1
A2
- 96K2
13
14
A1
A2
- 96K1
13
14
+MJ B_211
aux. oi l pump
mot or f aul t
cl osed = heal t hy
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4
M
M
+24. 4
+24. 2
+24. 2
/ 47. 5
+LCP- X31: 8
/ 47. 6
+LCP- X31: 9
/ 48. 6
+LCP- X32: 10
/ 48. 6
+LCP- X32: 11
/ 94. 9
+LCP- X90: 2
/ 97. 1
+LCP- X90: 5
/ 96. 3
/ 96. 6
/
9
6
.
6
/
9
6
.
3
di gi t al i nput
aux. oi l pump r unni ng
14
I 5. 2
- 60A1
/ 60. 3
di gi t al i nput
aux. oi l pump f aul t
15
I 5. 3
- 60A1
/ 60. 3
J acobs
13
14
- 97K1
13
14
- 97K2
100 mA
5
- X90
17
100 mA 6
- X90
18
cl osed = r un
emer g. oi l pump
r unni ng
13
- X
14 15 16
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Emer g. Oi l Pump
sheet 97
of 108

+LCP
=
5 18 269- 110
96
98
A1
A2
- 97K2
13
14
A1
A2
- 97K1
13
14
emer g. oi l pump
mot or f aul t
cl osed = heal t hy
+MJ B_211
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 4 +24. 4
+24. 2
+24. 2
/ 47. 6
+LCP- X31: 9
/ 47. 6
+LCP- X31: 10
/ 48. 6
+LCP- X32: 11
/ 48. 7
+LCP- X32: 12
/ 96. 8
+LCP- X90: 4
/ 99. 1
+LCP- X90: 7
/ 97. 3 / 97. 6
/
9
7
.
6
/
9
7
.
3
di gi t al i nput
emer g. oi l pump r unni ng
18
I 5. 6
- 60A1
/ 60. 3
di gi t al i nput
emer g. oi l pump f aul t
19
I 5. 7
- 60A1
/ 60. 3
J acobs
A1
A2
- 98K1
13
14
- 98K1
A1
A2
- 98K2
12 14
11
- 98K2
emer g. oi l pump
st ar t
aux. oi l pump
st ar t
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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o
f
,

f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Aux. / Emer g. Oi l Pump
St ar t
sheet 98
of 108

+LCP
=
5 18 269- 110
97
99
13
14
1
2
1
1
1
4
+MJ B_211
110V AC 110V AC
1, 5mm or ange
110VAC !
1, 5mm or ange
110VAC !
17
- X
18 19 20
4 6
630 mA
3
- X91
630 mA 5
- X91
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
/ 47. 6
+LCP- X31: 10
/ 47. 7
+LCP- X31: 11
/ 98. 2
/ 98. 6
/
9
8
.
3
/
9
8
.
7
di gi t al out put
aux. oi l pump st ar t
13
O1. 1
- 61A1
/ 61. 2
di gi t al out put
emer g. oi l pump st ar t
22
O2. 0
- 61A1
/ 61. 2
J acobs
13
14
- 99K1
13
14
- 99K2
100 mA
7
- X90
19
100 mA 8
- X90
20
+LCP
21
- X
22 23
- X
24
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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f
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Mai n Mot or
Bear i ng/ Wi ndi ng Temp.
sheet 99
of 108

+LCP
=
5 18 269- 110
98
100
A1
A2
- 99K1
13
14
A1
A2
- 99K2
13
14
+DCS
mai n mot or
bear i ng t emper at ur e heal t hy
mai n mot or
wi ndi ng t emper at ur e heal t hy
cl osed = t emp. heal t hy cl osed = t emp. heal t hy
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4 +24. 4
M
M
+24. 2
+24. 2
/ 47. 7
+LCP- X31: 11
/ 47. 7
+LCP- X31: 12
/ 48. 7
+LCP- X32: 12
/ 48. 7
+LCP- X32: 13
/ 97. 9
+LCP- X90: 6
/ 100. 1
+LCP- X90: 9
/ 99. 3
/ 99. 6
/
9
9
.
3
/
9
9
.
6
di gi t al i nput
mot or bear i ng
t emper at ur e ok.
33
I 7. 1
- 60A1
/ 60. 3
di gi t al i nput
wi ndi ng t emper at ur e ok.
32
I 7. 0
- 60A1
/ 60. 3
J acobs
13
14
- 100K1
13
14
- 100K2
100 mA
9
- X90
21
100 mA 10
- X90
22
+LCP
cl osed = r un
28 27
- X
26 25
- X
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Mai n Mot or
sheet 100
of 108

+LCP
=
5 18 269- 110
99
101
A1
A2
- 100K2
13
14
A1
A2
- 100K1
13
14
+MJ B_211
mai n mot or
swi t ch gear heal t hy
cl osed = heal t hy
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4
M
M
+24. 4
+24. 2
+24. 2
/ 47. 7
+LCP- X31: 12
/ 47. 8
+LCP- X31: 13
/ 48. 7
+LCP- X32: 12
/ 48. 7
+LCP- X32: 13
/ 99. 9
+LCP- X90: 8
/ 102. 1
+LCP- X90: 11
/ 100. 3
/ 100. 6
/
1
0
0
.
6
/
1
0
0
.
3
di gi t al i nput
mai n mot or f aul t
13
I 5. 1
- 60A1
/ 60. 3
di gi t al i nput
12
I 5. 0
- 60A1
/ 60. 3
J acobs
A1
A2
- 101K1
mai n mot or
per mi ssi ve
13
14
- 101K1
emer gency st op
13
14
- 68K1
A1
A2
- 101K2
13
14
- 101K2
mai n mot or
per mi ssi ve
mai n mot or
st ar t
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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o
f
,

f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Mai n Mot or
Per mi ssi ve/ St ar t
sheet 101
of 108

+LCP
=
5 18 269- 110
100
102
13
14
13
14
+MJ B_211
29
- X
30 31 32
630 mA
7
- X91
8
630 mA 9
- X91
10
1, 5mm or ange 1, 5mm or ange
cont act s ar e cl osed =
cont act cl ose i mpul se 2 sec. =
110V DC 110V DC
110VDC ! 110VDC !
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
/ 47. 8
+LCP- X31: 13
/ 47. 8
+LCP- X31: 14
/ 101. 2
/ 68. 2
/ 101. 6
/
1
0
1
.
3
/
1
0
1
.
8
di gi t al out put
PERM
14
O1. 2
- 61A1
/ 61. 2
di gi t al out put
START
15
O1. 3
- 61A1
/ 61. 2
J acobs
13
14
A1
A2
- 102K1
13
14
- 102K1
13
14
- 102K2
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
SPARE
sheet 102
of 108

+LCP
=
5 18 269- 110
101
103
13
14
A1
A2
- 102K2
13
14
630 mA
35
- X90
36
100 mA 11
- X90
23
- X
Mot or l ube oi l syst em
Al ar m
Mot or
Oi l syst em
Panel
cont act cl osed: heal t hy/ no Al ar m
cont act open: Al ar m
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4
M
M
+24. 4
+24. 2
/ 47. 6
+LCP- X31: 9
/ 47. 9
+LCP- X31: 14
/ 48. 7
+LCP- X32: 12
/ 100. 9
+LCP- X90: 10
/ 103. 1
+LCP- X90: 12
/
1
0
6
.
7/ 102. 2
/ 102. 6
/
1
0
2
.
3
/
1
0
2
.
6
di gi t al out put
Spar e
23
O2. 1
- 61A1
/ 61. 2
di gi t al i nput
Al ar m
16
I 1. 4
- 59A1
/ 59. 2
J acobs
13
14
630 mA
37
- X90
100 mA 12
- X90
24
38
13
14
- 103K1
13
14
- 103K2
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
,

f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
SPARE
sheet 103
of 108

+LCP
=
5 18 269- 110
102
105
13
14
A1
A2
- 103K1
A1
A2
- 103K2
13
14
Mot or
Oi l syst em
Panel
- X
cont act cl osed: heal t hy/ r eady t o st ar t
cont act open: Tr i p
TRI P
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+24. 4
M
M
+24. 2
/ 47. 6
+LCP- X31: 9
/ 47. 6
+LCP- X31: 10
/ 48. 6
+LCP- X32: 11
/ 102. 9
+LCP- X90: 11
/
1
0
6
.
7
/ 103. 2
/ 103. 6
/
1
0
3
.
3
/
1
0
3
.
6
di gi t al out put
Spar e
24
O2. 2
- 61A1
/ 61. 2
di gi t al i nput
f aul t
17
I 1. 5
- 59A1
/ 59. 2
J acobs
UNI GATE RS232/ 485- MPI
X
1 2
M
1
+24V
- 105A2
8 SH
PROFI BUS DP
+DCS
M
o
d
b
u
s

R
S
4
8
5
I nt er f ace
485
Ter mi nat i on
ON
Rx/ 485- Pi n 3
Rx/ 485+ Pi n 4
0V ( RS) Pi n 5
Ter mi nat i on
ON
7
- X
8
Modbus t o
DCS
7
- X70
0 ... 100 %
4 ... 20 mA
CLOSE ->OPEN
UB+
UB-
I
Input
I
6 5
2 1
7+
8-
- 105A1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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e
o
f
,

f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
Modbus t o DCS
Remot e Set Poi nt I GV
sheet 105
of 108

+LCP
=
5 18 269- 110
103
106
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
M
+24. 1
+24. 3
/ 47. 6
+LCP- X31: 10
/ 47. 7
+LCP- X31: 11
/ 48. 1
+LCP- X32: 2
/ 49. 2
+LCP- X32: 14
/ 53. 8
+LCP- 53A1: X2: out
M-
anal og i nput
MI +
r emot e set poi nt I GV
4
I W290
5
- 56A1 / 56. 2
J acobs
13
14
- 106K1
630 mA
1
- X70
4
630 mA 2
5
630 mA 3
cl osed = st ar t
1
- X
2 4
13
14
- 106K2
13
14
- 106K3
Impulse
3
- X
5
- X
6
6
No Pr ocess I nt er l ock
i n Local Mode
+DCS
cl osed = no pr ocess i nt er l ock
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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PHASE II
Remot e Si gnal s DCS
sheet 106
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=
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105
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A2
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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PHASE II
I GV Cl osed t o DCS
sheet 107
of 108

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=
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106
108
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A1
A2
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13
14
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01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
CABLE PROFI BUS
CABLE MODBUS
sheet 108
of 108

=
5 18 269- 110
107
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J acobs
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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PHASE II
Cover Sheet
sheet 0

+LCP
=
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Ter mi nal Li st
of 18
1
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E: \ Pr oj ekt e\ 5 18 269 HZL I I \ El pr o\ 518269t l
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
AviComp
Controls GmbH
TYPE: SFO11
SO BLOWER
2
Pl ant :
1050124
5 18 269
P oetenweg 49
D- 04155 Lei pzi g
KKK J ob No: 1. 050. 124
30. 05. 2006
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
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Dat e Name
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KKK No. : 1050124
PHASE II
ext er nal
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01 t er mi nal st r i p LCP
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power 400V AC L1 - 40Q1 1 / 40. 1
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0
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HINDUSTAN ZINC
Document No. :
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KKK No. : 1050124
PHASE II
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
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30. 05. 2006
+LCP- X03
UPS power 110V AC L - 42F1 E2 / 42. 1
UPS power 110V AC N - 42F1 E4 / 42. 1
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sheet 3
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X05
U KW- 01 I GV x - 92Q1 2 - KW- 01 U / 92. 1
+
L
C
P
-
W
-
6
.
2

4
x
2
,
5
m
m
1
V KW- 01 I GV x - 92Q1 4 - KW- 01 V / 92. 1 2
WKW- 01 I GV x - 92Q1 6 - KW- 01 W / 92. 1 3
PE - KW- 01 PE / 92. 1 PE
sheet 4
of 18
3
5
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
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s
s

a
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y

b
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A
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b
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
i nt er nal
P
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D
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X10
( +) TT P235 gear box HS NDS 1 - 54A1 2 +J B2- X10 1 / 77. 3
+
L
C
P
-
W
_
J
B
2

2
5
x
0
,
7
5
m
m
1
( - ) TT P235 gear box HS NDS 2 - 54A1 3 +J B2- X10 2 / 77. 3 2
( +) TE P236 gear box axi al HS NDS 3 - 54A1 4 +J B2- X10 3 / 77. 7 3
( - ) TE P236 gear box axi al HS NDS 4 - 54A1 5 +J B2- X10 4 / 77. 7 4
( +) TE P238 gear box HS DS 5 - 54A1 6 +J B2- X10 5 / 78. 3 5
( - ) TE P238 gear box HS DS 6 - 54A1 7 +J B2- X10 6 / 78. 3 6
( +) TE P239 gear box axi al HS DS 7 - 54A1 8 +J B2- X10 7 / 78. 7 7
( - ) TE P239 gear box axi al HS DS 8 - 54A1 9 +J B2- X10 8 / 78. 7 8
( +) TE P229 gear box LS NDS 9 - 54A1 12 +J B2- X10 9 / 79. 3 9
( - ) TE P229 gear box LS NDS 10 - 54A1 13 +J B2- X10 10 / 79. 3 10
( +) TE P230 gear box axi al LS NDS 11 - 54A1 14 +J B2- X10 11 / 79. 7 11
( - ) TE P230 gear box axi al LS NDS 12 - 54A1 15 +J B2- X10 12 / 79. 7 12
( +) TE P231 gear box LS DS 13 - 54A1 16 +J B2- X10 13 / 80. 3 13
( - ) TE P231 gear box LS DS 14 - 54A1 17 +J B2- X10 14 / 80. 3 14
( +) TE P233 gear box axi al LS DS 15 - 54A1 18 +J B2- X10 15 / 80. 7 15
( - ) TE P233 gear box axi al LS DS 16 - 54A1 19 +J B2- X10 16 / 80. 7 16
( +) TT P221 compressor beari ng NDS 17 - 55A1 2 +J B2- X10 17 / 81. 3 17
( - ) TT P221 compressor beari ng NDS 18 - 55A1 3 +J B2- X10 18 / 81. 3 18
( +) TT P227 compressor beari ng axi al DS 19 - 55A1 4 +J B2- X10 19 / 81. 7 19
( - ) TT P227 compressor beari ng axi al DS 20 - 55A1 5 +J B2- X10 20 / 81. 7 20
( +) TT P225 compressor beari ng DS 21 - 55A1 6 +J B2- X10 21 / 82. 3 21
( - ) TT P225 compressor beari ng DS 22 - 55A1 7 +J B2- X10 22 / 82. 3 22
( +) TT P202 suct i on t emp. 23 - 55A1 8 +J B2- X10 23 / 84. 5 23
( - ) TT P202 suct i on t emp. 24 - 55A1 9 +J B2- X10 24 / 84. 5 24
( +) TT P204 oi l t emp. 25 - 55A1 12 +J B3- X1 46 / 85. 3
+
L
C
P
-
W
_
J
B
3
-
1

5
x
0
,
7
5
m
m
1
( - ) TT P204 oi l t emp. 26 - 55A1 13 +J B3- X1 47 / 85. 3 2
( +) PT P208 oi l pressure 27 - 55A1 14 +J B3- X1 41 / 85. 6 3
( - ) PT P208 oi l pressure 28 - 55A1 15 +J B3- X1 42 / 85. 7 4
( +) GC P012 set poi nt 29 - 57A1 3 - GC P012 ( +) / 92. 6
+
L
C
P
-
W
-
6
1
.
1

5
x
0
,
7
5
m
m
BU
sheet 5
of 18
4
6
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
s

a
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b
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A
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a
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b
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t
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
i nt er nal
P
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D
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X10
( - ) GC P012 set poi nt 30 - 57A1 6 - GC P012 ( - ) / 92. 7
+
L
C
P
-
W
-
6
1
.
1

5
x
0
,
7
5
m
m
WH
( +) GC P012 posi t i on 31 - 55A1 16 - GC P012 ( +) / 92. 7 BU
( - ) GC P012 posi t i on 32 - X31 6 - GC P012 ( - ) / 92. 8 WH
sheet 6
of 18
5
7
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
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A
C
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.

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b
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t
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
i nt er nal
P
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D
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X20
( +) PSL P209 oi l pressure 1 +J B3- X1 6 / 86. 2
+
L
C
P
-
W
_
J
B
3
-
2

2
5
x
0
,
7
5
m
m
1
PSL P209 oi l pressure 2 - 59A1 2 +J B3- X1 8 / 86. 3 2
( +) PSL P210 oi l pressure 3 +J B3- X1 10 / 86. 5 3
PSL P210 oi l pressure 4 - 59A1 3 +J B3- X1 12 / 86. 5 4
( +) PSLL P211 oi l pressure 5 +J B3- X1 14 / 86. 7 5
PSLL P211 oi l pressure 6 - 59A1 4 +J B3- X1 15 / 86. 8 6
( +) PDSH P203 oi l f i l t er 7 +J B3- X1 18 / 87. 5 7
PDSH P203 oi l f i l t er 8 - 59A1 5 +J B3- X1 20 / 87. 5 8
GND 9 - X31 5 +J B3- X1 21 / 87. 5 9
( +) LSL P242 oi l l evel t ank 10 +J B3- X1 26 / 88. 3 10
LSL P242 oi l l evel t ank 11 - 59A1 9 +J B3- X1 28 / 88. 3 11
( +) LSLL P242 oi l l evel t ank 12 +J B3- X1 24 / 88. 6 12
LSLL P242 oi l l evel t ank 13 - 59A1 12 +J B3- X1 23 / 88. 6 13
( +) TSL P244 oi l t emp. l ow 14 +J B3- X1 3 / 89. 3 14
TSL P244 oi l t emp. l ow 15 - 89K1 A1 +J B3- X1 4 / 89. 3 15
( +) TSH P244 oi l t emp. l i mi t er hi gh 16 +J B3- X1 1 / 89. 6 16
TSH P244 oi l t emp. l i mi t er hi gh 17 - 89K2 A1 +J B3- X1 2 / 89. 6 17
( +) PDSH P201 ant i surge prot ect i on 18 - PDSH P201 3 / 91. 4
+
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C
P
-
W
-
1
2

2
x
1
,
5
m
m
1
PDSH P201 ant i surge prot ect i on 19 - 59A1 8 - PDSH P201 4 / 91. 5 2
( +) GSL P012 I GV cl osed 20 - ( +) GSL P012 11 / 92. 3
+
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C
P
-
W
-
6
0
.
1

2
x
1
,
5
m
m
1
GSL P012 I GV cl osed 21 - 59A1 7 - ( - ) GSL P012 12 / 92. 4 2
sheet 7
of 18
6
8
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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a
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a
b
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t
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
i nt er nal
P
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n
D
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X31
1 - 53A1 M - XB PE PE / 47. 1
1 - 54A1 20 - 53A2 M M / 47. 2
2 - 55A1 20 - 51A1 ( - ) - OP / 47. 2
2 - 55A1 11 - 63K1 A2 M / 47. 2
3 - 55A1 10 - X33 2 M / 47. 2
3 - 56A1 20 - 68K1 A2 M / 47. 3
4 - 57A1 20 - 72K1 A2 M / 47. 3
4 - 59A1 20 - 72K2 A2 M / 47. 3
5 - 59A1 40 - X20 9 M / 47. 3
5 - 60A1 20 - 89K1 A2 M / 47. 4
6 - 60A1 40 - 89K2 A2 M / 47. 4
6 - 61A1 10 - X10 32 M / 47. 4
7 - 61A1 20 - 94K1 A2 M / 47. 5
7 - 61A1 30 - 94K2 A2 M / 47. 5
8 - 61A1 40 - 95K1 A2 M / 47. 5
8 - 69A1 11 - 96K1 A2 M / 47. 5
9 - 102K2 A2 - 96K2 A2 M / 47. 6
9 - 103K1 A2 - 97K1 A2 M / 47. 6
10 - 103K2 A2 - 97K2 A2 M / 47. 6
10 - 105A1 8- - 98K1 A2 M / 47. 6
11 - 105A2 2 - 98K2 A2 M / 47. 7
11 - 106K1 A2 - 99K1 A2 M / 47. 7
12 - 106K2 A2 - 99K2 A2 M / 47. 7
12 - 106K3 A2 - 100K1 A2 M / 47. 7
13 - 107K1 A2 - 100K2 A2 M / 47. 8
13 - 107A1 11- - 101K1 A2 M / 47. 8
14 - 101K2 A2 M / 47. 8
14 - 48G1 ( - ) - 102K1 A2 M / 47. 9
sheet 8
of 18
7
9
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
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Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X32
power 1 - 48F1 2 / 48. 1
1 - 53A1 L+ - 51A1 ( +) +OP / 48. 1
2 - 105A2 1 +24. 1 / 48. 1
2 +24. 1 / 48. 2
3 - 53A2 +24V +24. 1 / 48. 2
3 / 48. 2
4 - 48F2 2 - 49F1 33 +24. 2 / 48. 2
4 - 54A1 1 - 41F1 33 +24. 2 / 48. 3
5 - 55A1 1 - X33 32 +24. 2 / 48. 3
5 - 56A1 1 - 68K1 41 +24. 2 / 48. 3
6 - 59A1 1 - 63K1 23 +24. 2 / 48. 4
6 - 60A1 1 - 71A1/ 3 ARM +24. 2 / 48. 4
7 - 61A1 1 - 92Q1 13 +24. 2 / 48. 4
7 - 61A1 11 +24. 2 / 48. 4
8 - 71A1/ 8 COM +24. 2 / 48. 5
8 - 89K2 13 +24. 2 / 48. 5
9 - 89K1 13 +24. 2 / 48. 5
9 - 94K2 13 +24. 2 / 48. 5
10 - 94K1 13 - 106K1 13 +24. 2 / 48. 6
10 - 96K2 13 - 106K2 13 +24. 2 / 48. 6
11 - 96K1 13 - 106K3 13 +24. 2 / 48. 6
11 - 97K2 13 - 103K2 13 +24. 2 / 48. 6
12 - 97K1 13 - 102K2 13 +24. 2 / 48. 7
12 - 99K2 13 - 100K1 13 +24. 2 / 48. 7
13 - 99K1 13 - 100K2 13 +24. 2 / 48. 7
13 - X33 1 +24. 2 / 48. 8
14 - 49F1 E2 / 49. 2
14 - 57A1 1 - 105A1 7+ +24. 3 / 49. 2
15 - 61A1 21 - 69A1 10 +24. 3 / 49. 2
sheet 9
of 18
8
10
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
s

a
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b
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A
C
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
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Funct i on
Tar get Si gn.
ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X32
15 - 61A1 31 - 107A1 10+ +24. 3 / 49. 3
16 +24. 3 / 49. 3
16 +24. 3 / 49. 3
17 - 49F2 E2 / 49. 6
17 - X20 1 +24. 4 / 49. 6
18 - 68K1 A1 - X90 1 +24. 4 / 49. 7
18 - X70 1 +24. 4 / 49. 7
19 +24. 4 / 49. 7
19 +24. 4 / 49. 7
20 +24. 4 / 49. 8
20 +24. 4 / 49. 8
sheet 10
of 18
9
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J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
s

a
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b
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
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/
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Funct i on
Tar get Si gn.
ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X33
1 - 63S1 13 - X32 13 +24. 2 / 63. 1
2 - 63H1 X2 - X31 3 M / 63. 1
3 - 63S1 14 - 59A1 22 / 63. 2
4 - 63S2 22 - 59A1 23 / 63. 4
spare 5 / 63. 6
6 - 63S4 14 - 63K1 A1 / 63. 8
7 - 64S1 14 - 59A1 32 / 64. 2
8 - 64S2 22 - 59A1 33 / 64. 4
9 - 64S3 14 - 59A1 38 / 64. 6
10 - 64S4 22 - 59A1 39 / 64. 8
11 - 65S1 14 - 59A1 34 / 65. 2
12 - 65S2 22 - 59A1 35 / 65. 4
13 - 65S3 14 - 59A1 36 / 65. 6
14 - 65S4 14 - 59A1 37 / 65. 8
Lampt est / Buzzer 15 - 67S1 14 - 59A1 29 / 67. 2
16 - 67S2 14 - 59A1 27 / 67. 4
17 - 67S2 32 - 59A1 25 / 67. 6
18 - 67S2 44 - 59A1 26 / 67. 8
19 - 68S1 21 - 68K1 S12 / 68. 2
20 - 68S1 22 - 68K1 S11 / 68. 2
21 - 63H1 X1 - 61A1 2 / 63. 2
22 - 63H3 X1 - 61A1 3 / 63. 6
23 - 63H4 X1 - 61A1 4 / 63. 8
24 - 64H1 X1 - 61A1 5 / 64. 2
25 - 64H3 X1 - 61A1 12 / 64. 6
26 - 65H1 X1 - 61A1 6 / 65. 2
27 - 65H3 X1 - 61A1 7 / 65. 6
28 - 61A1 8 / 65. 8
29 - 67H1 E1 - 61A1 9 / 67. 2
sheet 11
of 18
10
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J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
s

a
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b
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A
C
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
e
/
p
a
t
h

Funct i on
Tar get Si gn.
ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X33
( +) mot or current 30 - 69A1 7 - 69P1 ( +) / 69. 4
( - ) mot or current 31 - 69A1 9 - 69P1 ( - ) / 69. 4
32 - X32 5 - 40Q1 13 / 50. 2
33 - 60A1 6 - 40Q1 14 / 50. 2
sheet 12
of 18
11
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J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s

a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
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Funct i on
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ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X40
XT P215 vi brat i on si gnal s 1 - 71A1/ 4 PWR/ B +J B1- X40 1 / 73. 1
+
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XT P215 vi brat i on si gnal s 2 - 71A1/ 4 COM +J B1- X40 2 / 73. 1 RD
XT P215 vi brat i on si gnal s 3 - 71A1/ 4 SI G/ A +J B1- X40 3 / 73. 1 BU
XT P220 vi brat i on si gnal s 4 - 71A1/ 4 PWR/ B +J B1- X40 4 / 73. 3 2WH
XT P240 vi brat i on si gnal s 13 - 71A1/ 6 PWR +J B1- X40 13 / 75. 1 WH
14 - 71A1/ 6 SI G/ A +J B1- X40 14 / 75. 1 BU
XT P240 vi brat i on si gnal s 15 - 71A1/ 6 SI G/ B +J B1- X40 15 / 75. 1 LBU
XT P241 vi brat i on si gnal s 16 - 71A1/ 6 PWR +J B1- X40 16 / 75. 3 WH
17 - 71A1/ 6 SI G/ A +J B1- X40 17 / 75. 3 BU
XT P241 vi brat i on si gnal s 18 - 71A1/ 6 SI G/ B +J B1- X40 18 / 75. 3 LBU
YT P223 di spl acement 19 - 71A1/ 5 PWR/ B +J B1- X40 19 / 74. 5 5WH
YT P223 di spl acement 20 - 71A1/ 5 COM +J B1- X40 20 / 74. 5 RD
YT P223 di spl acement 21 - 71A1/ 5 SI G/ A +J B1- X40 21 / 74. 5 BU
YT P226 di spl acement 22 - 71A1/ 5 PWR/ B +J B1- X40 22 / 74. 7 6WH
YT P226 di spl acement 23 - 71A1/ 5 COM +J B1- X40 23 / 74. 7 RD
YT P226 di spl acement 24 - 71A1/ 5 SI G/ A +J B1- X40 24 / 74. 7 BU
spare 25 / 74. 8
spare 26 / 74. 8
spare 27 / 74. 8
spare 28 / 74. 8
sheet 13
of 18
12
14
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
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p
a
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Funct i on
Tar get Si gn.
ext er nal
Tar get Si gn.
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X70
( +) remot e st art 1 +DCS- X 1 / 106. 1
( +) remot e st op 2 +DCS- X 3 / 106. 4
( +) remot e st andby 3 +DCS- X 5 / 106. 6
remot e st art 4 - 106K1 A1 +DCS- X 2 / 106. 2
remot e st op 5 - 106K2 A1 +DCS- X 4 / 106. 4
remot e st andby 6 - 106K3 A1 +DCS- X 6 / 106. 6
( +) remot e set poi nt I GV 7 - 105A1 1 +DCS- X 7 / 105. 1
( - ) remot e set poi nt I GV 8 - 105A1 2 +DCS- X 8 / 105. 2
I GV cl osed t o DCS 9 - 107K1 14 / 107. 3
I GV cl osed t o DCS 10 - 107K1 13 / 107. 4
I GV posi t i on t o DCS 11 - 107A1 7 / 107. 6
I GV posi t i on t o DCS 12 - 107A1 9 / 107. 6
sheet 14
of 18
13
15
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
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ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X90
( +) oi l heat er MCB ok. 1 +MJ B_211- X 3 / 94. 1
( +) oi l heat er runni ng 2 +MJ B_211- X 5 / 94. 4
( +) aux. oi l pump MCB ok. 3 +MJ B_211- X 9 / 96. 1
( +) aux. oi l pump runni ng 4 +MJ B_211- X 11 / 96. 5
( +) emerg. oi l pump ok. 5 +MJ B_211- X 13 / 97. 1
( +) emerg. oi l pump runni ng 6 +MJ B_211- X 15 / 97. 5
( +) mai n mot or beari ng t emperat ure ok. 7 +DCS- X 21 / 99. 1
( +) mai n mot or wi ndi ng t emperat ure ok. 8 +DCS- X 23 / 99. 5
( +) mai n mot or no error 9 +MJ B_211- X 25 / 100. 1
( +) mai n mot or runni ng 10 +MJ B_211- X 27 / 100. 5
( +) spare 11 - X x / 102. 5
( +) spare 12 - X x / 103. 5
oi l heat er MCB ok. 13 - 94K1 A1 +MJ B_211- X 4 / 94. 2
oi l heat er runni ng 14 - 94K2 A1 +MJ B_211- X 6 / 94. 4
aux. oi l pump MCB ok 15 - 96K1 A1 +MJ B_211- X 10 / 96. 2
aux. oi l pump runni ng 16 - 96K2 A1 +MJ B_211- X 12 / 96. 5
emerg. oi l pump ok. 17 - 97K1 A1 +MJ B_211- X 14 / 97. 2
emerg. oi l pump runni ng 18 - 97K2 A1 +MJ B_211- X 16 / 97. 5
mai n mot or beari ng t emperat ure ok. 19 - 99K1 A1 +DCS- X 22 / 99. 2
mai n mot or wi ndi ng t emperat ure ok. 20 - 99K2 A1 +DCS- X 24 / 99. 5
mai n mot or no error 21 - 100K1 A1 +MJ B_211- X 26 / 100. 2
mai n mot or runni ng 22 - 100K2 A1 +MJ B_211- X 28 / 100. 5
spare 23 - 102K2 A1 - X x / 102. 5
spare 24 - 103K2 A1 - X x / 103. 5
( +) spare 35 - 102K1 14 / 102. 3
spare 36 - 102K1 13 / 102. 4
( +) spare 37 - 103K1 14 / 103. 3
spare 38 - 103K1 13 / 103. 4
( +) current mai n mot or 39 - 69A1 4 +MJ B_211- X 1 / 69. 4
sheet 15
of 18
14
16
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
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a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
p
a
g
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/
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a
t
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Funct i on
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ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X90
( - ) current mai n mot or 40 - 69A1 6 +MJ B_211- X 2 / 69. 5
41 - 68K1 24 / 68. 4
42 - 68K1 23 / 68. 4
sheet 16
of 18
15
17
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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a
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
ext er nal
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Termi nal Stri p:
Cabl e Ter m
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
+LCP- X91
oi l heat er st art 1 - 95K1 14 +MJ B_211- X 7 / 95. 3
aux. oi l pump st art 3 - 98K1 14 +MJ B_211- X 17 / 98. 3
emerg. oi l pump st art 5 - 98K2 11 +MJ B_211- X 19 / 98. 8
mai n mot or permi ssi ve 7 - 68K1 14 +MJ B_211- X 29 / 101. 3
mai n dri ve permi ssi ve 8 - 101K1 13 +MJ B_211- X 30 / 101. 4
mai n mot or st art 9 - 101K2 14 +MJ B_211- X 31 / 101. 8
mai n dri ve st art 10 - 101K2 13 +MJ B_211- X 32 / 101. 8
sheet 17
of 18
16
18
J acobs
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Dat e Name
+LCP
KKK No. : 1050124
PHASE II
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Termi nal Stri p:
Cabl e Ter m
Spar e
5 18 269- 120
01 com. UI L 06. 09. 06 J ac
01
+LCP- X91
mai n mot or permi ssi ve 7 - 68K1 14 +MJ B_211- X 29 / 101. 3
mai n dri ve permi ssi ve 8 - 101K1 13 +MJ B_211- X 30 / 101. 4
mai n mot or st art 9 - 101K2 14 +MJ B_211- X 31 / 101. 8
mai n dri ve st art 10 - 101K2 13 +MJ B_211- X 32 / 101. 8
sheet 18
of 18
17
J acobs
30. 05. 2006
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Dat e
PHASE II
Cover Sheet
sheet 0

+LCP
=
J acobs
TYPE: SFO11
SO BLOWER
2
Pl ant :
KKK J ob No: 1. 050. 124
Cabl e Pl an
5 18 269- 130 of 11
1
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
AviComp
Controls GmbH
1050124
5 18 269
P oetenweg 49
D- 04155 Lei pzi g
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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d
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n
pr ep.
chec.
nor m
Ti t l e: =
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
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i
t
y

b
y

A
C
C
.

O
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t
o
Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Contents from
000 00 Cover Sheet 5 18 269- 130
001 00 Drawing List Cable plan 5 18 269- 130
005 00 System P rincipal View 5 18 269- 130
006 00 P ower Supply, Main/Auxilary Drives 5 18 269- 130
007 00 +J B1 Vibration Signals 5 18 269- 130
008 00 +J B2,+J B4 RTD Signals 5 18 269- 130
009 00 +J B2,+J B5 RTD Signals Suction Temperature 5 18 269- 130
010 00 Anti Surge P rotection I GV Signals 5 18 269- 130
011 00 5 18 269- 130
sheet 1
of 11
0
5
5 18 269- 130
J acobs
Dr awi ng Li st
Cabl e pl an
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
+J B3 Di gi tal Signals
F
i
e
l
d
BN 3500 Moni t or
+J B01
DP MPI
I / O I / O CPU
Bi nar y si g
emg st op
Bi nar y Si g.
Si emens S7
MPI
+DCS
MPI
RS485
Modbus
Sl ave
Modbus
dat a t r ansf er
f or RTD si g. f or f i el d si g f or vi br at i on
Pr of i bus
PB/ Modbus
+J B02 +J B03
MP270
Si emens
Mul t i panel
+MCC
MAI N DRI VE
cont r ol
i nst r ument
MPI Bus
+J B4 +J B5
. . . . . .
. . .
+LCP
D
C
S
/
M
C
C
C
l
i
e
n
t
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
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d
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n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
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i
t
y

b
y

A
C
C
.

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a
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b
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t
o
Modi f y
Dat e
PHASE II
Syst emPr i nci pal Vi ew
5 18 269- 130
sheet 5
of 11
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ El pr o\ 518269CP
+
=
J acobs
1
6
Modbus
Gat eway
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
+MCC +DCS
- X70
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
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s

a
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l
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b
l
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t
o
Modi f y
Dat e
PHASE II
Power Suppl y,
Mai n/ Auxi l ar y Dr i ves
5 18 269- 130
sheet 6
of 11
+
=
J acobs
5
7
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
- X90
Mai n Mot or
Auxi l ar y Oi l Pump
Oi l Heat er
Emer gency Oi l Pump
- X91
+MCC
L ocal control
panel
+LCP
- X01 - X02
P
o
w
e
r

S
u
p
p
l
y
4
1
5
V
A
C
/
5
0
H
z
/
3

p
h
,
N
,
P
E
M
Aumamatic
IGV Actuator
Pos. 6.2
P
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S
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p
p
l
y

2
3
0

V

A
C
- X03
- X05
W
-
6
.
2
4

c
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s
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1
1
0
V
A
C
/
5
0
H
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/
1

p
h
,
N
,
P
E
Power Suppl y
+MCC
Mai n Mot or
l ube oi l
syst em
- X40
axial displ.
compressor shaft
axial displ.
compressor shaft
compressor
bearing NDS
compressor
bearing NDS
compressor
bearing DS
compressor
bearing DS
blower
skid
L ocal control
panel
+LCP
- X40
AD01
XE
P219
+J B1
AD01
XE
P 220
AD01
XE
P 222
AD01
XE
P 224
AD01
XE
P 240
AD01
XE
P241
AD01
YE
P 223
AD01
YE
P 226
AD01
YT
P 226
AD01
XT
P219
AD01
XT
P 220
AD01
XT
P 222
AD01
XT
P 224
AD01
XT
P 240
AD01
XT
P241
AD01
YT
P 223
M32
W
-
6
4
.
1
o
r
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g
.

c
a
b
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W
-
6
4
.
2
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g
.

c
a
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W
-
6
4
.
3
o
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g
.

c
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W
-
6
4
.
4
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.

c
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W
-
6
4
.
5
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.

c
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W
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6
4
.
6
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.

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W
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6
5
.
1
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c
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W
-
6
5
.
2
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.

c
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b
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e
Pos. 64.1 Pos. 64.2 Pos. 64.3 Pos. 64.4 Pos. 64.5 Pos. 64.6 Pos. 65.1 Pos. 65.2
J uncti on box
f or vi brati on si g.
Bentl y Nevada 3500
Vi brati on Moni tori ng System
-
W
_
J
B
1
1
2

t
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p
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s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
+J B1
Vi br at i on Si gnal s
5 18 269- 130
sheet 7
of 11
+
=
J acobs
6
8
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
motor bearing
DE2
motor bearing
DE1
gear box bearing
HS NDS
gear box bearing
HS DS
gear box bearing
LS NDS
gear box bearing
LS DS
gear box bearing
axial HS DS
gear box bearing
axial HS DE
gear box bearing
axial LS DS
gear box bearing
axial LS DS
- X10
L ocal control
panel
+LCP
- X10
J uncti on box
temperature si g.
- X
J uncti on box
on gear box
+J B4
AD01
TE
P 235
AD01
TT
P 235
Pos. 53.3.1 Pos. 53.3.2 Pos. 53.3.3 Pos. 53.3.4 Pos. 53.3.5 Pos. 53.3.6 Pos. 53.3.7 Pos. 53.3.8
+J B2
AD01
TE
P 236
AD01
TT
P 236
AD01
TT
P 238
AD01
TE
P 238
AD01
TE
P 239
AD01
TT
P 239
AD01
TE
P 229
AD01
TT
P 229
AD01
TE
P 230
AD01
TT
P 230
AD01
TT
P231
AD01
TE
P231
AD01
TE
P 233
AD01
TT
P 233
-
W
_
J
B
2
2
5

c
o
r
e
s
W
-
5
3
.
3
-
1
2
5

c
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s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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f
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r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
+J B2, +J B4
RTD Si gnal s
5 18 269- 130
sheet 8
of 11
+
=
J acobs
7
9
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
- X10
L ocal control
panel
+LCP
J uncti on box
temperature si g.
+J B2
AD01
TT
P221
AD01
TT
P 227
AD01
TT
P 225
suction temp.
Pos. 53.2
AD01
TE
P 202
AD01
TT
P 202
compressor
bearing NDS
Pos. 53.1.1
AD01
TE
P221
Spare
Pos. 53.1.2
compressor
bearing axial DS
Pos. 53.1.3
AD01
TE
P 227
Spare
Pos. 53.1.4
compressor
bearing DS
Pos. 53.1.5
AD01
TE
P 225
Spare
Pos. 53.1.6
+J B5
- X
J uncti on box
compressor beari ng
- X10
W
-
5
3
.
2
4

c
o
r
e
s
-
W
_
J
B
2
2
5

c
o
r
e
s
W
-
5
3
.
1
2
5

c
o
r
e
s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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f
,

f
o
r
b
i
d
d
e
n
pr ep.
chec.
nor m
Ti t l e:
bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

O
f
f
e
n
d
e
r
s

a
r
e

l
i
a
b
l
e

t
o
Modi f y
Dat e
PHASE II
+J B2, +J B5 RTD Si gnal s
Suct i on Temper at ur e
5 18 269- 130
sheet 9
of 11
+
=
J acobs
8
10
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
L ocal control
panel
+LCP
Pos 61.1
AD01
GIC
P012
AD01
GIC
P012
W
-
6
1
.
1
5

c
o
r
e
s
Pos. 61.1
IGV setpoint IGV position
W
-
6
0
.
1
2

p
a
i
r
s
AD01
TSL
P 244
IGV closed
Pos. 60.1
W
-
1
2
1

p
a
i
r
AD01
PDSH
P201
antisurge
protection
Pos. 12
- X10 - X20 - X10
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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a
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Modi f y
Dat e
PHASE II
Ant i Sur ge Pr ot ect i on
I GV Si gnal s
5 18 269- 130
sheet 10
of 11
+
=
J acobs
9
11
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
L ocal control
panel
+LCP
-
W
_
J
B
3
-
2
2
5

c
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s
- X20
+J B3
oil pressure
switch L
oil pressure
switch L
oil pressure
switch LL
oi l fi l ter
dif.-pressure H
AD01
PSL
P 209
AD01
PSL
P210
AD01
PSLL
P211
AD01
PDISH
P 203
Pos. 41.2 Pos. 41.3 Pos 41.4 Pos. 42.1
W
2
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c
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s
- X1
oi l l evel L oil level LL
Pos. 59
AD01
LSL
P 242
AD01
LSLL
P 242
w
6
6

c
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s
temp. regulator
oil heater
temp. limiter
oil heater
AD01
TSL
P 244
AD01
TSH
P 244
Pos. 51.1
W
-
5
1
.
1
4

c
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oil temp.
Pos. 51.2
AD01
TE/TT
P 204
Pos. 41.1
oil pressure
AD01
PT
P 208
W
8
5

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- X1
-
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5

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- X10
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
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s
s

a
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y

b
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C
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t
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Modi f y
Dat e
PHASE II
5 18 269- 130
sheet 11
of 11
+
=
J acobs
10
com. UI L 06. 09. 06 J ac
30. 05. 2006
01
01
+J B3
Di gi t al Si gnal s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
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h
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t
y

b
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A
C
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ For m. . . \ Mat er i al l i st e
01 com. UI L 06. 09. 06 J ac
01
cabl e l i st 30. 05. 2006
sheet 0
1
=
Cabl e Li st
5 18 269- 140
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
AviComp
Controls GmbH
TYPE: SFO11
SO BLOWER
2
Pl ant :
1050124
5 18 269
P oetenweg 49
D- 04155 Lei pzi g
KKK J ob No: 1. 050. 124
J acobs
of 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
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t
h
o
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t
y

b
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A
C
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
01 com. UI L 06. 09. 06 J ac
01
cabl e l i st 30. 05. 2006
cabel l i st:
pos. field device cabel tag cabel type number of
conductors
target
sheet :
5 18 269- 140
1 518269WD
1 5
+LCP- W1 oi l t emper at ur e cont r ol
+LCP- TSL P244
J Z603 5x1, 5mm
2 4
+LCP- W2 oi l pr essur e l ow
+LCP- PSL P209
J Z603 4x1, 5mm
3 4
+LCP- PSL P210
J Z603 4x1, 5mm
4 4
+LCP- PSLL P211
J Z603 4x1, 5mm
5 5
+LCP- W5 GND
+LCP- PDI SH P203
J Z603CY 5x0, 75mm
6 7
+LCP- W6 oi l l evel l ow
+LCP- LSLL P242
J Z603 7x1mm
7 5
+LCP- W7 oi l pr essur e
+LCP- PT P208
J Z603CY 5x1, 5mm
8 5
+LCP- W8 oi l t emper at ur e
+LCP- TE/ TT P204
J Z603CY 5x1, 5mm
9 4
+LCP- W- 6. 2 I nl et Gui de Vane
+LCP- KW- 01
J Z600 4x2, 5mm
10 2
+LCP- W- 12 Ant i Sur ge
+LCP- PDSH P201
J Z600 2x1, 5mm OZ
11 9
+LCP- W- 53. 1 53. 3. 1 t emper at ur e
+J B5- X
J Z600- Y- CY 25G0, 75mm
12 3
+LCP- W- 53. 2 53. 3. 1 t emper at ur e
+LCP- TE P202
J Z600- Y- CY 4x1, 5mm
13 24
+LCP- W- 53. 3- 1 53. 3. 1 t emper at ur e
+J B4- X
J Z600- Y- CY 25G0, 75mm
14 2
+LCP- W- 60. 1 ( +) GSL P012 I GV cl osed
+LCP- ( +) GSL P012
J Z600 2x1, 5mm OZ
15 4
+LCP- W- 61. 1 set poi nt
+LCP- GC P012
J Z600- Y- CY 5G0, 75mm
16 24
+LCP- W_J B1 XT P215 vi br at i on si gnal s
+J B1- X40
12I T05EI SF
17 24
+LCP- W_J B2 ( - ) TT P235 gear box HS NDS
+J B2- X10
J Z600- Y- CY 25G0, 75mm
18 4
+LCP- W_J B3- 1 ( +) TT P204 oi l t emp.
+J B3- X1
J Z600- Y- CY 5G0, 75mm
19 17
+LCP- W_J B3- 2 ( +) PSL P209 oi l pr essur e COM
+J B3- X1
J Z600- Y- CY 25G0, 75mm
sheet 1
of 1
0
J acobs
Equi pment Li st s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
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s
s

a
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y

b
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.

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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Cover Sheet
5 18 269- 150
sheet 0

=
J acobs
1
TYPE: SFO11
SO BLOWER
2
Pl ant :
KKK J ob No: 1. 050. 124
01 com. UI L 06. 09. 06 J ac
01
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ El pr o\ 518269EL
of 2
30. 05. 2006
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
AviComp
Controls GmbH
1050124
5 18 269
P oetenweg 49
D- 04155 Lei pzi g
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
C
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

p
r
e
s
s

a
u
t
h
o
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i
t
y

b
y

A
C
C
.

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b
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t
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Name No. Qua. Type Desi gnat i on Manuf act ur er
Equi pment Li st
Equi pment Li st
5 18 269- 150
01 com. UI L 06. 09. 06 J ac
01
30. 05. 2006
1 6 BProxi - AD 01 Y T P 223, - AD 01 Y T P 226, - AD 01 XT P 219
- AD 01 XT P 220, - AD 01 XT P 222, - AD 01 XT P 224
2 249 ST 2,5 spri ng cage termi nal bl ock Phoenix Contact - X40, - X11, - X10, - X10, - X70, - X40, - X33, - X91, - X20, - X90
- X05
3 12 00248- 1601-0001 Kit, Hardw. for Mounting Rosemount
4 12 Rosemount 248H A Head Mount Transmitter Rosemount - AD 01 TT P 233, - AD 01 TT P 235, - AD 01 TT P 230
- AD 01 TT P 229, - AD 01 TT P 236, - AD 01 TT P 238
5 1 6AV6542-0AG10-0AX0 Multipanel MP270 - 51A1
6 1 6AV6574- 2AC00- 2AA0 CF Card 32MB for MP Siemens -51A1.1
7 1 6ES7315-2AG10-0AB0 Central P rocessor Unit CP U 315-2DP , 128 Kbyte Siemens - 53A1
8 1 6ES7953-8LG00-0AA0 Micro Memory Card 128KByte Siemens
9 1 6ES7972-0BB12-0XA0 Bus Connector for P rofibus with P G Socket Siemens
10 1 LUFP7 Gateway Profibus DP/ ModbusRTU Telemecanique - 53A2
11 3 6ES7331-7KF02-0AB0 analog input module SM 331, 8x24V DC Siemens - 56A1, - 54A1, - 55A1
12 1 6ES7332-5HB01-0AB0 anal og output modul e SM 332, 2x24V DC Siemens - 57A1
13 4 6ES7392-1BJ 00-0AA0 frontconnector wi th spri ng contacts 20 pi n Siemens
14 2 6ES7321-1BL00-0AA0 di gi tal i nput module SM 321, 32x24V DC, 40 pins Siemens - 59A1, - 60A1
15 3 6ES7392-1BM01-0AA0 frontconnector wi th spri ng contacts 40 pi n Siemens
16 1 6ES7322-1BL00-0AA0 di gi tal output modul e SM 322, 32x24V DC, 40 pins Siemens - 61A1
17 1 MCR- F L- C- UI - 2UI - DCI /1/0, 0/24, 0 Si gnal Mul ti pl i er, 4 way i sol ati ng Phoenix Contact - 69A1
18 1 UNI GATE RS232/485-MPI uni versal e fi el dbus- gateway RS232/485-MP I Deutschmann - 105A2
19 2 MC R - C - I - I - 00- DC Si gnal Mul ti pl i er, 3 way isolating Phoenix Contact -107A1, -105A1
20 2 Velomitor 300500 - AD 01 XT P 240, - AD 01 XT P 241
21 1 5SX2210-7 miniatur circuit breaker 10A, Char. C - 42F 1
22 4 5SX2206- 7 mi ni atur ci rcui t breaker 6A, Char. C Siemens - 42F 3, - 41F 2, - 41F 1, - 42F 2
23 3 5SX2104-7 mi ni atur ci rcui t breaker, 4 A, Char. C Siemens - 49F 1, - 48F 2, - 48F 1
24 3 5SX9101 auxiliary contact, 2NO Siemens
25 1 5SX2102-7 mi ni atur ci rcui t breaker, 2 A, Char. C Siemens - 49F 2
26 1 QUI NT-P S-100-240AC/24DC/10 uni versal 24V power supply unit, 10A Phoenix Contact - 48G1
27 1 Rittal 4155.100 cubicle lamp 26W, 110VAC - 43H1
28 5 3SB3244-6BA40 i nd. l i ght wi th i ntegrated LED green, 24 V UC Siemens - 63H3, - 64H1, - 65H1, - 63H1, - 64H3
29 1 3SB3244-6BA20 i nd. l i ght wi th i ntegrated LED red, 24 V UC Siemens - 63H4
30 20 3SB3923-0AV fl at hol der for i nscri pti on pl ate 27x27 mm Siemens
31 1 3SB3644-6BA60 i nd. l i ght wi th i ntegrated LED wihte, 24 V UC Siemens - 65H3
sheet 1
of 2
0
2
J acobs
Bently Nevada
Bently Nevada
Siemens
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Name No. Qua. Type Desi gnat i on Manuf act ur er
Equi pment Li st
Equi pment Li st
5 18 269- 150
01 com. UI L 06. 09. 06 J ac
01
30. 05. 2006
32 1 3SB3244-6BA70 i nd. l i ght wi th i ntegrated LED cl ear, 24 V UC Siemens - 65H3
33 1 3SB3233-7BA10 Buzzer, 24 V UC, plastic Siemens - 67H1
34 2 P LC-RSC-24DC/1-1ACT pl uggabl e mul ti - l ayer contact rel ay 2 x NO Phoenix Contact - 63K1, - 89K2
35 1 PNOZ X2.8P emergency stop relay, 24VDC/AC, 3S, 1O P ilz - 68K1
36 1 P LC-RSC-24DC/ 21 pl uggabl e mul ti - l ayer contact rel ay 1 x SP DT Phoenix Contact - 98K2
37 25 PLC-RSC-24DC/1ACT pl uggabl e mul ti - l ayer contact rel ay, 1 NO Phoenix Contact - 106K1, - 106K2, - 103K2, - 106K3, - 103K1, - 96K1, - 102K2, -107K1
- 89K1, - 94K1, - 94K2, - 95K1, - 72K1, - 102K1, - 96K2, - 97K2, - 97K1
- 100K1, - 99K1, - 99K2, - 100K2, - 98K1, - 72K2, - 101K1, - 101K2
38 1 DS72 AQ board- mounted i nstrument Excelsior - 69P 1
39 1 T0- 4- 15682/EA/SVB- SW mai n swi tch 6- pol e, front mounti ng - 40Q1
40 1 3RV1011-1KA10 ci rcui t breaker, si ze S00, 0, 9-1, 25 A Siemens - 92Q1
41 1 3RV1901-1F Transverse Auxiliary Switch, 2NO Siemens
42 2 3SB3202-0AA41 pushbutton with flat pushbutton green, 1 NO Siemens - 63S 1, - 64S 3
43 1 3SB3202-0AA31 pushbutton with flat pushbutton yellow, 1 NO Siemens - 63S 4
44 4 3SB3203-0AA21 pushbutton wi th flat pushbutton red, 1 NC Siemens - 64S 2, - 63S 2, - 65S 2, - 64S 4
45 20 3SB3903-1AA i nscri pti on pl ate, 27x27 mm Siemens
46 2 3SB3602-0AA41 round pushbutton with flat pushbutton green, 1NO Siemens - 65S1, - 64S1
47 2 3SB3245-0AA61 illuminated pushbutton white,integ.LED, 1NO Siemens - 65S 3, - 65S 4
48 1 3SB3202-0AA11 pushbutton wi th fl at pushbutton black, 1 N0 Siemens - 67S1
49 1 3SB3000-4DD11 Actuator S afety Look, F l at I - O- I I Siemens - 67S 2
50 2 3SB3400-0A Actuator with two Contacts, 1NO+1NC Siemens
51 1 3SB3603-1HA20 mushroom push- pul l pushbutton 40 mm, 1 NC Siemens - 68S1
52 1 3SB3921-0AK accessory for 3SB3 protecti ve col l ar, yel l ow Siemens
53 4 USLKG 35 ground termi nal bl ock 35 mm 04 44 01 9 Phoenix Contact - X01, - X02, - X03
54 2 UK35 blue termi nal bl ock 35 mm 30 08 02 5 Phoenix Contact - X01, - X02
55 6 UK35 grey termi nal bl ock 35 mm 30 08 01 2 Phoenix Contact - X03, - X02, - X01
56 34 ST2,5-QUATTRO spri ng cage termi nal bl ock Phoenix Contact - X32, - X31
57 22 UK5-HESI fuse termi nal bl ock 4 mm Phoenix Contact - X91, - X90, - X70
58 28 04 21 03 2 Terminal AKG4 BK f.busbar - XS H, - XS
59 2 30 25 16 3 Shi el d termi nal bl ock SK8 -XSH
sheet 2
of 2
1
J acobs
Layout s
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Dat e
PHASE II
Cover Sheet
sheet 0
of 24

+LCP
=
1
5 18 269- 160
E: \ Pr oj ekt e\ 5 18 269 HZL I I \ El pr o\ 518269MP
j ob no. :
j ob no. :
T el . : +49- 341- 21787- 0
F ax. : +49- 341- 21787- 15
F ax. : +49- 6233- 85- 25 48
T el . : +49- 6233- 85- 0
AG KKK
AviComp
Controls GmbH
TYPE: SFO11
SO BLOWER
2
Pl ant :
1050124
5 18 269
P oetenweg 49
D- 04155 Lei pzi g
KKK J ob No: 1. 050. 124
J acobs 01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.

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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Contents from
000 00 Cover Sheet 5 18 269- 160
001 00 Drawing List Layouts 5 18 269- 160
015 00 +LCP P rincipal View 5 18 269- 160
016 00 +LCP Mount. Plate, Swing Frame 5 18 269- 160
017 00 +LCP Mounting P late 5 18 269- 160
018 00 +LCP Flange 5 18 269- 160
019 00 Handling 5 18 269- 160
020 00 +J B1, +J B2 Genal View 5 18 269- 160
021 00 +J B1 Mounting Plate 5 18 269- 160
022 00 +J B1 Area for F i tti ngs 5 18 269- 160
023 00 +J B2 Mounting P late 5 18 269- 160
024 00 +J B2 Area for F i tti ngs 5 18 269- 160
sheet 1
of 24
0
15
Dr awi ng Li st Layout s
5 18 269- 160
J acobs 01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
D
O F F
ON
ON
OFF
C
AUX.OILPUMP
AUX.OILPUMP
AUX. OIL
E
OILHEATER
OILHEATER ON
OILHEATER OFF
F
OPEN
CLOSE
G
INLETGUIDEVANE
INLETGUIDEVANE
ALARMHORN
p l u g
Mai n S wi tch
B A
1
2
3
MAINDRIVE
MAINDRIVE ON
MAINDRIVE OFF
ALARM STAND-BY
RESET STAND-BY
SIMATICMULTIPANEL
800 625
+LCP
F i tti ng for water
connection 10 mm (0,39")
85
1
5
5
0
1
7
6
0
2
2
0
0
Type: Haewa H355 special (800mm x2000mm x625mm)
P lint 200mm
Local Control Panel +LCP
F i tti ng for ai r
connection Rc (Pc) 1/4
G 1/4
Main Switch
-40Q1
Heat Exchanger
- 43B1
Main Motor Current
- 69P 1
Operator Panel
-51A1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+LCP
Pr i nci pal Vi ew
sheet 15
of 24

J acobs
5 18 269- 160
1
16
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
- X 4 0 - X 2 0
RACK
ADDR
N
E
V
A
D
A
B
E
N
T
L
Y
- X 7 0
- X 1 0
- 5 1 A 1 1
-
9
2
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1
- 6 8 K 1
-
X
0
1
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5
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1
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1
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2
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7
3
5
0
0
1 0 5 A 1
1 0 7 A 1
1 0 7 K 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II sheet 16
of 24

J acobs
5 18 269- 160
15
17
+LCP Mount . Pl at e,
Swi ng Fr ame
- X 9 0 , X 9 1
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
- X 4 0 - X 1 0 - X 2 0
- X 7 0
- 5 1 A 1 1
- 6 8 K 1
-
X
3
3
-
X
3
2
-
X
3
1
-
X
0
1
-
X
0
5
1 0 7 A 1
1 0 5 A 1
1 0 7 K 1
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+LCP
Mount i ng Pl at e
sheet 17
of 24

J acobs
5 18 269- 160
16
18
- X 9 0 , X 9 1
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
bor ehol e f i t t i ngs
M16
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- W_ J B2
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- W_ J B3- 1 - W_ J B3- 3
- W_ J B3- 2
-W
Modbus spare
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- W- 5
- W- 6. 2
Power Supply
Cabl es from/to
MCC or DCS
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+LCP
Fl ange
sheet 18
of 24

J acobs
5 18 269- 160
17
19
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
H A B C D E F G
1
2
3
II 0 I
MAIN DRIVE ALARM AUX. OIL
PUMP
EMERGENCY
OIL PUMP
AUX. OIL PUMP
ON
RESET MAIN DRIVE
ON
MAIN DRIVE
OFF
I-REMOTE
0-LOCAL
II-SERVICE
AUX. OIL PUMP
OFF
plug
EMERGENCY
OIL PUMP
ON
EMERGENCY
OIL PUMP
OFF
OIL HEATER
OFF
OIL HEATER
ON
ALARM
BUZZER
OPEN
OIL HEATER
LAMP TEST/
BUZZER OFF
CLOSE
INLET GUIDE
VANE
INLET GUIDE
VANE
plug plug
plug
READY
TO START
Emergency Stop
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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s

a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
Handl i ng
sheet 19
of 24

J acobs
5 18 269- 160
18
20
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
J unction Box +J B1; +J B2
Material: Stailess Steel 1.4301
10 210
O10,2 /
530
500
4
4
2

5
0
0

Type: Rittal AE 1007.600 (500mm x 500mm x 210mm)
Areas for conduit fittings for cable entry:
from below
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5
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AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
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a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+J B1, +J B2
Genal Vi ew
sheet 20
of 24

=
J acobs
5 18 269- 160
19
21
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
m
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3
0
0
AD01
XT P219
AD01
XT P220
AD01
XT P222
AD01
XT P224
AD01
XT P240
AD01
XT P241
AD01
XT P223
AD01
XT P226
-
X
4
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2
7
1
free for cable entry
0 1 2 3 4 5 6 7 8 9
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
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a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+J B1
Mount i ng Pl at e
sheet 21
of 24

=
J acobs
5 18 269- 160
20
22
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
mounti ng pl ate / Montagepl atte
M16
M20
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20, 5 o
25, 5 o M25
32, 5 o M32
40, 5 o
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next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
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s

a
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+J B1
Ar ea f or Fi t t i ngs
sheet 22
of 24

=
J acobs
5 18 269- 160
21
23
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
m
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.

3
0
0
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AD01
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AD01
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1
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1
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free for cable entry
0 1 2 3 4 5 6 7 8 9
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
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s
s

a
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y

b
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A
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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+J B2
Mount i ng Pl at e
sheet 23
of 24

=
J acobs
5 18 269- 160
22
24
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
M16
M20
M40
/
/
/
/
/ 16, 5 o
20, 5 o
25, 5 o M25
32, 5 o M32
40, 5 o
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mounti ng pl ate / Montagepl atte
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bef or e
next
AG KKK
HINDUSTAN ZINC
Document No. :
Rev.
Rev.
p
r
e
s
s

a
u
t
h
o
r
i
t
y

b
y

A
C
C
.

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Modi f y
Dat e
Dat e Name
+LCP
KKK No. : 1050124
PHASE II
+J B2
Ar ea f or Fi t t i ngs
sheet 24
of 24

=
J acobs
5 18 269- 160
23
01
01 com. UI L 06. 09. 06 J ac
30. 05. 2006
Hindustan Zinc
Chanderiya, India

ACC
Document No.:
5 18 269_220

Page 1 of 14

Date:17.10.2006

Aktiengesellschaft
67227 Frankenthal
SO
2
Blower Type SFO11
Local Control Panels
+ LCP

Location and Job Description:

KK&K J ob No.:
2 250 001

Rev.: 00

Section/ Pos. Description Page

00

First Issue 16.10.2005

Walther Jacobs

Schne

Rev. Status Date Prepared Description Checked Approved
Categ. Status Definition (Latest Rev.) Document (Doc. ld. Code)
5 18 269_220

1 Deutschmann

1.1 Universal Fieldbus-Gateway
UNIGATE
RS232/ RS485/ RS422 Profibus DP

1.1.1 User Manual 2

2 Hwa

2.1 19 Swing Frame
Type 0361-7006-80-02 2

2.2 Elongated barrel
Type 3070-0933-30-00 3

Section 0 Data Sheets - Local Control Panel
Table of Contents
Page 1 of 14
Hindustan Zinc
Chanderiya, India

ACC
Document No.:
5 18 269_220

Page 2 of 14

Date:17.10.2006

Aktiengesellschaft
67227 Frankenthal
SO
2
Blower Type SFO11
+ LCP


KK&K J ob No.:
2 250 001

Rev.: 00


00


Walther Jacobs

Schne

5 18 269_220

2.3 Combination work plate/ diagram pocket
Type 0396-7114-40-00 4

2.4 Fluorescent and Linestra lamp
Type 3080-9041-80-21 5

3 Kiesewetter

3.1 Rotationary measurement instrument
DS72 AQ

3.1.1 Overview 2

3.1.2 Drawings and specific data 3

3.1.3 Ranges 4
Table of Contents
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4 Mller

4.1 Rotary switches
Type T0-4-15682/ EA/ SVB-SW

4.1.1 Technical Overview 3

4.1.2 SystemOverview 5

4.1.3 Key to Type References, Modular System 6

4.1.4 Order Number 7

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5 Phoenix Contact

5.1 Power terminal block
5.1.1 AKG 4 BK
#0421032 5

5.2 MCR

5.2.1 MCR 3-Way isolating amplifier
5.2.1.1 MCR-C-I-I-00-DC
#2814508 10

5.2.2 MCR signal multiplier
5.2.2.1 MCR-FL-C-UI-2UI-DCI
#2814854 16

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5.3 PLC

5.3.1 PLC Relay
5.3.1.1 PLC-RSC-24DC/ 21
#2966171 22

5.3.2 PLC Actuator Relay

5.3.2.1 PLC-RSC-24DC/ 1/ ACT
#2966210 30

5.3.2.2 PLC-RSC-24DC/ 1-1/ ACT
#2967109 38

5.4 Power Supply Unit
5.4.1 QUINT-PS-100-240AC/ 24DC/ 10
#2938604 45

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5.5 Ground Terminal Blocks

5.5.1 ST 2.5 PE
#3031238 54

5.5.2 ST 6 PE
#3031500 60

5.5.3 ST 16 PE
#3036165 65

5.6 Feed-Through Terminal Block

5.6.1 ST 2.5
#3031212 71

5.6.2 ST 6 BU
#3031490 79
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5.7 Multiple Position Modular Terminal Block

5.7.1 ST 2.5 QUATTRO
#3031306 85

5.8 Fuse Terminal Block

5.8.1 UK 5 HESI
#3004100 93

6 Pilz

6.1 Emergency Stop Relay, Safety Gate Monitor

6.1.1 PNOZ X2.8P
#787301 2
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7 Red Lion

7.1 Three Way Isolated Serial Converter Module
(RS232C/ RS485)

7.1.1 Model
#ICM5 2

8 Rosemount

8.1 Rosemount 248 Transmitter and
Temperature Monitoring Assembly

8.1.1 Temperaturetransmitter
Type 248HANANONS 2
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9 Schneider Electric

9.1 LUPF Telemecanique gateway
Profibus-DP/ Modbus RTU

9.1.1 Users Manual 2

10 Siemens

10.1 Series BETA & SIGNUM

10.1.1 Coupling Relays

10.1.1.1 9A, 9KW
#3RT10 16-1J B41 6

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10.1.2 Motor Starter Protectors up to 100A

10.1.2.1 5A, 1.5KW
#3RV10 11-1FA10 7
10.1.2.2 12A, 5.5KW
#3RV10 11-1KA10 7

10.1.3 Auxiliary Switches

10.1.3.1 Transverse Auxiliary Switch
#3RV19 01-1F 8
10.1.3.2 Auxiliary Switch 0.5A
#5SX9 101 9

10.1.4 Miniature Circuit Breakers

10.1.4.1 1-pole

10.1.4.1.1 2A #5SX2 102-7 10
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10.1.4.1.2 4A #5SX2 104-7 10

10.1.4.2 2-pole

10.1.4.2.1 6A #5SX2 206-7 10
10.1.4.2.2 10A #5SX2 210-7 10
10.1.4.2.3 63A #5SX2 263-7 10

10.1.5 Pushbuttons and Indicator Lights

10.1.5.1 Pushbutton with flat button

10.1.5.1.1 Black #3SB32 02-0AA11 11
10.1.5.1.2 Red #3SB32 02-0AA21 11
10.1.5.1.3 Yellow #3SB32 02-0AA31 11
10.1.5.1.4 Green #3SB32 02-0AA41 11

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10.1.5.2 Pushbutton with flat button (metal, round)

10.1.5.2.1 Green #3SB36 02-0AA41 12

10.1.5.3 Pushbutton with flat button (LED integrated)

10.1.5.3.1 White #3SB36 45-0AA61 13

10.1.5.4 Accoustic signal devices IP65

10.1.5.4.1 24AC/ DC black #3SB32 33-7BA10 14

10.1.5.5 Indicator lights with lens with concentric rings

10.1.5.5.1 Red #3SB32 44-6BA20 15
10.1.5.5.2 Green #3SB32 44-6BA40 15
10.1.5.5.3 White #3SB32 44-6BA60 15
10.1.5.5.4 Clear #3SB32 44-6BA70 15

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10.1.5.6 Mushroom pushbutton (Emergency Stop)

10.1.5.6.1 Rotate to unlatch #3SB36 03-1HA20 16

10.1.6 Key-operated switches with holder

10.1.6.1 2 keys, 3 switch positions #3SB30 00-4DO11 17

10.2 Series SIMATIC S7

10.2.1 CPU 315-2 DP
#6ES7315-2AG10-0AB0 18

10.2.2 Analog Input Module SM331
#6ES7331-7KF02-0AB0 25

10.2.3 Analog Output Module SM331
#6ES7331-5HB01-0AB0 36

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10.2.4 Digital Input Module SM321
#6ES7321-1BL00-0AA0 42

10.2.5 Digital Output Module SM 322
#6ES7322-1BL00-0AA0 45

10.2.6 Simatic HMI Multi Panel MP270
#6AV6542-0AG10-0AX0 48

11 SMC - Pneumatik

11.1 Precision Regulator
Series IR1000/ 2000/ 3000

11.1.1 Data Sheet 2
Table of Contents
Page 14 of 14
SO2 BLOWER MANUAL
Revision 1 / 10.10.2006

Designation : Local Control Panel for Main Blower

Supplier : AviComp Controls GmbH

Project : HINDUSTAN ZINC II, INDIA

Project-No. : 518269

KKK-Job-No. : 1.050.124

Drawings-No. : 518269 - 300

Year of construction : 2006

Poetenweg 49
04155 Leipzig
Germany

Tel: +49 341 217 87 0
Fax: +49 341 217 87 15
e-mail: service@avicompcontrols.de
http: www.avicompcontrols.de
SO2 BLOWER MANUAL

10.10.2006 Revision 1 Page 2 of 47
AviComp Controls GmbH 518269-300_R01A_MANUAL.DOC
SO2 BLOWER MANUAL

TABLE OF CONTENTS
0 PREFACE.....................................................................................................................................................5
1 SAFETY INSTRUCTIONS AND DIRECTIONS .....................................................................................6
1.1 SAFETY INSTRUCTIONS..........................................................................................................................6
1.2 SAFETY DIRECTIONS..............................................................................................................................6
2 INSTALLATION REGULATIONS...........................................................................................................7
3 OPERATING INSTRUCTIONS.................................................................................................................8
3.1 GENERAL ...............................................................................................................................................8
3.2 CONTROL ELEMENTS AT CUBICLE..........................................................................................................8
3.3 OPERATOR PANEL................................................................................................................................11
3.3.1 General operation ..........................................................................................................................11
3.3.1.1 Keyboard.........................................................................................................................................11
3.3.1.2 Entering values................................................................................................................................11
3.3.1.3 Entering symbolic values................................................................................................................11
3.3.2 Screens ...........................................................................................................................................12
3.3.2.1 Process Screens...............................................................................................................................12
3.3.2.1.1 Main Menu (K1) .............................................................................................................................12
3.3.2.1.2 Compressor (K9).............................................................................................................................14
3.3.2.1.3 Compressor bearing (K10)..............................................................................................................15
3.3.2.1.4 Gearbox (K11) ................................................................................................................................16
3.3.2.1.5 Main Motor (K12)...........................................................................................................................17
3.3.2.1.6 Circuit Oil (K13).............................................................................................................................18
3.3.2.1.7 Start Conditions (K15)....................................................................................................................19
3.3.2.1.8 Inspection Interval (K16)................................................................................................................20
3.3.2.1.9 System Menu..................................................................................................................................21
3.3.2.1.10 Password.........................................................................................................................................23
3.3.2.2 Screens for Adjustment...................................................................................................................24
3.3.3 Messages ........................................................................................................................................26
3.3.3.1 Displaying Messages.......................................................................................................................27
3.4 BENTLY NEVADA 3300 MONITORING SYSTEM .................................................................................28
3.5 DESCRIPTION OF WORK........................................................................................................................29
3.5.1 General...........................................................................................................................................29
3.5.2 Manual Mode .................................................................................................................................29
3.5.2.1 Actuators.........................................................................................................................................29
3.5.2.2 Auxiliary Drives..............................................................................................................................30
3.5.3 Control of Auxiliary Drives............................................................................................................30
3.5.4 Work of Main Blower .....................................................................................................................31
3.5.4.1 Control Local/Remote.....................................................................................................................31
3.5.4.2 General............................................................................................................................................31
3.5.4.3 Main Blower Start...........................................................................................................................31
3.5.4.4 Main Blower Run............................................................................................................................32
3.5.4.5 Stop Main Blower...........................................................................................................................32
3.5.4.6 Disturbances during Operation........................................................................................................32
3.6 INTERLOCKS / ALARMS........................................................................................................................33
3.6.1 Alarms ............................................................................................................................................33
3.6.2 Trips Shutdown............................................................................................................................33
3.6.3 Ready to Start Conditions ..............................................................................................................34
3.6.4 Start Conditions for main drive......................................................................................................34
Appendix I Measuring Points at Operator Panel................................................................................................................35
Appendix II Parameters.......................................................................................................................................................37
Appendix III Alarm Messages..............................................................................................................................................39
Appendix IV Password.........................................................................................................................................................47

SO2 BLOWER MANUAL


SO2 BLOWER MANUAL

0 Preface

This manual consists of all important descriptions for commissioning, operating and shutting
down the local control panel for the S02 Blower type SF011.

Please read this manual carefully before putting the control panel into operation, to ensure the
correct work with the local control panel.

Any repairs should be made by qualified staff only. Any interference and unauthorised
modification during the warranty time is not allowed, as otherwise we cannot come up to our
warranty commitments according to the terms of supply.

The local control panel is maintenance-free.

If you have further questions, please do not hesitate to contact us.

We wish you a trouble- and failure-free operation.

The management

SO2 BLOWER MANUAL

1 Safety instructions and directions

A T T E N T I O N

Read the safety instructions carefully!

1.1 Safety instructions

Please observe all safety instructions, which are valid for your country.

1.2 Safety directions

The local control panel is designed for the control of the SO2 Blower type SFO 11 exclusively.
Any other or additional use is not permitted. We do not grant any warranty for damages caused
by unauthorized use.

Please observe the following safety directions while working with the local control panel:

- The local control panel should be used by qualified staff only.

- Any person, working with the local control panel has to be familiar with the manual and
in particular the valid safety instructions contained in it.

- Unauthorised modifications are not permitted, otherwise we give no warranty.

- Observe all labels on and in the cubicle. The opening of the cubicle is allowed to
qualified electrical staff only.

- Removal of safety equipment or making it ineffective is not permitted.

- Switch off the power supply before any maintenance work.

- The emergency stop push button shuts down the main drive only.

- The main switch disconnects the 415 VAC and the 230 VAC power supply only.

SO2 BLOWER MANUAL

2 Installation regulations

DIN 40050 degrees of protection (IP-code); protection against foreign
objects; water and contact; electrical equipment
DIN 40719 Diagrams, charts, tables; item designation
DIN 41494 Mechanical structures for electronic equipment; mechanical
structures of the 482,6 mm (19")series; components on front
panels; mounting conditions, dimensions
DIN 57 660 Switchgear and control gear; low-voltage switchgear and
control gear; additional requirements for trackless and rail-born
vehicles [VDE Specification]
DIN EN 60204 Electrical equipment of industrial machines; part 1:
General requirements
DIN V 19251 Process control technology - Requirements and measures for
safeguard function
DIN VDE 0100 Erection of power installations with rated voltages up to 1000V
General requirements
DIN VDE 0110 Insulation coordination for equipment within low-voltage
systems - Part 1: Principles, requirements and tests (IEC 60664-
1:1992, modified);
DIN VDE 0304 Thermal properties of electrical insulating materials; endurance
properties; instructions for calculating the thermal endurance
profile; identical with IEC 60216-4, edition 1980

SO2 BLOWER MANUAL

3 Operating instructions
3.1 General

The programmable logic controller (PLC) is a SIMATIC
S7-300. All necessary measuring

values are connected to this PLC and are checked for limits.
The control functions are integrated in this PLC. For the visualisation a SIMATIC MP 270 is
used. At this operator panel all values can be read and parameters can be adjusted.
The vibration signals are observed by a Bently-Nevada 3300 System. The alarm contacts of
this unit are connected to the PLC.
For handling the Bently-Nevada-System please refer to the separate manual by Bently-Nevada.

3.2 Control elements at cubicle

SIMATIC is a registered trademark of SIEMENS AG

SO2 BLOWER MANUAL

No. Designation Function
P
u
s
h

b
u
t
t
o
n

I
l
l
.

p
u
s
h

b
u
t
t
o
n

S
w
i
t
c
h

L
a
m
p

MP 270 Operator panel
EMERGENCY
STOP
emergency stop for the Main Blower. The main
drive stops immediately, but the aux. drives run for
the run out time.
X
A2 MAIN DRIVE
ON
starts the Main Blower in operating mode "local". X
A3 MAIN DRIVE
OFF
stops the Main Blower in operating mode "local".
Before stopping the main drive, the control valves
are moved into the start position.
X
B3 LOCAL
/SERVICE
REMOTE /

LOCAL: The operator can control the Main Blower
using the push buttons at the cubicle. The set point
for the IGV can be set with push button IGV
OPEN and IGV CLOSE.
REMOTE : The Main Blower is controlled by a
remote system (start, stop, set point)
SERVICE: The aux. drives can be start and stop by
her respective button.
X
C2 RESET Reset-function:
The operator has to press this push button:
after a trip, after switching the cubicle on.
Also acceptance function for all alarms /trips.
X
H2 LAMP TEST/
BUZZER OFF
Switches on all lamps for test purposes and switched
off the buzzer.
X
D2 AUX. OIL
PUMP ON
Switches the aux. oil pump on, only if the
compressor is in service mode.
X
D3 AUX. OIL
PUMP OFF
Switches the aux. oil pump off, if the compressor is
in service mode or the aux. oil pump is switched on
automatically by a low oil pressure during the
compressor is running.
X
F2 OIL HEATER
ON
Switches the oil heater on, only if the compressor is
in service mode.
X
F3 OIL HEATER
OFF
Switches the oil heater off, only if the compressor is
in service mode.
X
E2 EMERG. OIL
PUMP ON
Switches the emerg. oil pump on, only if the
X
E3 EMERG. OIL
PUMP OFF
Switches the emerg. Oil pump off, only if the
X
G1 IGV OPEN In local mode or service mode (selector switch) the
push button opens the Inlet Guide Vane, see the
position of the Inlet Guide Vane on the multi panel
Please note: During start, stop and stand by
sequence the Inlet Guide Vane is controlled always
X
SO2 BLOWER MANUAL

No. Designation Function
P
u
s
h

b
u
t
t
o
n

I
l
l
.

p
u
s
h

b
u
t
t
o
n

S
w
i
t
c
h

L
a
m
p

automatically, not dependently on the position of the
switch.
Attention: By manipulating the Inlet Guide Vane the
Main Blower can fall in surging regime.

The light is on, if the limit switch open is active..
G2 IGV CLOSE In local mode or service mode (selector switch) the
push button closes the Inlet Guide Vane, see the
position of the Inlet Guide Vane on the text display
Please note: During start, stop and stand by
sequence the Inlet Guide Vane is controlled always
automatically, not dependently on the position of the
switch.
Attention: By manipulating the Inlet Guide Vane the
Main Blower can fall in surging regime.
The light is on, if the limit switch close is active.

A1 MAIN DRIVE Flash light in start and stop phases, steady on when
running.
X
B1 READY TO
START
The light is permanently on, when the compressor is
ready for start up.
X
C1 ALARM Flashing light fast: non-accepted alarm or trip,
reason for alarm or trip is not eliminated.
flashing light slow: non-accepted alarm or trip,
reason for alarm or trip is eliminated.
steadily on: accept alarm or trip, reason for alarm is
not eliminated.
Please note: After elimination of the trip reason it is
necessary to press the RESET button to clear the
trip.
X
D1 AUX. OIL
PUMP
Running indication of the auxiliary oil pump X
E1 EMERGENCY
OIL PUMP
Running indication of the emergency oil pump
F1 OIL HEATER On indication of the oil heater. X
1 MAIN SWITCH main switch for 415V and 230V power supply.
Attention: Do not switch off, if the Main Blower is
running!
X

SO2 BLOWER MANUAL


3.3 Operator Panel

The operator panel MP 270 is used for visualisation of all measuring values, to indicate and
record error and status messages and for adjustment of the Main Blower control. All
parameters are password-protected.
For more information please refer to the SIEMENS "Equipment manual MP 270B,TP 270,
OP270".
Attention: Observe the safety instructions in this manual!

3.3.1 General operation
3.3.1.1 Keyboard

For the keyboard assignment and the functions please refer to the SIEMENS "Equipment
manual MP 270B, TP 270, OP270" in section 4.2 "Operating MP 270B Key or OP 270 ".

3.3.1.2 Entering values

Use the input fields on the OP to enter values which can then be downloaded to the PLC.
The input fields can include:

numeric values
alphanumeric values
symbolic values

Input values at the OP:

Use the cursor keys on additional keyboard to position the cursor on the necessary input
field.
Enter the appropriate value.
Confirm the entry with the system key ENTER on the additional keyboard or cancel
incorrect input by pressing the system key ESC on the additional keyboard

3.3.1.3 Entering symbolic values

Symbolic values are entered via a pop-up menu, which provides items for selection. Open pop-
up window with ENTER key on the additional keyboard.
Select the entry with cursor keys on the additional keyboard.
Confirm the entry with the system key ENTER on the additional keyboard or cancel incorrect
input by pressing the system key ESC on the additional keyboard.
SO2 BLOWER MANUAL

3.3.2 Screens

Logically related process values are compiled on screens and thus provide an overview of a
process or a system. Apart from this graphic mapping of processes, screens provide an
opportunity of entering new process values and, thus, of controlling the process. For showing a
screen select the respective function keys on the OP.

3.3.2.1 Process Screens
3.3.2.1.1 Main Menu (K1)

This screen is the start screen after switching the MP 270 on. Within this screen the following
screens can be called with the function keys [ F3 .. F12 ]:

Status Main Motor running (green background)
Open process screens by function keys at the main menu
SO2 BLOWER MANUAL

Function Key Description Content
F3 COMPRESSOR Shows the Main Blower and the IGV measuring points,
temperature.
Includes the function key: alarm [F18], menu [F17] and
trend diagram [F13].
F5 COMPRESSOR
BEARING
Shows the bearing temperature, the shaft vibrations, the
axial displacement.
trend diagrams [F13, F14].
F7 GEAR BOX Shows the bearing temperature.
trend diagrams [F13].
F9 MAIN MOTOR Shows the bearing temperature, winding temperature, the
vibration, main motor current, state of the main heater,
state of the main motor.
F11 CIRCUIT OIL Shows the oil pressure, oil temperature, state of the
emergency and the auxiliary oil pump, state of the oil
heater and oil heater controller, state of the oil level, state
of the oil filter difference pressure.
F4 ALARM Shows the active alarms. To quit an screen ALARM,
please press the key [F4] or [ESC].
F6 ALARMBUFFER Once issued, alarm messages are stored on the OP in a
alarm buffer. To quit an screen ALARMBUFFER, please
press the key [F6] or [ESC].
F8 START
CONDITIONS
Shows state of the start conditions.
Includes the function key: alarm [F18] and menu [F17]
F10 INSPECTION
INTERVALL
Show the inspection messages.
Includes the function key: alarm [F18] and menu [F17]
F12 SYSTEM Within this screen can be called the screen PASSWORD,
LIMITS COMPRESSOR and GEAR BOX,
PARAMETER IGV and TIMER, ENABLE
ALARMS/TRIPS, DP DIAGNOSTIC, STATUS
MESSAGES, STATUS BUFFER, and can be the
runtime shutdown.

SO2 BLOWER MANUAL


3.3.2.1.2 Compressor (K9)
Call this screen with function key COMPRESSOR [F3] in the Main Menu.

F13 TREND
temp/pos
Shows the trend diagram of the following measuring
points:
TE_202, GT_012, GIC_012
To quit an screen TREND, please press the key [F20].
F17 MENU Opens the screen MAIN MENU.
F19 BACK Opens the previous screen.
F20 NEXT Opens the screen COMPRESSOR BEARING.

IGV setpoint from DCS
IGV position
Setpoint IGV
State IGV OPEN/CLOSED IGV control
active/not active
SO2 BLOWER MANUAL


3.3.2.1.3 Compressor bearing (K10)
Call this screen with function key COMPRESSOR BEARING [F5] in the Main Menu.

F13 TREND
temp/vibr
points:
TE_221, TE_225, TE_227,
XE_219, XE_220, XE_222, XE_224
F14 TREND
axial
points:
YE_223, YE_226
F20 NEXT Opens the screen GEARBOX.

SO2 BLOWER MANUAL


3.3.2.1.4 Gearbox (K11)
Call this screen with function key GEAR BOX [F7] in the Main Menu.

F13 TREND
temp
points:
TE_229, TE_230, TE_231, TE_233,
TE_235, TE_236, TE_238, TE_239
F20 NEXT Opens the screen MAIN MOTOR.

SO2 BLOWER MANUAL


3.3.2.1.5 Main Motor (K12)
Call this screen with function key MAIN MOTOR [F9] in the Main Menu.

F13 TREND
temp
points:
TE_240/1, TE_240/3, TE_240/5,
TE_240/7, TE_240/8
F14 TREND
vibr
points:
XE_240, XE_241
F20 NEXT Opens the screen CIRCUIT OIL.

Status Main Motor running
(green background)
Status Main Motor Heater running
(green background)
SO2 BLOWER MANUAL


3.3.2.1.6 Circuit Oil (K13)
Call this screen with function key CIRCUIT OIL [F11] in the Main Menu.

F13 TREND
temp/press
points:
TE_204, PI_208
F20 NEXT Opens the screen START CONDITIONS.

PSLL211 <0,8bar
(red background)
PSH209 >2,0bar
(green background)
PSL210 <1,2bar
(yellow background)
Oil level <min (red background ) Controller oil heater Emergency Oil Pump ON / OFF
Oil heater on/off
Auxiliary Oil Pump ON / OFF Oil level min (yellow background )
Motor lube oil alarm/ trip
(yellow/ red background)
SO2 BLOWER MANUAL


3.3.2.1.7 Start Conditions (K15)
Call this screen with function key START CONDITIONS [F8] in the Main Menu.

F20 NEXT Opens the screen INSPECTION INTERVALL.

Start Condition OK(green background) or NOT OK ready to start
SO2 BLOWER MANUAL


3.3.2.1.8 Inspection Interval (K16)
Call this screen with function key INSPECTION INTERVALL [F10] in the Main Menu.

F20 NEXT Opens the screen SYSTEM.

Please Note: The Reset function for oil quality check is possible only with password level 2.
The Reset function for alignment check is possible only with password level 5.

RESET Inspection message
SO2 BLOWER MANUAL


3.3.2.1.9 System Menu
Call this screen with function key SYSTEM [F12] in the Main Menu.

SO2 BLOWER MANUAL

F3 PASSWORD Opens the screen PASSWORD.
F5 LIMIT
COMPRESSOR
Opens the screen for adjustment LIMITS
COMPRESSOR.
F7 LIMIT GEAR BOX Opens the screen for adjustment LIMITS GEAR BOX.
F9 PARAMETER IGV Opens the screen for adjustment PARAMETER IGV.
F11 PARAMETER
TIMER
Opens the screen for adjustment PARAMETER
TIMER.
F4 ENABLE ALARMS
/ TRIPS
Opens the screens ENABLE ALARMS / ENABLE
TRIPS. The operator has to login with a password.
F6 DP DIAGNOSTIC Opens the diagnostic screens. The operator has to login
with a password.
F8 STATUS
MESSAGES
Shows the active messages. To quit an screen STATUS
MESSAGES, please press the key ESC.
F10 STATUS BUFFER Once issued, status messages are stored on the OP in a
status message buffer. To quit an screen STATUS
BUFFER, please press the key ESC.
F12 RUNTIME
SHUTDOWN
Shutdown the Runtime.
F18 ALARMS Shows the active alarms. To quit an screen ALARM,
F13 PRINT Alarms Prints the Alarm buffer to the default printer
F14 PRINT Status Prints the status buffer to the default printer

SO2 BLOWER MANUAL


3.3.2.1.10 Password
Call this screen with function key PASSWORD [F3] in the System Menu.

F11 PASSWORD
EDIT
Opens the screen PASSWORD EDIT.
F12 LOGOUT User logout.
F16 SYSTEM Opens the screen SYSTEM.

SO2 BLOWER MANUAL


3.3.2.2 Screens for Adjustment

On these screens parameters and limits can be adjusted.
To change the limiting values and parameters, the operator has to login with a password. Opens
the following screens in the System Menu for adjustment the parameter and limits:

F5 LIMITS
COMPRESSOR
Adjustment for limits of the following measuring points:
TE_221, TE_225, TE_227, TE_202,TE_204
F7 LIMITS GEAR
BOX
Adjustment for limits of the following measuring points:
TE_229, TE_230, TE_231, TE_233,
TE_235, TE_236, TE_238, TE_239
F9 PARAMETER
IGV
Adjustment of limiting values IGV.
F11 PARAMETER
TIMER
Adjustment of values timer.

SO2 BLOWER MANUAL


F16 SYSTEM Opens the screen SYSTEM MENU.
F20 NEXT Opens the next screen of adjustment values

SO2 BLOWER MANUAL


3.3.3 Messages

Messages on the OP indicate events and statuses related to control processes. The following
types of message are displayed on the OP:
alarm messages
status messages

Once issued, alarm or status messages are stored on the OP in a message buffer which is
protected against a power failure.

Status messages can be called in the screen SYSTEM with the STATUS MESSAGE button.
Status messages in the buffer can be called into the screen STATUS MESSAGES with the
STATUS BUFFER button.
Alarm messages can be called in all screens with the alarm button. Alarm messages in the
buffer can be called in the main screen with the ALARM BUFFER button .
Close the message screen by pressing the system key ESC .

C come
G go
A acknowledge
SO2 BLOWER MANUAL


3.3.3.1 Displaying Messages

An event message is displayed in the message line, whereas an alarm message is displayed in
the message window. The alarm message window is opened automatically, when an alarm
message occurs. When an alarm message is acknowledged, the alarm message window
disappears, if no other alarm messages are waiting.

System messages indicate internal OP operating statuses. They indicate, for example, male
operations or communication malfunctions. Close the system message window by pressing the
system key ESC on the additional keyboard.
SO2 BLOWER MANUAL

3.4 Bently Nevada 3300 Monitoring System

The monitoring system controls the following signals.

Tag description function
XT_219 vibration compressor NDS alarm, trip
XT_220 vibration compressor NDS alarm, trip
XT_222 vibration compressor DS alarm, trip
XT_224 vibration compressor DS alarm, trip
XT_240 vibration motor DE alarm, trip
XT_241 vibration motor NDE alarm, trip
YE_223 compressor shaft axial
displacement
alarm, trip
YE_224 compressor shaft axial
displacement
alarm, trip
For further information please refer to the Documentation of Bently-Nevada.

Adjusted limits:

Tag Function Limit
XT_240 A+
S+
6 mm/s
11 mm/s
XT_241 A+
S+
4.5 mm/s
7.1 mm/s
XT_219 A+
S+
65 m
95 m
XT_220 A+
S+
65 m
95 m
XT_222 A+
S+
65 m
95 m
XT_224 A+
S+
65 m
95 m
YE_223 A+
A-
S+
S-
0.1 mm
-0.1 mm
0.2 mm
-0.1 mm
YE_224 A+
A-
S+
S-
0.2 mm
-0.1 mm
0.2 mm
-0.1 mm
SO2 BLOWER MANUAL

3.5 Description of work
3.5.1 General

After connecting the power supply, the local control panel is ready for operation.

After a self test the PLC starts with the control program. The lamp "ALARM" starts to flash.
The operator has to press the push button "RESET" to enable the fail safe emergency logic. As
soon, as all values are within their limits, the lamp " ALARM " is switched off. The Main
Blower can be prepared for start, also if the Alarm lamp is steady on. If The blower is ready for
start up, this will be indicated with the "Ready for start up"- lamp.

3.5.2 Manual Mode
3.5.2.1 Actuators

The actuator:

inlet guide vane (IGV)

can be switched to manual mode with the switch " LOCAL/SERVICE/REMOTE" is set to
local or is set to service. In manual mode the set point for the actuators can be set with the push
button IGV open or IGV close. The actual position can be read at the operator panel.

A T T E N T I O N

In manual mode the operator is fully responsible for the correct position of the actuators.

SO2 BLOWER MANUAL

3.5.2.2 Auxiliary Drives

For the operation of the auxiliary drives, the MAIN SWITCH on the control cabinet should
be switched on.

A T T E N T I O N !

For maintenance work with the auxiliary drives, the main switch should be locked in off
position.

The auxiliary drives

Auxiliary oil pump
Emergency oil pump
Oil heater

can be switched ON with the respective ON push button. It is only possible the compressor
is in service mode. Selector switch Local/Service/Remote is in service position. Control lights
indicate the running state of these consumers.

3.5.3 Control of Auxiliary Drives

Control of Auxiliary Oil Pump
The auxiliary oil pump switches automatically on for the prepare to start and stop sequence.
The auxiliary oil pump stays as reserve in case of failures in the main oil circuit and
switches automatically on, if the pressure falls below under a limit PSL_210. If the auxiliary
oil pump is automatically switched on by the oil pressure low PSL_210, the auxiliary oil
pump must be switched off by pressing the push button aux. oil pump off. If the Main
Blower is not running, the oil heater switched automatically on the auxiliary oil pump.
If the Main Blower is running, the auxiliary oil pump should be able to be started
automatically in every moment, to prevent destruction of the machine.

Control of emergency oil pump
The emergency oil pump switches automatically on, if the auxiliary oil pump will be
switched on automatically, but the auxiliary oil pump has an MCB (motor circuit breaker)
error or the oil pressure PSLL_211 is under the low low limit. The emergency oil pump
switches automatically on, if the power supply fails on the Local Control Panel.

Control of oil heater

The temperature controller TSL_244 controls the oil heater. The oil heater is possibly needed
to reach the oil temperature for the start condition of the Main Blower. As soon as the oil heater
is switched on, the auxiliary oil pump is automatically switched on as well.
The heater is interlocked with the oil level switch LSLL_242. The hardwired switch TSH_244
protects the heater against dangerous overtemperature.

SO2 BLOWER MANUAL

3.5.4 Work of Main Blower
3.5.4.1 Control Local/Remote

The control of the Main Blower is possible at the cubical (local) or remote. With the switch
"LOCAL/SERVICE/REMOTE" the operator can select the mode.

Description Local Distance
Compressor START push button "START" signal Compressor ON
Compressor STOP push button "STOP" signal Compressor OFF
IGV set point adjustable with the push
button IGV open or IGV
close
remote set point

All other handling is possible at cubicle only, independent of local/remote mode. In the
following chapters only the local mode is described, because the functions are identical.

3.5.4.2 General
During the normal work, all measuring points are permanently checked to correct values. If the
PLC detects a failure, the alarm lamp starts to flash. The detected failure is indicated at the text
display. In case of critical failures the compressor will be shut down automatically.

3.5.4.3 Main Blower Start
For start the Main Blower must be in ready to start up mode. The lamp READY TO START
signalises the Main Blower is ready for start. For ready to start up mode the following
conditions must be OK:
- no trip
- compressor not running
- the oil temperature is ok (no TIAH_204)
- no hot start blocking
- no DCS interlock for start up (in local mode only)

To start the Main Blower, press the push button "START" for the local mode or send the
hardwired START signal for the remote mode.

At the first the auxiliary oil pump will switched automatically on and the IGV will go to closed
position. After the oil pressure PSH_209 is ok and after the pre lube time for the lube oil circuit
the compressor will started.
The auxiliary oil pump is automatically switched off with a delay time.
During the start-up phase, the PLC locks the IGV and the vibration alarm and trips (trip
multiply).
After the start-up time of the Main Blower (20 sec) the IGV starts to work.

SO2 BLOWER MANUAL

3.5.4.4 Main Blower Run

During Main Blower run, all important measuring values are permanently checked regarding
their limits.

If the actual flow through the compressor is lower than its minimum flow, surge shocks can
appear. The PLC detects these surge shocks and generates an alarm. If surging continues, the
PLC shuts down the compressor.

The adjustment of the parameters is contained in Appendix II (Parameters).

3.5.4.5 Stop Main Blower

To stop the Main Blower press the push button "STOP" for the local mode or send the
hardwired STOP signal from the DCS for the remote mode.

After the get the stop command a stop sequence will be started. The PLC performs the
following steps:

1. Closes the inlet guide vane
2. Switches the main drive off
3. Switches the aux. oil pump on.

The stop sequence runs for 10 minutes (adjustable) after switching the main drive off. After
this, the actuators can be moved manually in every position. The aux. oil pump is stopped
afterwards.

By pressing the push button emergency stop, the main drive is immediately switched off. After
this, the stop sequence starts.

3.5.4.6 Disturbances during Operation

To prevent any damages, a safety shutdown for cases of critical errors is implemented (refer to
section 3.6.2 Trips Shutdown). Before the Main Blower will be switched off, an alarm is
indicated.
After a shutdown, the push button "RESET" at the cubicle must be pressed, if the trip reason is
eliminated.

Non-accepted errors are indicated with a flashing indicator "COMPRESSOR FAILURE". If the
error is accepted, but already there, than the indicator is steadily on.
The operator panel stores all messages with date/time in a buffer.

SO2 BLOWER MANUAL

3.6 Interlocks / Alarms

3.6.1 Alarms

Bearing temperatures gearbox high
(TI_229,TI_230,TI_231,TI_233,TI_235,TI_236,TI_238,TI_239)
Bearing temperature compressor high
(TI_221,TI_225,TI_227)
Temperature oil before gear high (TI_204)
Oil pressure before gear low (PSL_210)
motor lube oil system alarm
Sensor fault temperatures, position of actuators, pressures
Shaft vibration compressor and motor high
(XT_219,XT_220,XT_222,XT_224,XT_240,XT_241)
(common alarm as contact from BN3500, each own alarm by modbus from BN3500)
Vibration channel error (XT_219,XT_220,XT_222,XT_224,XT_240,XT_241)
Axial displacement channel error (YT_223,YT_226)
Axial displacement compressor shaft high/low (YT_223,YT_226)
(common alarm as contact from BN2500, each own alarm by modbus from BN3500)
fuse fault, power supply fault
BN3500 not ok
differential pressure oil filter high (PDISH_203)
over temperature oil heater (TSH_244)
motor circuit breaker error of auxiliary drives (aux. oil pump, emergency oil pump, oil
heater)
tolerance between actual value igv and setpoint igv to big
surge impuls (PDSH_201)

3.6.2 Trips Shutdown

Bearing temperature gearbox high high
(TI_229,TI_230,TI_231,TI_233,TI_235,TI_236,TI_238,TI_239)
Bearing temperature compressor high high
(TI_221,TI_225,TI_227)
Bearing temperature main motor high high as common contact from DCS
(TI_240/7,TI_240/8)
Motor winding temperature high high as common contact from DCS
(TI_240/1,TI_240/3,TI_2405)
Oil pressure before gear low low (PSLL_211)
motor lube oil system trip
vibration compressor and motor high high (common contact from Bently Nevada System)
(XT_219,XT_220,XT_222,XT_224,XT_240,XT_241)
Axial displacement compressor shaft low low/ high high (contact from Bently Nevada
System) (YT_223,YT_226)
SO2 BLOWER MANUAL

Surge protection (PDSH_201)
Timeout start up

3.6.3 Ready to Start Conditions

oil temperature is ok (TI_204)
auxiliary oil pump is ok
main drive is ok
no general trip
no DCS interlock (in local mode only)
no service mode
no hot start blocking (2 minutes after stopping main drive)
run out time lapsed

3.6.4 Start Conditions for main drive

oil pressure is ok (PSH_209)
IGV start position (IGV closed ) (GSL_012)

SO2 BLOWER MANUAL

Appendix I Measuring Points at Operator Panel

Push button Tag-No Unit Description Remarks
Compressor
GIC_012
SP_DCS
GT_012
TI_202
GSH_012
GSL_012
PDSH_201
%
%
%
C
Setpoint to IGV
Setpoint IGV from DCS
Actual value IGV
suction temperature
Lim Limit switch IGV open
Lim Limit switch IGV closed
Surge impuls

digital signal
digital signal
digital signal
Circuit oil
PSH_209
PSL_210
PSL_211
PDISH_203
TE_204
PI_208
LSL_242
LSLL_242
TC_244

Oil pressure >2bar
Oil pressure <1.2 bar
Oil pressure <0.8 bar
Differential pressure on oil filter
Oil temperature
Oil pressure
Oil level <min
Oil level <min min
Controller oil heater
Motor lube oil system alarm
Motor lube oil system trip
digital signal
digital signal
digital signal
digital signal

digital signal
digital signal
digital signal
Bearing
Compressor

TE_221
TE_227
TE_225
XE_219
XE_222
XE_220
XE_224
YE_223
YE_226
C
C
C
m
m
m
m
mm
mm
Temp. Compressor NDS
Temp. Compressor DS
Temp. Axial Compressor DS
Shaft vibration compressor NDS
Shaft vibration compressor DS
Shaft vibration compressor NDS
Shaft vibration compressor DS
Axial displacement compr. Shaft
Axial displacement compr. shaft

gearbox
TE_235
TE_236
TE_238
TE_239
TE_229
TE_230
TE_231
TE_233
C
C
C
C
C
C
C
C
Temp. gearbox HS NDS
Temp. gearbox HS DS
Temp. gearbox HS DS
Temp. gearbox HS DS
Temp. gearbox LS NDS
Temp. gearbox LS DS
Temp. gearbox LS DS
Temp. gearbox LS DS

Main
motor

TE_240/7
TE_240/8
TE_240/1
TE_240/2
TE_240/3
TE_240/4
TE_240/5
C
C
C
C
C
C
C
Temp. main motor DS
Temp. main motor NDS
Winding temp. main motor U1
Winding temp. main motor U2
Winding temp. main motor V1
Winding temp. main motor V2
Winding temp. main motor W1

SO2 BLOWER MANUAL

Push button Tag-No Unit Description Remarks
TE_240/6

XE_240
XE_241
C
A
m
m
Winding temp. main motor W2
Motor current
Vibration motor DS probe 1
Vibration motor DS probe 2
Start
conditions

oil pressure pre lube time
oil temperature
IGV start position
service mode
auxiliary oil pump
hot start blocking
general Trip
main motor ok
DCS interlock
run out time lapsed
Show all start
conditions
Parameter
IGV
Appendix 4
parameter IGV adjustment of
parameter for IGV
Parameter
limits
Appendix 3
parameter limits adjustment of limits
Parameter
timers
Appendix 5
Parameter timer Adjustment of
timers
Enable
alarms

Enable/disable
alarms
Menue
show a list of all
screens

SO2 BLOWER MANUAL

Appendix II Parameters

All parameters can be adjusted to modify the PLC. These parameters are password-protected.
Limits
Operator Panel
push button Limits on screen SYSTEM
Tag Parameter Description Initial
setting

TT_235 Bear . t emp. gear box HS NDS al er t :
Bear . t emp. gear box HS NDS danger :
Alarm level
shut down level
100C
110C

TT_236 Bear . t emp. gear box axi al HS NDS al er t :
Bear . t emp. gear box axi al HS NDS danger :
Alarm level
shut down level
100C
110C

TT_238 Bear . t emp. gear box HS DS al er t :
Bear . t emp. gear box HS DS danger :
Alarm level
shut down level
100C
110C

TT_239 Bear . t emp. gear box axi al HS DS al er t :
Bear . t emp. gear box axi al HS DS danger :
Alarm level
shut down level
100C
110C

TT_229 Bear . t emp. gear box LS NDS al er t :
Bear . t emp. gear box LS NDS danger :
Alarm level
shut down level
100C
110C

TT_230 Bear . t emp. gear box LS axi al NDS al er t :
Bear . t emp. gear box LS axi al NDS danger :
Alarm level
shut down level
100C
110C

TT_231 Bear . t emp. gear box LS DS al er t :
Bear . t emp. gear box LS DS danger :
Alarm level
shut down level
100C
110C

TT_233 Bear . t emp. gear box axi al LS DS al er t :
Bear . t emp. gear box axi al LS DS danger :
Alarm level
shut down level
100C
110C

TT_221 Bear . t emp. compr essor NDS al er t :
Bear . t emp. compr essor NDS danger :
Alarm level
shut down level
100C
110C

TT_227 Bear . t emp. compr essor axi al DS al er t :
Bear . t emp. compr essor axi al DS danger :
Alarm level
shut down level
100C
110C

TT_225 Bear . t emp. compr essor DS al er t :
Bear . t emp. compr essor DS danger :
Alarm level
shut down level
100C
110C

TT_204 Oi l t emper at ur e st ar t condi t i on :
Oi l t emper at ur e al er t :
start condition
alarm level
10C
50C

TT_202 i nl et t emper at ur e al er t :
I nl et t emper at ur e danger :
Alarm level
shut down level
65C
70C

Parameter inlet guide vane
Operator Panel
push button Parameter IGV on screen SYSTEM

Par amet er descr i pt i on I ni t i al
val ue

LMN_HLM : ######%
LMN_LLM : ######%
DF_OUTV : ######%
mani pul at ed val ue hi gh l i mi t
mani pul at ed val ue l ow l i mi t
def aul t out put var i abl e
100 %
0 %
0 %

LMN_URLM: ######%/ s
LMN_DRLM: ######%/ s
up r at e l i mi t
down r at e l i mi t
03 %/ s
03 %/ s

SO2 BLOWER MANUAL


Timer
Operator Panel
Push button Parameter timer on screen SYSTEM

Parameter Description Initial
setting

switch off aux. oil pump 30s
pre-lube time 30s
run out time 900s
Time out communication 130s
start up time 120s
Start up time (alarm bypass) 30s
time off delay emergency oil pump. 300s
Time tolerance time for IGV 20s
Max time start-up 60s
Hot start block time 120s
SO2 BLOWER MANUAL

Appendix III Alarm Messages

Number Message Remark
0001 A: AD2_TI _221 t emper at ur e
compr essor bear i ng NDS Hi gh
Check t he t r end of t hi s val ue
and cont act t he compr essor
manuf act ur er f or f ur t her
assi st ance.
Hi gh
assi st ance.
compr essor bear i ng DS Hi gh
assi st ance.
0004 DB51 DBX1. 3 i nt er nal f aul t . Pl ease cont act
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
0009 A: AD2_TI _235 t emper at ur e gear
box bear i ng HS NDS Hi gh
assi st ance.
box bear i ng axi al HS DS Hi gh
assi st ance.
box bear i ng HS DS Hi gh
assi st ance.
box bear i ng HS DE Hi gh
assi st ance.
box bear i ng LS NDS Hi gh
assi st ance.
box bear i ng LS DS Hi gh
assi st ance.
assi st ance.
assi st ance.
SO2 BLOWER MANUAL

0017 A: wr ong sel ect i on ser vi ce Swi t ch t he sel ect or at t he l ocal
or r emot e posi t i on.
0018 A: er r or auxi l i ar y oi l pump Check t he mot or ci r cui t br eaker
and t he adj ust ed cur r ent .
0019 A: er r or oi l heat er Check t he mot or ci r cui t br eaker
0020 A: er r or emer gency oi l pump Check t he mot or ci r cui t br eaker
t he suppl i er .
t he suppl i er .
0023 A: mai n mot or f aul t Check f ur t her messages f or t he
r eason of t hi s al ar m. Check t he
MCC.
0024 A: pr of i bus DP er r or Check t he pr of i bus connect i on.
0025 A: AD2_TI _202 suct i on
t emper at ur e Hi gh
assi st ance.
0026 A: AD2_TI _204 oi l t emper at ur e
Hi gh
assi st ance.
0027 A: AD2_PDSH_201 sur ge pr ot ect i on
al ar m
Sur ge al ar m. Check t he t r end of
t hi s val ue and cont act t he
compr essor manuf act ur er f or
f ur t her assi st ance.
0028 A: AD2_GT_012 I GV t ol er ance t o
bi g
Check t he act uat or f or t he I GV
and t he connect i on t o t he I GV.
0029 A: AD2_PSL_210 oi l pr essur e <
1. 2 bar
Check t he t r end of t he oi l
pr essur e PT_208, t he oi l pumps,
pr essur e swi t ches and cont act
t he compr essor manuf act ur er f or
0030 A: AD2_PDI SH_203 oi l f i l t er Hi gh Change/ cl ean t he oi l f i l t er .
0031 A: AD2_LSL_242 oi l l evel <mi n Check of l ow oi l l evel i n t he
t ank
0032 A: AD2_TSH_244 oi l heat er over
t emper at ur e
Check t he mot or ci r cui t br eaker
0033 A: BN3500 not ok Check t he f unct i on of al l
pr obes.
0034 A: mai n swi t ch of f Swi t ch on t he mai n swi t ch.
0035 A: f use heat exchange not ok Check t he f use.
0036 A: MCB I GV Check t he mot or ci r cui t br eaker
0037 A: 24V out put s not ok Check t he f use.
0038 A: 24V ext er nal not ok Check t he f use.
0039 A: BN3500 vi br at i on al ar m Check t he t r end of t he vi br at i on
val ues and cont act t he
0040 A: BN3500 axi al di spl acement
al ar m
Check t he t r end of t he axi al
di spl acement val ues and cont act
0041 A: i nspect i on check oi l I nspect i on message
0042 A: i nspect i on check
cont ami nat i on
I nspect i on message
0043 A: i nspect i on check t he I nspect i on message
SO2 BLOWER MANUAL

al i gnment
0044 A: mot or l ube oi l syst emal ar m Check t he oi l pr essur e, t he oi l
pumps, pr essur e swi t ches and
cont act t he compr essor
assi st ance.
t he suppl i er .
t he suppl i er .
t he suppl i er .
0048 A: communi cat i on er r or Check t he Modbus connect i on t o
t he DCS.
0049 A: SF AD2_TI _221 t emper at ur e
Check of t he connect i on and t he
sensor .
sensor .
sensor .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
sensor .
gear box bear i ng axi al HS DS
sensor .
sensor .
gear box bear i ng HS DE
sensor .
sensor .
sensor .
sensor .
sensor .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
SO2 BLOWER MANUAL

t he suppl i er .
t he suppl i er .
0073 A: SF AD2_TI _202 suct i on
t emper at ur e
sensor .
0074 A: SF AD2_TI _204 oi l t emper at ur e Check of t he connect i on and t he
sensor .
0075 A: SF AD2_PI _208 oi l pr essur e Check of t he connect i on and t he
sensor .
0076 A: SF AD2_GT_012 I GV posi t i on Check of t he connect i on and t he
sensor .
0077 A: SF mot or cur r ent Check of t he connect i on and t he
sensor .
0078 A: SF set poi nt DCS Check of t he connect i on and t he
sensor .
t he suppl i er .
t he suppl i er .
0081 A: AD2_XE_222 danger Check t he t r end of t hi s val ue
assi st ance.
0082 A: AD2_XE_224 channel er r or Check t he connect i on and t he
pr ob of t hi s val ue.
0083 A: AD2_XE_224 al er t Check t he t r end of t hi s val ue
assi st ance.
assi st ance.
assi st ance.
assi st ance.
assi st ance.
assi st ance.
pr obe of t hi s val ue.
SO2 BLOWER MANUAL

assi st ance.
assi st ance.
assi st ance.
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
assi st ance.
assi st ance.
assi st ance.
assi st ance.
assi st ance.
assi st ance.
0113 S: AD2_TI _221 t emper at ur e
compr essor bear i ng NDS Hi gh
Hi gh
Compressor Shutdown. Check t he
t r end of t hi s val ue and cont act
0114 S: AD2_TI _227 t emper at ur e Compressor Shutdown. Check t he
SO2 BLOWER MANUAL

Hi gh Hi gh
0115 S: AD2_TI _225 t emper at ur e
compr essor bear i ng DS Hi gh Hi gh
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
0121 S: AD2_TI _235 t emper at ur e gear
box bear i ng HS NDS Hi gh Hi gh
box bear i ng axi al HS DS Hi gh
Hi gh
box bear i ng HS DS Hi gh Hi gh
box bear i ng HS DE Hi gh Hi gh
box bear i ng LS NDS Hi gh Hi gh
box bear i ng LS DS Hi gh Hi gh
0129 S: mai n dr i ve t i meout st op Compressor Shutdown. Check t he
Si gnal s bet ween LCP and MCC.
Cont act t he suppl i er f or f ur t her
assi st ance.
0130 S: mai n dr i ve t i meout st ar t Compressor Shutdown. Check t he
assi st ance.
0131 S: mai n dr i ve ext er nal er r or Compressor Shutdown. Check t he
SO2 BLOWER MANUAL

assi st ance. Check ot her al ar m
messages f or t he r eason of t hi s
t r i p.
0132 S: emer gency st op Compressor Shutdown. Check
f ur t her t r i p messages f or t he
r eason of t hi s t r i p
0133 S: mot or wi ndi ng t emper at ur e not
ok
0134 S: mot or wi ndi ng bear i ng not ok Compressor Shutdown. Check t he
0135 S: BN3500 vi br at i on Compressor Shutdown. Check t he
0136 S: BN3500 axi al di spl acement Compressor Shutdown. Check t he
0137 S: AD2_TI _202 suct i on
t emper at ur e Hi gh Hi gh
0138 S: mot or l ube oi l syst emt r i p Compressor Shutdown. Check t he
oi l pr essur e, t he oi l pumps,
pr essur e swi t ches and cont act
0139 S: AD2_PDSHH_201 sur ge
pr ot ect i on
Surge Protection. Compressor
Shutdown. Check t he t r end of
t hi s val ue and cont act t he
0140 S: AD2_PDS_201 sur ge pr ot ect i on
f ai l ur e
Surge Protection failure.
connect i on t o t he sur ge
pr ot ect i on uni t ( PDS_201) and
cont act t he compr essor
assi st ance.
0141 S: AD2_PSLL_211 oi l pr essur e <
0. 8 bar
t r end of t he oi l pr essur e
PT_208, t he oi l pumps, pr essur e
swi t ches and cont act t he
0142 Ti meout st ar t up Compressor Shutdown.Oi l pr essur e
not r eachend t he hi gh l evel or
i nl et gui de vane not cl osed
dur i ng t he st ar t up t i me. Check
t he aux. oi l pump and t he i nl et
gui de vane.
0143 S: AD2_LSLL_242 oi l l evel <mi n
mi n
Compressor Shutdown. Check of
l ow l ow oi l l evel i n t he t ank
0144 S: per i pher i e f aul t Compressor Shutdown. Check t he
I nput / Out put car d of PLC.
SO2 BLOWER MANUAL

assi st ance.
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .
t he suppl i er .

SO2 BLOWER MANUAL

Appendix IV Password

To change the parameters, the operator has to log in with a password.
Remark: After 10 minutes without any key pressing, the operator panel logs automatically off.

Log in on the OP
using the Password screen
by calling a function for which the current password level is too low. In this case the OP
automatically requests a password.

Password-
level
name password
9 admin 1050124
8 user 80808080
7 user2 77007700
6 user3 66660000
5 user4 55005500
2 user5 22222222

0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6
rev.no revision name
date
date
prep.
chec.
norm
before
next
rev.no.
+
=UCP
Chanderiya, India
Khnle,Kopp & Kausch
Heheimer Str. 2
D-67227 Frankenthal
AviComp
Controls GmbH
Poetenweg 49
04155 Leipzig
KKK Job.no: 2250001
Jacobs
Jacobs
Project: Hindustan Zinc II
1
SO2 Blower
Type SFO11
Modbus Data
Exchange List
19.07.06
Doc no: 518 269-460
02
sheet 0
off 7
chec. chec. 19.07.2006 00
01
02
15.08.2006
10.10.2006
MODBUS DATA EXCHANGE LIST
Project: HINDUSTAN ZINC II, INDIA
Purchaser: AG Khnle, Kopp & Kausch
Revision: 2
General communicating configuration
All signals are transmit as 16Bit Integer.
Analog signals use one word for every signal. They will be transmitted as number between 0-4096 scaled by range begin/ range end.
Digital signals are transmit as 16Bit Integer, that are 16 signals per word.
Connector to the external device (RS-interface)
The connection cable to the external device must be plugged in
at the connector accessible on the underside of the device.
Pin assignment (5-pin screw-type plug connector)
Pin No. Name Function
1 10.8..30 V/DC power supply Power supply
2 0 V power supply Power supply
3 RX / RS485- (RS485 B) Receive signal
4 TX / RS485+ (RS485 A) Transmit signal
5 GND Reference for PIN 3 + 4
Interface Data: Please refer to attached document "uni_pb_e.pdf"
at page 53 (16.1.1 Interface data)
Device/ Slave Address : 2
Baud rate : 19200
Parity : even
Data bits : 8
Stop bits : 1
Interface Type : 2 wire RS485 preferred
Protocol : Modbus RTU
KKK
HINDUSTAN ZINC II, INDIA 1 of 7
518269-460_R02_SignalExchange.xls
General
Revision: 2
Analog to DCS
Tag Name as in
the third party
system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Data Type
(with ref.
to DCS)
To DCS
Data
Format
Engg.Unit Range
Scale
format
(16 charcters only) (24 characters) (DCS side)
(AI\ AO\
DI\ DO)
(For AI\AO) (For AI\AO) (For AI\AO) (For AI\AO)
AD2_TI_235 AD2_TI_235 gear. bear. HS NDS 40021 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_236 AD2_TI_236 gear. bear. ax. HS DS 40022 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_238 AD2_TI_238 gear. beer. HS DS 40023 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_239 AD2_TI_239 gear. bear. ax. HS DE 40024 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_229 AD2_TI_229 gear. bear. LS NDS 40025 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_230 AD2_TI_230 gear. bear. ax. LS DS 40026 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_231 AD2_TI_231 gear. bear. LS DS 40027 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_233 AD2_TI_233 gear. bear. ax. LS DS 40028 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_221 AD2_TI_221 compr. bear. NDS 40029 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_227 AD2_TI_227 compr.bear. axial DS 40030 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_225 AD2_TI_225 compr. bear. DS 40031 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_202 AD2_TI_202 suction temperature at igv 40032 AI To DCS integer DegC. 0..200 0..4096
AD2_TI_204 AD2_TI_204 oil temperature 40033 AI To DCS integer DegC. 0..200 0..4096
AD2_PI_208 AD2_PI_208 oil pressure 40034 AI To DCS integer bar 0..6 0..4096
AD2_GT_012 AD2_GT_012 igv position 40035 AI To DCS integer % 0..100 0..4096
[TAG NO.] [TAG NO.] motor current 40036 AI To DCS integer A 0..400 0..4096
[TAG NO.] [TAG NO.] remote setpoint from DCS 40037 AI To DCS integer % 0..100 0..4096
AD2_GIC_012 AD2_GIC_012 setpoint to igv 40038 AI To DCS integer % 0..100 0..4096
AD2_XE_219 AD2_XE_219 vibr. compr. shaft NDS 40039 AI To DCS integer m 0..150 0..4096
AD2_XE_220 AD2_XE_220 vibr. compr. shaft NDS 40040 AI To DCS integer m 0..150 0..4096
AD2_XE_222 AD2_XE_222 vibr. compr. shaft DS 40041 AI To DCS integer m 0..150 0..4096
AD2_XE_224 AD2_XE_224 vibr. compr. shaft DS 40042 AI To DCS integer m 0..150 0..4096
AD2_XE_240 AD2_XE_240 vibr. motor DE probe 1 40043 AI To DCS integer m 0..150 0..4096
AD2_XE_241 AD2_XE_241 vibr. motor DE probe 2 40044 AI To DCS integer m 0..150 0..4096
AD2_XE_223 AD2_XE_223 axial displacement 40045 AI To DCS integer mm -1..+ 1 0..4096
AD2_XE_226 AD2_XE_226 axial displacement 40046 AI To DCS integer mm -1..+ 1 0..4096
KKK
Analog_Input
Revision: 2
Digital to DCS
Tag Name
as in the third
party system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Bit No.
Data Type
(with ref.
to DCS)
To DCS 0 - State 1 - State
(AI\ AO\
DI\ DO)
live bit Y 40001 0 DI To DCS
[SPARE] 1 DI To DCS
[SPARE] 2 DI To DCS
[SPARE] 3 DI To DCS
[SPARE] 4 DI To DCS
[SPARE] 5 DI To DCS
[SPARE] 6 DI To DCS
[SPARE] 7 DI To DCS
[SPARE] 8 DI To DCS
[SPARE] 9 DI To DCS
[SPARE] 10 DI To DCS
// Compressor status
AD2_STATUS_001 remote mode N 40002 0 DI To DCS REMOTE
AD2_STATUS_002 [SPARE] 1 DI To DCS
AD2_STATUS_003 igv manual mode N 2 DI To DCS IGV AUTO IGV MANUAL
AD2_STATUS_005 local mode N 4 DI To DCS LOCAL
AD2_STATUS_006 service mode N 5 DI To DCS SERVICE
AD2_STATUS_008 reset button pressed N 7 DI To DCS RESET
AD2_STATUS_009 compressor ready for startup N 8 DI To DCS
AD2_STATUS_010 status goto to standby N 9 DI To DCS GOTO
AD2_STATUS_011 status reday to start N 10 DI To DCS READY STRT
AD2_STATUS_012 status startup main drive N 11 DI To DCS STARTUP
AD2_STATUS_013 command run to main drive N 12 DI To DCS CMD RUN
AD2_STATUS_014 status main drive running N 13 DI To DCS RUNNING
AD2_STATUS_016 status run out time N 15 DI To DCS STOPPING
AD2_STATUS_017 [SPARE] 40003 0 DI To DCS
// Alarms
AD2_TIAH_221 AD2_ALARM_001 alert AD2_TI_221 high Y 40004 0 DI To DCS ok alarm
AD2_TIAH_227 AD2_ALARM_002 alert AD2_TI_227 high Y 1 DI To DCS ok alarm
AD2_ALARM_004 [SPARE] 3 DI To DCS
AD2_ALARM_017 wrong selection service Y 40005 0 DI To DCS ok alarm
AD2_ALARM_018 error aux. oil pump Y 1 DI To DCS ok alarm
AD2_ALARM_019 error oil heater Y 2 DI To DCS ok alarm
AD2_ALARM_020 error ermerg. oil pump Y 3 DI To DCS ok alarm
AD2_ALARM_021 Y 4 DI To DCS ok alarm
AD2_ALARM_022 Y 5 DI To DCS ok alarm
AD2_ALARM_023 main motor fault Y 6 DI To DCS ok alarm
AD2_ALARM_024 profibus DP error Y 7 DI To DCS ok alarm
AD2_DSH_201 AD2_ALARM_027 surge protection alarm Y 10 DI To DCS ok alarm
AD2_GT_012_Tol AD2_ALARM_028 alert igv tolerance to big Y 11 DI To DCS ok alarm
AD2_SL_210 AD2_ALARM_029 oil press.< 1.2 bar Y 12 DI To DCS ok alarm
AD2_DISH_203 AD2_ALARM_030 oil filter high Y 13 DI To DCS ok alarm
AD2_LSL_242 AD2_ALARM_031 oil level < min Y 14 DI To DCS ok alarm
AD2_TSH_244 AD2_ALARM_032 oil heater overtemperature Y 15 DI To DCS ok alarm
AD2_ALARM_033 BN3500 system not ok Y 40006 0 DI To DCS ok alarm
AD2_ALARM_034 Main switch off Y 1 DI To DCS ok alarm
AD2_ALARM_035 fuse heat exchange not ok Y 2 DI To DCS ok alarm
cycle inversion
KKK
Binary_Input
Revision: 2
Digital to DCS
Tag Name
as in the third
party system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Bit No.
Data Type
(with ref.
to DCS)
(AI\ AO\
DI\ DO)
AD2_ALARM_036 mcb igv Y 3 DI To DCS ok alarm
AD2_ALARM_037 24V outputs not ok Y 4 DI To DCS ok alarm
AD2_ALARM_038 24V external not ok Y 5 DI To DCS ok alarm
AD2_ALARM_039 BN3500 vibration alarm Y 6 DI To DCS ok alarm
AD2_ALARM_040 BN3500 axial displ. Alarm Y 7 DI To DCS ok alarm
AD2_ALARM_041 inspection check oil Y 8 DI To DCS ok alarm
AD2_ALARM_042 inspect. check contamination Y 9 DI To DCS ok alarm
AD2_ALARM_043 inspect. check the alignment Y 10 DI To DCS ok alarm
AD2_ALARM_044 motor lube oil system alarm Y 11 DI To DCS ok alarm
AD2_ALARM_048 Communication Error Y 15 DI To DCS ok alarm
AD2_TI_221ERR AD2_ALARM_049 sensor fault AD2_TI_221 Y 40007 0 DI To DCS ok alarm
AD2_TI_227ERR AD2_ALARM_050 sensor fault AD2_TI_227 Y 1 DI To DCS ok alarm
AD2_ALARM_052 [SPARE] Y 3 DI To DCS
AD2_ALARM_065 [SPARE] 40008 0 DI To DCS
AD2_PI_208ERR AD2_ALARM_075 sensor fault AD2_PI_208 Y 10 DI To DCS ok alarm
AD2_GT_012ERR AD2_ALARM_076 sensor fault AD2_GT_012 Y 11 DI To DCS ok alarm
AD2_ALARM_077 sensor fault motor current Y 12 DI To DCS ok alarm
AD2_ALARM_078 sensor fault setpoint DCS Y 13 DI To DCS ok alarm
AD2_ALARM_081 AD2_XE_222 danger Y 40009 0 DI To DCS ok alarm
AD2_ALARM_082 AD2_XE_224 channel error Y 1 DI To DCS ok alarm
AD2_ALARM_083 AD2_XE_224 alert Y 2 DI To DCS ok alarm
AD2_ALARM_084 AD2_XE_224 danger Y 3 DI To DCS ok alarm
AD2_ALARM_097 [SPARE] 40010 0 DI To DCS
// Trips
AD2_TISHH_221 AD2_TRIP_001 danger AD2_TI_221 hh Y 40011 0 DI To DCS ok trip
AD2_TISHH_227 AD2_TRIP_002 danger AD2_TI_227 hh Y 1 DI To DCS ok trip
KKK
Binary_Input
Revision: 2
Digital to DCS
Tag Name
as in the third
party system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Bit No.
Data Type
(with ref.
to DCS)
(AI\ AO\
DI\ DO)
AD2_TRIP_004 [SPARE] 3 DI To DCS
AD2_TRIP_017 main drive timeout stop Y 40012 0 DI To DCS ok trip
AD2_TRIP_018 main drive timeout start Y 1 DI To DCS ok trip
AD2_TRIP_019 main drive external error Y 2 DI To DCS ok trip
AD2_TRIP_020 emergency stop Y 3 DI To DCS ok trip
AD2_TRIP_021 motor winding temp. trip Y 4 DI To DCS ok trip
AD2_TRIP_022 motor bearing temp. trip Y 5 DI To DCS ok trip
AD2_TRIP_023 BN3500 vibration trip Y 6 DI To DCS ok trip
AD2_TRIP_024 BN3500 axial displ. Trip Y 7 DI To DCS ok trip
AD2_TRIP_026 motor lube oil system trip Y 9 DI To DCS ok trip
AD2_DSHH_201 AD2_TRIP_027 surge protection trip Y 10 DI To DCS ok trip
AD2_TRIP_028 surge protection failure trio Y 11 DI To DCS ok trip
AD2_PSL_211 AD2_TRIP_029 oil pressure p< 0.8 bar Y 12 DI To DCS ok trip
AD2_TRIP_030 timeout startup Y 13 DI To DCS ok trip
AD2_LSLL_242 AD2_TRIP_031 oil level < min min Y 14 DI To DCS ok trip
AD2_TRIP_032 danger periphery fault Y 15 DI To DCS ok trip
AD2_TRIP_033 [SPARE] 40013 0 DI To DCS
// Others digital signals
AD2_STATUS_033 oil pump running N 40014 0 DI To DCS stopped running
AD2_STATUS_034 emergency oil pump running N 1 DI To DCS stopped running
AD2_STATUS_035 oil heater on N 2 DI To DCS off on
AD2_STATUS_036 igv closed N 3 DI To DCS closed
AD2_STATUS_037 igv open N 4 DI To DCS open
AD2_STATUS_038 oil pressure >2bar N 5 DI To DCS >2bar
AD2_STATUS_039 oil heater temp. controller N 6 DI To DCS off on
AD2_STATUS_040 common alarm Y 7 DI To DCS ok alarm
AD2_STATUS_041 common trip Y 8 DI To DCS ok trip
KKK
Binary_Input
Revision: 2
Digital to DCS
Tag Name
as in the third
party system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Bit No.
Data Type
(with ref.
to DCS)
(AI\ AO\
DI\ DO)
KKK
Binary_Input
Revision: 2
Analog from DCS
Tag Name as in
the third party
system
TAG NAME
(to be configured
on DCS system)
Point Description
(on DCS side)
ALARM
(Y\N)
MODBUS
Address
Data Type
(with ref.
to DCS)
To DCS
Data
Format
Engg.Unit Range
Scale
format
(AI\ AO\
DI\ DO)
(For AI\AO) (For AI\AO) (For AI\AO) (For AI\AO)
AD2_TE_240/1 AD2_TI_240/1 motor winding temp. U 40101 AO From DCS integer Deg.C 0..200 0..4096
AD2_TE_240/3 AD2_TI_240/3 motor winding temp. V 40102 AO From DCS integer Deg.C 0..200 0..4096
AD2_TE_240/5 AD2_TI_240/5 motor winding temp. W 40103 AO From DCS integer Deg.C 0..200 0..4096
AD2_TE_240/2 AD2_TI_240/2 motor winding temp. 40104 AO From DCS integer Deg.C 0..200 0..4096
AD2_TE_240/7 AD2_TI_240/7 motor bearing DE 40107 AO From DCS integer Deg.C 0..200 0..4096
AD2_TE_240/8 AD2_TI_240/8 moor bearing NDE 40108 AO From DCS integer Deg.C 0..200 0..4096
KKK
Analog_Output

So2 Blower

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1D001ENV page 1 of 1

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

BN Internal Barrier I/O Modules.

* Barriers are not supported with this transducer option.

BN Internal Barrier I/O Modules.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

Calculate the input voltage.

24145-02 -15.05 * -2.75 * -8.90 *

330425 -11.37 -10.86

49578-01 -11.37 -10.86

155023-01 -11.37 * -5.63 * -8.50 *

BN Internal Barrier I/O Modules.

24145-02 -15.05 * -2.75 * -8.90 *

330425 -11.37 -10.86

49578-01 -11.37 -10.86

155023-01 -11.37 * -5.63 * -8.50 *

BN Internal Barrier I/O Modules.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

To input rms volts for rms full scale units:

To input peak to peak volts for peak full scale units:

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

2. Calculate the input voltage.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

signal buffered output and observe the two signals simultaneously.

3500/92 COMMUNCATON MODULE OPERATON AND MANTENANCE MANUAL

Sensor and probe tip with 1 foot of cable are at +25 C)

Sensor and probe tip with 1 foot of cable are at +25 C)

S7-300. All necessary measuring

SIMATIC is a registered trademark of SIEMENS AG

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