3500 25 Keyphasor Module Operations and Maintenance Manual 1

Part No. 129770-01 Revision H, November 1999

3500/25 ®

KEYPHASOR MODULE OPERATION AND MAINTENANCE MANUAL

© Bently Nevada Nevada Corporation Corporation 1999 Data subject to change without notice All Rights Reserved No part of this publication may be reproduced, transmitted, stored in a retrieval system or translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written permission of the copyright owner,

Bently Nevada Corporation 1617 Water Street 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 of Bently Nevada Corporation.

© Bently Nevada Nevada Corporation Corporation 1999 Data subject to change without notice All Rights Reserved No part of this publication may be reproduced, transmitted, stored in a retrieval system or translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written permission of the copyright owner,

Bently Nevada Corporation 1617 Water Street 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 of Bently Nevada Corporation.

3500/25 Operation and Maintenance

Additional Information NOTICE: This manual does not contain all the information required to operate and maintain the Keyphasor Keyphasor Module. Module. Refer to the following manuals manuals for other required information.

3500 Monitoring System Rack Installation and Maintenance Manual (129766-01) •

general description descriptio n of a standard system

•

general description descriptio n of a Triple Modular redundant (TMR) system

•

instructions for installing 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 3500 Rack Rack Configuration Configuration software for setting the operating 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

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

instructions for connecting connecting the rack to 3500 host computer

•

procedures procedures for verifying communication communication

•

procedures 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 communicat ions

3500 Field Wiring Diagram Package (130432-01) Package (130432-01) •

diagrams that show how to hook up a particular transducer

•

lists of recommended recommended wiring

iii


Contents 1

Rece Re ceiv ivin ing g and Hand Handli ling ng Inst Instru ruct ctio ions ns .... ...... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... .....1 ..1

1.1 1.2 1.3

Receivin Receiving g Inspectio Inspection n ...... ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............1 ......1 Handling Hand ling and Storing Storing Considera Considerations tions ...... ............ ............ ............ ............ ............ ............ ........... ........... ............ ........... ........... .........1 ...1 Disposa Disposall Statemen Statementt ...... ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............. ........1 .1

2

Genera Generall Informa Informatio tion...... n......... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ........ .....2 .2

2.1 Triple Mod Modular ular Redu Redundan ndantt (TMR) (TMR) Descripti Description on ..... ........... ........... .......... .......... ........... ........... .......... ........... ............ ........... ......2 .2 2.2 Availab Available le Data ...... ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ............. .........3 ...3 2.2.1 2.2 .1 Status Statuses es ...... ......... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......3 ...3 2.3 LED Descriptio Descriptions...... ns............ ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............5 ......5

3

Configur Configurati ation on Informat Information.... ion........ ....... ...... ...... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ......6 ...6

3.1 Hardware Hardware Con Conside sideratio rations ns ...... ............ ............ ............ ............. ............. ............ ............ ............ ............ ............. ............. ............ ............ ...........6 .....6 3.2 Software Software Con Configura figuration tion Options....... Options............. ............ ............ ............. ............. ............ ............ ............ ............ ............. ............. ............ .......7 .7 3.2.1 3.2 .1 Keyp Ke yphas hasor or Mo Modul dule e Con Configu figurat ration ion Con Consid sidera eratio tions..... ns........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....7 .7 3.2.2 3.2 .2 Keyp Ke yphas hasor or Mo Modul dule e Conf Configu igurat ration ion Option Options s ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....8 ..8 3.3 Software Software Switche Switches s ...... ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............. ............. ............ ............ ........12 ..12

4

I/O Module Module Des Descri criptio ption...... n......... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ...... .....14 ..14

4.1 Keyphaso Keyphasorr I/O I/O Modul Module e (Intern (Internal al Terminatio Termination) n) ..... ........... ............ ........... .......... .......... ........... ........... .......... ........... ...........15 .....15 4.2 Keyphaso Keyphasorr Internal Internal Barrier Barrier I/O Mod Module ule (Internal (Internal Terminatio Termination)... n)......... ........... .......... ........... ............ .........16 ...16 4.2.1 4.2 .1 Wiring Wiring Eu Euro ro Style Style Con Connec nector tors s ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......1 ...17 7 4.3 Keyphaso Keyphasorr I/O I/O Modul Module e (Extern (External al Termination Termination)) ..... .......... ........... ........... .......... .......... ........... ........... .......... ........... ...........18 .....18 4.3.1 4.3 .1 Exter Externa nall Termi Terminat natio ion n Bloc Blocks..... ks........ ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... .....19 ..19 4.3.2 4.3 .2 Cable Ca ble Pin Outs Outs ...... ......... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ......2 ..21 1

5

Mainten Maintenanc ance e .... ........ ....... ....... ........ ....... ....... ........ ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ........ ....... ....... ......22 ..22 ®

5.1 5.1 Verify Veri fyin ing g a 350 3500 0R Rac ack k - Key Keyph phas asor or Module ............................................................22 5.1.1 5.1 .1 Choosin Choos ing g a Ma Maint intena enance nce Interv Interval al ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....22 .22 5.1.2 5.1 .2 Requi Re quired red Test Test Eq Equi uipme pment... nt...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... .....23 ..23 5.1.3 5.1 .3 Typica Typicall Verifi Verificat cation ion test test setup... setup....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ...... ...... .....23 ..23 5.1.4 5.1 .4 Using Using the Ra Rack ck Con Config figura uratio tion n So Softw ftware... are...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....... ...... ...... ...... ...... ...... ......2 ...24 4 5.1.5 5.1 .5 Verify Ve rifying ing Ke Keyp yphas hasor or Cha Channe nnels ls ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....26 ..26 5.1.6 5.1 .6 If a Ch Chann annel el Fails Fails a Veri Verific ficati ation on Test Test ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....29 ..29 5.2 Performing Performing Firmware Firmware Upgrades.. Upgrades........ ............ ........... ........... ............ ........... ........... ............ ........... ........... ............ ........... ........... ..........30 ....30 5.2.1 5.2 .1 Instal Installat lation ion Proced Procedure.. ure..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....30 ..30

6

Troubles Troubleshoot hooting. ing.... ....... ....... ...... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ....... ....... ...... ...... ..... 34

6.1 6.2 6.3 6.4

Self-test.......... Self-test................ ............ ............ ............. ............. ............ ............ ............ ............ ............. ............. ............ ............ ............ ............ ............ ............. ........34 .34 LED Fault Fault Cond Condition itions...... s............ ........... ........... ............ ........... ........... ............ ........... ........... ............ ........... ........... ............ ........... ........... ...........35 .....35 System System Even Eventt List List Messa Messages... ges......... ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ .......35 .35 Alarm Alarm Event Event List Message Messages s ...... ............. ............. ............ ............ ............ ............ ............ ............. ............. ............ ............ ............ ............4 ......43 3

7

Orde Orderin ring g Info Informa rmati tion on ..... ....... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ....44 ..44

8

Spec Specif ific icat atio ions ns ..... ........ ..... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... ..... ..... ..... ..... .... ..... ..... .....46 ...46

iv


1 1.1

1 Receiving and Handling Instructions

Receiving and Handling Instructions Instructio ns Receiving Inspection 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.

1.2

Handling and Storing Considerations Circuit boards contain devices that are susceptible to damage when exposed to electrostatic electrost atic 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 may be lost when this module is removed from the rack.

1.3

•

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 plastics, and similar materials.

•

Personnel must be grounded with with a suitable grounding strap (such as 3M Velostat No. 2060) before handling or maintaining a printed circuit board.

•

Transport and store circuit boards boards in e electrically lectrically conductive conductive bags 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 performed properly, properly, this this module module may be installed installed into or or removed 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.

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, laws, United States federal laws, or any applicable international law. Bently Nevada Corporation is not responsible responsible for disposal of product at the end of its life or at the end of its use.

1

2 General Information

2


General Information The 3500/25 Keyphasor® Module is a half-height, 2-channel module used to provide Keyphasor signals to the monitor modules in a 3500 rack. The module receives input signals from proximity probes or magnetic pickups and converts the signals to digital Keyphasor signals that indicate when the Keyphasor mark on the shaft is under the Keyphasor Probe. The 3500 Monitoring System can accept four Keyphasor signals. A Keyphasor signal is a digital timing signal that is used by monitor modules and external diagnostic equipment to measure vector parameters like 1X amplitude and phase.

Front View

Rear View

1) Buffered Transducer Outputs Provides an unfiltered output for each of the four transducers. All are short circuit protected 2) I/O Module, Internal Termination Refer to Section 4.1 3) Barrier I/O Module, Internal Termination Refer to Section 4.2 4) I/O Module External Termination Refer to Section 4.3

2.1

Triple Modular Redundant (TMR) Description When a system Keyphasor input is required for TMR application, the 3500 should be equipped with two Keyphasor modules. In this application, the modules work in parallel to provide both a primary and secondary Keyphasor signal to the other modules in the rack.

2



When used in a TMR application, Keyphasor transducers may be connected to the 3500 rack in two ways: Redundant Keyphasor Transducers Two independent Keyphasor transducers at each measurement location. This configuration provides for both primary and secondary inputs and is the most fault tolerant and reliable configuration. In this configuration, the primary and secondary inputs will be connected to independent Keyphasor modules. Single Keyphasor Transducers This configuration requires only a single Keyphasor transducer. The signal from this transducer is wired to provide input to both Keyphasor Modules. When used in a TMR application, only two speed measurement locations can be supported.

2.2

Available Data The Keyphasor Module returns the rpm measured from each Keyphasor transducer. The rpm is the primary value and is used by the Communication Gateway Module and the Rack Interface Module. The Keyphasor Module also returns both module and channel statuses.

2.2.1

Statuses This section describes the available statuses and where they can be found. Module Status OK This indicates if the Keyphasor Module is functioning correctly. A not OK status is returned under any of the following conditions: Node Voltage Failure • Hardware Failure in the module • Configuration Failure • Slot ID Failure • 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 Keyphasor Module configuration is invalid.

3



Bypass This indicates if the Keyphasor Module has been bypassed. Any of the following conditions can cause the Keyphasor Module to be bypassed: Keyphasor Module has never been configured • • Keyphasor Module is in configuration mode • Fatal error was found during self-test • A channel has an invalid configuration • Any active channel is bypassed Channel Status OK This indicates whether or not a fault has been detected on the channel. The following will cause a channel not OK status AND a module not OK status: Node Voltage Failure • • Hardware Failure in the module • Bypass is active on the channel • Configuration Failure • Slot ID Failure The following will cause only a channel not OK status and will NOT cause the system OK relay on the Rack Interface Module to be driven. Keyphasor signal less than 1 rpm • Keyphasor signal greater than 99,999 rpm • Keyphasor signal has a 50% or greater change in period • Keyphasor Transducer Failure • Keyphasor signal greater than 20 kHz • Bypass This indicates if the associated Keyphasor Module channel has been bypassed. Any of the following conditions can cause a channel to be bypassed: • Keyphasor Module has never been configured • Keyphasor Module is in configuration mode • Fatal error was found during self-test • A channel has an invalid configuration • Any active channel is bypassed Off This indicates whether the channel has been turned off. The Keyphasor channels may be turned off (inactivated) by using the Rack Configuration Software.

4



The following table shows where the statuses can be found. Statuses

Communication Gateway Module

Rack Configuration Software

X

X

Module OK

2.3

Module Configuration Fault

X

Module Bypass

X

Operator Display Software

Channel OK

X

X

X

Channel Bypass

X

X

X

Channel Off

X

X

LED Descriptions The LED’s on the front panel of the Keyphasor 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 Keyphasor Module and the Keyphasor I/O Module are operating correctly. 2) TX/RX Flashes at the rate that messages between the Keyphasor Module and the Rack Interface Module are sent and received.

5

3 Configuration Information

3


Configuration Information To configure a Keyphasor Module, use this section to gather configuration information and then use the Rack Configuration Software to set the options and download the settings to the rack. The Rack Configuration and Utilities Guide (part number 129777-01) explains how to connect a computer to a rack and run the Rack Configuration Software.

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 Interface module goes into slot 1. Slots 2 through 15 are called “monitoring positions”. The 3500/25 Keyphasor module can be installed into any of the monitoring positions. However, if the 3500/20 Rack Interface Module and Data Manager I/O are to be used to interface to DDIX, TDIX or TDXnet, refer to the manual on the 3500/20 for slot restrictions this may place on your configuration.

6


3.2


Software Configuration Options Set the Keyphasor configuration options by using the following screen.

3.2.1

Keyphasor Module Configuration Considerations Keyphasor Orientation and Events Per Revolution configuration information are directly linked to monitors in the 3500 rack. When these parameters are changed, the configuration of the monitors which are associated with the changed Keyphasor must be downloaded to the 3500 rack.

7


3.2.2


Keyphasor Module Configuration Options Reference Information These fields contain information that indicates which module you are configuring. ConfigID A unique six character identifier which is entered when a configuration is downloaded to the 3500 rack. Slot The location of the Keyphasor Module in the 3500 rack. I/O Module The type of terminals used to connect the transducers to the module. Select Internal if the transducers are connected to a Keyphasor I/O Module (Internal Termination), and External if the transducers are connected to an External Termination Block. Select Internal Barriers if the transducers are connected to a Keyphasor Internal Barrier I/O Module (Internal Termination). Note that by selecting the Internal Barrier I/O option, this will disable the Magnetic Pickup transducer type option. Keyphasor Position Identifies whether the Keyphasor Module is physically in the upper or lower slot.

Channel 1 Channel 2 Active Enable or disable a Keyphasor channel. If no Keyphasor transducer is connected to this channel, then this box should be cleared.

Signal Polarity Notch An output pulse is produced, for use by the monitors, that is triggered by the leading edge of a negative-going pulse in the input signal. This type of pulse is produced by a Keyphasor transducer looking at a notch in the shaft. If a magnetic pickup is used, the Notch/Projection setting should be set to Notch since in most cases the positive side of the signal will be clipped. Projection An output pulse is produced, for use by the monitors, that is triggered by the leading edge of a positive-going pulse in the input signal. This type of pulse is produced by a Keyphasor transducer looking at a projection on the shaft.

8



Type The type of Keyphasor transducer. Available choices include Proximitor and Magnetic pickup. Magnetic pickups require a shaft rotative speed of at least 200 rpm (3.3 Hz). Hysteresis The difference between the level in the input signal where the Keyphasor pulse turns on and the level where it turns off. The larger the hysteresis, the greater the immunity to noise on the input signal.

1) 2) 3) 4)

Input Signal Keyphasor Pulse Threshold Hysteresis

Threshold The point where the Keyphasor pulse would turn on and off if the Hysteresis was zero. Auto The trigger threshold is automatically set to a value that is midway between the most positive peak and the most negative peak of the input signal. This value tracks any changes in the input signal. Auto threshold requires a minimum signal amplitude of 2 V pp and a minimum frequency of 120 cpm (2 Hz).

9



Manual The trigger threshold is set by the operator to any value in the range of -20.0 to 0.0 volts. Adjust Available when Manual Threshold is selected. Used to display a dialog box which will aid in the setting of the Manual Threshold value. Events Per Rev The number of pulses in a Keyphasor transducer signal for each shaft rotation. If the Keyphasor transducer is observing a multi-tooth gear, set the Events Per Revolution to the number of teeth on the gear. The available range is 1 to 255. The following graph shows the maximum settings for Events Per Revolution.

1) 2) 3) 4)

10

RPM Events Per Revolution Upper RPM Limit is 99,999 Upper Frequency Limit is 20kHz



Note Signals from a Keyphasor transducer that is observing a multi-tooth gear can be used for speed measurements only and not for phase measurements. Events Per Rev typically set to 1 event per revolution

Events Per Rev set to 24 events per revolution

Probe A

Probe A

Probe B Shaft with notch

Probe B 24 tooth gear

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:

1) 2) 3) 4) 5) 6) 7)

Shaft Driven end Driver end 0 degrees 90 degrees right 180 degrees 90 degrees left

This drawing is for horizontal shafts.

11



Upper RPM Limit Allows a full-scale RPM to be set for a Keyphasor channel. RPM data provided by this channel will be scaled to this upper RPM limit.

RPM Clamp Value The value of the RPM readings, provided by the Communication Gateway, when the channel is not OK.

3.3

Software Switches The Keyphasor Module supports one module software switch and one channel software switch. 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.

No changes will take effect until the Set button is pressed.

12



Module Switch Configuration Mode A switch that allows the Keyphasor Module to be configured. To configure a Keyphasor Module, 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.

Manual Keyphasor Threshold Adjust Used when adjusting the manual threshold. This switch will automatically be enabled and disabled when the Adjust button on the Keyphasor options screen is pressed. When in this mode the Keyphasor Module will operate with a temporary Manual Threshold supplied by the Rack Configuration Software. Monitor values such as 1X amplitude and phase that use Keyphasor signals may go invalid while the Manual Threshold is being adjusted.

The module switch number is used in the Communication Gateway or Display Interface Module. Module Switch Number

Switch Name

1

Configuration Mode

4

Manual Keyphasor Threshold Adjust

Channel Switch Bypass When enabled, the RPM value for the channel will be clamped and all the signal conditioning of the channel will be bypassed.

The channel switch number is used in the Communication Gateway or Display Interface Module. Channel Switch Number 4

Switch Name Bypass

13

4 I/O Module Description

4


I/O Module Description The Keyphasor® I/O Module receives signals from the Keyphasor transducers and routes the signals to the Keyphasor Module. The I/O module also transmits power to the Keyphasor transducers. A Keyphasor Module must have one Keyphasor I/O Module installed behind the Keyphasor Module (in a Rack Mount or a Panel Mount rack) or above the Keyphasor Module (in a Bulkhead rack). The 3500/25 Keyphasor Module can operate with the following types of I/O modules: Internal Termination Keyphasor I/O module Keyphasor Internal Barrier I/O module

External Termination Keyphasor I/O module

External Termination Block Terminal strip connectors Euro Style connectors

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. The 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01) shows how to mount External Termination Blocks. The 3500 Field Wiring Diagram Package (part number 130432-01) shows how to connect Keyphasor transducers to the I/O module or the External Termination Block.

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4.1


Keyphasor I/O Module (Internal Termination) Internal Termination I/O modules require you to wire each Keyphasor transducer to the I/O module individually. This section shows what this Internal Termination I/O module looks like and shows how to connect the wires to the Euro Style connector.

1) Connect the wires from the Keyphasor transducer associated with Channel 1 Top to the Keyphasor I/O Module. 2) Connect the Channel 1 and 2 Top Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet. 3) Connect the wires from the Keyphasor transducer associated with channel 2 Bottom to the Keyphasor I/O Module. 4) Connect the Channel 1 and 2 Bottom Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet. 5) Connect the wires from the Keyphasor transducer associated with Channel 1 Bottom to the Keyphasor I/O Module. 6) Connect the wires from the Keyphasor transducer associated with channel 2 Top to the Keyphasor I/O Module.

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4.2


Keyphasor Internal Barrier I/O Module (Internal Termination) The Internal Barrier I/O module requires that each Keyphasor transducer be connected to the Barrier I/O module individually. This module provides four channels of intrinsically safe signal conditioning for Keyphasor 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.

1) Connect the wires from the Keyphasor transducer associated with Channels 1 and 2 Bottom to the Keyphasor Barrier I/O Module. 2) Connect the Channel 1 and 2 Bottom Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet. 3) Connect the wires from the Keyphasor transducer associated with Channels 1 and 2 Top to the Keyphasor Barrier I/O Module. 4) Connect the Channel 1 and 2 Top Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet.

16


4.2.1


Wiring Euro Style Connectors To remove a terminal block from its base, loosen the screws attaching the 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

Refer to the 3500 Field W iring Diagram Package for the recommended wiring. Remove no more than 6 mm (0.25 inches) of insulation from the wires.

17


4.3


Keyphasor I/O Module (External Termination) External Termination I/O modules let you simplify the wiring to the I/O modules in a 3500 rack by using a 9-pin cable to route the signals from two Keyphasor transducers to the I/O module. This section describes the External Termination I/O Module and the External Termination Block. It also includes the pin outs of the cables that go between the External Termination I/O Module and the External Termination Block.

1) Connect Channel 1 and Channel 2 Top of the Keyphasor I/O Module to the Keyphasor External Termination Block using cable 129530-XXXX-XX 2) Connect Channel 1 and Channel 2 Bottom of the Keyphasor I/O Module to the Keyphasor External Termination Block using cable 129530-XXXX-XX 3) Connect the Channel 1 and 2 Bottom Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet. 4) Connect the Channel 1 and 2 Top Buffered Keyphasor Signals to external equipment, such as TDIX/TDXnet.

18


4.3.1


External Termination Blocks Two types of External Termination Blocks are used with a Keyphasor I/O Module. They are the Keyphasor External Termination Block with Terminal Strip connectors and the Keyphasor External Termination Block with Euro Style connectors.

4.3.1.1

Keyphasor External Termination Block (Terminal Strip connectors)

1) Connect the wire from the Keyphasor transducers to the Keyphasor External Termination Block.

19



2) Connect the Top and Bottom connectors on the Keyphasor I/O Module to the Keyphasor External Termination Blocks using cable 129530-XXXX-XX. 3) Channel 1 Bottom and Channel 2 Bottom 4) Channel 1 Top and Channel 2 Top

4.3.1.2

Keyphasor External Termination Block (Euro Style connectors)

1) Connect the wire from the Keyphasor transducers to the Keyphasor External Termination Block. 2) Connect the Top and Bottom connectors on the Keyphasor I/O Module to the Keyphasor External Termination Blocks using cable 129530-XXXX-XX. 20



3) Channel 1 Bottom and Channel 2 Bottom 4) Channel 1 Top and Channel 2 Top

4.3.2

Cable Pin Outs Cable Number 129530-XXXX-XX 3500 KPH Signal to External Termination Block Cable

21

5 Maintenance


5

Maintenance 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, 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. This section shows how to verify the operation of a 3500/25 Keyphasor® Module.

5.1

Verifying a 3500 Rack - Keyphasor ® Module The 3500 Monitoring System is a high precision instrument that requires no calibration. The functions of Keyphasor 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 Keyphasor Module. Section Number

5.1.1

Topic

Page Number

5.1.1

Choosing a Maintenance Interval

22

5.1.2

Required Test Equipment

23

5.1.3

Typical Verification test setup

23

5.1.4

Using the Rack Configuration Software

24

5.1.5

Verifying Keyphasor Channels

26

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: -

•

22

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 Procedure 10012-1 1992(E) to adjust the interval.


5.1.2

5 Maintenance

Required Test Equipment The test equipment needed to simulate the input for the Keyphasor channels is listed below: Keyphasor Channels Function Generator (Sync Output) • • Multimeter Power Supply (Single) •

5.1.3

Typical Verification test setup The following figure shows the typical test setup for verifying a Keyphasor® Module. 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) 2) 3) 4)

3500 Rack Test Equipment RS-232 Communications Laptop Computer

23

5 Maintenance


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 Keyphasor Module, connect the test equipment to the Keyphasor Module using one of the following methods:

1) 2) 3) 4) 5)

5.1.4

Connect test equipment here. Keyphasor Internal Barrier I/O Module (Internal Termination) Keyphasor I/O Module (Internal Termination) External Termination Block (Euro Style Connectors) External Termination Block (Terminal Strip Connectors)

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

24


5 Maintenance

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

Note It is important to save the original rack configuration before doing any Maintenance or Troubleshooting Procedures. The following figures show how the Verification screen displays Keyphasor channel output from a 3500 rack:

The Keyphasor Information section of this screen shows the information used for the Verification procedures.

25

5 Maintenance

5.1.5


Verifying Keyphasor Channels This section shows how to verify Threshold, RPM values, and Keyphasor OK status for channels of the Keyphasor Module. These values are verified by varying the input Keyphasor signal frequency and DC voltage and then observing that the correct results are reported in the Verification screen on the test computer.

Keyphasor Test Setup 1) 2) 3) 4)

Keyphasor Internal Barrier I/O Module OR Keyphasor I/O Module Multimeter Power Supply Function Generator

The Test Equipment outputs should be floating relative to earth ground. For external termination I/O modules, the test setup is identical except that the test equipment outputs connect to the external termination block.

26


5 Maintenance

The following table directs you to the starting page of each maintenance section associated with the Keyphasor Channels. Section Number

5.1.5.1

Topic

Page Number

5.1.5.2

Verify Keyphasor Threshold

27

5.1.5.3

Verify Keyphasor RPM Values

28

5.1.5.4

Verify Keyphasor OK

29

Test Equipment and Software Setup The following test equipment and software setup can be used to verify Keyphasor channels. Test Equipment Setup Simulate the Keyphasor transducer signal by connecting the sync out of the function generator and the power supply to the Keyphasor I/O Module as shown in the figure on page 26 (Keyphasor Test Setup). Set the function generator to an initial frequency of 100 Hz and the power Supply to -7.00 Vdc. 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.

5.1.5.2

Verify Keyphasor Threshold The Keyphasor Threshold value is the voltage level where the Keyphasor signal will turn on. This value can be set automatically or manually. Use the following procedure to verify that the Keyphasor Threshold is working correctly. 1. Disconnect PWR, COM, and KPH wiring from the channel 1 terminals on the Keyphasor I/O Module. 2. Connect test equipment and run software as described in Section 5.1.5.1 (Test Equipment and Software Setup). 3. Observe the Keyphasor Verification screen: If the channel is configured for Auto Threshold: Verify that the Channel OK State Line reads OK • • Verify that the Keyphasor RPM box display has an RPM value

27

5 Maintenance


If the channel is configured for Manual Threshold: Adjust the Power Supply voltage to 2.50 Vdc more than the Threshold • value voltage level. For example Displayed manual Threshold value = -10.00 Vdc + -2.5 Vdc --------------------Adjust the Power Supply voltage to: -12.50 Vdc Verify that the Channel OK State Line reads OK • Verify that the Keyphasor RPM box display has an RPM value • 4. If the Keyphasor channel will not produce a RPM reading, double check the input signal to ensure it is correct. If the module still does not meet specifications or fails any other part of this test, go to Section 5.1.6 (If a Channel Fails a Verification Test).

5.1.5.3

Verify Keyphasor RPM Values The general approach for testing this parameter is to simulate the Keyphasor signal with a function generator and power supply and verify that the correct RPM is produced. The RPM values are verified by varying the frequency of the function generator and observing that the correct results are reported in the Verification screen on the test computer.

Note Before this procedure can be used, check that the Threshold is set correctly and the channel is OK.

1. Disconnect PWR, COM, and KPH wiring from the channel terminals on the Keyphasor I/O Module. 2. Connect test equipment and run software as described in Section 5.1.5.1 (Test Equipment and Software Setup). 3. Adjust the function generator frequency to 100 Hz. Observe the Keyphasor Verification screen to find the number of Events Per Revolution. Use the following equation to determine what the displayed RPM value should be: Displayed Keyphasor RPM = (Frequency x 60) / Events Per Revolution Example: Frequency = 100 Hz Events Per Revolution = 10 Displayed Keyphasor RPM = (100 x 60) / Events Per Revolution = 6000 / 10 = 600

28


5 Maintenance

4. Verify that the displayed Keyphasor RPM is within the specified tolerance. Input Frequency (Hz)

RPM Error

0.0167 to 100

±1 RPM

101 to 500

±8 RPM

501 to 20,000

±1% of the RPM value

5. If the reading does not meet specifications, check that the input signal is correct. If the Keyphasor Module still does not meet specifications or fails any other part of this test, go to Section 5.1.6 (If a Channel Fails a Verification Test).

5.1.5.4

Verify Keyphasor OK The general approach for testing this parameter is to cause a not OK condition and observe that the correct results are reported in the Verification screen on the test computer. 1. Disconnect the wire from the test equipment to the KPH input of the Keyphasor I/O module. The OK LED on the Keyphasor Module should go off. 2. Observe the Keyphasor Verification screen: • Verify that the Channel OK State Line reads not OK Verify that the Keyphasor RPM box display reads Invalid • 3. If the above results do not occur, double check that there is no input signal to the Keyphasor Module. If the monitor still does not meet specifications or fails any other part of this test, go to Section 5.1.6 (If a Channel Fails a Verification Test). 4. Disconnect the test equipment and reconnect the PWR, COM, and KPH wiring to the channel 1 terminals on the Keyphasor I/O Module. 5. Repeat all these procedures for channel 2 of the Keyphasor Module.

5.1.6

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 module to Bently Nevada Corporation for repair. 29

5 Maintenance


4. Download the configuration for the spare module using the Rack Configuration Software. 5. Verify the operation of the spare.

5.2

Performing Firmware Upgrades Occasionally it may be necessary to replace the original firmware that is shipped with the 3500/25 Keyphasor Module. The following instructions describe how to remove the existing firmware and replace it with an upgrade firmware. The module 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 module: Phillips 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 firmware upgrade: Ensure that the module’s configuration is saved using the 3500 Rack Configuration software. Refer to Section 1.2 (Handling and Storing Considerations) before handling the module or the upgrade firmware IC. Remove the module from the 3500 rack. Remove the shield from the module. Remove the original firmware IC from the module PWA. Install the upgrade firmware IC into the socket on the module PWA. Replace the module shield. Replace the module into the 3500 system. Reconfigure the module 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.

30


5 Maintenance

Shield Removal

Step 1. Remove the 4 screws (item 1) that hold the shield and PWA together using a Phillips screwdriver. Step 2. Remove the 2 nuts (item 2) from the BNC connectors on the front of the Keyphasor Module. Step 3. Remove the shield (item 3) from PWA.

31

5 Maintenance


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.

32


5 Maintenance

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. Shield Replacement Replace the shield. Replace nuts for the BNC connectors on the front of Keyphasor Module. Align the holes in the shield with the standoffs and replace the 4 Phillips-head screws to fasten the shield to the PWA.

33

6 Troubleshooting


6

Troubleshooting This section describes how to use the self-test, the LED’s, the System Event List, and the Alarm Event List to troubleshoot a problem with the Keyphasor Module or the Keyphasor I/O Module.

6.1

Self-test To perform the Keyphasor Module self-test: 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 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 may be lost while the self-test is being performed. 5. Select the upper or lower slot that contains the Keyphasor Module and press the OK button. The Keyphasor Module will perform a full self-test and the System Events screen will be displayed. This 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 Keyphasor Module self-test. 8. See if the Keyphasor Module passed self-test. If the module does not pass, refer to Section 6.3 since there is a problem with the Keyphasor Module.

34


6.2

6 Troubleshooting

LED Fault Conditions The following table shows how to use the LED’s to diagnose and correct problems.

OK Led

TX/RX

1 Hz

1 Hz

5 Hz ON

Flashing

OFF

Not flashing

Condition

Solution

Keyphasor Module is not configured.

Reconfigure the Keyphasor Module.

Keyphasor Module had detected an internal fault and is not OK.

Check the System Event List.

Keyphasor Module is operating correctly.

No action is required.

Keyphasor Module is not operating correctly or the Keyphasor transducer has faulted or has stopped providing a valid signal.

Check the System Event List and the Alarm Event List.

Keyphasor Module is not communicating correctly.

Check the System Event List.

= behavior of the LED is not related to the condition

6.3

System Event List Messages This section describes the System Event List Messages that are entered by the Keyphasor Module and gives an example of one. Example of a System Event List Message:

Sequence Number

Event Information

Event Number

Class

Event Date DDMMYY

Event Time

0000000123

Device Not Communicating

32

1

02/01/90

12:24:31:99

Event Specific

Slot

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.

35

6 Troubleshooting

Class:


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:

Additional information for the events that use this field.

Slot:

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).

The following System Event List Messages may be placed in the list by the Keyphasor Module and are listed in numerical order. If an event marked with a star (*) occurs, the Keyphasor signal will stop being provided and the RPM value will be invalid. If you are unable to solve any problems contact your nearest Bently Nevada Corporation office.

EEPROM Memory Failure Event Number: 13 Event Classification: Potential Problem Action: Replace the Keyphasor Module as soon as possible. Device Not Communicating Event Number: 32 Event Classification: Potential Problem Action: Check to see if one of the following components is faulty: • the Keyphasor Module • the rack backplane

36


6 Troubleshooting

Device Is Communicating Event Number: 33 Event Classification: Potential Problem Action: Check to see if one of the following components is faulty: the Keyphasor Module installed in the slot • the rack backplane • Fail Main Board +5V-A (Fail Main Board +5V - upper Power Supply) Event Number: 100 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the upper slot • Pass Main Board +5V-A (Pass Main Board +5V - upper Power Supply) Event Number: 101 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the upper slot Fail Main Board +5V-B (Fail Main Board +5V - lower Power Supply) Event Number: 102 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the lower slot

Pass Main Board +5V-B (Pass Main Board +5V - lower Power Supply) Event Number: 103 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the lower slot •

37

6 Troubleshooting

* Fail Main Board +5V-AB


(Fail Main Board +5V - upper and lower Power Supplies)

Event Number: 104 Event Classification: Severe / Fatal Event 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 Keyphasor Module • the Power Supply installed in the lower slot • • the Power Supply installed in the upper slot Pass Main Board +5V-AB

(Pass Main Board +5V - upper and lower Power Supplies)

Event Number: 105 Event Classification: Severe / Fatal Event 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 Keyphasor Module • the Power Supply installed in the lower slot • the Power Supply installed in the upper slot • Fail Main Board -24V-A (Fail Main Board -24V - upper Power Supply) Event Number: 112 Event Classification: Potential Problem 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 Keyphasor Module the Power Supply installed in the upper slot • Pass Main Board -24V-A (Pass Main Board -24V - upper Power Supply) Event Number: 113 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the upper slot

38


6 Troubleshooting

Fail Main Board -24V-B (Fail Main Board -24V - lower Power Supply) Event Number: 114 Event Classification: Potential Problem 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 Keyphasor Module • the Power Supply installed in the lower slot Pass Main Board -24V-B (Pass Main Board -24V - lower Power Supply) Event Number: 115 Event Classification: Potential Problem 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 Keyphasor Module • • the Power Supply installed in the lower slot * Fail Main Board -24V-AB

(Fail Main Board -24V - upper and lower Power Supplies)

Event Number: 116 Event Classification: Severe / Fatal Event 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 Keyphasor Module • the Power Supply installed in the lower slot • the Power Supply installed in the upper slot • Pass Main Board -24V-AB

(Pass Main Board -24V - upper and lower Power Supplies)

Event Number: 117 Event Classification: Severe / Fatal Event 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 Keyphasor Module • the Power Supply installed in the lower slot • the Power Supply installed in the upper slot Device Configured Event Number: 300 Event Classification: Typical Logged Event Action: No action required.

39

6 Troubleshooting


Configuration Failure Event Number: 301 Event Classification: Severe/Fatal Event Action: Replace the Keyphasor Module immediately. Configuration Failure Event Number: 301 Event Classification: Potential Problem Action: Download a new configuration to the Keyphasor Module. If the problem still exists replace the Keyphasor Module as soon as possible. Module Entered Cfg Mode (Module Entered Configuration Mode) Event Number: 302 Event Classification: Typical Logged Event Action: No action required. Software Switches Reset Event Number: 305 Event Classification: Potential Problem Action: Download the software switches to the Keyphasor Module. If the software switches are not correct replace the Keyphasor Module as soon as possible. Module Reboot Event Number: 320 Event Classification: Typical Logged Event Action: No action required. Module Removed from Rack Event Number: 325 Event Classification: Typical Logged Event Action: No action required. Module Inserted in Rack Event Number: 326 Event Classification: Typical Logged Event Action: No action required. Device Events Lost Event Number: 355 Event Classification: Typical Logged Event Action: No action required.

40


6 Troubleshooting

Module Alarms Lost Event Number: 356 Event Classification: Typical Logged Event Action: No action required. Module Entered Calibr. (Module Entered Calibration Mode) Event Number: 365 Event Classification: Typical Logged Event Action: No action required. Module Exited Calibr. (Module Exited Calibration Mode) Event Number: 366 Event Classification: Typical Logged Event Action: No action required. Pass Module Self-test Event Number: 410 Event Classification: Typical Logged Event Action: No action required. Enabled Ch Bypass (Enabled Channel Bypass) Event Number: 416 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Disabled Ch Bypass (Disabled Channel Bypass) Event Number: 417 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Enabled Threshold Adj (Enabled Threshold Adjustment) Event Number: 418 Event Classification: Typical logged event Action: No action required. Disabled Threshold Adj (Disabled Threshold Adjustment) Event Number: 419 Event Classification: Typical logged event Action: No action required.

41

6 Troubleshooting


Fail Slot Id Test Event Number: 461 Event Classification: Severe/Fatal Event Action: Verify that the Keyphasor Module is fully inserted in the rack. If the Keyphasor Module is installed correctly, check to see if one of the following components is faulty: • the Keyphasor Module • the rack backplane Pass Slot Id Test Event Number: 462 Event Classification: Severe/Fatal Event Action: Verify that the Keyphasor Module is fully inserted in the rack. If the Keyphasor Module is installed correctly, check to see if one of the following components is faulty: the Keyphasor Module • • the rack backplane

Fail DAC Test (Fail Digital to Analog converter Test) Event Number: 471 Event Classification: Severe/Fatal Event Event Specific: Ch x Action: Replace the Keyphasor Module immediately. Pass DAC Test (Pass Digital to Analog converter Test) Event Number: 472 Event Classification: Severe/Fatal Event Event Specific: Ch x Action: Replace the Keyphasor Module immediately. Enabled Test Signal Event Number: 481 Event Classification: Typical logged event Action: No action required. Disabled Test Signal Event Number: 482 Event Classification: Typical logged event Action: No action required.

42


6.4

6 Troubleshooting

Alarm Event List Messages The following Alarm Event List Messages are returned by the Keyphasor Module. Alarm Event List Message

When the message will occur

Entered not OK

Module went not OK

Left not OK

Module returned to the OK state

43

7 Ordering Information


7

Ordering Information A

B

C

Part number 3500/25-  -  -  A

B

Number of Channels 01 Single Half Height 2 Channel Keyphasor Card (Order for 2 channels) 02 Two Half Height 2 Channel Keyphasor Cards (Order for 4 channels) Type of I/O Module 01 02 03

C

I/O Module with Internal Terminations I/O Module with External Terminations* I/O Module with Internal Barriers

Agency Approval Option 00 No Approvals Required 01 CSA-NRTL/C

* When ordering I/O modules with external terminations the external termination blocks and cables must be ordered separately for each I/O module. Note If the 3500/25 Keyphasor Module is to be used with the Internal Barrier I/O option, then the following (or later) firmware and software versions are required: 3500/25 Keyphasor Module Firmware – Revision D 3500 Rack Configuration Software – Version 2.30 Spares Keyphasor Module Keyphasor I/O Module (Internal Terminations) Keyphasor Internal Termination Module Internal Termination Headers Keyphasor I/O Module (External Terminations) Keyphasor Internal Barrier I/O Module (Internal Terminations) Internal Termination Headers Blue Internal Termination Headers Keyphasor External Termination Module (Euro Style Connectors) Keyphasor External Termination Module (Terminal Strip Connectors) Keyphasor Module Manual Grounding Wrist Strap (single use only) Firmware IC 44

125792-01 125800-01 00580438 126648-01 135473-01 00502133 00580438 128718-01 128726-01 129770-01 04425545 128754-01


7 Ordering Information

3500 Keyphasor (KPH) Signal to External Termination (ET) Block Cable A

B

Part number 129530 -  -  A 0005 0007 0010 0025 0050 0100 B 01 02

Cable Length 5 feet (1.5 metres) 7 feet (2.1 metres) 10 feet (3 metres) 25 feet (7.5 metres) 50 feet (15 metres) 100 feet (30.5 metres)

Assembly Instructions Not Assembled Assembled

45

8 Specifications


8

Specifications INPUTS Power Consumption: 3.2 watts typical. Signal:

Each Keyphasor® module accepts up to two transducer signals from proximity probe transducers or magnetic pickups (note: if a Keyphasor Internal Barrier I/O Module is used, then the Magnetic Pickup transducer type option is disabled). The input signal range is +0.8 V to 21.0 V. Signals exceeding this range are limited internally by the module. Magnetic pickups require a shaft rotative speed greater than 200 rpm (3.3 Hz).

Input Impedance:

21.8 k Ω minimum (Keyphasor I/O Module). 10.11 k Ω minimum (Keyphasor Internal Barrier I/O Module).

SIGNAL CONDITIONING Speed/Frequency Range:

RPM range of 1 to 99,999 rpm. Supports multiple events per revolution to a maximum of 20 kHz.

RPM Accuracy (Specified at +25 ° C (77° F)): Input Frequency (Hz)

RPM Error

0.0167 to 100

±1 rpm

101 to 500

±8 rpm

501 to 20000

±1 % of rpm Value

TRANSDUCER CONDITIONING

46

Auto Threshold:

Minimum signal amplitude for triggering is 2 volts peak to peak and minimum frequency is 120 cpm (2 Hz).

Manual Threshold:

Use for any input above 0.0167 Hz (1 rpm for 1 event/revolution). User-selectable from 0 to -20 volts DC. Minimum signal amplitude for triggering is 500 millivolts peak to peak.

Hysteresis:

User-selectable from 0.2 to 2.5 volts.


8 Specifications

OUTPUTS Buffered Keyphasor:

Two buffered Keyphasor outputs are available at the front of the rack via coaxial connectors. Two buffered Keyphasor outputs are also available at the back of the rack via Euro Style Connectors. The following specifications assume a load impedance of 100 Kohms +/- 1%. If a load is connected to both the coaxial connector and the I/O module for the same channel, those loads are in parallel with each other. Output Impedance: 504

Ω maximum.

DC Offset: 25 mV maximum. DC or AC gain: 0.99 to 1.00. Keyphasor Transducer Power Supply: Front Panel LED’s: OK LED: TX/RX LED:

The output signal range is –22.33 Vdc to –24.18 Vdc, 40 mA maximum per channel. Indicates when a fault has been detected in the Keyphasor Module. Indicates when the Keyphasor Module is communicating with the Rack Interface Module (RIM).

ENVIRONMENTAL LIMITS Keyphasor Module: Temperature:

-30° C to 65 ° C (-22° F to 150° F) operating, when used with Internal/External Termination Keyphasor I/O Module. 0° C to 65° C (32° F to 150 ° F) operating, when used with Keyphasor Internal Barrier I/O Module (Internal Termination). -40° C to 85° C (-40° F to 185° F) storage.

Humidity:

95% non-condensing.

47

8 Specifications


CE MARK DIRECTIVES: EMC Directives: EN50081-2: Radiated Emissions: Conducted Emissions:

EN 55011, Class A EN 55011, Class A

EN50082-2: Electrostatic Discharge: Radiated Susceptibility: Conducted Susceptibility:

EN 61000-4-2, Criteria B ENV 50140, Criteria A ENV 50141, Criteria A

Electrical Fast Transient: Surge Capability: Magnetic Field:

EN 61000-4-4, Criteria B EN 61000-4-5, Criteria B EN 61000-4-8, Criteria A

Power Supply Dip: Radio Telephone:

EN 61000-4-11, Criteria B ENV 50204, Criteria B

Low Voltage Directives: Safety Requirements:

EN 61010-01

HAZARDOUS AREA APPROVALS CSA-NRTL/C: When used with Internal/External Termination I/O Module When used with Internal Barrier I/O Module (Internal Termination) CENELEC: When used with Internal Barrier I/O Module (Internal Termination)

48

Class I, Division 2, Groups A through D

Class I, Division 1, Groups A through D Class I, Division 2, Groups A through D [Ex ia] IIC, Class I, Zone 0

[EEx ia] IIC


8 Specifications

BARRIER PARAMETERS The following parameters apply for both CSA-NRTL/C and CENELEC approvals. Circuit Parameters: Vmax (PWR) = 26.8 V (KPH) = 14.05 V Imax (PWR) = 112.8 mA (KPH) = 2.82 mA Rmin (PWR) = 237.6 Ω (KPH) = 4985 Ω Channel Parameters (Entity): Vmax = 28.0 V Imax = 115.62 mA Rmin (PWR) = 237.6 Ω (KPH) = 4985 Ω

PHYSICAL Keyphasor Main Module: Dimensions (Height x Width x Depth): 119.9 mm x 24.4 mm x 256.5 mm (4.72 in x 0.96 in x 10.10 in) Weight: 0.34 kg (0.76 lbs) Internal/External Termination Keyphasor I/O Module: Dimensions (Height x Width x Depth): 241.3 mm x 24.4 mm x 103.1 mm (9.50 in x 0.96 in x 4.06 in) Weight: 0.20 kg (0.44 lbs) Keyphasor Internal Barrier I/O Module (Internal Termination): Dimensions (Height x Width x Depth): 241.3 mm x 24.4 mm x 163.1 mm (9.50 in x 0.96 in x 6.42 in) Weight: 0.46 kg (1.01 lbs)

RACK SPACE REQUIREMENTS Keyphasor Main Module:

1 half-height front slot. A special mounting adapter is required to allow the half-height modules to be mounted in the full-height slots. The Keyphasor Modules can be placed in any one of the 14 available slots. There may be no more than two Keyphasor Modules in a rack, one in a top half-slot and one in a bottom half-slot.

I/O Modules:

1 full-height rear slot

49

3500 25 Keyphasor Module Operations and Maintenance Manual 1

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