97453_Rev.0 CSI 2600

Reference Manual MHM-97453, rev. 0 March 2011

CSI 2600 Machinery Health™ Expert

Copyright © 2011 by Emerson Process Management. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written permission of Emerson Process Management.

Disclaimer This manual is provided for informational purposes. Emerson Process Management makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Emerson Process Management shall not be liable for errors, omissions, or inconsistencies that may be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is subject to change without notice and does not represent a commitment on the part of Emerson Process Management. The information in this manual is not all-inclusive and cannot cover all unique situations.

Trademarks and Service marks Machinery Health, PeakVue, and the CSI logo are the marks of one of the Emerson Process Management group of companies. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.

Patents The product(s) described in this manual are covered under existing and pending patents.

License Agreement IMPORTANT: CAREFULLY READ ALL THE TERMS AND CONDITIONS OF THIS AGREEMENT BEFORE OPENING THE PACKAGE OR PROCEEDING WITH INSTALLATION. OPENING THE PACKAGE OR COMPLETING THE INSTALLATION INDICATES YOUR ACCEPTANCE OF THE TERMS AND CONDITIONS CONTAINED IN THIS AGREEMENT. IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS CONTAINED IN THIS AGREEMENT, CANCEL ANY INSTALLATION AND PROMPTLY RETURN THIS PRODUCT AND THE ASSOCIATED DOCUMENTATION TO CSI, AND YOUR MONEY WILL BE REFUNDED. NO REFUNDS WILL BE GIVEN FOR PRODUCTS WITH DAMAGED OR MISSING COMPONENTS.

Definition of Software As used herein, “software” refers to any computer program contained on any medium. Software includes downloadable firmware for use in devices such as analyzers or MotorStatus units and it includes computer programs executable on computers or computer networks.

Software License You have the non-exclusive right to use this software on only one device at a time. You may back-up the software for archival purposes. For network systems, you have the non-exclusive right to install this software on only one server. Read/write access is limited to the number of concurrent use licenses purchased. The number of guestonly accesses is up to a maximum of 250. CSI grants you a non-exclusive right to use the Software solely for your own internal data processing operations on the CSI-designated supported operating platform for up to any applicable maximum number of licensed users. You may not relicense the Software or use the Software for third-party training, commercial time sharing, rental, or service bureau use. Client may not use the Software in, as, or with an Application Service Provider (ASP).

Software Updates CSI agrees to provide you, at no charge except for media, preparation and shipping charges, for one (1) year from the date of purchase, all updates to the software made at the sole discretion of CSI. Should you purchase a software support agreement forof the next succeeding year following the first year from the date purchase, and thereafter on an annual basis, and if CSI is still providing support, you may purchase the same, annually, at the then existing rate.

Updates/Upgrades Upon receipt of new CSI software replacing older CSI software, you have 30 days to install and test the new CSI software on the same or a different device. At the end of the 30-day test period, you must both remove and return the new CSI software or remove the older CSI software.

Ownership The licensed software and all derivatives are the sole property of Computational Systems, Inc. You may not disassemble, decompile, reverse engineer or otherwise translate the licensed program. You may not distribute copies of the program or documentation, in whole or in part, to another party. You may not in any way distort, or otherwise modify the program or any part of the documentation without prior written consent from CSI.

Transfer You may transfer the software and license to another party only with the written consent of CSI and only if the other party agrees to accept the terms and conditions of this Agreement. If you transfer the program, you must transfer the documentation and any backup copies copies.or transfer only the documentation and destroy any backup

Copyright The software and documentation are copyrighted. All rights are reserved.

Termination If you commit a material breach of this Agreement, CSI may terminate the Agreement by written notice.

Virus Disclaimer CSI uses the latest virus checking technologies to test all its software. However, since no antivirus system is 100% reliable, we strongly advise that you use an anti-virus system in which you have confidence to verify the software is virus-free. CSI makes no representations or warranties to the effect that the licensed software is virus-free.

No Warranty THE PROGRAM IS PROVIDED “AS-IS” WITHOUT ANY WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Limitation of Liability and Remedies IN NO EVENT WILL CSI BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY DAMAGES, INCLUDING ANY LOST PROFITS, LOST SAVINGS, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR THE INABILITY TO USE THIS PROGRAM. THE LICENSEE’S SOLE AND EXCLUSIVE REMEDY IN THE EVENT OF A DEFECT IN WORKMANSHIP OR MATERIAL IS EXPRESSLY LIMITED TO THE REPLACEMENT OF THE DISKETTES OR OTHER MEDIA. IN NO EVENT WILL CSI'S LIABILITY EXCEED THE PURCHASE PRICE OF THE PRODUCT.

Export Restrictions You agree to comply fully with all laws, regulations, decrees and orders of the Unites States of America that restrict or prohibit the exportation (or re-exportation) of technical data and/or the direct product of it to other countries, including, without limitation, the U.S. Export Administration Regulations.

U.S. Government Rights When provided to the U.S. government, the computer software and related materials and documentation are provided subject to the same license rights as those enumerated above.

Hardware Repair Emerson Process Management repairs and updates its hardware products free for one year from the date of purchase. This service warranty includes hardware improvement, modification, correction, recalibration, update, and maintenance for normal wear. This service warranty excludes repair of damage fromby misuse, abuse, carelessness, or modification performed anyone otherneglect, than Emerson Process Management. After the one year service warranty expires, each return of a Emerson Process Management hardware product is subject to a minimum service fee. If the cost of repair exceeds this minimum fee, we will call you with an estimate before performing any work. Contact Emerson Process Management’s Product Support Department for information concerning the current rates.

Obsolete Hardware Although Emerson Process Management will honor all contractual agreements and will make every effort to ensure that its software packages are “backward compatible,” to take advantage of advances in newer hardware platforms and to keep our programs small, Emerson Process Management reserves the right reasonably to discontinue support for old or out-of-date hardware items.

Software Technical Help 1. Please have the number of the current version of your software ready when you call. The version number for software operating under Windows® is displayed by selecti ng “About” under the Help menu bar item. 2. If you have a problem, explain the exact nature of your problem. For example, what are the error messages? (If possible, make a printout of the error message.) When do they occur? Know what

you were doing when the problem occurred. For example, what mode were you in? What steps did you go through? Try to determine before you call whether the problem is repeatable. 3. Please be at your computer when you call. We can serve you better when we can work through the problem together.

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Contents Special Text ..................................................................................... 3 Chapter 1

CSI 2600 Machinery Health™ Expert ............................................... 5 CSI 2600 Machinery Health Expert™ overview...............................................................5 Dimensions and weights ..............................................................................6 Accessories ...................................................................................................................7 Provided accessories ........................................................................................7 CSI 2600 Operating environment ..................................................................................9

Chapter 2

The CSI 260 0 Syste m ..................................................................... 17 Introduction............................................................................................................... 17 View Windows Services associated with the CSI 2600................................................. 19 Field wiring ................................................................................................... 24 Configuration: Network ............................................................................................. 26 Configuration: Memory.............................................................................................. 27 CSI 2600 .................................................................................................................... 29 Power input .................................................................................................. 29 Ethernet ports............................................................................................... 30 Signal inputs ................................................................................................. 30 Optional 4-channel relay inputs/outputs ....................................................... 31 Hardware configuration ............................................................................................. 33 Introduction ................................................................................................. 33 Data types .................................................................................................... 66 Online server.............................................................................................................. 75

Chapter 3

Operating the CS I 2600 ................................................................. 81 Introduction............................................................................................................... 81 Definitions and terms.................................................................................... 81 Verify network addresses ........................................................................................... 83 Verify network address of online server......................................................... 83 Verify or edit IP addresses........................................................................................... 83 Add CSI 2600 addresses to the laptop ........................................................... 85 Description of boot parameters.................................................................................. 92 The CSI 2600 database............................................................................................... 94 Before building a CSI 2600 database ............................................................. 94 When building a CSI 2600 database .............................................................. 95 1

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CSI 2600 operation: Online Watch ............................................................................112 Managing archives ....................................................................................................120 Changing from one database to another......................................................121

Chapter 4

Basic Maintenance and Troubleshooting ..................................... 125 Introduction .............................................................................................................125 Installing new firmware ...............................................................................125 Installing new software................................................................................127 Software patches.........................................................................................128 Maintenance: change CSI 2600 boot settings............................................................130 Important rules when changing boot parameters ........................................132 IP addresses stored in the CSI 2600..............................................................133 General.....................................................................................................................135 Troubleshooting: Measurements in Online Watch and/or Diagnostic Analysis appear incorrect .......................................................................................... 135 Troubleshooting: CSI 2600 status is “Node(Unit)Down”...............................138 System Status LED is red ..............................................................................141 CSI 2600 does not communicate with online server .....................................143 Automatic archive was not created .............................................................. 145 Archive was truncated .................................................................................148 Unable to make changes to a database ........................................................149

Appendix A

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Internal Wiring of the CSI 2600........ .....................................................151

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Special Text The following conventions are used throughout this manual to call special attention to the associated text:

Note A note paragraph contains special comments or instructions.

CAUTION! A caution paragraph alerts you to actions that may have a major impact on the equipment, stored data, etc.

WARNING! A warning paragraph alerts you actions that may have extremely serious consequences for equipment and/or personnel.

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CSI 2600 Machinery Health Expert

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CSI 2600 Machinery Health Expert™ overview

Figure 1. CSI 2600 Machinery Health Expert

The portable, multi-channel CSI 2600 Machinery Health™ Expert, unattended, will record continuous waveform data at multiple bearing locations simultaneously for your turbo machinery and balance of plant machinery needs. Connect the CSI 2600 to the buffered outputs of your existing protection rack, and you are ready to record, store, view live, and 5

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analyze up to 24 vibration or process channels and up to 4 speed inputs both simultaneously and continuously. Data is viewed using Emerson's AMS™ Suite: Machinery Health™ Manager software. Orbits, shaft center lines, Bode, polar, cascade, waveform and spectrum plots can be viewed live and simultaneously, but are also archived for future reference.

Figure 2. CSI 2600 case with retractable handle

Dimensions and weights The CSI 2600 Machinery Health Expert comes in a case with a retractable handle and two wheels for roll around transport. The case measures 19.5 in. wide x 24.5 in. deep x 13.75 in. high and weighs 23 lb. The CSI 2600 is 8.25 in. wide x 16 in. deep x 20.5 in. high and weighs 30 lb. Total weight of both items is approximately 53 lb.

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Accessories Provided accessories In addition to the CSI 2600 and its case, the following items are provided: CSI 4500/6500/2600 Machinery Health Monitor CD • •

AMS Suite Operating Manuals & Extras CD

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One Ethernet cable

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One serial cable

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One package of replacement filters

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One standard IEC 320 C13 to NEMA 5-15P power cord

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One 3-pin screw mount connector plug

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International AC adapter kit (3 pieces)

Please make sure you have these accessories.

To remove the CSI 2600 from its case Reach down along the top and bottom of the CSI 2600 and extract the device straight up from its case. The CSI 2600 should be placed on a dry, level, cool surface where the vents and fans are not blocked.

CAUTION! Avoid hot, wet surfaces and do not block the vents or fans.

Note You cannot operate the CSI 2600 while it is still in the case.

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Recommended accessories Minimum laptop specifications: •

Dell D620, Intel, Dual Core, 2.33 GHz

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WXGA+ (1440 x 900) display

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2.0 GB memory 256 MB NVIDIA Quadro NVS 110M video driver

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80 GB hard drive, 7200 rpm

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Windows XP Professional

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8X DVD +/- RW

Note The laptop is configured as an AMS Machinery Manager server. DellwirelessLAN.

Figure 3. Recommended laptop

Recommended laptop specifications:

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Dell D820, Intel, Dual Core, 2.33 GHz

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WUXGA (1920 x 1200) display

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2.0 GB memory

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512 MB NVIDIA Quadro NVS 120M video driver

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80 GB hard drive, 7200 rpm

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Windows 7

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8X DVD +/- RW

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Dell Wireless LAN

Optional accessories •

Sensors

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Mounting pads

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BNC cables

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Extension cords

Optional software •

PeakVue

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OPC

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Modbus

Optional services •

MHM training in the Online Prediction Operation and Maintenance course and rolling element bearing vibration

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Remote analysis

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Turbo machinery diagnostic training and AMS Machinery Manager transient analysis training

CSI 2600 Operating environment The enclosure should never be subjected to direct sunlight for long periods of time. It should not be exposed to water or where condensation could occur.

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Environmental •

0 to 150 F (-17 to 65 C), 0 - 50% R.H. non-condensing

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0 to 130 F (-17 to 55 C), 0 - 95% R.H. non-condensing

°

°

°

°

CSI 2600 Power input and consumption •

120 - 240 VAC, 50 - 60 Hz input, autosensing

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80 W consumption

Note A 500 W UPS is recommended.

Two 10 A fuses for the power input are accessible through a small access panel between the receptacle and the power switch. The access panel can be opened with a flathead screwdriver.

Figure 4. Power input access panel

The CSI 2600 offers up to 24 sensor channels. The connections are made through the BNC connectors on the rear of the CSI 2600.

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In addition, the CSI 2600 offers up to 4 tach channel connections, up to 4 digital relay channel connections, and 1 Ethernet HUB and 1 NIC. The CSI 2600 can accept any sensor type with AC component 10V pk-pk and DC component < +/-24 V, AC+DC not to exceed +/-24 V. Accelerometers can be powered by the CSI 2600 system’s power supply whenpanel, sensoraccessible power is enabled DIP switches on the termination throughvia thethe rear panel (see Figure 98). Displacement probes can be powered by the auxiliary -24 VDC power supply. The output for this -24 VDC power supply is on the rear of the CSI 2600. Tachometers should provide 1/rev pulses of >0.5V pk-pk with tach pulse 2x noise.

WARNING! Make sure that the sensor power is disabled when connecting to a protection system with unbuffered BNC outputs.

Termination board access The two thumbscrews at the bottom of the CSI 2600 rear panel can be loosened by hand to allow for access to the termination board which is where the DIP switches that control sensor power are mounted. Toggle the DIP switch to the left to turn sensor power off or to the right to turn sensor power on. The set of four DIP switches on SW1 controls sensor power for channels 1 - 4. Sensor power for the subsequent channels is controlled by the DIP switches on SW2, SW3, SW5, SW6, and SW7. The rear panel’s hinges can be locked in the open position to keep the panel open while the DIP switches are adjusted. In order to lock the panel open, lift the panel all the way up and then gently push downward near the top center of the panel, as shown.

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Figure 5. Rear panel access

Reverse the process to unlock the panel so that it may be closed again after adjusting the DIP switches.

CAUTION! Be sure to close the panel before powering the CSI 2600. It is not recommended to power the CSI 2600 while the rear panel is opened.

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Before turning on the CSI 2600 Before powering up the CSI 2600, connect the sensors, tachometers, and relays to the BNC panel.

CAUTION! Whenever making connections to unbuffered sensor signals, ensure that physical contact with these signals will not perturb other monitoring or protection systems.

If connecting the laptop to the CSI 2600 for the first time, you will need to use the RS-232 serial connection cable for HyperTerminal to properly program and initialize the CSI 2600.

Turning on the CSI 2600 (the first time) To turn the CSI 2600 on for the first time, plug the power cord into a standard 120 - 240 VAC input. First, press the toggle switch to ON at the rear of the case. Then, press the toggle switch to ON at the front of the case. The host laptop/server must already be powered up, configured with downloadable firmware, and connected to the CSI 2600. HyperTerminal is used to monitor/modify CSI 2600 boot. HyperTerminal should be pre-configured at 9600 N 8 1 (see Configuring a CSI 2600 with HyperTerminal on page 52).

Monitoring communications Monitoring communications between the CSI 2600 and the laptop is done by way of the HUB port on the front of the CSI 2600 when connected with the included standard ethernet cable. Alternatively, you may use the NIC port when connecting the CSI 2600 to a local area network.

Running the CSI 2600 Once the CSI 2600 is running, you can disconnect the laptop. With the laptop disconnected, the CSI 2600 runs in “dat recorder mode” optimized for turbo machinery transient data. That is, waveform 13


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from up to 24 channels and 4 tachs is recorded continuously and simultaneously at 40 MB/hr per channel for up to 80 GB. Once the laptop is reconnected, portions of this recorded data can be extracted for use with the AMS Machinery Manager Diagnostic Plotting Transient Analysis Tools. Field-based processing of multiplexed predictive data will continue, but this type of data is optimized laptop being the laptop disconnected, the datafor is abuffered in theconnected. CSI 2600’s With internal memory. The amount of time it will take to fill up the CSI 2600’s internal memory is dependent upon how the data storage settings are configured in the database. While the CSI 2600 is in “dat recorder mode,” data will not be written to the database on the laptop. Once the storage capacity of the CSI 2600 is reached, it will automatically start recording over the oldest data. For example, each transient signal connection will store approximately 40 MB of data per hour, and will transfer up to one hour of transient information to the laptop when a predefined transient event occurs (that is, machine trip). If the laptop is not connected, loss of data or data overwrite may occur.

Turning off the CSI 2600 Before powering off the CSI 2600, make sure that the laptop has been connected long enough to allow all of the desired data to be transferred to the laptop for storage. You can verify this by checking the timestamps of the data being reported in the Online Watch application and once those times have progressed past the time range of interest, data collection can be stopped and the CSI 2600 can be powered off. Turn the toggle switch to OFF on the front of the CSI 2600 and on the rear of the case. After the CSI 2600 has powered down, remove the cables connected to the BNC panel. Disconnect the external

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hard drive (if one is connected). Disconnect the laptop. Unplug the CSI 2600. The CSI 2600 can now be lowered back into its case.

CAUTION! Whenever making connections to unbuffered sensor signals, ensure that physical contact with these signals will not perturb other monitoring or protection systems.

Connecting an external NAS hard drive If the NAS drive is to be used as the primary drive for transient storage, that NAS drive should be connected to the same port that is used to connect to the hub that is between the CSI 2600 and the server. The NAS drive should be housed in a location acceptable to the NAS drive manufacturer. The NAS drive should be capable of continuous write at >20 MB/s 100Base-T minimum. Power supplied to the NAS drive should be supplied according the NAS drive requirements.

Storing data on the NAS hard drive The CSI 2600 supports NAS drives up to 200 GB in size. A 200 GB NAS drive can store around 4500 channel-hours of Transient data, based on an average of 40 MB an hour of data, per transient channel. The CSI 2600 has up to 24 transient channels. If the 200 GB NAS drive is storing data from 24 transient channels, then it can store approximately 220 hours per channel of data before it begins to overwrite the oldest measurements. If 12 channels are connected, about 440 hours can be stored.

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TheCSI2600System Introduction The CSI 2600 portable transient monitoring requires: •

Field wiring to installed sensors

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Connection points (usually a buffered output panel) for cabling to CSI 2600 monitoring unit

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CSI 2600 monitoring unit

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Laptop

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CSI 2600 firmware (loaded on Online server, downloaded into CSI 2600 monitoring unit)

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Machinery Health Manager online software

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Online Database

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Ethernet cable

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The Overview Diagram below shows an overview of how the various hardware and software components of the system connect and work together.

Figure 6. Overview Diagram

This system is fairly complex when viewed as a whole, but becomes easier to understand when each component is regarded individually. In the following list of definitions, two terms are used: applications and services. Applications are programs which are accessed from within the AMS Machinery Manager tool set.

Figure 7. AMS Machinery Manager tool set

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View Windows Services associated with the CSI 2600 Services are programs that run in the background on the laptop, permitting the Operating System and applications, to manage online measurements and reporting. Services may be viewed by using the following sequence: 1. Right click “My Computer” and select “Manage.” 1

Figure 8. Entering the Services application

2.

In the left hand panel, expand the “Services and Applications” folder.

3.

In the left hand panel, select the “Services” subfolder. 2

Figure 9. Services subfolder screen

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Services used in CSI 2600 operation include: CSI_MhmRemote, CsiMtdbMgr, CsiNetAdmin, CsiO_server, and FTP Publishing. These services were initialized when the laptop was configured as an online server. They automatically startup whenever the laptop is powered up (note column “Startup Type” in the Services subfolder screen).

CSI 2600 This is the hardware portion of the monitoring system. It is a portable unit which is connected to the server via Ethernet.

O_server This service is the central process which handles all non-transient activity on the online system. It is responsible for processing most requests from the client, sending configuration information to and receiving data from the CSI 2600. On the laptop, this is a service running under .

NetAdmin This service is responsible for handling the user's access to the various programs within the AMS Machinery Manager software. On the laptop, this is a service running under .

MtDbMgr This is the database server service which handles most of the reading and writing operations performed on databases stored on the server. It also indexes and verifies the integrity of databases. On the laptop, this is a service running under .

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MHMRemote This service handles transient data generated by the CSI 2600 as well as the database access required by the Diagnostic Analysis program. On the laptop, this is a service running under .

Online Configuration Also referred to as O_config, this program allows the user to create new and modify existing databases for use with the online system. System commissioning is also handled through O_config. On the laptop, this is an application inside the AMS Machinery Manager Tools tab.

Online Watch Also known as O_watch, this program provides the user with a graphic interface that allows the viewing of data sent to the server by the CSI 2600, management of transient acquisition and autoextraction, adjustment of alarm levels and on-demand data acquisition. On the laptop, this is an application inside the AMS Machinery Manager Tools tab.

Vibration Analysis This application allows the user to request and save transient data, view live streaming data and provides a variety of analysis functions necessary for analyzing the data generated by the CSI 2600. On the laptop, this is an application inside the AMS Machinery Manager on the Vibration Analysis tab.

IIS FTP Microsoft's IIS includes an FTP server which needs to be installed to allow the CSI 2600 to load firmware from the server. On the laptop,

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this is a service running under .

Firmware The firmware is a set of two files, which are loaded from the laptop during up of the most system update updatesthe to boot be installed onCSI the2600. laptopThis likeallows any other program without the requirement of any special interaction with the CSI 2600 beyond rebooting it to allow it to load the new version. The firmware files are stored in the directory C:\Inetpub\ftproot\bin.

Database structure for prediction processing For detailed instructions on building a database, refer to the online help within the Online Configuration program. The structure of an online database is designed to mirror the real world structure of the equipment being monitored. The Database structure for prediction processing diagram shows the relationships of the various elements of an online database.

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Figure 10. Database structure for prediction processing

Collection criteria AP Set - The analysis parameter set defines a particular way to collect spectral data. The AP Set specifies the number of lines of resolution; any averaging modes and windowing; whether to be order-based, what FMax to use, and what parameters are to be collected. AL Set - A collection of Alarm Limits. Each AL Set is associated with a specific AP Set. There may be multiple AL Sets defined for any given AP Set to accommodate changing monitoring conditions. The alarm limit definition determines when alarms occur, data is stored and output relays are set. Collection Predicate - A predicate is an expression that compares the conditions of vibration levels and/or input relay states to determine when data is collected and transient auto-archives are extracted.

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Logical hierarchy Area - A user-defined grouping of equipment. An Area often corresponds to a building or section of a process line within a plant. Equipment - A group of coupled devices that logically should be monitored together. Most often a machine train made up of a driver component (such as a motor) and one or more driven components (such as a pump or fan). Component - A specific, single asset to be monitored, possibly with multiple sensors. Usually a driver or driven piece of machinery. Motors, engines, turbines, pumps, fans, etc. are examples of components. Measurement Point - Corresponds to a single physical sensor. Groups together all the data from all the collections that have been defined for a particular sensor. Any Gross Scan data collected on the sensor and reported for storage is logically associated with the Measurement Point in the database. Data Collection Sets (DCS) - The DCS is a grouping item that allows multiple collections to occur on a single Measurement Point. The DCS combines a particular predicate (when to collect) with a particular AP Set (what and how to collect) and a specific AL Set (limit bands and set points.)

Physical hierarchy CSI 2600 - The physical monitoring unit. Signal Channel - An AC vibration or DC process input. Tachometer Channel - A speed measurement input. Digital I/O Channel - A discrete relay, input or output.

Field wiring In addition to predictive monitoring, the CSI 2600 is also a portable transient monitoring system, which means in most applications it is

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being connected to already installed sensors, normally through existing patch panels or monitoring modules.

Figure 11. CSI 2600 Field wiring diagram

Portable transient monitoring has two important application distinctions, when compared to a fixed, permanently connected system. These are: •

The portable application includes actions of connecting and disconnecting cables between the CSI 2600 monitoring unit, and installed modules or even junction boxes. It will be critical to ensure that these actions do not perturb signals, in such a manner that any permanently installed monitoring systems, interpret temporary signal fluctuations as trip conditions. This is not a concern when connecting to module “buffered outputs.”

•

Modules may condition the input signal, and present a modified version to their own output connections (which are the input connections to the CSI 2600). For instance, some modules connect to a proximity probe sensor, which provides a DC output equivalent to gap voltage (usually about -10 V) and an AC voltage equivalent to vibration (millivolt signal).

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These modules are configured or programmed to provide a version of the input signal, at an output connection. The output signal could be a 0 to 10 V version of the input. An analyst must know the sensitivity and offset of signals connected to the CSI 2600, which may be the same (or different) as signals connected to existing modules. An analyst must also know if the CSI 2600 connections module outputs. are to buffered or unbuffered field wiring or

Configuration: Network A typical, complete CSI 2600 system is shown in the table, CSI 2600 system. IP addresses are unique addresses which systems on a network use to communicate with each other. Three are shown: •

Laptop (192.168.0.1)

•

CSI 2600 Prediction Processor (192.168.0.10)

•

CSI 2600 Transient Processor (192.168.0.11)

Note The IP addresses shown in this manual are examples only. Each system will have a unique IP address.

The laptop has an Ethernet port, which is connected to the CSI 2600. The port has an address. The CSI 2600 has two processing boards, both of which communicate using the same physical Ethernet connection on the CSI 2600 front panel. These boards have IP addresses that are stored in non-volatile memory (memory that does not get cleared when you turn the unit off). For a CSI 2600 system to communicate:

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IP address of the laptop must match a value stored in nonvolatile memory in each CSI 2600 processing board.

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IP address of the CSI 2600 CPU board must match a value listed in AMS Machinery Manager software, as “belonging to” the database in use.

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Later sections of this manual describe how to read IP addresses, and even how to change them. But the key point is that the CSI 2600 must “know” its server address, and the laptop must “know” IP addresses of its CSI 2600s.

Table 1: CSI 2600 system

LaptopIPaddress:

192.168.0.1

CSI 2600 Predictive Process IP:

192.168.0.10

CSI 2600 Transient Process IP:

192.168.0.11

Database nameonlaptop:

BFP61.rbm (example)

Firmware directory on laptop:

C:\inetpub\ftproot\bin\

Services(4):

CSI_MhmRemote,CsiMtdbMgr, CsiNetAdmin, CsiO_Server

CSI 2600 Predictive Process IP:

192.168.0.10

CSI 2600 Transient Process IP:

192.168.0.11

LaptopIP:

192.168.0.1

Configuration: Memory The CSI 2600 is a continuous online monitoring system. Once configured, and until stopped, it will collect both “predictive” and “transient” measurements, storing them in an AMS Machinery Manager database and archives, respectively. For the transient channels, the CSI 2600 continuously writes waveform measurements to the Hard Disk Drive (HDD). When the drive fills up, the system will begin writing over the oldest measurements.

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A rule of thumb to use for an 80 GB HDD when estimating the depth of the HDD (in hours) is to divide 1930 by the number of channels commissioned for transient operation. For example, consider a 4bearing boiler feed pump monitoring system which has a total of 14 sensors. This could include four radial pairs (proximity probes), two thrust, one case expansion, one eccentricity, and two horizontal accelerometers. The eight proximity probes are commissioned for transient and normal operation. An 80 GB HDD will hold the most recent 1930/8 hours of information for each transient channel; or approximately 240 hours (10 days). The CSI 2600 is both a continuous monitoring system, and a portable monitoring system. It can be moved from one piece of equipment to another, and measurements can be stored in one database (for the first equipment) and then in another (for the second equipment). For example, a CSI 2600 is connected to a set of protection modules, which are wired to sensors on a boiler feed pump. A database has been built, and is receiving measurements from the CSI 2600 monitoring unit. Transient waveform measurements are stored in an HDD, until a transient event occurs. Because this is also a portable system, the CSI 2600 and laptop may be disconnected from the Boiler Feed Pump monitoring rack, and moved to a rack of between modules disconnection monitoring a turbine. This requires intermediate step, from the feed pump an rack, and connection to the turbine rack. Data collection must be stopped into the feed pump database, the turbine database must be loaded into the laptop, and the turbine database configuration must be downloaded into the CSI 2600 monitoring unit. This prevents measurements (predictive and transient) from the turbine, from being accidentally loaded into the feed pump database. In this same example, one more intermediate step may also need to be performed. An “archive” of measurements is created by a trigger event on the feed pump. This archive is automatically sent to the laptop. However, there are a lot of other measurements stored on the CSI 2600. In the example, about 240 hours of information per transient channel is on the CSI 2600 for the boiler feed pump configuration. Machinery Health Manager software permits an analyst to view and extract some or all of these measurements,

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storing them on the laptop. If an analyst wishes to do this, he / she must remove the measurements from the CSI 2600, before starting up the turbine database on the laptop and downloading it into the CSI 2600. Changing databases, and extracting transient data from the CSI 2600 is described in the next chapter of this manual.

CSI 2600 The CSI 2600 monitoring unit consists of: •

An AC power connection (110 - 220 V, 50/60 Hz)

•

An Ethernet connection

•

Signal connections for 1 - 24 sensors

•

Tachometer connections for 1 - 4 sensors

•

Digital I/O relay connections for 1 - 4 relays

•

System power status LEDs

•

An attached cooling fan

Power input The AC power connection has an IEC 320 C13 receptacle. A North American 3-prong plug (NEMA 5-15P) is provided. However, the unit may be powered with either 110 V / 60 Hz or 220 V / 50 Hz input power. No internal switches need to be adjusted to select power type.

Note The quality of the power provided to the CSI 2600 is very important. Although the CSI 2600 contains input protection and some degree of line conditioning, it is important to provide the unit with good clean power when the power is ground isolated from the production equipment.

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Ethernet ports

Figure 12. Ethernet ports on the CSI 2600

The NIC port may be used when connecting the CSI 2600 to a LAN. The HUB port may be used when connecting directly to the laptop in situations where connection to the plant LAN is either not desired or not available.

Signal inputs The CSI 2600 is designed to receive voltage signals from sensors or external modules. The online database will include voltage-tovibration conversion specifics, such as sensitivity, DC and AC alarm levels, offsets (if any). But the system expects voltage signals. Signals such as 4-20 mA, (normally RTDs, Thermocouples require external conditioning electronics a programming or terminal option with installed modules to which the CSI 2600 connects). The 4 tachometer inputs on the CSI 2600 rear panel also provides BNC connections for up to 4 tachometer signals. These tachometers can be used for both “prediction” and “transient” signal collection.

Note Not all signals connected to a CSI 2600 need to be designated as transient. Some signals do not carry unique transient information, and an analyst does not wish to include high-speed samples of these signals in transient archives. These are referred to in this manual as prediction signals. Others, such as radially mounted pairs of proximity probes, do carry significant transient information. These are referred to in this manual as transient signals.

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Optional 4-channel relay inputs/outputs The CSI 2600 includes up to 4 I/O relay connections that provide optically isolated digital inputs or dry contact outputs. Inputs can be between 5 V and 24 VDC. Outputs are limited to 24 VDC @ 0.5A. Each I/O relay channel on the 6510 module contains both input and output hardware. The relays are configurable as either input or output relays, with a DIP switch (SW1) on the circuit board. A relay channel that is configured in software can not be utilized unless the corresponding DIP switch is set to the correct position. The firmware will detect the DIP switch state at startup and generates a flag in the HyperTerminal session if the software configuration does not match the DIP switch setting. The DIP switches are used to protect a user input device from inadvertently being shorted by a relay output configuration. Set the corresponding DIP switch to the “ON” position for output relays, and to the “OFF” position for input relays. The factory default state of the DIP switches is OFF (Input). DIP switch 1 is for the first relay channel and DIP switch 2 is for the second relay channel. The I/O relay DIP switches are shown in Figure 19 on page 52. The shelf-state of the output relays is normally open, meaning that they are open when the power is disconnected. During operation of the unit, the relays are closed until activated by an alarm, then they are open.

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Typical relay usage in online monitoring system includes: •

(input) Transient event indicator, perhaps from a switch, DCS, external module

•

(output) Bad / failed sensor indication

•

(output) Alarm level indication

•

(output) Speed level indication

•

(output) Radial Trip Predicate state

•

(output) Axial Thrust Predicate state

In most applications, the CSI 2600 will connect to buffered outputs of a protection system. These modules normally have relay outputs which indicate alarm levels, or bad / failed sensors. However, the CSI 2600 relays are different in that: •

A CSI 2600 alarm relay state may be based upon either overall vibration value (i.e., the attached module), or Analysis parameter signal level (i.e., energy at 1x turning speed, energy at 2x turning speed)

•

All, some, or one of the alarm indicators may be mapped to the same CSI 2600 alarm relay output. In other words, all of the “Bad/Failed sensor” signal levels may be (internally) connected to a single relay. All of the “High alarm” signal levels may be (internally) connected to a single relay.

Radial Trip and Axial Thrust predicates are special methods of configuring voting logic for relay closures and are explained in Emerson Machinery Health Manager manuals, such as the “Online Software” guide (MHM-97460). These are innovations provided by the CSI 2600 system, which have value in turbo machinery applications.

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Hardware configuration Introduction Description

The 6560 Processor Module (in combination with the 6510 Signal Input Module) is a multi-channel, multi-tasking, multi-processor data acquisition system primarily intended for monitoring heavy industrial rotating machinery. Typical signal inputs are dynamic AC machine vibration signatures from accelerometers, velocity probes, or proximity probes. These signals include two components: the dynamic AC component, which represents machine vibration, and a DC component, which represents the sensor bias level. In the case of a proximity probe, the DC component represents the gap, or average distance between the probe tip and the machine shaft. Other signal inputs include process signals; these are DC parameters such as temperature or pressure. Tachometer inputs are used to determine machine speed. These tachometer signals are typically generated from a proximity probe or passive magnetic sensor positioned at a machine shaft keyway or gear, producing a pulse train (not necessarily 1x machine speed) representing the machine phase and running speed. A final class of inputs are digital inputs which represent machine states, such as running, off, starting, etc. These inputs are used to control or modify the data acquisition state. Common state control inputs are relay closures or machine RPM. AC or DC signal levels can also be used for state control.

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Installing CSI 2600 modules into the chassis

Figure 13. Close-up photo showing how clips/ejectors work

To install a module, line up the guide rails and push the module into the slot until fully seated, then tighten the mounting screws. To remove a 6U high module, loosen the mounting screws, push outward on the handles as shown to eject the module from the backplane connectors, then pull from the slot by the handle.

Monitoring Methods The 6560 uses three basic data monitoring methods.

Overall Level Monitoring Overall Level Monitoring is defined as (1) the acquisition of the overall level of the dynamic AC vibration signal, typically the RMS value of the signal, and/or (2) the DC sensor bias level, or (3) measurement of a DC process signal. All these signal inputs are DC values (the RMS value is a DC value proportional to the overall 34

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energy content of the AC signal). The Overall Level inputs are multiplexed into a fast successive approximation ADC controlled by the 6560. Overall Level Monitoring is a continuous process, with all input channels AC+DC measured twice every second. When the Transient option is included, true waveform peak-to-peak may be included in Overall Level Monitoring.

Spectral Scan Spectral Scan is defined as the acquisition and analysis of dynamic AC signals only. The signals are acquired, two channels at a time (referred to as CHX and CHY), with a dual channel delta-sigma ADC controlled by the system DSP. The DSP performs analysis of the acquired time waveforms and transmits the results to the CPU host processor. Pre-programmed groups of Spectral Scan measurement parameters (AP Sets) may be assigned to specific machine state conditions to tailor data acquisition to specific machine operational states.

Transient Data Capture Transient data capture is the acquisition of continuous time waveforms of channels. dynamic AC signals. is captured in parallel for all Other dataTransient stored asdata Transient data include once per second Overall Level data, tach pulse records, and acquisition timestamps. The Transient data is stored on hard disk, and is available for real-time analysis via Ethernet.

Configuration The CSI 2600MS has a 6560 Processor module, and one or two 6510 Signal Input modules. The CSI 2600TS has a 6560 Processor module with a Transient Daughterboard, and one or two 6510 Signal Input modules with Transient Filter Boards.

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Processor Module The 6560 provides all data acquisition, data storage, and data communications functions for the CSI 2600 system. The 6560 is capable of simultaneous, continuous measurement of detailed Spectral analysis on two channels, RMS and DC values for Gross Scan measurements on all signal channels, machine speed measurement on all tachometer channels, and the states of all digital inputs. The 6560 provides all data acquisition, data storage, and data communications functions for the CSI 2600 system. The 6560 is capable of up to 24 simultaneous and continuous waveform measurements (for detailed Spectral analysis), up to 24 RMS and DC values for Gross Scan measurements, up to 4 tachometers for machine speed measurement, and up to 4 digital state inputs. Gross Scan values, tachometer values, and digital input states may be combined logically to determine machine operating state, which may be used to define specific data acquisition states. The system can be configured to transmit and store data on either time interval or based on the amount of change of the data values. Two 100Base-T Ethernet ports and one RS-232 serial port are provided for system communications and diagnostics. Additional connections are available for the calibration signal and a dr y contact SPDT "Sysfail" relay. diagram ofsuccessfully backplane.)boots. This relay energized when the(See Processor CPU On aisCPU failure or power loss, the relay will de-energize.

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Table 2: 6560 Processor Module Specifications

MemoryCapacity

32MBSDRAM,32MBFlash

NetworkCommunication

10/100Base-T EthernetdualRJ45jacks wiredfor NIC and HUB, with two additional jacks on

LocalCommunication

RS232(upto38.4Kbs)

OnboardTestGenerator

Allsensorchannels,tachometerchannels,AC,DC amplitude, phase (0 V - 3 V pk, 0.25 Hz - 50 kHz sine +/- 7.2 VDC, GND +/- 1 mV)

backplane

Rack Health Relay

SPDT 24

SensorChannelScan

RMS+DC,rateequivalentto16chper500ms

OverallVibrationUnits

RMS,RMSorpeak-to-peakwithTransientOption

DCScan

Simultaneouslyscannedwithoverallvibration scan (includes DC Gap, temperature, and accelerometer bias)

Overall Level and DC Accuracy

1% at input channel range full scale amplitude @ 1 kHz

GrossScanADCResolution Data Acquisition Event Basis

16bit Relay input, RPM, DC,AC or software controlled

DataCollection

Event-basedadaptive

DataCollectionInterval

Event-basedand/ortime-based

DataStorageInterval

Exception-basedand/ortime-based

SpectralADCResolution

24bit,2channelsimultaneous

DynamicRange

100dB,allfrequencyranges

SpectralResolution

100to6400lines

AnalysisBandwidth

10Hzto40kHz,discretesteps

SpectralScanRate

Dependsonanalysisconfiguration(1secondper two channels @ 400 lines, 400 Hz 1 avg)

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SpectralAmplitudeAccuracy

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5%0.2Hz-0.5Hz 2% 0.5 Hz - 25 kHz 4% 25 kHz - 40 kHz

FrequencyAccuracy

0.01%,crystalbased

TotalHarmonicDistortion

<-90dB,allranges

1XSynchronousPeakAccuracy

3%0.5Hz-3Hz 2% 3 Hz - 1 kHz 5% 1 kHz - 5 kHz

1X Synchronous Phase Accuracy

40 1 Hz - 1 kHz (not calibrated below 1 Hz) 50 >1 kHz

AnalysisandTrendTypes

Configurable,withuser-definedparameter names, multiple analysis types per machine and per sensor. (Total Energy, Energy in a range. Nonsync energy in a range, Sync energy in a range, Sync peak, Sync phase, True peak, HFD, Waveform peak-to-peak, RPM, Gap, Orbit)

AveragingTypes

Normal,PeakVue,OrderTracking,Synchronous

UnitsTypes

English,Metric,HZ,CPM,Order

ScalingTypes

Linear,Log,dB

WindowsTypes

Hanning,Uniform

Time Averaging

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Figure 14. Processor Module Front Panel

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Figure 15. Processor Module PCB

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Signal Input Module The 6510 Signal Input module combines the features of Signal Input, Tachometer Input, and I/O Relays to allow a combination of sensor and relay types in one module. The 6510 provides 12 channels of vibration or process sensor inputs, 2 channels of tachometer sensor inputs, and 2 optically-isolated I/O relay channels.

Vibration Signal Inputs The vibration sensor types include accelerometer, passive velocity, active velocity, and displacement. The Signal Input module will also accept non-specific AC or DC inputs from any source that conforms to the CSI 2600 input range limits. The vibration inputs provide the following programmable functions for each channel: Input Attenuator /1, /2, Gain x1, x10, integrator on/off. The combination of input attenuator and gain setting provide four input range combinations as shown in the table Signal Input Module Input Ranges. Table 3: Signal Input Module Input Ranges Attenuator

Gain

InpuRt ange +/-

/2

x1

10.0 100 V,100 g,ips, 50 mil

/1

x1

5.0 50 ips, g, V,25 mil

/2

x10

1.0 10 50 V, g, ips, mil 5

/1

x10

ips, 52.5 g, 0.5 5V, mil

The integrator allows acceleration signals to be converted to velocity. The 6510 Signal Input module selects 2 of the 12 vibration channels at a time and routes them to the Processor module for Spectral analysis. RMS-to-DC conversion is performed on all 12 channels. The RMS and DC signals are routed to the Processor module for Overall Level collection. 41


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The Transient Filter Board is required for Transient data acquisition. 4-20 mA signals may be measured provided a resistor is added across the channel input. A typical value is 250 ohms, which converts 4-20 mA to 1-5 V. Maximum series resistor value is 1000 ohms.

Tachometer Inputs The Tachometer inputs allow measurement of two pulse tachometer sources per 6510 Signal Input module. Tachometer sensor types may include, but are not limited to: active displacement sensor, passive magnetic, or TTL pulse type from various sources. The Tachometer Input module features either fixed voltage trigger or “adaptive” automatic triggering. Triggering parameters may be set independently for each tachometer sensor input. An input gain selection of x1 or x5 may be selected for each channel. A gain of x5 is recommended for tachometer inputs smaller than 1 V pk-pk. If the x5 input gain is used, care should be taken to make sure that the input signal remains within +/-24 V, including any sensor bias or gap voltage.

I/O Relay Channels Each 6510 Signal Input module has two I/O Relay channels that provide optically isolated digital inputs or dry contact outputs. Inputs can be between 5 V and 24 VDC. Outputs are limited to 24 VDC @ 0.5A.

Note AC relays are not provided.

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Figure 16. Signal Input module PCB

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Table 4: 6510 12-2-2 Signal Input Module Spe cifications (@ 25 C) °

SensorInputTypes

Dynamicdisplacementprobe,Accelerometer, Velocity probe, AC input - custom definable (e.g., Flux, Dynamic pressure sensor, Dynamic basis weight input, etc.), DC input - custom definable (e.g., Temperature or other process input), 4-20 mA Signal (with external shunt resistor).

NumberofSensorInputs

16inputspermodule(12sensor,2tach,2I/O,2 modules per rack)

AnalysisBandwidth ACCouplingCornerFrequency RMSConversionAccuracy

0.2Hzto40kHz(0.2Hzto2kHzforTransient Analysis) 0.5Hz 1%atfullscaleamplitude30Hz-40kHz 2.5% at full scale amplitude 20 Hz 5% at full scale amplitude 10 Hz (uncalibrated below 10 Hz)

DCAccuracy

1%atfullscaleamplitude

AnalogIntegration

1perchannel(accelerationtovelocityorvelocity

AnalogIntegratorAccuracy

2%(frequencyandamplitude)

ACInputRange

Softwareconfigurable:+5Vpk,+10Vpk

to displacement)

DC Input Range MaximumAC+DCInputRange

+22 VDC +22V

PoweredSensorTypes

ICPAccelerometerandvelocityprobesbyeach sensor channel, and displacement probes by fused -24 VDC power supply on each channel

SensorPower

4mA(nominal)constantcurrent,with22V compliance per current

Powered Channel Input Impedance

500 kOhm (single ended)

Non-Powered Channel Input Impedance

1 MOhm (differential)

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Non-PoweredSensorType

Displacement,ACorDCprocess

RMStoDCConverter

1perchannel,1Hzto40kHz

Number of Tachometer Channels

2 inputs per module, 4 total per rack

TachometerFrequencyRange

0.1 Hzto2 kHz (6 RPMto120,000RPM)

TachometerFrequencyAccuracy

0.1%

TachometerResolution

0.002Hz@60Hz(0.1RPM)

TachometerTypes

Eddycurrentdisplacementprobe,TTL,passive magnetic

TachometerAmp.Range

Inputandtriggerpulserange+0.5Vpkto+22V pk

PulseCharacteristics

1pulseperrevolution,500uSminimumpulse width, tach divider on module

Modes

Voltcompare,automaticadaptive,dividebyN (N=1-1024)

InputImpedance

1MOhm(differential)

Number of Digital I/O Channels

2 per module (configurable as input or output), 4 total per rack

RelayType DigitalInputCurrentMax.

[email protected] 10mA@24VDC

DigitalInputHighVoltage

5VDC-24VDC

DigitalInputLowVoltage

<3VDC

Each I/O Relay channel on the 6510 Signal Input module contains both input and output hardware. The relays are configurable as either input or output relays, with a DIP switch (SWI) on the circuit board. A relay channel that is configured in software cannot be utilized unless the corresponding DIP switch is set to the correct position. The firmware will detect the DIP switch state at startup and generates a flag in the HyperTerminal session if the software

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configuration does not match the DIP switch setting. The DIP switches are used to protect a user input device from inadvertently being shorted by a relay output configuration. Set the corresponding DIP switch to the “ON” position for output relays, and to the “OFF” position for input relays. The factory default state of the DIP switches is OFF (Input). DIP switch 1 is for the first relay channel and DIP switch 2 is for the second relay channel. The shelf state of the output relays is normally open, meaning that when they are open the power is disconnected. During operation of the unit, the relays are closed until activated by an alarm, then they open.

Transient Daughterboard The Transient Daughterboard adds the capability for parallel, continuous time waveform acquisition on all channels. All collected time waveform data, along with Overall Level data and up to four tachometer pulse records is stored on an internal hard drive, which provides approximately 80 minutes per GB of storage. The Transient Daughterboard can also stream data via Ethernet to analysis applications in near real time, without affecting data collection or on-board data storage. While collecting time waveforms and tachometer pulses, the Transient Daughterboard continuously calculates the peak-to-peak value of each channel's waveform. When configured, this value may be sent to the 6560 Processor module for use as the overall level instead of the RMS value produced by the 6510 Signal Input module. The hard drive used on the Transient Daughterboard is specially rated for 24/7 operation. It is recommended that this drive be replaced on a yearly basis of continuous use. In emergencies, any 21/2 inch parallel IDE drive may be used temporarily, but these drives are not generally rated for continuous operation. When installing the Transient Daughterboard on the 6560 Processor module, make sure all five mating connectors are fully engaged, and then install all six mounting screws.

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Table 5: CS I 2600 Transient Specifications

NumberofChannels

Upto24channels

MemoryCapacity ACChannelSpectralAccuracy

64MBSDRAM,16MBFlash 5%0.2Hz-0.5Hz 2% 0.5 Hz - 2 kHz

FrequencyAccuracy

0.01%,crystalbased

1XSynchronousPeakAccuracy

3%0.5Hz-3Hz 2% 3 Hz - 1 kHz 5% 1 kHz - 5 kHz

1X Phase Accuracy

40 1Hz - 1 kHz (not calibrated below 1Hz) 50 >1 kHz

THD

70 dB, ranges all

OverallLevelsAccuracy

2%0.5to2kHz,Truepeak-to-peak

ADC Resolution

16 bits

SpectralResolution

200lines-51,200lines

Dynamic Range NumberofTachChannels On-BoardDataStorage Communications

>80 dB 4 80GB,upgradeable 10/100Base-TEthernetHUBandNIC100Base-T recommended for Transient

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Figure 17. Transient Daughterboard PCB (mounted on the Processor module)

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Figure 18. Transient Daughterboard (Hard drive inset)

Replace the Transient Daughterboard Hard Drive 1.

Remove the four hard drive mounting screws as shown in the above photo.

2.

Gently remove the hard drive ribbon cable from the hard drive and remove the old hard drive.

3.

Install the new hard drive in the bracket. Do not over tighten the screws.

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4.

Replace the ribbon cable, taking care that it is correctly lined up.

Format the Hard Drive using the Transient Daughterboard Before the new hard drive can be used, it must first be formatted by the Transient Daughterboard. Apply power to the system. Ignore any hard drive error messages produced byCSI the2600 Transient Daughterboard on the HyperTerminal monitor. When the CSI 2600 System has booted, use the DHM_III program (located in the directory) to format the hard drive: 1.

Launch DHM_III.exe

2.

Select the “Transient”menu

3.

Click the “Format Hard Drive” option

When the drive has been formatted, reboot the CSI 2600. Again, ignore any hard drive error messages produced by the Transient Daughterboard on the HyperTerminal monitor. When the POST process is complete, the firmware will automatically prepare the hard drive with the Transient File System. This process may take up to an hour. When this process is complete, reboot the CSI 2600. The boot process should completeTransient normally,data withcollection no hard drive error messages, and,now if configured, should begin (indicated by a flashing hard drive indicator on the Processor front panel).

Note Emerson provides an industrial rated HDD, capable of 100% duty cycle. Emerson recommends that an equivalent replacement HDD be utilized.

Transient Filter Board The Transient Filter Board provides parallel anti-aliasing filters for the signal channels on the Signal Input module. Either one or two

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Transient Filter Boards may be used to configure either a 12- or 24channel Transient System. When installing the Transient Filter Board on the Signal Input module, make sure both mating connectors are fully engaged, then install all three mounting screws.

Transient Filter Board Specifications: •

Number of channels: 12

•

Filter type: 8th order elliptic low pass

•

Filter passband frequency: DC to 2 kHz

•

Attenuation: 80 dB

•

Passband ripple: <1 dB

•

Stop band frequency: 3.12 kHz

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Figure 19. Transient Filter Board PCB (mounted on Signal Input module)

Configuring a CSI 2600 with HyperTerminal Connecting Using a standard serial cable make a connection from the serial port on your PC to the serial port on the Processor front panel.

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Configure HyperTerminal on your PC to use the serial port (typically COM 1) with the following settings: •

9600 baud

•

8 data bits

•

1 stop bit

•

no parity

•

no flow control

Turn power on to the CSI 2600. From here, you can watch the boot process. You may interrupt boot by pressing the “Space” bar after the VxWorks copyright is displayed as shown below. By the time “Press any key to stop auto-boot…” is displayed, most of the time allotted for pressing a key has passed. Interrupting the boot process will allow the configuration of boot specific parameters. VxWorks System Boot Copyright 1984-2002 Wind River Systems, Inc. CPU: CSI 6500 Version: 5.5 BSP version: 1.2/4.00f Creation date: May 5, 2008, 10:38:03 Image: bootrom Press any key to stop auto-boot...

If allowed to complete without interruption, the boot process should finish with a screen similar to this: Cfg Table Last “Put” (GUID: 0x774059b0-e72b-4e09a690fc0c10ab007d) (GUID time: 2008-08-13 19:09:29) Component

Last Calibrated

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MHM-97453.0

---------------- ------------------------------------DIO

2008-08-1319:09:25

GS

2008-08-1319:09:25

TACH

2008-08-1319:09:25

SCHED

2008-08-13 19:09:26

PRED

2008-08-1319:09:25

LIMIT

2008-08-1319:09:26

TRANS

2008-08-13 19:09:29

EGU_FAC

Default Table

EGU_ASN

Default Table

BRS_initRamdisk_i32f: No browser disk image found in FLASH Initializing empty browser RAM disk /browser...Succeeded.

/browser/ - Volume is OK Base Modbus register table size (excluding DCS info): 0xcf8a (53130) This unit will begin announcing its availability in 84 seconds

0x7942148 (t_startup): HLTMON_sysCheck_i32f: All expected modules were successfully registered.

Navigation The following list is printed to the screen by interrupting boot and typing “?” or help. •

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•

@ - boot (load and go)

•

P - print boot params

•

C - change boot params

•

l - load boot file

•

g adrs - go to adrs

•

d adrs[,n] - display memory

•

z adrs - modify memory

•

f adrs, nbytes, value - fill memory

•

t adrs, adrs, nbytes - copy memory

•

e - print fatal exception

•

n netif - network interface device address and other important information

Using the above commands, you should be able to navigate through the boot configuration console. Typically the only commands that will be used here are the “?”, the “@”, the “p”, and the “c”.

Note

When modifying an entry simply type new setting in, do not attempt to backspace over existing entry.

Transient console redirect If the Transient system has the 0x0400 boot flag set, its I/O text output is redirected to COM1 on the front of the 6560 Processor module, and •

No output will be seen when connected to the internal COM2 port on the Transient circuit board.

•

Pressing CTRL-B will switch between the Main Processor and Transient output on the COM1 HyperTerminal session.

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•

Pressing CTRL-T will display which current console output is currently being shown in the COM1 HyperTerminal session.

Changing configuration Once the boot process has been interrupted, you should get the prompt [VxWorks Boot]: At parameter this prompt, “c” and presswill “Enter” to configure the unit. Each in type the configuration be brought up and you can type a new value and press “Enter” to replace the old value, press “Enter” to accept the old value, type “.” and press “Enter” to clear the value or type “-” and press “Enter” to go back to the previous parameter.

Main Processor Module configurations Processor configuration boot device

: shend0

processor number

:0

host name

:

file name

:bin/6500

inet on ethernet (e)

:192.168.0.10:ffffff00

inet on backplane (b)

:

host inet (h)

:192.168.0.1

gateway inet (g)*

:

user (u)

:anonymous

ftp password (pw) (blank = use rsh) :anonymous

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flags (f)

:0x1009

target name (tn)

:

startup script (s)

:

other (o)

:

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* If a gateway is used, the address must be specified as a boot parameter. Transient configuration boot device

: shend0

processor number

:0

host name

:

file name

: bin/6500t

inet on ethernet (e)

:192.168.0.11ffffff00

inet on backplane (b)

:

host inet (h)

:192.168.0.1

gateway inet (g)

:

user (u) ftp password (pw) (blank = use rsh)

:anonymous :anonymous

flags (f)

:0x1409

target name (tn)

:

startup script (s)

:

other (o)

:(IP Address of WINS server, if configured)

Explanation of the Main Processor and Transient boot flags 0x0001 - skip SDRAM testing on cold boot (for testing) 0x0002 - load local system symbols (for debug) 0x0004 - don't autoboot (for testing) 0x0008 - quick autoboot (no countdown) 0x0010 - disable input from shell

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0x0020 - disable login security 0x0040 - use bootp to get boot parameters (network boot only) 0x0080 - use tftp to get boot image (network boot only) 0x0100 - use proxy arp (network boot only) 0x0200 - ignore BOOTROM update image in FLASH (for testing) 0X0400 - change Ethernet speed from 100 Mbps to 10 Mbps (Main Processor only) 0x0400 - redirect the console I/O to COM1 (Transient only) 0x0800 - disable boot file update in FLASH (for development) 0x0800 - boot over a WAN, requiring extended FTP timeouts

The 0x0800 flag applies only if one of the three flags below is set: 0x1000 - attempt network, fallback on FLASH boot (legacy 4500 mode) 0x2000 - boot ALWAYS from network, never fallback on FLASH 0x4000 - boot ONCE from network. This flag clears itself after one boot The system will normally try to get boot parameters, boot image, and startup script first from FLASH. If the FLASH boot fails, the system will revert to a network boot as a backup. The 0x1000, 0x2000, and 0x8000 flags modify this default behavior (listed with highest precedence first).

Typical Main Processor boot flags in the field CPU

WithBootp

Main

0x1449

Transient

58

0x1449

WithoutBootp 0x1409 0x1409

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General boot flag notes For the Main Processor, and Transient systems, boot flags can be listed by typing a question mark (?) into the HyperTerminal at the vxWorks boot prompt. For Transient systems, if redirect is used, do not connect internal transient board com port to PC since all output will be directed to the external com port.

Subnet masks A subnet mask is normally represented in Windows as a series of four decimal numbers, each of which can have a value from 0 to 255, separated by periods (e.g., 255.255.248.0). In the 6560 Processor module, the subnet mask is represented as a series of four hexadecimal pairs with no separators (that is, 255.255.248.0 is represented as fffff800). A hexadecimal conversion table can be used to convert the subnet mask numbers from decimal to hexadecimal. The calculator in the Windows' Accessories folder will also perform this conversion when it is set to the scientific mode. The subnet mask on a 6560 Processor module defaults to 255.255.255.0 (ffffff00). When configuring the 6560 Processor module, the subnet mask should be set to match the subnet mask used on the server PC. If they do not match, network communication failure is possible. To specify a subnet mask, enter it on the configuration labeled "inet on ethernet." The IP address of the unit should be entered first, followed by a colon and then the subnet mask in the hexadecimal format.

Processor Module LEDs The 6560 Processor module has seven (7) two-color LEDs. From top to bottom these are: Input Power, CPU Status, Transient Status, System Status, Server Connect, Modbus Connect, and Hard Drive Active.

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Figure 20. Processor Module LEDs

Input Power The Input Power LED indicates the status of the power converters that distribute various voltages within the 6560 Processor module. A steady green color indicates that all power converters are within the proper voltage ranges, while a steady or blinking red condition indicates a power fault somewhere inside the 6560 Processor module.

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CPU Status The CPU Status LED indicates the status of the Main Processor board. The four (4) status conditions are listed in Table 6 along with their assigned priorities.

Note It is possible for more than one status condition to be active at one time. When this happens, the LED will indicate the active status condition with the highest priority. For example, if the module is both “Uncalibrated” (3) and is also currently “Performing POST” (1), the LED would indicate “Performing POST.” Additionally, if the module is both “Uncalibrated” (3) and in “Failure” (2) then the LED will indicate the “Failure.”

Table 6: CPU Module LED Status LEDColor BlinkingGreen

Status InPOST

Priority 1

Comments Typicallyonlyseenduringsystem startup. Indicates that POST (Power On Self Test) is being performed, which involves Processor board resources.

SolidRed

Failure

2

Failuresinclude:PowersupplyPOST failure, or other hardware failure on processor board.

AlternatingRed/Green

Uncalibrated

3

TheonboardTestFunctiongenerator is uncalibrated.

Solid Green

OK

4

Normal Operation.

Transient Status The Transient Status LED indicates the status of the Transient Daughter Board. The LED is always off when a Transient board is not installed in the system. The four (4) Transient board status

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conditions are listed below along with their assigned priorities. It is possible for more than one status condition to be active at one time. When this happens, the LED will indicate the active status condition with the highest priority.

Table 7: Transient Board LED Status LEDColor

Status

Priorit y

Comments

BlinkingGreen

InPOST

1

Typicallyonlyseenduringsystem startup. Indicates that POST (Power On Self Test) is being performed, which involves Processor board resources.

SolidRed

Failure

2

Failuresinclude:PowersupplyPOST failure, or other hardware failure on processor board.


Uncalibrated

3

OneormoreTransient channels are uncalibrated.

Solid Green

OK

4

Normal Operation.

System Status The System Status LED indicates the status of the overall system. It reflects the worst case state of all boards in the system. For example, if the Test Function generator on the Main Processor board is uncalibrated, and the first MSIG module has a power fault, then the LED will show a solid red color to indicate the worst case of these two which is a “Failure” state. When all the firmware components are operating as expected, this LED overlays a “heartbeat” pulse pattern on top of the system status. The heartbeat pattern occurs in a 4-count cycle. The LED is pulsed off briefly during each of the first and second counts, and then left on during the 3rd and 4th counts. In practice, it gives the appearance of a human heartbeat. If the heartbeat stops, it indicates a firmware fault has occurred. Many times the system is capable of recovering from a missed heartbeat. However, if the 62

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system cannot recover quickly it will automatically reboot itself to clear up the fault and then it will resume monitoring.

Server Connect The Server Connect LED indicates when Machinery Health Manager software or thethat DHM software are connected. green color indicates at diagnostic least one Machinery Health ManagerAsoftware client is connected or that the DHM software is connected in the client mode. A red color indicates the DHM software is connected in the Single User mode. In this state, no other clients can connect. If the LED is OFF it indicates that none of these types of software clients are connected. There is no indication of client data transfer, only the presence of at least one established connection.

Modbus Connect The Modbus Connect LED indicates when a Modbus client, Web Browser, or Transient Live client are connected. A green color indicates that at least one of these types of clients has established a connection. If the LED is OFF it indicates that none of these types of clients are connected. There is no indication of client data transfer, only the presence of atthis least one established connection. The red color is not used with LED.

Hard Drive Active The Hard Drive Active LED indicates when the onboard Transient Hard Drive is being accessed with read/write activity. The green LED blinks on each time a read or write activity accesses the Transient hard drive. The more time the LED is green, the more hard drive activity. This LED is always off if there is no Transient board installed in the system.

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Signal Input module LEDs Every 6510 Signal Input module has two (2), two-color LEDs. The top LED indicates the power converter status and the bottom LED indicates overall module status.

Figure 21. Signal Input module LEDs

Power LED The Power LED indicates the status of the MSIG module power converters. A steady green color indicates that all voltage levels are OK, while a steady or blinking red condition indicates a power fault somewhere within the module.

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Status LED The Status LED indicates the overall status of the module. The four (4) module status conditions are listed in Table 8 along with their assigned priorities. Note It is possible for more than one status condition to be active at one time. When this happens, the LED will indicate the active status condition with the highest priority.

If the Status LED is off entirely, it indicates that this module is being ignored by the 6560 Processor module. This is a special case which should not be encountered in practice. Modules are only ignored if the addition of the module would exceed the maximum channel count limits that the 6560 Processor module can support (24 analog, 4 Tach, 4 I/O) as channels are counted starting in the left most slot and working toward the right. Table 8: Signal Input Module LED Status LEDColor

Status

Priority

Comments

BlinkingGreen

InPOST

1

Typicallyonlyseenduringsystem startup. Indicates that POST (Power On Self Test) is being performed, which involves Processor board resources

SolidRed

Failure

2

Failuresinclude:PowersupplyPOST failure, or other hardware failure on processor board


Uncalibrated

3

Oneormorechannelsare uncalibrated.

Solid Green

OK

4

Normal Operation.

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Data types Overall Level Parameters All Overall Level inputs must be DC in nature. Any Overall Level input of a dynamic nature must be fed through the RMS / DC converter path. It is not technically valid to convert RMS values from an RMS/DC converter to pk or pk-pk Measurement Units unless the input is sinusoidal in nature. However, the CSI 2600 allows this. RMS values are multiplied by 1.414 or 2.828 to convert from RMS to pk and pk-pk, respectively. Spectral Scan Parameters All Spectral Scan Parameters must be AC in nature. It is possible to convert some analysis type results between Measurement Unit types and Display Unit types. Analysis Type: Overall Level Includes Overall RMS Level, Sensor DC Bias, Gap, DC, or AC Process signals. Note Some DC Process Inputs could provide pk, pk-pk, or other Measurement Units.

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Table 9: Overall Level Units Conversion Options InputType

InputUnit

DC

E.U./ V

AC

E.U. / V

ACCEL

VEL

DISP

HWInt. no

no

no

RMS/DC

Meas. Unit

DC

E.U.

yes

RMS

Disp. Unit

E.U.

V 32.2 / ft/s

no

yes

RMS

g

V / 32.2 ft/s

yes

yes

RMS

in./s

V / 9.81 m/s

no

yes

RMS

g

V / 9.81 m/s

yes

yes

RMS

mm/s

i/s/ V

no

yes

RMS

i/s

V / i/s

yes

yes

RMS

mil

V / mm/s

no

yes

RMS

mm/s

V / mm/s

yes

yes

RMS

micron

no

yes

RMS

mil

no

yes

RMS

micron

mil /V

V / micron

Analysis Type: Spectral Includes: Total Energy, Energy within a Frequency Range, Synchronous Energy within a Frequency Range, Non-Synchronous Energy within a Frequency Range, HFD, Relative Synchronous Harmonics, Average, Synchronous Peak

Note RMS, pk, pk-pk Measurement Units are valid and can be freely converted.

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Table 10: Spectral Units Conversion Options Spectral Units Conversion Options InputType

InputUnit

HWInt.

SWInt.

SW

Disp. Unit

Diff. AC ACCEL

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E.U./ V

no

no

no

E.U.

V 32.2 / ft/s

no

no

no

g

V / 32.2 ft/s

no

single

no

in./s

V / 32.2 ft/s

no

double

no

mil

V / 32.2 ft/s

yes

no

no

i/s

V / 32.2 ft/s

yes

single

no

mil

V / 32.2 ft/s

yes

no

single

g

V / 9.81 m/s

no

no

no

g

V / 9.81 m/s

no

single

no

mm/s

V / 9.81 m/s

no

double

no

micron

V / 9.81 m/s

yes

no

no

mm/s

V / 9.81 m/s V / 9.81 m/s

yes yes

single no

no single

micron g

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Spectral Units Conversion Options (Continued) InputType

InputUnit

HWInt.

SWInt.

SW

Disp. Unit

Diff. VEL

DISP

i/s/ V

no

yes

no

i/s

V / i/s

no

yes

no

mil

V / i/s

yes

no

mil

V / i/s

no

yes

single

g

V / i/s

yes

yes

single

i/s

V / mm/s

no

no

no

mm/s

V / mm/s

no

single

no

micron

V / mm/s

yes

no

no

micron

V / mm/s

no

no

single

g

V / mm/s

yes

no

single

mm/s

mil /V

no

no

no

mil

V / mil

no

no

single

i/s

V / mil

no

no

double

g

V / micron

no

no

no

micron

V / micron

no

no

single

mm/s

V / micron

no

no

double

g

Analysis Type: Time Waveform Includes Variance, True Peak, Waveform pk-pk

Note Measurement Unit Type is specific to Analysis Type. No Soft ware Integration Differentiation can be performed.

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Table 11: Time Waveform Units Conversion Options InpuTt ype AC ACCEL

VEL

DISP

InpuU t n it E.U./ V

HWInt. no

DispU . n it E.U.

V 32.2 / ft/s

no

g

V / 32.2 ft/s

yes

in./s

V / 9.81 m/s

no

g

V / 9.81 m/s

yes

mm/s

no

i/s

V / i/s

yes

mil

V / mm/s

no

mm/s

V / mm/s

yes

micron

no

mil

no

micron

i/s/ V

mil /V V / micron

Non-Vibration unit analysis types Includes Peak to Average Ratio, Average to Minimum Ratio, Kurtosis, Skewness, Synchronous Phase These analysis types produce non unit ratios or specific unit types such as degrees of phase. Measurement Unit Type will not apply to these parameters.

Offset adjustment For thrust probes, the input channel is defined as a DC Process input. To set the DC offset so that the thrust reading may be zeroed, use a DC voltmeter (or the DHM program) to measure the DC voltage as

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seen directly on the inputs. Enter this value into the offset field in the sensor set up page in OCONFIG.

CSI 2600 system calibration The CSI 2600 system calibration consists of two steps: 1.

Calibrate the on board signal generator.

2.

Calibrate the system.

The Processor Module signal generator should be recalibrated at least once a year. The CSI 2600 should be recalibrated at least once a year, or if the processor or a signal input module has been replaced.

Calibrating the CSI 2600 The CSI 2600 uses internal calibration tables to compensate for slight measurement variations that can occur across the temperature, voltage ranges, and variations in individual electronic components used by processing circuitry. These calibration tables are stored in each CSI 2600 when it is assembled and verified at the factory. The units apply calibration corrections automatically during signal measurement and processing.

The Main Processor module Four circuits are calibrated. These are: •

Test Signal Generator (TSG)

•

Gross Scan (GS)

•

Digital Signal Processor (DSP)

•

Transient

A key element is the TSG circuit. This circuit provides an extremely precise output signal, which is used as an input during GS, DSP,

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Tachometer, and Transient Calibrations. During calibrations, the TSG output is routed internally in the 6560 Processor Module, to processing electronics (GS, DSP, Tach, Transient), and individual calibration tables for each processing circuit are created and stored in the 6560 Processor Module memory. These tables are stored in non-volatile memory, which means that the tables are not erased if the 6560 Processor Module is powered down. Calibration circuit inputs and outputs are shown in the table, Calibration Circuit Inputs and Outputs: Table 12: Calibration Circuit Inputs and Outputs Calibration Circuit TSG (Test Signal Generator) GS(GrossScan) DSP(DigitalSignalProcessor) Transient

Input (external) signal TSGsignal TSGsignal TSGsignal

Output TSG table (internal) TSG signal GStable DSPtable Transienttable

The TSG circuit provides an output signal, which is used to create all of the other calibration tables. The TSG circuit has its own calibration table, stored in the CPU board. If a CPU board is replaced, then the other calibrations need to be rerun for that 6560 Processor Module, since their (srcinal) calibration tables used the TSG signal from the srcinal CPU board. Calibration tables may be copied from each 6560 Processor Module onto an online server, and those can be downloaded into the same 6560 Processor Module. Emerson Online Product Support personnel, and Online Systems Engineers, can assist customers with this type of operation. Should it be desirable or necessary to recalibrate an installed system, it is recommended that this be accomplished with the support of the local Emerson Online Product Support office, and that it be scheduled during an equipment outage. Calibrations can be accomplished in less than an hour (per CSI 2600), but during that time, the units cannot be monitoring rotating equipment.

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Test Signal Generator calibration All CPU boards provided by Emerson are shipped with a calibrated TSG circuit. If the CPU board is purchased as part of a system (that is, the initial shipment), the entire system is calibrated, using the CPU board TSG circuit. The TSG circuit is the only element which requires an external piece of test equipment, and special connection cables. TSG calibration requires: •

Digital Multi Meter (such as the HP 34401A)

•

Laptop configured as online server

•

Special calibration utility program (DHM)

•

Cable which connects the laptop to the 6560 Processor Module Ethernet port

•

Cable which connects the laptop to the Digital Multi Meter

•

Cable which connects the Digital Multi Meter to the test port on the CSI 2600

TSG calibration is unique in that it requires a separate test instrument, unique cables, and a laptop which is configured as an online server.be It isperformed recommended that TSG calibration or Systems recalibration by qualified Emerson Online Engineers.

Gross Scan (GS) calibration GS calibration: •

uses a 6560 Processor module's TSG output signal.

•

does not require that any wire harnesses be disconnected.

•

is completed in about 10 minutes (per CSI 2600).

•

does not require any special cables or test equipment.

•

uses a special calibration utility program (DHM).

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GS recalibration should be performed: •

annually.

•

whenever a 6510 Signal Input module is replaced.

•

whenever a 6560 Processor module is replaced.

•

if calibration table has a status of "Unknown."

Product Support personnel, can guide a plant engineer or technician through GS calibration over the phone.

DSP calibration Digital Signal Processing (DSP) calibration: •

uses a CPU board's TSG output signal.

•

does not require that any wire harnesses be disconnected.

•

is completed in about 30-40 minutes (per CSI 2600).

•


•


DSP recalibration should be performed: • annually. •

whenever a 6510 Signal Input module is replaced.

•

whenever a 6560 Processor module is replaced.

•

if calibration table has a status of “Unknown.”

Product Support personnel can guide a plant engineer or technician through DSP calibration over the phone.

Transient calibration The CSI 2600T includes two processing boards; a Main Processor board and a Transient board. Both boards include separate Digital Signal Processors. The DSP on the Transient board uses an internal 74

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calibration table, in much the same way that the Main Processor DSP circuit does. However, it is calibrated separately, it is not calibrated as part of a DSP calibration for a Main Processor. Transient calibration: •

uses a Processor module's TSG output signal.

• •

does not require that any wire harnesses be disconnected. is completed in about 30-40 minutes (per CSI 2600T).

•


•


•

should be performed: - annually - whenever a 6510 Signal Input module is replaced - whenever a Transient board is replaced - whenever a Main Processor board is replaced - if calibration table has a status of “Unknown.”

Product Support personnel can guide a plant engineer or technician through Transient calibration over the phone.

Online server A laptop is a computer which has been configured to include: •

Four background services.

•

Modification to default operating system local security policies.

•

CSI 2600 firmware (two files), loaded at a specific directory location.

•

AMS Machinery Manager online and transient software modules.

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•

Network connection, with addresses expected by CSI 2600.

An analyst will normally interact with the laptop through AMS Machinery Manager software interfaces. This is described in Emerson Machinery Health Manager manuals and training courses. Other laptop operations are described in this section, and in Chapter 4 of this manual. When a laptop is purchased from Emerson, it will have four background services installed, configured, and initialized. System O/S policies will have been modified to permit data movement and control required by AMS Machinery Manager software. Software and firmware will be loaded, the network connection will be initialized. During the product life of a CSI 2600 system, an analyst will periodically need to: •

load new firmware.

•

update AMS Machinery Manager software.

•

change the network connection.

Firmware is installed in directory “ .” Each time a CSI 2600 powers up, it scans its network connection (looking for the laptop address which matches an address stored in internal CSI 2600 memory), and then for firmware at this directory location. If firmware is found, its version is read and compared to a copy of firmware stored in internal CSI 2600 memory. If the firmware is the same revision, then the CSI 2600 boots from its internal copy. If it has a different revision, then the CSI 2600 downloads newer firmware, boots using it, and stores a copy of this newer firmware in internal memory. This means that when new firmware is loaded onto a laptop: •

It must be loaded at directory “

,” and

•

The CSI 2600 must be rebooted to cause it to detect and use the new firmware.

It is likely that a CSI 2600 server will be multi-purpose, and may be connected to a customer internal LAN, even for non-online usages. If this occurs, the Ethernet address assigned to the computer Ethernet 76

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port, will need to be changed. Therefore, an analyst needs to know how to change an address, and return it to the address expected by a CSI 2600. Computer network port addresses are assigned using the “Control Panel” and “Network Connections” facility. Changing addresses involves the following sequence: 1.

Select “Control Panel”

2.

Select “Network Connections”

3.

Select the Ethernet port

4.

Select “Properties”

5.

Scroll down in the text window at the center of the “Local Area Connection Properties” pop-up screen, and select “Internet Protocol (TCP/IP)”

6.

Click the “Properties” button

7.

Change IP address

Figure 22. Select Control Panel

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Figure 23. Select Network Connections

Figure 24. Select Properties after selecting the network port

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Figure 25. Scroll down to Internet Protocol (TCP/IP)

Figure 26. IP Address value

It is expected that the laptop will sometimes be connected to an existing plant / mill LAN. Existing LANs normally assign, dynamically, addresses to devices on the network. To permit this, click the “Obtain an IP address automatically” radio button shown in the IP Address value screen. However, when connecting the laptop to the CSI 2600, it needs to have the address which the CSI 2600 expects, that is, it must match the server address stored in CSI 2600 memory. For the “Obtain an IP address automatically” example, the CSI 2600 expects its online server to have an address of 192.168.0.1. To set this address in the laptop, perform the steps described above, and select “Use the

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following IP address” button in the last step. Then enter the IP address and appropriate subnet mask, as shown above. Establish a HyperTerminal connection as described in Configuring a CSI 2600 with HyperTerminal earlier in this chapter to determine (or change) the laptop’s configured IP address.

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Operating the CSI 2600 Introduction The heart of a CSI 2600 system is a database. Database construction is described in other AMS Machinery Manager manuals, and is taught during an Emerson online training course. This section identifies steps and sequences of steps, which are particularly important during CSI 2600 operation. Three fundamental system characteristics need to be understood, when using the CSI 2600 system. The CSI 2600 is a network-based system. The CSI 2600 monitoring unit communicates with a server, through an Ethernet connection. Both must have addresses, known to each other, for successful communication to take place. The addresses can be changed, but the laptop must “know” address of its CSI 2600, and the CSI 2600 must “know” the address of its laptop. The CSI 2600 is a continuous monitoring system. It is always recording transient information that remains in the CSI 2600 system and can be manually extracted, or will be extracted based on a preconfigured transient event. And the CSI 2600 is a portable monitoring system. It can be moved from one set of signal connections to another.

Definitions and terms Several terms will be used to describe CSI 2600 operation, some of which are unique to the Emerson system. These include: Archive:

A folder which includes several files (one per “transient” channel, one per transient tachometer). There are two types of “archives;” manually created, and automatically created. In both cases, the archive is a folder which is collected from measurements on a CSI 2600 81


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HDD, and sent to the online server. Archive predicate:

A collection predicate used to trigger automatic creation of an archive. Automatically created archives are sent to the online server, without any operator / analyst actions.

Bearing clearance: The difference in diameters, between the inner surface of a bearing, and the outer surface of a shaft. This is the distance a shaft may move, without rubbing against the bearing sur face. Extract:

To move transient measurements from one location to another. First (starting) location may be the CSI 2600 HDD, or an archive (information from one archive may be extracted into a second, usually smaller, archive).

Hard Disk Drive:

The disk drive used to store transient waveforms. This is not the same HDD as the one mounted inside the online server. The HDD will eventually overwrite the oldest measurements. CSI 2600 system may be configured with two HDDs; a primary drive, and a failover drive. At least one of these is external to the CSI 2600 monitoring unit.

Resting DC Voltage: Voltage measurement taken from a proximity probe, when a shaft is at rest (against bearing surface). This corresponds to an initial shaft position, and is used to create shaft centerline plots. Transient channel: A monitored input, which has been designated for both “normal” and “transient” data collection. Measurements and operation are simultaneous. “Normal” signal measurements are stored in a database on the online server (“.rbm” file). Transient archives are stored in a directory (archives) on the online server.

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Verify network addresses Network addresses of both Ethernet connections should be verified. Establish a HyperTerminal connection to the CSI 2600 to determine what IP addresses are stored in the unit. This sequence was described in Chapter 2 of this manual and is listed below: 1. 2.

Connect to the CSI 2600 via HyperTerminal. Type the command “bootChange” (this is case sensitive; all lower case letters except for the “C” in Change).

3.

Use the Enter key to advance down the list of parameters until “inet on ethernet” comes into view. This is where the IP address for the CSI 2600 is shown.

4.

The next parameter is called “host inet.” This is where the IP address of the firmware host (laptop) is shown.

Verify network address of online server The network address of the online server may be verified by the following sequence: 1.

Select “Control Panel.”

2.

Select “Network Connections.”

3.

Select the E thernet port w hich is used to communicate with the CSI 2600 monitoring unit.

4.

Select“P roperties.”

5.

In the “Properties” screen, scroll down to “Internet Protocol (TCP/IP),” and then click the “Properties” button.

Verify or edit IP addresses The online database must “know” the IP addresses of assigned monitoring units (CSI 2600s). To verify or edit addresses assigned to a CSI 2600 database, perform the following sequence of steps: 83


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1.

Log into Machinery Health Manager software using an Administrator account.

2.

Locate the RBM Network Administration Icon, and click on it.

3.

In the RBM Network Administration screen, select the “Online Server” listed in the bottom center panel.

Figure 27. RBM Network Administration Screen

4.

If the system is configured to store data into a database, the database will be listed, the two “Edit” buttons will be grayedout, and the bottom left button will be labeled “Stop Data Collection.” In the center panel, CSI 2600 addresses are listed.

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These are the units which are available for the online server. The IP address of the CSI 2600 CPU board should be listed in this panel.

Figure 28. Online Server Setup window

Add CSI 2600 addresses to the laptop To change the IP address of the laptop, use the sequence described earlier. To add a CSI 2600 IP address to the online server configuration, use the sequence described above, with the following additional steps: 5.

Click the “Stop Data Collection” button. The button label will change to “Start Data Collection,” and while the system is stopped, online server setup can be changed. Click the “Edit” button beside the “Active Units” panel.

6.

In the “Online Server’s Active Unit List” screen, type the IP address of a (new) CSI 2600 in the “New Unit” field.

7.

Click the “Add New” button.

8.

Click the “OK” button.

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9.

In the “Online Server Setup” window, click the “Start Data Collection” button.

Once a CSI 2600 IP address is listed in “RBM Network Administration,” that address may be used for any existing or future database built with the online server. This task does not need to be performed each time a new database is built.

Figure 29. Online Server Active Units screen

Change network addresses in the CSI 2600 via HyperTerminal 1.

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Attach a standard RS232 cable between the laptop serial port and the CSI 2600 9-pin front connector to change IP addresses stored in the CSI 2600. The cable will need a male/plug connector on one end, and a female/receptacle connector on the other (CSI 2600) end. This cable has been included with your accessories.

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Figure 30. CSI 2600 9-pin connection

2.

Configure the online server serial port as follows: •

9600 baud

•

8 data bits

•

1 stop bit

•

No parity

•

No flow control

3.

Connect the serial cable to both the CSI 2600 9-pin connection and the laptop.

4.

From the Windows Start menu, select , as shown in Figure 31, HyperTerminal utility.

Figure 31. HyperTerminal utility

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When connected to a CSI 2600, an analyst will use five commands or key strokes to interact with the boot settings stored in each processing board (CPU, Transient). These are: •

bootChange - (case sensitive). This will cause the boot parameters for the specific circuit board to be listed, one at a time. To change a parameter, type the new value beside the stored value.

CAUTION! Do not attempt to backspace\delete the stored parameters.

•

Ctrl-B - (Hold down the Ctrl key and press the B key). This will toggle from one board to the other (if serial port is connected to CPU board, it will toggle to the Transient board).

•

Ctrl-T - This will cause the board to display an identifier (tell you the board with which you are communicating).

•

reboot - (case sensitive, all lower case). This will cause the board to reboot, using new boot settings.

•

. - the period key. Type a period at the end of a stored value, to clear this value.

Important rules when changing boot parameters Rule 1: No boot parameters take effect until the unit is rebooted. Rule 2: Do not attempt to delete stored values. Type a new value beside the stored value. Rule 3: Only change the IP address values. Do not change FTP password, boot file name, flags, etc. If a unit boots up with incorrect values, the system will probably not operate and in some cases, the unit may need to be returned to Emerson. Rule 4: In most cases, changes will need to be made to both processing boards. Both the CPU and Transient boards will need to be updated. They have separate boot parameters, 88

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changing one set does not change the other. Rule 5: Review changes, before using the reboot command. Rule 6: If network addresses are changed, update any drawings or documents which use the old addresses.

Change IP addresses stored in the CSI 2600 1.

Write down the IP addresses which need to be changed. Normally this will be either the online server address, or the CPU address.

2.

Connect to the CSI 2600 and start a HyperTerminal session.

3.

Type the command “bootChange” (this is case-sensitive; all lower case letters except for the “C” in Change).

4.

Use the “Enter” key to advance down the list of parameters, until “inet on ethernet (e): 192.168.0.10” or other parameter to be changed is in view.

5.

Type the new parameter value beside the old value.

6.

Use the “Enter” key to advance through the list of parameters.

Figure 32. Example CSI 2600 CPU board settings

7.

At the command prompt, type Ctrl-B (hold “Ctrl” key down, press the “B” key) to toggle to the other circuit board and then type “bootChange” again.

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8.

Use the “Enter” key to advance through the list of parameters on the other circuit board, making changes as necessary.

9.

Press the “Enter” key until at the end of the parameter list.

10.

On the second board, type the command “bootChange” a second time, press the “Enter” key to review settings.

Figure 33. Example Transient board boot settings

11.

Type Ctrl-B (hold “Ctrl” key down, press the “B” key) to switch to the other (first) circuit board.

12.

Type “bootChange” a second time, review boot settings on the first board.

When settings have been changed, type the command reboot to cause the CSI 2600 to boot up using the new settings. Disconnect and store the serial cable.

Changing network addresses in the CSI 2600 via Telnet There is a second way to change boot parameters which are stored in the CSI 2600. To use this method, the CSI 2600 and online server must already be able to communicate. This method does not use a serial connection to the CSI 2600, rather it uses an Ethernet connection between the server and CSI 2600. There are two major differences between a “Telnet” access, and serial port access with the CSI 2600. 90

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•

Telnet access is to one circuit board only (CPU or Transient). With HyperTerminal, an analyst may “toggle” between the two circuit boards. With Telnet, an analyst must individually access each circuit board.

•

Analyst must “log onto” the board using a name and password with Telnet, but not with HyperTerminal.

The user name and password are csi and csiSupport . Both are case sensitive. A Telnet sequence is as follows: 1.

Determine the present IP addresses of both CSI 2600 circuit boards. For this example, a CSI 2600 with addresses of 192.168.0.10 (CPU) and 192.168.0.11 (Transient) was used.

2.

Select “Run” from the server Start Menu, and type the command “telnet” followed by the IP address of the circuit board.

Figure 34. Telnet to CSI 2600 CPU board that has address 192.168.0.10

3.

Click the “OK” button on the “Run” window.

4.

Type “csi” at the login prompt, and “csiSupport” at the Password prompt.

Figure 35. Telnet login

5.

Type the command “bootChange” (case sensitive). Scroll through the existing boot parameters using the “Enter” key, change values as necessary.

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6.

Type the command “bootChange” a second time, review settings.

7.

Type “exit” or close the Telnet window when you are done. New boot settings will not take effect yet, not until the CSI 2600 is rebooted.

Figure 36. Example CSI 2600 CPU board boot settings

8.

Select “Run” from the server Start Menu, and open a Telnet session with the other circuit board. Make changes as necessary, review changes, close the Telnet window.

9.

Rebootto the 2600. Either thecommand power on and off, or Telnet theCSI CPU board andtoggle type the “reboot.”

Note While the CSI 2600 is rebooting, it will not initially respond to a Telnet command. Internal memory and processors must be initialized (late in the boot sequence) before the system will respond to Ethernet commands (that is, Telnet, reboot, bootChange).

Description of boot parameters The CSI 2600 boot parameters are stored in non-volatile memory (memory that keeps its contents even when power is removed).

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Parameters for a CSI 2600 system are shown in the figure, CSI 2600 CPU board boot parameters, and explained as follows.

Figure 37. CSI 2600 CPU board boot parameters

Item 1 is the boot device and processor number.

WARNING! Only the IP addresses should be change. If the other values are changed, the unit will not successfully boot.

The “host name” is normally the name assigned to the online server in RBM Network Administration. Item 2 is the boot file name. The CPU and transient boards use different boot files. These files are stored on the online server at directory “ .” When the CSI 2600 boots up, it will search for the server, and in directory “ ,” it will look for subdirectory “bin,” and then the boot files within that subdirectory. Item 3 is the IP address of this circuit board (CPU board in this example). This address must be listed in Machinery Health Manager “RBM Network Administration,” “Online Server Setup,” to make the unit available for databases. Item 4 is the IP address of the server. This address is stored in memory in both the CPU board, and in the Transient board. If the

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server address is changed, then both this boot parameter must be updated in both boards. Item 5 (user, ftp password) is the file transfer name and password that the CSI 2600 will use when downloading firmware from the server into the CSI 2600. Item 6 is a specific set of “flags,” which should not need to be changed.

The CSI 2600 database The process of building an online database is described in manual part number MHM-97460, and in the Emerson Online monitoring product course.

Before building a CSI 2600 database CSI 2600 applications will normally need the following information, while building a database: •

Sensors connected to each CSI 2600 signal channel; sensitivity, offset (proximity probes, thrust probes), signal range.

•

Source of sensor power for accelerometers.

•

Definition of the transient event; speed drops below 3585, input relay from external control system changes state, etc.

•

Sensors for which transient measurements are desired.

•

IP address of CSI 2600(s).

•

Bearing clearances (radial proximity probes).

•

Resting DC voltage measurements for radially mounted proximity probes.

This series of tasks is different for a CSI 2600 application, than for other online monitoring applications. In most cases, the CSI 2600 is not connected directly to sensors (proximity probe drivers, accelerometers, etc.). Rather, it is connected via coax cable with 94

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BNC terminations to a panel of monitoring modules. These modules are connected to field wiring.

Figure 38. CSI 2600 Module Outputs, Sensor Outputs

Therefore, one of the most important items, when building a database, is a drawing or listing which shows what sensors are connected to which monitoring modules. In addition, an analyst who builds a CSI 2600 database needs to know if the monitoring modules perform any signal conditioning on the input signals before passing them through to their output connectors. The CSI 2600 monitoring unit has the capability to provide bias voltage and current (+24 V / 4 mA) for accelerometers and must be in this configuration if connecting directly to accelerometers. However, if connecting to a module, it is likely that the module powers/biases the accelerometers and sensor power should not be turned on at each CSI 2600 signal connection.

When building a CSI 2600 database The program used to build a CSI 2600 database is “Online Configuration.” Many database concepts are discussed in this manual in general terms. For more detailed instructions on building a database refer to the 95


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online help within the Online Configuration program. This program includes conditional statements, called “Collection Predicates,” used to define machine events. A collection predicate can be defined to automatically archive transient data from the CSI 2600 to a permanent location on the laptop. The transient event is defined by a “collection predicate.” The predicate has a true or false value, depending upon its definition. A typical collection predicate for CSI 2600 transient operation would be “Speed below 3585 RPM.” This predicate will have a value of “False” if speed is above 3585 RPM. It would have a value of “True” if speed is below 3585. This could be the transient event. The collection predicate is used by the CSI 2600 to automatically collect transient waveforms from the CSI 2600, and send them in a (large) folder to the laptop. Once on the laptop, the measurements are saved and they may be examined by the CSI 2600 analyst.

Create a transient collection predicate To create this transient collection predicate in Online Configuration: 1.

Right click on the “Predicates” folder beneath the CSI 2600 and select “Add Collection Predicate.”

Figure 39. Transient Event Collection Predicate

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2.

Enter a name for the predicate, do not include any blanks in the name.

3.

Click the down arrow button beside the “Tach” field, and select the tachometer to be used during transient acquisition. This will be a tachometer connected to CSI 2600 tach location 1, 2, 3, or 4.

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4.

Click the arrow button beside the tach “Comparison” field, and select the equation to be used for the predicate.

Figure 40. Select predicate equation

5.

Enter a value in the Speed1 field, in this example, 3585.

Figure 41. Transient Collection Predicate

6.

Click “OK.”

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Sensor (or module) characteristics are also described to a database with Online Configuration.

Figure 42. Sensor (Module) sensitivity and range

When using the CSI 2600 to monitor turbo machinery, rely on the following plots and measurements: •

Shaft centerline plots; displays of the shaft position within a bearing area.

•

Orbits; displays of shaft vibration from a pair of probes.

•

Bode/Nyquist plots, which show phase and signal amplitude.

Information is built into the CSI 2600 database, so that software program Diagnostic Analysis can create these plots. Details of database construction are described in other Emerson manuals. However, the following information summarizes important sensor mounting characteristics.

Proximity Probe Initial Position Two values are entered in a CSI 2600 database, which are used by both the shaft centerline and orbit plots for pairs of proximity probes. These are: • 98

Resting DC voltage

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•

Bearing clearance

The resting DC voltage is a measurement taken when a shaft is not turning, and is resting at the bottom of the bearing. Bearing clearance is the difference in diameters between the rotating shaft, and the internal area of the bearing. These are shown in the figure, Resting DC voltage, Bearing clearance, although the clearances are exaggerated for the purposes of illustration.

Figure 43. Resting DC voltage, Bearing clearance

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As the shaft rotates, it rises up in the bearing clearance area, as shown in the figure, At speed centerline location.

Figure 44. At speed centerline location

The “resting DC voltage” and “bearing clearance” values are used to calculate this change in position. The Diagnostic Analysis program uses these stored values, and values measured while the shaft is rotating, to show how the shaft is moving.

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Figure 45. Prox Probe initial (resting) DC voltage, bearing clearance

Figure 46, Diagnostic Analysis shaft centerline plot, is an actual shaft centerline plot. The bearing clearance is theplaced circle which surrounds the measurements. A cursor has been on the running speed (1802.7 RPM) location. The plot shows a series of measurements, taken at different speeds for the pair of probes. The first position plotted corresponds to 161 RPM (not labeled on the plot). The shaft has moved up in the bearing area as speed increased.

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Figure 46. Diagnostic Analysis shaft centerline plot

Probe mounting geometry is described to the CSI 2600 database using a screen associated with a component. This information includes the convention used to define “clockwise” and “counter clockwise” (from driven or driver end), probe mounting angles, and tachometer (phase reference) mounting angle.

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Figure 47. Probe mounting geometry

Commissioning a database for transient operation The CSI 2600 system may simultaneously be used to monitor machinery under normal operating conditions, and also to create a large “archive” of information those signals which areAll sensor designated (while building thefor database) as “transient.” connections to the CSI 2600 are “commissioned” for normal operation. Some (or all) of these are designated as “transient,” and are “commissioned” for transient operation as well. Commissioning for transient operation involves three steps: 1.

Create collection predicate for transient auto archive operation.

2.

Commission transient channels.

3.

Create an “Auto-Archive” definition.

Step 1 is to create a collection predicate for transient operation. Often this will be a “Trip” event; such as “speed for tachometer channel 13 drops below 3585 RPM.” This collection predicate will be used (in Step 3) to cause the CSI 2600 to automatically transfer a 103


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large folder (an archive) of transient measurements to the online server. Once on the server, they may be viewed and studied by an analyst. Archives stored on the server are not affected by CSI 2600 HDD operation (that is, old measurements on HDD will eventually be written over by new measurements). Step 2 is to commission transient channels. This is a quick process, and channel commissioning, bedesignate done all at onceunlike for allprediction of the transient channels. An analystcan may some or all of the already commissioned predictive channels, for transient operation. Some signals (that is, case expansion, motor horizontal outboard) may not include valuable transient information. In this case, they do not need to be commissioned as transient, only as predictive signals. To commission channels for transient operation, right click on the CSI 2600 in the left-hand panel (in Online Configuration) and then select “Commission Transient Channels.”

Figure 48. Commission Transient channels (1)

Note In Figure 48,Commission Transient channels (1), channels 1-6 are already commissioned for “normal” operation, as indicated by the green circle and check mark at each channel connection.

A pop-up window will appear. Signals which are commissioned for predictive operation are listed in the window. Left click in each box 104

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to designate the channel as transient and then click the “Acquire” button. Measurements for the entire set of signals will be shown. A vertical scroll bar at the right side of the waveform display may be used to view signals not shown in the pop-up window. At the bottom of the waveform display window, is a single “Commission” button. Left click on this button to commission the channels for transient operation.

Figure 49. Designate transient channels

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Figure 50. View signals, Commission for Transient

Channels which asviewing transient will be indicated several places in are thecommissioned database. When the “Unit” image, in

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these will have a letter “T” inside the green commissioned signal indicator.

Figure 51. Note “T”: channel is transient

Figure 52. Measurement Point Transient Indicator

The Online Configuration program may be used to create a report which lists an overview of connections to a CSI 2600. This report is described later, however, one column in the report shows which channels have been commissioned for transient operation.

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Figure 53. Transient Channels in Unit Report

After the channels are commissioned as transient, the system will begin writing information from those channels onto the CSI 2600 HDD (assuming the database was downloaded into the CSI 2600). However, one step remains. This step tells the CSI 2600 when to automatically send an archive of measurements from the CSI 2600 to the online server. This is step 3 of the transient commissioning sequence. To tell the system when to automatically send transient information to the online server, right click on the transient tachometer (location 13, 14, 15, or 16), and select “Transient Auto-Archive Properties.”

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Figure 54. Define Transient Auto-Archive

A pop-up window will appear. In this window, three characteristics of the automatically generated archive are described. First, a name is assigned. In Figure 55, Auto-Archive Properties, a name of “RANGE 1500_2985” has been assigned. All automatically created archives will use this text, and will add to it a date-time indicator, to create individual (and unique, different date-times) archive folder names.

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Figure 55. Auto-Archive Properties

The second auto-archive characteristic is the collection predicate which is to be used to trigger the archive creation. The Auto-Archive Properties screen shows a collection predicate which will be “TRUE” when speed at tachometer connection 13 is above 1500 RPM and below 2985 RPM. The third and final auto-archive characteristic the window of time, around the transient predicate change. In the is collection predicate example just stated, an auto-archive will include 5 minutes of measurements (already in the CSI 2600) before the collection predicate changes to TRUE, and then 2 minutes of measurements which follow the predicate change. When all 7 minutes of measurements have been collected, the archive will be sent from the CSI 2600 to the online server. Only one archive is created when the predicate changes to TRUE. For instance, if at 0130 AM, speed drops below 2985 RPM. The five minutes of measurements already in the CSI 2600 are grabbed and put in a folder (still on the HDD). Two additional minutes of measurements are collected, put in the folder, and that folder is sent to the online server, at about 0132 AM. The collection predicate may still be TRUE at 0132. However, a second archive will not be started, and sent to the server. Automatic archives are created when the collection predicate changes to TRUE. 110

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An automatic archive may include up to one hour of measurements, which is a tremendous amount (remember, about 40 MB/channel/ hour). Archives may also be manually created (described later in this section), these can have more than one hour of information in them.

Reviewing and saving a transient database After building a CSI 2600 database, an analyst should review it. Mounting probe angles, rotation direction, resting DC voltages, bearing clearances, etc. A database report is generated by rightclicking the CSI 2600 in the left-hand panel and then selecting “Report.” A large listing of CSI 2600 characteristics and physical connections will be shown.

Figure 56. CSI 2600 report

This report includes: •

Firmware revision used by the CSI 2600

•

Calibration information for the CSI 2600

•

Predicates and their definitions

•

Signal connections: which are transient, which are not transient

•

Tachometer definitions

•

Relay definitions

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Figure 57. A CSI 2600 report

After a transient database is built and verified, go to to save the database. This causes the database configuration to be downloaded into the CSI 2600.

CSI 2600 operation: Online Watch Machinery Health Manager program Online Watch is used to monitor system status, and view latest measurements. Transient system status includes: •

Streaming / not streaming to HDD (and which HDD)

•

Time of oldest recorded information

•

Progress of archive creation

When a database is downloaded into the CSI 2600, the unit reorganizes internal software and schedules to conform to the database definition. While it is doing this, the unit status will be “Acknowledged.”

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Figure 58. Transient Status: acknowledged

When the unit is ready to monitor using the database definition, status will change to “Node(Unit)Up.” A single Online Watch screen displays CSI 2600 status, and the status of any archives. This display has two tabs, “Transient status” and “Transient Archive Status.” The “Transient Status” tab is shown in the figure, Online Watch: Transient Status tab.

Figure 59. Online Watch: Transient Status tab

CSI 2600 unit status is shown at the top. It should be “Node(Unit)Up,” unless a database was just downloaded into the unit (status will be “Acknowledged” for a minute or two). The Current Acquisition State is normally “Transient Acquisition has started.” If a database was just downloaded, this field will temporarily have the value of “Unknown.” If an analyst has manually stopped recording transient measurements to the CSI 2600, it will 113


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have a status of “Transient Acquisition has stopped.” The Active Streaming Location field is new to software version 5.0. Software version 5.0 permits a transient system to record to one of two destinations, one of which is external to the CSI 2600. One location is designated as the “Primary” drive, the one which transient measurements are normally written. The second is designated as the “Failover” drive, which will be written to if the system detects a problem with the primary drive. The Primary drive may be the CSI 2600 internal HDD, or it may be external. The system may be configured to use only one drive, which is the case in the Online Watch: Transient Status tab.

Note The transient drive is the location where transient data is recorded during normal/constant CSI 2600 operation. Measurements from this drive are extracted when an archive is created, and sent as a folder (archive to the online server.

The Transient Status tab also shows the time of oldest and newest measurements currently stored in the CSI 2600 for a specific database configuration. These fields may be updated by clicking the Refresh button. The final status indicator is the state of transient auto-archive predicate. For the Online Watch: Transient Status tab, the database is using a collection predicate which is TRUE if speed is above 1500 RPM and below 2985 RPM. Actual speed for tachometer signal 13 is shown, it is 187 RPM. Therefore the collection predicate is FALSE, as shown in the last column. When the auto-archive predicate changes to TRUE, an analyst may select the second tab Transient Archive Status to monitor progress of archive creation. For the Auto-Archive Predicate = TRUE (Figure 60) and Auto-Archive status = Archiving (Figure 61) screens, the auto-archive definition created in Online Configuration is to create archives with a name of RANGE 1500_2985 (plus date-time stamp), and to include 5 minutes of measurements before the predicate changes to TRUE, and then 2 minutes of measurements that follow. For the sequence shown in the Figure 60, Auto-Archive Predicate=TRUE and Figure 114

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61, Auto-Archive Status=Archiving, speed was increased from 187 RPM, causing the predicate to change to TRUE.

Figure 60. Auto-Archive Predicate = TRUE

The Transient Archive Status tab shows that an archive is being created. Initially, it has a status of “Pending.” This is because the system is adding two more minutes of measurements to a folder. When it has the complete set of measurements (5itminutes the predicate changed to TRUE, 2 minutes after), will sendbefore this folder to the online server. While it is doing this, the archive status is “Archiving,” and extraction progress is shown in the last column.

Figure 61. Auto-Archive status = Archiving

The auto-archive has the name assigned in Online Configuration (RANGE 1500_2985) with a date time stamp (05-30-2007 10.17.07). This means that every automatically created archive has a unique name. If the Transient archive predicate changes to “FALSE,” and then changes back to “TRUE,” a new archive will be

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created, but it will have a different name since the date-time is different. Once all of the measurements are sent to the online server, archive status changes to “Complete.”

Figure 62. Auto-Archive status = Complete

Archives are stored in folders in the server “…\CustData” directory. Two items will be created in that directory, having the same name as the CSI 2600 database. One is the actual database (“.rbm” file). The other is a folder.

Figure 63. CustData directory, CSI 2600 database “CSI 2600”

Inside folder “CSI 2600” there are a collection of other folders. One of these, the “archives” folder, is where archives of transient information are stored. Three specific transient operations may also be performed using Online Watch. These are: • 116

Manual archives may be created.

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•

Archive predicates may be disabled.

•

Transient streaming (to the CSI 2600) may be stopped.

Manual archives are created in Online Watch by a three-step process: 1.

Select a component which has transient signals.

2.

Right click and select “Start Transient Archive.”

3.

Define the manual archive characteristics.

Figure 64. Steps 1 and 2, Manual Archive Creation

Figure 65. Step 3, Manual Archive Characteristics

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Archive progress may be observed using the Transient Archive Status tab for the CSI 2600 unit.

Figure 66. Manual Archive Status

There are three major differences between a manually created archive, and an automatically created archive. These are: 1.

Manual archives only include information already in the CSI 2600. Automatically-generated archives can include information which is received after the transient collection predicate = TRUE.

2.

Manual archives do not automatically have a date-time stamp appended to them. Ensure that unique names are assigned.

3.

Manual archives may have more than one hour of measurements in them. Automatically generated archives have a maximum of 60 minutes (one hour) of measurements.

Three other operations may be performed using Online Watch. First, automatic archive creation can be disabled. An analyst may wish to do this during startup, or if the machine is being cycled, and multiple archives are not desired. To disable automatic archive creation, right click on the archive predicate on the Transient Status tab and select “Disable Archive Predicate.” A pop-up, caution window will be displayed, asking the analyst to verify the disable command. The predicate state will be “Disabled” in Online Watch until it is reenabled. It may be manually re-enabled by right-clicking and selecting “Enable Archive Predicate.” When an archive predicate changes from “Disabled” to “True,” no archive is created. Consider the following sequence: 118

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1.

Archive predicate is false.

2.

Archive predicate is disabled, prior to machinery start-up.

3.

Machine starts up, goes to speed of 1800 RPM.

4.

Archive predicate is re-enabled.

5.

Archive predicate immediately changes to value of TRUE.

6.

No archive is created.

7.

Machine speed continues to rise, goes to a speed of 3000 RPM.

8.

Archive predicate changes to value of FALSE.

9.

Machine trips, speed drops below 2985 RPM.

10.

Archive predicate changes to value of TRUE.

11.

Archive is automatically created and sent to online server.

Disabling/re-enabling archive predicates only determine if the CSI 2600 will send an archive to the online server, or not. This does not stop measurements from being recorded by the CSI 2600. In the previous sequence, a manual archive could be extracted, starting at the time when the archive predicate was initially false, and ending at the time that the machine was at 3000 RPM. However, an analyst may command the CSI 2600 to stop recording transient information using a single command. To stop transient acquisition, right click on the CSI 2600 and select “Stop Transient Acquisition.” A pop-up window will indicate that this has happened, and the status indicator will be:

Figure 67. Stop Transient Acquisition

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Figure 68. Transient Status = Stopped

Analysts may remove items from the Transient Archive Status tab (Figure 69, Acknowledging Transient Archives). This does not delete archives from the online server, it only removes them from the list shown on the Transient Archive Status tab. To remove an archive from the listing, right click on it and select “Acknowledge Transient Archive.”

Figure 69. Acknowledging Transient Archives

Managing archives Typical CSI 2600 operation will involve moving around, and examining, extremely large amounts of transient information. A one hour archive for a CSI 2600 which has 10 channels commissioned for transient operation, will be approximately 400 MB in size. The CSI 2600 will permit an analyst to manually extract 10, 20, 30, etc. hours of measurements from the CSI 2600. Obviously, these files can be extremely large. Even an online server with a very large HDD will eventually fill up. Efficient CSI 2600 system operation will be achieved if the analyst regularly reviews extracted archives (automatic, manual), and keeps 120

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only those of interest, or keeps only the por tions of interest in each archive. Other Emerson documentation describes how to extract a smaller archive from a large one, using program Diagnostic Analysis. Archive movement and display is significantly affected by characteristics of the laptop. An archive consists of a continuous waveform, the length of the Laptops have a of finite amount of video display memory thatarchive. may limit the amount graphic data viewed in an archive. If an analyst wants to extract and view large amounts of information from the CSI 2600, individual archives of 1 2 hours of measurements should be sequentially extracted.

Changing from one database to another The CSI 2600 is a continuous but portable monitoring system. Because it is continuous, it normally has an active database into which it stores measurements from a CSI 2600 monitoring unit. Because it is portable, it may be moved from one piece of rotating machinery to another. This portability places one significant requirement on analysts; ensure that measurements from one machine do not become stored in a database or archive folder for a different one.

WARNING! Ensure that the following sequence is observed, whenever moving the CSI 2600 from one m onitoring rack/machine to another. Incorrect performance of this sequence could result in the storage of one (the second machine) in the database of another (the first machine).

1.

Before disconnecting from the f irst machine, open program “RBM Network Administration.”

Note You will need to logon to AMS Machinery Health Manager as an Administrator to access this program.

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Figure 70. Tools tab

2.

Click on the “Online Server” listed in the bottom center panel. This panel is named “Online Servers” and the entry listed in the panel is normally 2600Host, or localhost, or the laptop’s name. 4

Figure 71. Online Server Setup

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3.

In the Online Server pop-up window, click the “Stop Data Collection” button. 5

Figure 72. Online Server Setup

4.

Disconnect the CSI 2600 from the first machine, move to the second machine.

5.

Click the “Edit” button (not shown in Figure 72), which is to the right of the “Machinery Health Manager Database” field. Select the second machine’s database from the pop-up window.

6.

Click the “Start Data Collection” button at the bottom of the Online Server Setup machine. This is the same button that was labeled “Stop Data Collection” when this sequence was begun (Dual purpose button; label shows the operation that can be commanded). The system will now store any measurements or archives in the second database.

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Basic Maintenance and Troubleshooting Introduction

During the lifetime of a CSI 2600 system, an analyst can expect to perform the following maintenance tasks: •

Installing new firmware

•

Installing new software

•

Change CSI 2600 boot settings

Also during the lifetime of a CSI 2600 system, an analyst may need to troubleshoot one of the following situations: •

Measurements in Online Watch and/or Diagnostic Analysis appear incorrect

•

Online Watch CSI 2600 status is “Node(Unit)Down”

•

System Status LED is red

•

CSI 2600 does not communicate with online server

•

Automatic archive was not created

•

Archive was truncated

•

Unable to make changes to a database

Installing new firmware Periodically, Emerson will revise firmware used by the CSI 2600 (and companion products). This may be downloaded from the CSI Technologies website, and it often is included in a folder with a software update CD.

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Each time the CSI 2600 starts up, it steps through the following sequence: •

Verifies firmware revision of firmware image copy stored in local (CSI 2600) memory.

•

Using the server address stored in local memory, contacts the server, and looks for firmware in server directory “ .”

•

Checks firmware revision of files on the server, compares to revision of image stored in local memory.

•

If firmware revision on server is newer, it downloads that firmware using a server O/S service utility (not software written by Emerson).

•

Updates image stored in local memory with the new files, boots up using the new files.

An important point to note in the above sequence is that the CSI 2600 loads firmware when it boots up. The CSI 2600 will not use new firmware on the online server, unless the unit is rebooted after the new firmware was loaded on the server. After the firmware installation to the server is complete, perform the following steps:

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1.

Cycle power on all CSI 2600 units.

2.

After 5 minutes, look for the Server Connect LED to be lit green, and the System Status LED to be pulsing green, indicating a healthy heartbeat.

3.

Enter “Online Config” and click on the level below the unit branch of the tree to bring up the CSI 2600 mimic screen.

4.

Right click on the CSI 2600 and select “Properties.” Verify that the firmware revision listed matches what was just installed.

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Installing new software It is strongly recommended that databases and accompanying transient archives which were created and managed by one software revision, be copied to a safe folder location, prior to updating software. Major software changes (that is, version 4.90 to 5.0) will re-indexdatabase a database when is opened in the the earlier new software. The re-indexed cannot beitopened with software revision. Software will always notify an analyst before it reindexes a database. Copying databases and archives to a safe folder is an easy operation, performed using the online server operating system tools (click and drag, etc.), with one exception. If the CSI 2600 is prepared to store data in a specific database, the operating system will not let you make a copy of that database. In this case, you must stop data collection first. To stop data collection, perform the following sequence of steps: 1.

Log on to Machinery Health Manager software using an administrator account.

2.

Open program RBM Network Administration.

3.

Right click the online server from the bottom center panel and select “Online Server Setup.”

Figure 73. Netadmin Online Server Setup

4.

Click the “Stop Data Collection” button. This is a multipurpose selector and not a status indicator. it is used to both stop and start data collection. The button is labeled with the

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operation which an analyst may command. For instance, if the system is currently storing data in a database, the button will be labeled “Stop Data Collection.”

Figure 74. Stopping data collection

5.

Click the “Done” button and then exit RBM Network Administration.

Both the database, and accompanying archives, should be at least temporarily copied prior to updating software. Archives are located in a folder which has the same name as the CSI 2600 transient database. Both are in the “ directory.

”

Periodically, Emerson will revise software used by the CSI 2600 (and companion products). This may be downloaded from the CSI Technologies website and is sometimes received on a CD. Firmware on the CD may include a “Setup” file, which will install the software, performing. If a setup file is supplied, simply run the setup file.

Software patches If software “patches” (changes to one or more of the Machinery Health Manager software programs, but not to all of them) are supplied, the following sequence should be used. 1. 128

Stop data collection (RBM Network Administration).

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2.

Stop CSI 2600 services (see next paragraph).

3.

Copy patches to a ppropriate folder. Machinery Health Manager software “executable files” are normally located at directory “ ”

4.

Restart CSI 2600 services.

CSI 2600 software uses five “services.” Services are programs, running in the background on the server. These specific programs are configured to start up automatically, whenever the online server starts up. To access these, use the following sequence: 1.

Right click on “My Computer” and select “Manage.”

Figure 75. Under My Computer select Manage

2.

Select “Services” in the left hand panel.

3.

Scroll down in the service listing in the right-hand panel, right click on “CsiO_Server” and select “Stop.”

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Figure 76. CSI 2600 Services

Figure 77. Stopping service “CsiO_Server”

4.

In this order, stop services CsiNetAdmin, CsiMtdbMgr, Csi_MhmRemote.

Maintenance: change CSI 2600 boot settings During normal usage, it is unlikely that boot settings initially programmed into the CSI 2600 CPU and Transient circuit boards,

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will ever need to be changed. However at least two unusual situations may require that these settings be changed. These are: •

CPU or Transient board is being replaced, if replacement board has different boot settings.

•

CSI 2600 is added to an existing Ethernet network, not directly connected to the online server through a dedicated cable.

Note Do not add a CSI 2600 to an existing Ethernet network until its IP addresses (CPU board, Transient board) have been verified and changed if necessary, to be compatible with addresses already in use on the existing network.

Default/factory boot settings may be correct for a CSI 2600 system. Normally, a CPU board will be programmed with address 192.168.0.10, a Transient board with 192.168.0.11, and both will expect the server to be at address 192.168.0.1. These may be the exact values for your CSI 2600 system. To determine the initial settings for a replaced board, insert the board in the CSI 2600, and power it up. When it has finished its “boot cycle,” use a HyperTerminal connection to determine its addresses. The recommended method of changing CSI 2600 boot settings is via a “HyperTerminal” session. This was described in Chapter 3 of this manual, and is repeated here. To change IP addresses stored in the CSI 2600, a standard RS232 cable is needed, connected between the online server serial port, and the CSI 2600 9-pin front connector. The cable will need a male/ plug connector on one end and a female/receptacle connector on the other (CSI 2600) end. Configure the online server serial port as follows: •

9600 baud

•

8 data bits

•

1 stop bit

•

No parity

•

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Connect the serial cable to both the CSI 2600 9-pin connection, and the laptop. Open operating system utility “HyperTerminal.” This is usually selected from , as shown in Figure 78, HyperTerminal utility.

Figure 78. HyperTerminal utility

When connected to a CSI 2600, an analyst will use four commands or key strokes to interact with the boot settings stored in each processing board (CPU, Transient). These are: •

bootChange - (case sensitive). This will cause the boot parameters for the specific circuit board to be listed, one at a time. To change a parameter, type the new value beside the stored value. DO NOT ATTEMPT TO BACKSPACE/DELETE THE STORED PARAMETERS.

•

Ctrl-B - (Hold down Ctrl key and press the B key.) This will toggle from one board to the other (if serial port is communicating with the CPU board, Ctrl-B will toggle to the Transient board).

•

Ctrl-T - will cause the board to display an identifier (tell you with which board you are communicating).

•

reboot - (case sensitive, all lower case). This will cause the board to reboot, using new boot settings.

•

. - the period key. Type a period at the end of a stored value, to clear this value.

Important rules when changing boot parameters Rule 1: No boot parameters take effect, until the unit is rebooted. 132

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Rule 2: Do not attempt to delete stored values. Type a new value beside the stored value. Rule 3: Only change the IP address values.

CAUTION! Do not change ftp password, boot file name, flags, etc. If a unit boots up with incorrect values for these parameters, the system will probably not operate and in some cases, the unit may need to be returned to Emerson.

Rule 4: In most cases, changes will need to be made to both processing boards. Both the CPU and Transient boards will need to be updated. They have separate boot parameters, changing one set does not change the other. Rule 5: Review changes, before using the reboot command. Rule 6: If network addresses are changed, update any drawings or documents which use the old addresses.

IP addresses stored in the CSI 2600 Perform the following sequence: 1.

Write down the IP addresses that need to be changed. Normally this will be either the online server address, or the CPU address or Transient board address.

2.

Connect to the CSI 2600, start a HyperTerminal session.

3.

Type the command bootChange (note this is case-sensitive; all lower case letters except for the “C” in Change).

4.

Use the “Enter” key to advance down the list of parameters, until the specific parameter is listed.

5.

Type the new parameter value beside the old value.

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6.

Use the “Enter” key to advance through the list of parameters.

Figure 79. Example of CSI 2600 CPU board settings

7.

At the end of the list, type Ctrl-B (hold “Ctrl” key down, press the “B” key) to toggle to the other circuit board.

8.

Type “bootChange” for this board.

9.

Use the “Enter” key to advance through the list of parameters on the other circuit board, making changes as necessary.

10.

Press the “Enter” key until at the end of the parameter list.

11.

On the second board, the command “bootChange” second time, press thetype “Enter” key to review settings. a

Figure 80. An example of Transient board boot settings

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12.

Type “Ctrl-B” (hold “Ctrl” key down, press the “B” key) to switch to the other (first) circuit board.

13.

Type “bootChange” a second time, review boot settings.

When settings have been changed and reviewed, type the command “reboot” to cause the CSI 2600 to boot up using the new settings, or power cycle the unit. Disconnect and store the serial cable.

General There are other maintenance activities which may need to be performed during the product life of the CSI 2600. These can include: •

Recalibration

•

Board replacement

These activities should be coordinated with the appropriate Emerson Product Support office.

Troubleshooting: Measurements in Online Watch and/or Diagnostic Analysis appear incorrect Since the CSI 2600 is a portable system using existing field wiring, it is likely that CSI 2600 values will be compared to values measured by some other instrument (that is, the monitor rack which the CSI 2600 connects to, or a hand-held vibration monitoring instrument such as the CSI 2130). If two instruments are showing different measurements for the same signal, it is likely that: •

Different units are being used by the two instruments.

•

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•

The monitoring rack output signal is a current-level signal (i.e., 4-20 mA) not a voltage signal.

The CSI 2600 can display measurements in acceleration, velocity, or displacement. In addition, spectral displays can be in peak-to-peak, peak, or RMS. Displayed values may be changed on the appropriate display by right-clicking over the vertical axis in most displays and selecting desired units.

Figure 81. Online Watch, changing display units

Another possible cause for incorrect measurements, is a mismatch between the sensitivity programmed into a CSI 2600 database, and the sensitivity (and offset) of the value which is actually being supplied to the CSI 2600. The CSI 2600 is normally not connected directly to sensors, but rather to the output of a module. If the 136

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module is conditioning the sensor input, and presenting a modified value to the CSI 2600, the database must be configured for this in order to compensate for it. To determine if this is happening, examine the Gross Scan DC readings in Online Watch. For accelerometers, the Gross Scan DC should be in a range of 8-12 VDC. This value should be shown in Online Watch. Proximity probes are normally gapped atlevel. about -10.0 Volts, Gross Scan DC should display approximately this In the figure, Online Watch Gross Scan DC values, signals POH and PIH are accelerometers. Notice the Gross Scan DC values of 9.442 V and 10.325 V. Signals CH1Y1, CH2X1, CH3Y2, and CY4X2 are proximity probes, which were gapped in a range of -6.77 to -6.896 V DC. As mentioned earlier, a more typical setting would be about 10.0 V. The values shown in the figure are for proximity probes mounted on a rotor kit, which because of small shaft and bearing pedestal size, are mounted close to the shaft.

Figure 82. Online Watch Gross Scan DC values

If Gross Scan DC values shown in Online Watch are not typical for the type of sensor in use, the module which the CSI 2600 is attached to is probably conditioning the output signal. In this case, the CSI 2600 database must be updated (using program Online Configuration). The CSI 2600 product expects sensor signals whose voltage is proportional to vibration or position. This is not the case with a 4-20 mA output from a monitoring module (current is proportional to vibration or position). If 4-20 mA signals are provided to the CSI 2600, then a suitable sized resistor needs to be placed in parallel

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with sensor BNC inputs (across ground and signal), to convert the current to voltage.

Figure 83. 4 - 20mA conversion and compensation

In the example shown in Figure 83, 4 - 20 mA conversion and compensation, a 500 ohm resistor converts signals in the range of 420 mA to 2-10 V. After the conversion, the database must be configured so that it interprets a 2 V input as a zero value (offset), and each 1 V change in input signal as corresponding to 2 ips of vibration change (sensitivity).

Troubleshooting: CSI 2600 status is “Node(Unit)Down” This can be a temporary condition, or it may be an indicator of a communication configuration problem. When the CSI 2600 is powering up, and has not yet identified itself to the online server, its status (in Online Watch and in Online Configuration) is “Node(Unit)Down.” This is a temporary condition. An online server periodically (every 15 minutes) interrogates its CSI 2600 network connection, to see if any assigned units are available. Within 15 minutes of power-up, a temporary communication

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problem will be resolved. An analyst may “short-circuit” this 15 minute interval by performing the following steps: 1.

Right click on “My Computer,” select “Manage.”

2.

In the left-hand panel, click on “Services and Applications” to expand this folder.

3.

Select “Services” in the “Services and Applications” folder.

4.

In the right-hand panel, right click on CsiO_Server and select “Restart.” This causes service “O_server” to stop and start. It will immediately interrogate the CSI 2600 network port and connect to any CSI 2600s that are assigned to it.

Figure 84. Restarting Csi_O_Server

A status of “Node(Unit)Down” may also be an indicator of a communication configuration problem. Successful communication between an online server and CSI 2600 requires: •

IP address of CSI 2600 matches IP addresses assigned to the online server (RBM Network Administration, Online Server Setup).

•

IP address of server matches server IP address stored in CSI 2600 boot memory.

•

CSI 2600 configuration must match configuration created in Online Watch for the unit.

•

Ethernet connection between online server and CSI 2600 must be functioning.

•

Other CSI 2600 boot parameters must be correct.

•

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View or set IP address of the Online Server 1.

Select “Control Panel.”

2.

Select “Network Connections.”

3.

Select the Ethernet port used to communicate with the CSI

4.

2600. Select“P roperties.”

5.

In the “Properties” screen, scroll down to “Internet Protocol (TCP\IP),” then click the “Properties” button.

6.

Verify that “Use the Following IP address” button is on, and that the IP address (of the server) matches the address stored in the CSI 2600.

Change IP addresses using a HyperTerminal connection

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1.

Connect a null-modem serial cable between the online server and CSI 2600 DB9.

2. 3.

Open “HyperTerminal” on the online server. Connect to the 2600.

4.

Type the command “bootChange.”

5.

Scroll down the boot parameters by using the “Enter” key. To change a boot parameter (that is, IP address of server, IP address of CSI 2600 board), type the new value beside the displayed current setting.

6.

Review all changes by typing the command “bootChange” again. To erase a setting, type the period (.) character.

7.

DO NOT CHANGE boot parameters not necessary for communication. The only boot parameters that an analyst should ever need to change are: IP address of server, IP address of board and in rare occasions, file location for the boot file.

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8.

After reviewing changes, use the Ctrl-B key sequence to toggle to the other circuit board which has stored boot parameters in it. Use the above sequence on the second board.

9.

When boot parameters have been changed AND REVIEWED, reboot the unit.

A CSI 2600 may not communicate (status = Node(Unit)Down) if boot parameters are incorrect, including those not used for addressing. For instance, the first boot parameter “boot device,” must have a value of shend0. If this value is changed, the unit will not communicate with online server. If parameters “user” or “ftp password” are changed, the unit may communicate, but it will not download new firmware. In most applications, the CSI 2600 is connected directly to the online server. However it is possible to connect the CSI 2600 to a network, and then for the online server to be also connected to the network, some distance away. If there is a gateway (not a switch or hub) between the CSI 2600 and online server, then that gateway IP address must also be programmed into the CSI 2600 (both boards; the CPU board, and Transient board) at boot setting “gateway inet.”

System Status LED is red Each time a CSI 2600 starts up, it runs a series of Power On Self Tests (POST). These are tests of internal electronics, signal paths, memory access, etc. Some details about the failure may be shown by establishing a “Telnet” session with the unit (assuming it can communicate with the online server). If the CSI 2600 is able to communicate with the online server, then a Telnet session may be used, which may give some details about the POST failure.

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•

Type telnet (example: telnet 192.168.0.10) on the “Run” line.

Figure 85. Telnet to CPU board •

Type “csi” at the login prompt, and” csiSupport” at the Password prompt (login, password and commands are case sensitive).

•

Type the command “showUnitStatus” (case sensitive).

Figure 86. showUnitStatus command •

Scroll down in the listing until the flags are shown. If there was a POST failure, a flag will be set, and the title of the failure will also be listed.

Figure 87. Flags in showUnitStatus listing

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•

Scroll down in the listing until the Transient board flags are listed.

Figure 88. Flags in showUnitStatus listing

These steps will not correct a POST failure, but they will give more details. It is possible that a failed unit may temporarily be used in a specific application, prior to shipment back to CSI for repair. For instance, if a signal path on the circuit board with signals 17-32 has failed, but the analyst wishes to operate the system in a configuration that only uses signal connections at 1-16, the system may function for that measurement.

CSI 2600 does not communicate with online server If the CSI 2600 is not communicating with the online server, it will have a status of “Node(Unit)Down” in both Online Watch and Online Configuration. This may be a temporary or permanent condition, as described in an earlier section. Valid network communication requires the following: •

Physical connection between CSI 2600 and online server

•

IP address matching; server, CSI 2600

•

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•

Service “CsiO_Server” running on online server

The first troubleshooting step for a suspected communication problem is to “ping” the CPU board. To ping the CPU board, open a “command” window ( ), then type the command ping “192.168.0.10”.

Note If CSI 2600 CPU address is different, type that address instead of 192.168.0.10.

A valid ping indicates that the two Ethernet addresses can communicate, and that the problem is probably a configuration mismatch between the CSI 2600 and online server.

Figure 89. Valid “ping” exchange

If the ping message fails, the problem is probably a physical error between the CSI 2600 and online server (bad Ethernet connection, gateway between the two units, wrong CPU IP address programmed into CSI 2600).

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Figure 90. Failed “ping” exchange

Automatic archive was not created As part of database creation for a CSI 2600 transient system, an auto-archive is defined. This definition associates a TRUE/FALSE condition (predicate) with a set of transient signals, and with a timewindow, which starts before the predicate becomes TRUE and ends after it has become TRUE. The most likely cause of a situation where an archive is not automatically created is one of the following: •

Archive predicate condition not TRUE.

•

Archive predicate has been disabled in Online Watch.

•

Data streaming to HDD was halted in Online Watch.

To trigger automatic creation of an archive, the predicate used with that archive must change state from either “FALSE” to “TRUE,” or from “INDETERMINATE” to “TRUE.” The archive predicate does not need to remain true for the entire archive sequence, it only has to change state to TRUE.

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Figure 91. Archive predicate state (last line)

The following two events will not cause an archive to be created: •

Predicate changes from “Disabled” to “TRUE.”

•

Predicate remains “TRUE” after initial archive is created.

Archive creation can be disabled in Online Watch by right-clicking on the predicate and then selecting “Disable Archive Predicate.”

Figure 92. Disabling Archive Predicate

An analyst may wish to disable an archive predicate, for instance, if a machine is being cycled (which would cause multiple archives to be created), or is initially starting up. When an analyst disables an

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archive predicate, a pop-up window will ask him or her to verify this request. A transition from “Disabled” to “TRUE” will not cause an archive to be created. Consider the following sequence for the predicate shown in Figure 92, Disabling Archive Predicate (archive will be created when speed goes above 1500 RPM, or drops below 2985 RPM from a higher speed): • 13:00 -- Analyst disables predicate, turbine speed is 300 RPM •

13:15 -- Turbine begins to start up

•

14:00 -- Turbine is now at 2500 RPM

•

14:15 -- Analyst enables predicate, turbine speed is 2600 RPM, archive predicate is TRUE, but

Disabling an archive predicate does not stop measurements from being written to the CSI 2600 HDD. The values are still there. In the above sequence, an analyst may manually extract measurements from the CSI 2600 HDD for the time period 13:00 to 14:15. An analyst may actually command the system to stop writing measurements to the HDD. This feature should be exercised with caution. To stop transient acquisition, right click on the unit and select “Stop Transient Acquisition.”

Figure 93. Stop Transient Acquisition

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This condition is indicated on the Transient Status tab for the CSI 2600 unit.

Figure 94. Transient Acquisition stopped indication

Archive was truncated An archive will have a status of “Truncated” if an analyst extracts a block of data across a gap in the time frame requested. Consider the following sequence:

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•

13:00 -- Turbine speed is 300 RPM

•

13:15 -- Turbine begins to ramp up

•

13:30 -- Analyst stops transient acquisition

•

14:00 -- Turbine is now at 2500 RPM

•

14:15 -- Analyst starts transient acquisition

•

15:00 -- Turbine is at running speed (3600 RPM)

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•

15:15 -- Analyst attempts to manually extract an archive, starting at 13:00, continuing until 15:15. An archive will be created, with a start time of 13:00, and an end time of 13:30 (time that transient acquisition was halted). Archive status will be ‘Truncated.”

Figure 95. Archive status = truncated

Unable to make changes to a database If an analyst is not able to make changes to a database, there are two likely causes: •

System is in the process of storing an archive, created with an earlier database configuration.

•

Online server is attached to a different database.

If an archive is being created (status in Online Watch is “Pending” or “Archiving”), a pop-up window will be displayed when an analyst connects to the online server in program Online Configuration, as shown in Figure 96, Archive Pending notification: Online Configuration.

Figure 96. Archive Pending notification: Online Configuration

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This is a temporary condition, which may be resolved by either of the following actions: •

Wait for the archive to complete.

•

Cancel the archive. Open Online Watch, go to the “Transient Archive Status” tab, right click on the archive and select “Cancel Transient Archive.”

Figure 97. Cancel Transient Archive

Should another database problem occur, contact the Emerson Product Support office. For instance, if an analyst cannot open a database, it is possible that this is because the online server is attached to a different database. In this situation, the analyst would open RBM Network Administration program, and select “Online Server Setup” for the server shown in the bottom center panel, and then click the “Stop Data Acquisition” button. In most cases, however, either waiting for an archive to finish, or cancelling a transient archive, will permit an analyst to change the database which the online server is using at the time.

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Appendix A Internal Wiring of the CSI 2600 The rear termination panel, shown in the following photo, plugs directly onto the backplane. This termination panel has connectors for sensor inputs, tachometer inputs, and discrete input/output relays into the 12-2-2 modules. All these connections are available via BNC connectors on the rear of the CSI 2600.

Figure 98. A6500-M-RTRM Rear Termination Panel

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Termination Panel: 1. Sensor inputs MSIG1 (Ch1 - 12) and MSIG2 (Ch13 - 24) 2. Tach inputs MSIG1 (Ch1 - 2) and MSIG2 (Ch 3 - 4) 3. Relay I/O MSIG1 (I/O 1 - 2) and MSIG2 (I/O 3 - 4) 4. DIP switches for routing buffered sensor/tach inputs from A6500-P-RTRM side of the rack of the backplane 5. DIP switches for configuring sensor power On or Off (SW 1, SW2, SW3, SW5, SW6, and SW7) 6. Calibration test signal output port (SMB connector) 7. -24 V sensor power input for eddy current sensors

Backplane: 8. SysFail relay connector 9. DC Power input connector for Prediction Side 10. HUB network connector 11. NIC network connector 12. Chassis Ground lug 13. Power On LED 14. +24 V Input LED 15. Status LED

Note For the TACH and Relay channels, the DIP switches must be left in the OFF position.

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There are DIP switches for turning accelerometer power ON or OFF. Each signal input channel has an associated DIP switch for connecting accelerometer power (see callout number 5 in Figure 98, A6500-M-RTRM Rear Termination Panel). For accelerometer channels that require power, set the associated DIP switch to the right (ON position). For sensor channels that do not require power from the CSI 2600, set the associated DIP switch to the left (OFF position).

The table, Terminal Panel Definitions, describes the function of the terminals on the termination panel. Each channel has five terminals. The first two are for the + and - signal inputs. If the associated DIP switch is set to ON, these terminals will also supply +24 V constant current accelerometer power. The second two are for the -24 V power supply for eddy current probes. These terminals only supply power if an external -24 V power supply is connected to the J19 power input terminal at the edge of the termination panel.

Note For the CSI 2600, this connection is not used and the -24 V power is available on the panel-mounted Phoenix connector on the rear of the case.

The last terminal for each channel is a chassis ground for connecting the sensor cable shield.

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Table 13: Terminal Panel Defi nitions - MSIG 1

SIG+1/+24V SIG- 1 / +24V return -24V

SIG+5/+24V

SIG+9/+24V

SIG- 5 / +24V return -24V Gnd (-24V return)

Chassis GND (Shield)


SIG+ 2 / +24V

SIG+6/+24V

-24V

SIG- 6 / +24V return


Gnd (-24V return*)

Gnd (-24V return*)

Shield SIG+4/+24V SIG- 4 / +24V return -24V

Shield SIG+8/+24V

-24V Gnd (-24V return)


SIG+11/+24V


I/O+1


I/O- 1

-24V

-24V

Gnd (-24V return*) Shield SIG+12/+24V

SIG- 8 / +24V return -24V

Gnd (-24V return)

Gnd (-24V return)



Gnd (-24V return*) Shield

I/O+2

SIG- 12 / +24V return -24V Gnd (-24V return) Chassis GND (Shield)

*NOTE: -24V terminals on I/O channels are not used for I/O connections.

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Tach- 2

Gnd (-24V return)

SIG- 7 / +24V return -24V

Chassis GND (Shield) Tach+2

-24V


-24V



-24V

SIG+7/+24V

Gnd (-24V return)

SIG+10/+24V

Gnd (-24V return)


-24V

Gnd (-24V return)

Gnd (-24V return)

SIG+3/+24V

Tach- 1

-24V

Gnd (-24V return)


Tach+1


I/O- 2 -24V Gnd (-24V return) Chassis GND (Shield)

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Table 14: Termination Panel Definitions - MSIG 2

SIG+13/+24V SIG- 13 / +24V return -24V Gnd (-24V return)

SIG+17/+24V SIG- 17 / +24V return -24V Gnd (-24V return)

Shield

Shield

SIG+ 14 / +24V

SIG+18/+24V

SIG- 14 / +24V return -24V Gnd (-24V return) Shield SIG+15/+24V SIG- 15 / +24V return -24V Gnd (-24V return) Shield SIG+16/+24V SIG- 16 / +24V return -24V Gnd (-24V return) Shield

SIG- 18 / +24V return -24V Gnd (-24V return) Shield SIG+19/+24V SIG- 19 / +24V return -24V Gnd (-24V return) Shield SIG+20/+24V SIG- 20 / +24V return -24V Gnd (-24V return) Shield

SIG+21/+24V

Tach+3


Tach- 3

-24V

-24V

Gnd (-24V return)

Gnd (-24V return)

Shield

Shield

SIG+22/+24V

Tach+4


Tach- 4

-24V

-24V

Gnd (-24V return)

Gnd (-24V return)

Shield SIG+23/+24V

Shield I/O+3


I/O- 3

-24V

-24V

Gnd (-24V return) Shield SIG+24/+24V

Gnd (-24V return) Shield I/O+4

SIG- 24 / +24V return -24V Gnd (-24V return) Shield

I/O- 4 -24V Gnd (-24V return) Shield

*NOTE: -24 V terminals on I/O channels are not used for I/O connections.

Rear terminal power connections Figure 99, Power wiring to the Rear Terminal Panel, shows the power wiring detail to the rear termination panel inside the unit.

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Figure 99. Power wiring tothe Rear Terminal Panel

Internal wiring diagram The following figure, Figure 100, shows the internal wiring diagram for the CSI 2600.

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Figure 100. Internal wiring to the CSI 2600 157


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Index A Accessories optional 9 services provided 7 9 recommended 3, 8 archive truncated 148

B Backplane 152 BNC connectors 151 boot parameters changing rules 132 boot parameters rules 88 boot setting CSI 2600 hyperterm session 131 boot settings 130

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Collection Criteria 23 Logical Hierarchy 24 Physical Hierarchy 24 Definitions, terms 81 Archive 81 Archive predicate 82 Bearing clearance 82 Extract 82 HDD (Hard Disk Drive) 82 Resting DC Voltage 82 Transient channel 82 Diagnostic Analysis 21 measurements appear incorrect 135 Diagram online database structure 23 system overview 18 Dimensions and weights 6 Disconnecting the laptop 13

F Firmware CSI 2600 22

H C Configuration 35 CSI 2600 20 Calibrating 71 Field Wiring 24 Installing 2600 modules 34 Introduction 17 monitoring unit 29 Operating environment 9 Overview 5 CSI 2600 Configuration Memory 27 Network 26 CSI 2600 Machinery Health™ Expert 5

D Database Structure 22

HyperTerminal 13 HyperTerminal, Configuring a CSI 2600 52

I internal wiring diagram 156 Internal Wiring of the CSI 2600 151 IP address changing network addresses 85 IP addresses 26 change 133 verifying or editing 83

M measurements display 4 - 20mA conversion and compensation

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138 changing display units 136 in what forms 136 Gross Scan DC readings 137 MHMRemote 21 Microsoft IIS FTP 21 Monitoring Methods 34 MtDbMgr 20

N NAS hard drive 15 NetAdmin 20 new firmware installing 125 new software installing 127 patches 128 services 129 Node(Unit)Down CSI 2600 troubleshooting 138

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S Signal Input Module 41 Spectral Scan 35 System Status LED is red 141

T telnet 142 csiSupport 142 showUnitStatus 142 Transient Archive cancel 150 status tab 150 Transient Data Capture 35 Troubleshooting automatic archive not created 145 database unable to change 149 online server and CSI 2600 do not communicate 143

W Windows Services 19

O O_server 20 Online Configuration 21 Online Server 75 no communication with CSI 2600 143 ping 144 Online Software guide 32 Online Watch 21 measurements appear incorrect 135

P Power On Self Tests (POST) 141 power wiring detail 155 Processor Module 36

R Rear Termination Panel 152

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