9770M1 3500 25.pdf

Part No. 129770-01 Revision M, June 2005

3500/25 ENHANCED KEYPHASOR MODULE

OPERATION AND MAINTENANCE MANUAL

Copyright 2003 Bently Nevada LLC

All Rights Reserved.

The information contained in this document is subject to change without notice.

Trademarks

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

Actionable Information, Actionable Information to the Right People at The Right Time, ADRE, Bently Nevada, CableLoc, Data Manager, Decision Support, DemoNet, Dynamic Data Manager, Dynamic Transmitor, Engineer Assist, FieldMonitor, FluidLoc, FlexiTIM, FlexiTAM, Helping you Protect and Manage All Your Machinery, HydroVU, Key , Keyphasor, Machine Condition Manager 2000, MachineLibrary, MicroPROX, Move Data, Not People, Move Information, Not Data, Performance Manager, PROXPAC, Proximitor, REBAM, Seismoprobe, System 1, TDIXconnX, Tecknowledgy, TipLoc, TorXimitor, Transient Data Manager, Trendmaster, TrimLoc, VAM, Velomitor, Xlerometer

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

Contacting Bently Nevada

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

Mailing Address 1631 Bently Parkway South Minden, NV 89423 USA

Telephone 1 775 782 3611 1 800 227 5514

Fax 1 775 782 9259 Internet www.bently.com

3500/25 Operation and Maintenance

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Additional Information

NOTE: This manual does not contain all the information required to operate and maintain the 3500/25 Keyphasor Module. Refer to the following manuals for other required information.

3500 Monitoring System Rack Installation and Maintenance Manual (129766-01) general description of a standard system general description of a Triple Modular redundant (TMR) system instructions for installing and removing the module from a 3500 Rack

3500 Monitoring System Rack Configuration and Utilities Guide (129777-01) guidelines for using the 3500 Rack Configuration software for setting the operating

parameters of the module guidelines for using the 3500 test utilities to verify that the input and output terminals on

the module are operating properly

3500 Monitoring System Computer Hardware and Software Manual (128158-01) instructions for connecting the rack to 3500 host computer procedures for verifying communication procedures for installing software guidelines for using Data Acquisition / DDE Server and Operator Display Software procedures and diagrams for setting up network and remote communications

3500 Field Wiring Diagram Package (130432-01) diagrams that show how to hook up a particular transducer lists of recommended wiring


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Contents 1 Receiving and Handling Instructions......................................... 1 1.1 Receiving Inspection.................................................................................................. 1 1.2 Handling and Storage Considerations ....................................................................... 1 1.3 Disposal Statement ................................................................................................... 1

2 General Information .................................................................... 2 2.1 Module Compatibility ................................................................................................. 3 2.2 Expanded Signal Processing Capability..................................................................... 3 2.3 Paired Keyphasor Capability...................................................................................... 4 2.3.1 Special Considerations: ......................................................................................... 6 2.4 Triple Modular Redundant (TMR) Description............................................................ 6 2.5 Available Data ........................................................................................................... 6 2.5.1 Statuses................................................................................................................. 7 2.6 LED Descriptions....................................................................................................... 9

3 Configuration Information ........................................................ 10 3.1 Hardware Considerations ........................................................................................ 10 3.1.1 Paired Keyphasor Hardware Considerations........................................................ 10 3.2 Software Configuration Considerations.................................................................... 10 3.2.1 Keyphasor Module / 3500 Monitor Configuration Interaction ................................ 10 3.2.2 Signal Paths And Signal Options ......................................................................... 11 3.2.3 Event Setup Options ............................................................................................ 11 3.2.4 Keyphasor Signal Rate Division By 3500 Monitors............................................... 12 3.2.5 Restrictions On Absolute Phase Information Availability ...................................... 12 3.2.6 Phase Accuracy Limitations Of Processed Signals .............................................. 13 3.2.7 Limitations When Specifying An "Event Ratio" Event Setup................................. 14 3.3 Software Configuration Options............................................................................... 15 3.3.1 Keyphasor Module Configuration Options ............................................................ 15 3.3.2 Keyphasor Module Configuration Screen, Example 1 .......................................... 21 3.3.3 Keyphasor Module Configuration Screen, Example 2 .......................................... 22 3.3.4 Keyphasor Module Configuration Screen, Example 3 .......................................... 23 3.3.5 Keyphasor Module Configuration Screen, Example 4 .......................................... 24 3.3.6 Paired Keyphasor Configuration .......................................................................... 25 3.3.7 Paired Keyphasor Configuration Screen Example 1............................................. 26 3.3.8 Paired Keyphasor Configuration Screen Example 2............................................. 26 3.3.9 Software Switches................................................................................................ 27 3.3.10 Software Switch Options ...................................................................................... 28

4 Keyphasor I/O Module Descriptions ........................................ 29 4.1 Internal Termination Keyphasor I/O Modules........................................................... 30 4.1.1 Non-Isolated Internal Termination Keyphasor I/O Module.................................... 30 4.1.2 Isolated Internal Termination Keyphasor I/O Module............................................ 31 4.1.3 Internal Barrier Internal Termination Keyphasor I/O Module................................. 32 4.1.4 Euro Style Connectors ......................................................................................... 33 4.2 External Termination Keyphasor I/O Modules.......................................................... 34 4.2.1 Non-Isolated External Termination Keyphasor I/O Module................................... 34 4.2.2 Isolated External Termination Keyphasor I/O Module .......................................... 35 4.2.3 External Termination Blocks................................................................................. 36


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4.2.4 External Termination Block Cable Signal Pin Outs ...............................................38

5 Maintenance............................................................................... 39 5.1 Verifying Keyphasor Module Operation ....................................................................39 5.1.1 Choosing A Maintenance Interval .........................................................................39 5.1.2 Required Verification Test Equipment ..................................................................39 5.1.3 Typical Verification Test Setup .............................................................................40 5.1.4 Using Rack Configuration Software For Verification Testing ................................42 5.1.5 Procedure For Verifying Keyphasor Module Channels .........................................43 5.1.6 If A Channel Fails A Verification Test ...................................................................46 5.2 Performing Firmware Replacement / Upgrade .........................................................47 5.2.1 Determine The Firmware Replacement Process To Use ......................................47 5.2.2 Replace The Firmware IC.....................................................................................47 5.2.3 Firmware Download Via Rack Configuration Software..........................................52

6 Troubleshooting ........................................................................ 54 6.1 Self-Test ..................................................................................................................54 6.2 LED States...............................................................................................................55 6.3 System Event List Messages ...................................................................................55 6.3.1 List Of System Event List Messages ....................................................................56 6.4 Alarm Event List Messages......................................................................................63 6.4.1 List Of Alarm Event List Messages .......................................................................63

7 Ordering Information................................................................. 64

8 Specifications ............................................................................ 66

3500/25 Operation and Maintenance 1 Receiving and Handling Instructions

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1 Receiving and Handling Instructions

1.1 Receiving Inspection Visually inspect the module for obvious shipping damage. If shipping damage is apparent, file a claim with the carrier and submit a copy to Bently Nevada LLC.

1.2 Handling and Storage Considerations Circuit boards contain devices that are susceptible to damage when exposed to electrostatic charges. Damage caused by obvious mishandling of the board will void the warranty. To avoid damage, observe the following precautions in the order given.

Application Alert

Machinery protection may be lost when this module is removed from the rack.

Do not discharge static electricity onto the circuit board. Avoid tools or procedures that would subject the circuit board to static damage. Some possible causes include ungrounded soldering irons, nonconductive plastics, and similar materials.

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

Transport and store circuit boards in electrically conductive bags or foil. Use extra caution during dry weather. Relative humidity less than 30% tends

to multiply the accumulation of static charges on any surface.

1.3 Disposal Statement Customers and third parties that are in control of product at the end of its life or at the end of its use are solely responsible for proper disposal of product. No person, firm, corporation, association or agency that is in control of product shall dispose of it in a manner that is in violation of United States state laws, United States federal laws, or any applicable international law. Bently Nevada LLC is not responsible for disposal of product at the end of its life or at the end of its use.

2 General Information 3500/25 Operation and Maintenance

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2 General Information

The 3500/25 Enhanced Keyphasor Module is a half-height, two-channel module used to provide Keyphasor signals to the Monitor modules in a 3500 Rack. The Keyphasor module receives analog input signals from proximity probes or magnetic pickups and converts them to conditioned digital signals that indicate when the Keyphasor mark on the shaft is in line with the probe. The 3500 Monitoring System can accept four such Keyphasor signals, which are used by 3500 Monitoring System modules and external diagnostic equipment to measure vector parameters such as 1X amplitude and phase.

A 3500 Rack may have one or two Keyphasor Main Modules in a normal configuration, three or four Keyphasor Main Modules for a paired keyphasor configuration, and one of five types of Keyphasor I/O Modules installed.

1) Keyphasor Main Module (front panel buffered output connectors indicated) 2) Keyphasor I/O Module, with Isolated Internal Terminations 3) Keyphasor I/O Module, with Isolated External Terminations 4) Keyphasor I/O Module, with Non-Isolated Internal Terminations 5) Keyphasor I/O Module, with Non-Isolated External Terminations 6) Keyphasor I/O Module, with Barriers (Non-Isolated, Internal Terminations)

Views of the Keyphasor Main Module and Keyphasor I/O Module Components

3500/25 Operation and Maintenance 2 General Information

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2.1 Module Compatibility The 3500/25 Enhanced Keyphasor Main Module is an upgraded version of the original 3500/25 Keyphasor Main Module. It offers enhanced signal processing capabilities while maintaining complete downward-compatibility with the original Keyphasor Main Module and all Keyphasor I/O Modules for use in legacy systems. The form, fit and function of the two modules are essentially identical, with the additional enhanced features incorporated into the internal design of the new module. The enhanced features are accessible with upgraded Rack Configuration software.

Throughout this manual, the term "Keyphasor Module" refers interchangeably to both the original Keyphasor Main Module, PWA 125792-01, and the Enhanced Keyphasor Main Module, PWA 149369-01. The physical and mechanical characteristics of these two main modules, including product labeling, are identical. The interface to the 3500 Rack remains unchanged. As well, each of the various Keyphasor I/O Modules remain unchanged. The full name, "Enhanced Keyphasor Module", is used in those circumstances where the unique, enhanced signal processing capability of the new module is being referenced.

2.2 Expanded Signal Processing Capability The Enhanced Keyphasor Module expands on the original design by using a digital signal processor (DSP) to optionally generate an arbitrary number of output Keyphasor events in proportion to the number of input events. The generated output rate may be greater than or less than the input rate and is not limited to a small range of integral event ratios. Virtually any practical real numbered ratio of input events to output events may be programmed into the module, independently for each of two channels.

There are two types of Keyphasor signals available from an Enhanced Keyphasor Module. These may be selected on a per-channel basis, and further selected individually for routing to the Monitor modules in a 3500 Rack and to the buffered outputs. The two types are referred to as "Processed" and "Non-Processed" signals.

Processed signals are those that have undergone a change in frequency, from the input transducer signal to the output conditioned Keyphasor signal. This type of signal is only available from an Enhanced Keyphasor Module, and is only available for certain configuration options as detailed in Section 3.

Non-Processed signals are those that have not undergone a change in frequency, from the input transducer signal to the output conditioned Keyphasor signal. This is the only type of signal that is produced by the original design Keyphasor Module.


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2.3 Paired Keyphasor Capability P/N 149369-01 Keyphasor Modules that are revision C or newer have additional circuitry that was not on previous revisions. This circuitry provides the customer with Paired Keyphasor capability.

Paired Keyphasor Capability is meant to be used by customers who have speed input sets to be used as a primary and a backup speed signal entering the Keyphasor Module. The Keyphasor Module then determines which signal in each set will be transmitted down the backplane and passed to monitors in the 3500 rack. Only one of the two signals being input to each Keyphasor module will be transmitted to the rest of the 3500 system. It should be noted that although only one signal will be output from the Keyphasor module to the 3500 system, both channels will be monitored continuously.

In a Paired Keyphasor application, the customer will be able to insert four half-height keyphasor modules, which would allow them to have up to eight Keyphasor input module signals at one time. The four Keyphasor modules can be placed anywhere in the rack except for the slots designated for the RIM and the Power Supplies. The Keyphasor modules must be placed in adjacent slots with two modules on top and two on the bottom half of the rack.

The 3500 system backplane only has the ability to accept four speed input signals. Therefore, during Paired Keyphasor operation each of the four Keyphasor modules will drive one backplane trace with one of the two input signals received. The signal placed on the backplane is based upon by the module configuration and the status of each Keyphasor channel.

The Keyphasor module must avoid conflicts or contention on the four system Keyphasor lines when it switches from primary to the backup input signals. To accomplish this, the Keyphasor module performs a test checking to see if the system line is being driven by another module previous to actively driving the line itself. This test for conflicts will be done on power up or whenever Keyphasor signals are switched.

If a backplane drive conflict is detected, the module will behave in a manner consistent with reporting a fatal error, e.g. upon detection of an invalid configuration or fatal node voltage error. This has the effect of disabling the primary function and rendering the Module OK status as NOT OK. In cases where this is brought on simply by invalid module configurations, and not hardware malfunctions, recovery can be accomplished by downloading valid configuration(s) to the one or more 3500 modules in the rack causing, or affected by this condition. In cases where a hardware failure is causing the situation, replacing the offending module(s), followed by a valid configuration download to the 3500 rack should resolve the problem.

To determine which input signal will be transmitted to the 3500 system during Paired Keyphasor operation, the Keyphasor module takes the following into consideration:


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If an input channel is Not Active, it can be considered to be non-existent, so it cannot source the output.

If an input channel is in Bypass, it can be considered to be temporarily non-existent while Bypass is active, so it cannot source the output. Note that Threshold Adjust mode overrides Bypass and makes a channel act as if it is not in Bypass. Only one channel at a time can be in Threshold Adjust mode.

If the Primary input channel is Active, and not in Bypass, and its OK state is Valid, the Primary input channel will source the output; -or- If the Primary input channel is Active, and not in Bypass, and the Backup input channel is either Not Active or is in Bypass, the Primary input channel will source the output.

If the Backup input channel is Active, and not in Bypass, and the Primary input is not sourcing per the previous bullet, then the Backup input channel will source the output.

If neither the primary nor the backup input signals are being used to drive the system Keyphasor lines, then the output will not be driven (i.e., it will be tri-stated to high impedance).

The following table explains the possible circumstances and what outputs will be sent to the system:

Paired Keyphasor Output Table Case Primary

Active Primary

Threshold Adjust

Primary Bypass

Primary Valid

Backup Active

Backup Threshold

Adjust Backup Bypass

Backup Valid

Output Chann

el 1 No X X X No X X X High-Z 2 No X X X Yes No No X Backup 3 No X X X Yes Yes X X Backup 4 No X X X Yes No Yes X High-Z 5 Yes No Yes X No X X X High-Z 6 Yes No Yes X Yes No No X Backup 7 Yes No Yes X Yes Yes X X Backup 8 Yes No Yes X Yes No Yes X High-Z 9 Yes Yes X Yes X X X X Primary

10 Yes Yes X No No X X X Primary 11 Yes Yes X No Yes No No X Backup 12 Yes Yes X No Yes No Yes X Primary 13 Yes No No Yes X X X X Primary 14 Yes No No No No X X X Primary 15 Yes No No No Yes No No X Backup 16 Yes No No No Yes Yes X X Backup 17 Yes No No No Yes No Yes X Primary


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2.3.1 Special Considerations: The following considerations should be taken into account when using the Paired Keyphasor Capability:

Following a transition from a Primary to a Backup Keyphasor signal, or a switch from Backup to Primary, there will be a period in which the Keyphasor signal is likely to be invalid on the system line that is being switched. Because the Primary and the Backup signals may closely resemble each other, it is possible that a monitor will not detect a switch from Primary to Backup. The result of this is that monitors will not be able to always detect that the phase has potentially become invalid. So in the end, unless both the Primary and Backup signal sources can provide absolute phase information, the validity of the phase information from a given Primary/Backup signal pair cannot be guaranteed.

Due to the inability of the monitors to detect a switch of Keyphasor signals, additional system events have been created to inform the user that these switches have occurred. System Event numbers 494 through 496 were created.

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

When used in a TMR application, Keyphasor transducers may be connected to the 3500 Rack in two ways:

Redundant Keyphasor Transducers Two independent Keyphasor transducers are at each measurement location. This configuration provides for both primary and secondary inputs and is the most fault tolerant and reliable configuration. In this configuration, the primary and secondary inputs will be connected to independent Keyphasor Modules.

Single Keyphasor Transducers This configuration requires only a single Keyphasor transducer. The signal from this transducer is wired to provide input to both Keyphasor Modules.

When used in a TMR application, only two speed measurement locations can be supported.

2.5 Available Data The Keyphasor Module returns the machine speed in RPM, measured from each Keyphasor transducer. The RPM reading is the primary value and is used by the Communication Gateway Module and the Rack Interface Module. The Keyphasor Module also returns both module and channel statuses.


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2.5.1 Statuses This section describes the available statuses and where they can be found.

MODULE STATUS

OK This indicates if the Keyphasor Module is functioning correctly. A Not OK status is returned under any of the following conditions: Node Voltage Failure Hardware Failure in the module Configuration Failure Slot ID Failure

If the Module OK status goes Not OK, then the system OK Relay on the Rack Interface I/O Module will be driven Not OK.

Configuration Fault This indicates if the Keyphasor Module configuration is invalid.

Bypass This indicates if the Keyphasor Module has been bypassed. Any of the following conditions can cause the Keyphasor Module to be bypassed: Keyphasor Module has never been configured Keyphasor Module is in configuration mode Fatal error was found during self-test A channel has an invalid configuration Any active channel is bypassed

CHANNEL STATUS

OK This indicates whether or not a fault has been detected on the channel. The following will cause a Channel Not OK status AND a Module Not OK status: Node Voltage Failure Hardware Failure in the module Bypass is active on the channel Configuration Failure Slot ID Failure

The following will cause only a Channel Not OK status and will NOT cause the System OK Relay on the Rack Interface I/O Module to be driven: Keyphasor Signal less than 1 RPM Keyphasor Signal greater than 99,999 RPM Keyphasor Signal has a 50% or greater Change in Period Keyphasor Transducer Failure Keyphasor Signal greater than 20 kHz


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Bypass This indicates if the associated Keyphasor Module channel has been bypassed. Any of the following conditions can cause a channel to be bypassed: Keyphasor Module has never been configured Keyphasor Module is in configuration mode Fatal Error was found during self-test A channel has an invalid configuration Any active channel is bypassed

Off This indicates whether the channel has been turned off. The Keyphasor channels may be turned off (inactivated) using the Rack Configuration software.

The following table shows where the statuses can be found.

Statuses

Communication Gateway Module

Rack Configuration

Software

Operator Display

Software

Module OK

X

X

Module Configuration Fault

X

Module Bypass

X

Channel OK

X

X

X

Channel Bypass

X

X

X

Channel Off

X

X


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2.6 LED Descriptions The LEDs on the front panel of the Keyphasor Module indicate the operating status of the module as shown in the following figure. Refer to Section 6.2 for all of the available LED conditions.

1) OK Indicates that the Keyphasor Module and the Keyphasor I/O Module are operating correctly.

2) TX/RX Indicates communication between the Keyphasor Module and the Rack Interface Module as messages are transmitted and received.

3 Configuration Information 3500/25 Operation and Maintenance

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3 Configuration Information

This section describes how the 3500/25 Keyphasor Module is configured using the Rack Configuration software. It also describes configuration restrictions associated with this module. Refer to the 3500 Monitoring System Rack Configuration and Utilities Guide and the Rack Configuration software for details on how to operate the software.

3.1 Hardware Considerations The slots in the rack are numbered from 0 to 15, counting from left to right. The power supplies go into slot 0 and the Rack Interface Module goes into slot 1. Slots 2 through 15 are called monitoring positions. The 3500/25 Keyphasor Module can be installed into any of the monitoring positions. However, if the 3500/20 Rack Interface Module and Data Manager I/O are to be used to interface to DDIX, TDIX or TDXnet, refer to the manual on the 3500/20 for slot restrictions this may place on your configuration.

3.1.1 Paired Keyphasor Hardware Considerations In a paired keyphasor application the customer will be able to insert up to four half height keyphasor modules which would allow them to have up to eight Keyphasor module input signals at one time. The four keyphasor modules can be placed anywhere in the rack besides the slots designated for the RIM and the Power Supplies. The Keyphasor modules must however be placed in adjacent slots with two modules on the top half and two on the bottom half of the rack.

*When using the 3500/25 in a Paired Keyphasor application, the following modules must have the listed, or more recent firmware:

Management 4 Channel Monitors (PWA 140734-XX): Firmware rev 2.30 3500/22 Transient Data Interface (PWA 1388607-XX): Firmware rev 1.20

3.2 Software Configuration Considerations The Keyphasor Module configuration options are for the most part, very straightforward; however, the increased signal processing options warrant a discussion of some configuration considerations that should be taken into account. This section covers those items and also introduces some new terms used in the Enhanced Keyphasor Module configuration.

3.2.1 Keyphasor Module / 3500 Monitor Configuration Interaction

Keyphasor probe orientation and Event Setup configuration parameters are directly linked to monitor operation in the 3500 Rack. When these parameters are changed, the configuration of the monitors which are associated with the changed Keyphasor channels, must also be downloaded (or re-downloaded) to the 3500 Rack. The Rack Configuration software displays messages and confirmation dialog boxes to assist in the proper selection of affected monitors for configuration downloading as appropriate.

3500/25 Operation and Maintenance 3 Configuration Information

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3.2.2 Signal Paths And Signal Options

There is an important distinction to be made between the Rack Signal and Buffered Output signal paths, and the selection of Processed and Non-Processed signals one wishes to place on them. These terms are defined here.

The Rack Signal path is that Keyphasor signal path which runs down the 3500 System Backplane, for use by monitors in the rack.

The Buffered Output path is that Keyphasor signal path which runs to the front panel BNC connectors and to the Keyphasor I/O Module Buffered Output terminals.

The Buffered Output signal paths have no bearing on how monitors in the rack handle Keyphasor signals, as the monitors do not operate on the Buffered Output signals. The selection of the signal type put on the Rack Signal path does however, affect monitor operation as described herein.

Non-Processed signals are simply those that have not undergone a change in frequency, from the input transducer signal to the output conditioned signal.

Processed signals are those that have undergone such a change. They may be at a rate higher or lower in frequency than the input transducer signal with which they are derived.

The effect of using Processed vs. Non-Processed signals can be illustrated by considering that, if an identical, 100 RPM test signal were applied to the inputs of two Enhanced Keyphasor Module channels, with the Event Ratio for Channel 1 specified to be 0.5, and that for Channel 2 specified to be 2.0, then the Processed signal output on Channel 1 would be at 200 RPM, while that for Channel 2 would be at 50 RPM, and the Non-Processed signal on either channel, if selected, would show an output signal at 100 RPM.

The Keyphasor signals generated by the original Keyphasor Module are always of the Non-Processed type. The Enhanced Keyphasor Module is capable of producing both Non-Processed and Processed signals.

3.2.3 Event Setup Options

The expanded signal processing capabilities of the Enhanced Keyphasor Module leads to the introduction of a new configuration parameter known as the Event Setup. This parameter adds the Event Ratio option to the already existing configuration options known as Events Per Revolution, or Events Per Rev, and Recip Multi-Event Wheel. Logically, each of these three mutually-exclusive options are variations of the same theme, as each describe a number of input events seen at the Keyphasor probe in relation to a single revolution of some primary rotor.

The Recip Multi-Event Wheel option is the most specialized of the three, with a fixed integer relationship of 13 input events per single rotation of the primary rotor, for reciprocating machine applications. The Events Per Rev option allows


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for an integer number of input Keyphasor events per single revolution of some primary rotor, in the range from 1 to 255. The Event Ratio option is the most flexible, allowing for a practically unlimited range of expression of the number of input Keyphasor events per single revolution of some primary rotor (or more generally, the ratio of the number of input events per generated output events), including fractional numbers. Generally speaking, Processed signals are synonymous with an Event Ratio Event Setup; whereas Non-Processed signals usually imply an Events Per Rev or Recip Multi-Event Wheel Event Setup.

To avoid redundant specifications of any particular configuration, the Rack Configuration software automatically reduces an Event Ratio Event Setup to an Events Per Rev Event Setup whenever they would be logically equivalent.

3.2.4 Keyphasor Signal Rate Division By 3500 Monitors

Individual monitors in a 3500 Rack are sensitive to the configuration being set up for Non-Processed Rack Signals, where the Event Setup parameter is specified to be an integer in the range of 2 to 255. It makes no difference whether the Event Setup is optioned as Events Per Rev, Event Ratio or Recip Multi-Event Wheel. For this configuration, the individual monitors configured to use such a Keyphasor channel will apply internal rate division of the received Keyphasor pulse train at the individual monitor level. Simply put, individual monitors divide down the Keyphasor signal they receive from the Rack Signal path by the integer specified in the Event Setup numeric input field on the Keyphasor Module configuration screen.

Note that in all cases where a Keyphasor channel is configured to use a Processed Rack Signal, monitors in the rack configured to use that channel will not do internal dividing of the Keyphasor signal rate.

This makes sense since the point of using a Processed Rack Signal is to let the Enhanced Keyphasor Module do the work of modifying the incoming signal rate to provide monitors with a "once-per-turn" Keyphasor signal.

3.2.5 Restrictions On Absolute Phase Information Availability

One caveat with which to be aware is that absolute phase information is not available from a monitor channel using a Processed Rack Signal, or when specifying an Events Per Rev other than one (1). This is because subsequent to a lost or invalidated Keyphasor input signal, the re-acquisition of the input signal may or may not correspond with the synchronizing events of past or future sessions, from run to run. As an illustration, consider that if an n-tooth gear is used as the input Keyphasor source, then from run to run there is no guarantee that any one gear tooth or notch will be observed as the "synchronizing event" during the re-synchronization process. So for this reason, phase information is disabled (made unavailable and/or marked as invalid), when using a Processed Rack Signal, or if specifying an Events Per Rev Event Setup with a value other than 1. The Recip Multi-Event Wheel option is a special case however, and phase information is retained with this setup. The Rack Configuration software displays messages and confirmation dialog boxes to


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assist in the proper identification and selection of such monitors that would be affected by this constraint.

Note that relative phase (from initial acquisition of the input Keyphasor signal until loss for whatever reason) is maintained to a fraction of a degree, but absolute phase cannot be guaranteed.

3.2.6 Phase Accuracy Limitations Of Processed Signals

As with any processed signal system with a finite response time capability, there are limitations to the precision and accuracy of the generated output Processed Keyphasor signal in response to the input signal. Both static and dynamic phase error components should be considered, however small they may be. The following discussion covers the phase error specifications for static and dynamic Processed output signals.

The Static Phase Error ("SPE") of the Processed output signal is the long-term deviation in the output signal while maintaining a constant-speed input signal. This deviation is due to unavoidable algorithm execution time deviation in processing asynchronous Keyphasor input events, and limited by the internal DSP clock rate. Approximately 6 microseconds of fixed, maximum deviation in the output signal over time is observed. The following table shows some representative performance numbers for Static Phase Error values that may be expected at typical output frequencies across the valid range. Note that as the output frequency decreases, so does the worst-case SPE, in a linear fashion.

Fout RPM/CPM SPE 1667 Hz 100,000 3.60 463 Hz 27,780 1.00 60 Hz 3,600 0.13 50 Hz 3,000 0.11

The Dynamic Phase Error ("DPE") of the Processed output signal is the short-term deviation in the output signal created in response to a changing-speed input signal. This deviation is due to several factors. There is an unavoidable natural response latency in the signal processing algorithms, mostly dictated by the finite internal DSP clock rate. In addition, the predictive nature of the algorithms employed tends to improve the response for frequency division (Event Ratio greater than or equal to 2.0) and degrade the response for frequency multiplication (Event Ratio less than 2.0). The Event Ratio strongly affects the dynamic response in a non-linear, natural logarithmic fashion. In addition to this, an essentially linear response of degrees of phase error per percent change in the input signal is observed, assuming constant acceleration.

The Specifications section of this manual contains more detailed information regarding the Static, and Dynamic Phase Error characteristics of the Enhanced Keyphasor Module in generating Processed signals.


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3.2.7 Limitations When Specifying An "Event Ratio" Event Setup

The numeric range specified to the left of the data entry field for an Event Ratio Event Setup is displayed as 0.0000001 to 10000000.0, reflecting the valid range of numbers with which the Event Ratio may be specified. This range, for all intents and purposes, should cover any practical user application. The Rack

Configuration software automatically performs limit checking to ensure that only numbers within the valid range may be entered.

Regardless of the specified Event Ratio, there are frequency limitations on both the input Keyphasor signal and on generated Processed Rack Signals which, among other things, affect the Channel and Module OK Statuses. These are detailed in the Specifications section of this manual.

The Event Ratio may be specified as a positive, real number (integer and/or fractional number), either less than or greater than unity (1.0). An Event Ratio of exactly 1.0 is disallowed. Functionally, this can be achieved by specifying the Event Setup option as Events Per Rev with a value of 1. This reflects the majority of typical customer applications, and maximum system performance is achieved with this configuration. This also eliminates what would otherwise be a redundant means of specifying unity Keyphasor rate processing.

It should be noted that in general, the higher the numeric value of the Event Ratio, the better the system is able to track the input since it has more "information" to work with in the form of input pulses; the better to respond to speed fluctuations or ramping conditions as the input is tracked.

There are a few extra considerations to keep in mind when specifying an Event Ratio less than two (2.0). The digital signal processing algorithm design uses two fundamentally different strategies, one for Event Ratios equal to or greater than 2.0 (which essentially implies frequency division), and the other for Event Ratios less than 2.0 (which implies frequency multiplication). Algorithm selection is automatic within the DSP code, based on the programmed Event Ratio for each channel. The large majority of applications will require dividing-down of the input signal, with the Event Ratio typically much greater than 2.0. As such, the DSP code has been optimized to support these applications, leading to an effect which improves the transient response for frequency division, but degrades it for frequency multiplication. For this reason, one should not expect any reasonable transient response to be achieved for Event Ratios approaching or less than 2.0.

There are also two additional side-effects of frequency multiplication processing that are not present when the Event Ratio is specified as 2.0 or greater. The two are similar in effect and are due to the limitations inherent in attempting to generate multiple output pulses in response to a single input pulse (or sequence of pulses), which is the essence of frequency multiplication. First, there can be a significant synchronization time required from the time a signal is first applied to the input to a Keyphasor channel to the time the first Processed Signal output appears. Generally speaking, the greater the number of significant digits specified to the right of the decimal point in the fractional Event Ratio, the longer


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it may take to synchronize to the input and therefore commence generating output pulses in response. The second effect is that, upon loss of the input Keyphasor signal, a multiplied output may persist at the programmed rate for some time after the input stimulus has gone away. These side effects may be observable for two minutes or more.

3.3 Software Configuration Options The Keyphasor Module configuration options are discussed in detail in this section. Following the descriptions of the options, figures are shown depicting screen views of the 3500 Rack Configuration software. Several examples are shown to illustrate the various option choices available on the Keyphasor Module configuration screen. Depending on the numeric values entered for some configuration parameters, certain options may be restricted, made unavailable, and/or "force-selected" automatically by the Rack Configuration software.

3.3.1 Keyphasor Module Configuration Options

REFERENCE INFORMATION These fields are shown at the top of the Configuration Screen and contain information to indicate the location of the Keyphasor Module in the 3500 Rack, the type of associated Keyphasor I/O Module, and an optional label to track configuration setups. The I/O Module parameter must be selected by the user as part of the configuration setup.

ConfigID This information field displays an optional identifier of up to six characters, which if present was entered upon last configuration download to the module.

Slot This information field indicates the slot monitoring position of the Keyphasor Module in the 3500 Rack.

Keyphasor Position This information field identifies where the Keyphasor Module is physically located in the 3500 Rack, either in the Upper or Lower slot.

I/O Module This user-input field specifies the type of interface module used to connect the transducers to the Keyphasor Main Module. Internal and External Termination options refer to the wiring points of the transducers, which either wire directly to the I/O module (Internal type) or to an external termination block (External type). The Barrier I/O type is offered only as an Internal Termination type, and does not support the Magnetic Pickup transducer type option. The Isolated types provide transformer isolation of the input channels from the rack common and from each other. The available Keyphasor I/O Module options are as follows:

Keyphasor I/O Module (Internal Termination) Keyphasor Barrier I/O Keyphasor I/O Module (External Termination)


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Isolated Keyphasor I/O (Internal Termination) Isolated Keyphasor I/O (External Termination)

Output Assignment This option is only available for paired Keyphasor configuration. Since two Keyphasors (with a total of 4 outputs) modules must share only two outputs, each paired Keyphasor can only be configured in a primary/backup manner, with each module allowed only 1 output assignment. For the module, select channel 1 or channel 2 to be this assignment. The user must select this assignment.

Input Assignment This option is only available for paired Keyphasor configuration. As described previously, output assignment is restricted to 1 channel only for paired Keyphasor configurations. The two inputs must be defined as primary & backup. The choice is channel 1 = Primary / channel 2 = Backup OR channel 2 = Primary / channel 1 = Backup. The user must select this assignment.

CHANNEL CONFIGURATION The two channels of a Keyphasor Module may be configured independent of each other, per the following configuration options. Channel 1 options are specified in the left half of the Configuration Screen, below the Reference Information fields; Channel 2 options are specified in the right half.

Active (Channel Activity) This check box enables or disables a Keyphasor channel. If no Keyphasor transducer is connected to this channel, then this box should be unchecked.

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

Type (Transducer Type) Proximitor Select this option if the Keyphasor signal for this channel is supplied through a Proximitor-type transducer. Magnetic Select this option if the Keyphasor signal for this channel is supplied through a Magnetic Pickup-type transducer. Magnetic Pickups require a shaft rotative speed of at least 200 RPM (3.3 Hz).

Buffered Output


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The Buffered Output signal is routed to the Keyphasor Module front panel BNC connector and to the Keyphasor I/O Module Buffered Output terminal for a given channel. Non-Processed Select this option if the Buffered Output signal is to be "Non-Processed". Processed Select this option if the Buffered Output signal is to be "Processed".

Rack Signal The Rack Signal is routed down the 3500 System Backplane, for use by monitors in the rack for a given channel. Non-Processed Select this option if the Rack Signal is to be "Non-Processed". Processed Select this option if the Rack Signal is to be "Processed".

Hysteresis

The difference between the voltage levels in the input signal where the Keyphasor pulse turns on and where it turns off. The larger the hysteresis, the greater the immunity to noise on the input signal.

1) Analog Input Signal 2) Digital Output Keyphasor Signal 3) Threshold 4) Hysteresis

Threshold The point where the Keyphasor pulse would turn on and off if the Hysteresis was zero. Auto The trigger threshold is automatically set to a value midway between the most positive peak and the most negative peak of the input signal. This tracks changes in the input signal. Auto threshold requires a minimum signal amplitude of 2 Vpp and a minimum frequency of 120 RPM (2 Hz). Manual The trigger threshold may be set manually by the operator to any value in the range of -20.0 to 0.0 volts. Adjust


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This option is made available when Manual Threshold is selected. A dialog box is displayed to aid in the setting of the Manual Threshold value.

Event Setup Events Per Rev This option specifies the number of pulses in a Keyphasor transducer input signal for each shaft revolution (rotation). If the Keyphasor transducer is observing a single notch or projection, set the Events Per Rev to 1. If the Keyphasor transducer is observing a multi-tooth gear, set the Events Per Rev to the number of teeth on the gear. The available range is 1 to 255. The following graph and figure shows the maximum settings for Events Per Rev and depicts typical applications.

(1) RPM (3) Upper RPM Limit is 99999 (2) Events Per Revolution (4) Upper Frequency Limit is 20 kHz

Note Signals from a Keyphasor transducer observing a multi-tooth gear (except for Recip Multi-Event Wheel) can be used for speed measurements only and not for phase measurements.

Events Per Rev typically set to Events Per Rev typically set to 1 event per revolution 24 events per revolution (Phase Available) (Phase Unavailable)


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Probe A Probe A

Probe B Probe B Shaft with notch 24 tooth gear


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Recip Multi-Event Wheel This option specifies the case for reciprocating machines where the Keyphasor transducer is observing a specially-designed 13-tooth gear with an inherent, distinguishable once-per-turn event built into the gear design. Event Ratio This option specifies the ratio of the number of input pulses to the number of desired output pulses in a Processed Keyphasor signal. The input pulses are those received via a Keyphasor transducer observing a shaft or gear. The output pulses are generated by the DSP in an Enhanced Keyphasor Module in proportion to the specified Event Ratio. The Event Ratio can be specified as any positive, real number other than 1.0 exactly, in the range 0.0000001 to 10000000. The Event Ratio can be specified to a precision of at least seven significant decimal digits. The Setup dialog box allows you to specify the Event Ratio in terms of an integer numerator and denominator.

Note Processed Keyphasor signals using the Event Ratio Event Setup option can be used for speed measurements only and not for phase measurements.

Orientation This specifies the transducer location on the machine. The orientation angle is 0 to 180 degrees left or right as observed from the driver to the driven end of the machine train. The following figure shows this for horizontal shafts.

1) Shaft 2) Driven end 3) Driver end 4) 0 degrees 5) 90 degrees right 6) 180 degrees 7) 90 degrees left

Upper RPM Limit This specifies the full scale maximum RPM value to use when reporting channel RPM data to the Communication Gateway and Operator Display software.

RPM Clamp Value This specifies the fixed RPM value to be provided by the Communication Gateway, when the channel is Not OK or is bypassed.


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3.3.2 Keyphasor Module Configuration Screen, Example 1

Example of a Rack Configuration Screen for the Keyphasor Module. This shows the default "Events Per Rev" Event Setup option, with Number of Events set to 1. Channel 2 is configured identical to channel 1.


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Example of a Rack Configuration Screen for the Keyphasor Module. This shows an "Event Ratio" Event Setup on Channel 1 and a "Recip Multi-Event Wheel" Event Setup on Channel 2.

For Channel 1, this Event Setup allows for the Buffered Output to be selected as Non-Processed or Processed, which is always the case when Event Ratio Event Setup is selected. The Rack Signal is force-selected as type Processed, since the Event Ratio is non-integer.

For Channel 2, this Event Setup makes both the Buffered Output and Rack Signal paths force-selected as type Non-Processed, which is always the case for the Recip Multi-Event Wheel option.


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Example of a Rack Configuration Screen for the Keyphasor Module. This shows an "Events Per Rev" Event Setup on Channel 1 and an "Event Ratio" Event Setup on Channel 2.

For Channel 1, this Event Setup makes both the Buffered Output and Rack Signal force-selected as Non-Processed, which is always the case for the Events Per Rev option.

For Channel 2, both the Buffered Output and Rack Signal may be optioned for Non-Processed or Processed, since the Event Ratio is an integer in the range 2 to 255 (in this case, 5).


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Example of a Rack Configuration Screen for the Keyphasor Module. This specifies an input-multiplying "Event Ratio" Event Setup on Channel 1 and an input-dividing "Event Ratio" Event Setup on Channel 2.

In both cases, the Rack Signal is force-selected as Processed, since the Event Ratios specified are non-integer.


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3.3.6 Paired Keyphasor Configuration Configuring the 3500/25 module for a Paired Keyphasor application using the Rack Configuration software is similar to configuring the module for a Standard application. The following items may help avoid confusion during configuration:

Output Assignment refers to the system Keyphasor line that will be driven by the module configured. There are four system lines. In Paired Keyphasor mode Output Assignment for each module must be different.

Input Assignment defines the priority of the signals input into the Keyphasor module. This determines the primary and backup signal within the Keyphasor module being configured.

The Input Active setting allows one to either enable or disable the monitoring functionality related to each channel in the Keyphasor module.

Output activity is no longer configurable. The output activity in a paired Keyphasor application is based on the Input Assignment, Output Assignment, and the validity, or OK state of the Keyphasor inputs.

When configuring the 3500 Rack configuration Software the following items should be taken into consideration:

Rack Configuration Software will not allow a configuration download in which more than two Keyphasor Modules are placed in the upper or the lower half of the rack.

Rack Configuration Software will not allow a configuration download in which a Paired Keyphasor and a Standard Keyphasor configuation are installed in either the upper or the lower half of the rack simultaneously. If both Paired Keyphasor and Standard Keyphasor capabilities are needed within one rack, the user will be forced to use the Paired Keyphasor configuration in the upper/lower half of the rack and the Standard Keyphasor configuration in the opposite half of the rack.

Rack Configuration software will not allow the use of more than two slots for Keyphasor modules. If two Keyphasor modules are placed in the upper half of the 3500 rack and it is desired to place either one or two additional Keyphasor modules in the lower half of the rack, they must be placed in the same slots that are being used in the upper half of the rack.

If multiple monitors are associated with one paired Keyphasor module, these monitors must be configured to have the same primary and backup Keyphasor association.

Restrictions are placed upon Paired Keyphasor applications because inputs are used as a primary/backup set for one system line. These restrictions force the two Keyphasor inputs to be input with the same events per revolution or be conditioned such that they have the same events per revolution before being placed on the system line. To accomplish this, the Keyphasor modules must be configured in one of the following ways:

1. Both channels will have an input with the same events per revolution and will not be processed.

2. Channel 1 and Channel 2 will both be processed. 3. One channel will be processed and the other channel will have a

1 event per revolution input.


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3.3.7 Paired Keyphasor Configuration Screen Example 1

To make Paired Keyphasor Capability available, Keyphasors must be placed and configured as shown above.

3.3.8 Paired Keyphasor Configuration Screen Example 2

After placing one of the three configurations in example one, each Keyphasor Module can be configured using the options menu.


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3.3.9 Software Switches The Keyphasor Module supports software switches which you can use to further control the operation of the module as a whole, or on an individual channel basis. These switches let you temporarily bypass, enable or cancel monitor and/or channel functions. These switches are accessed by selecting Utilities/Software Switches from the main menu screen of the Rack Configuration software.

Two special notes apply with regards to the use of Software Switches as follows.

The Software Switch control screen in the Rack Configuration software is common to all the 3500 System module types available. Several different types of software switches are listed, not all of which apply to the Keyphasor Module. The Keyphasor Module will only respond to the software switch options presented in this section.

Software Switch changes do not take effect until the Set button is clicked.


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3.3.10 Software Switch Options

MODULE SWITCHES These switches affect the Keyphasor Module as a whole.

Configuration Mode This switch reflects the status of the Keyphasor Module with regard to Configuration Mode. When downloading a configuration from the Rack Configuration software, this switch will automatically be enabled and disabled by the software. If the connection to the rack is lost during the configuration process, use this switch to remove the module from Configuration Mode.

Manual Keyphasor Threshold Adjust Mode This switch reflects the status of the Keyphasor Module with regard to Manual Keyphasor Threshold Adjust Mode. This switch will automatically be enabled and disabled when the Threshold Adjust button on the Keyphasor Module Configuration Screen is clicked on, if Manual Threshold is selected. While in this mode, the Keyphasor Module will operate with a temporary Manual Threshold supplied by the Rack Configuration software. Monitor values such as 1X amplitude and phase that use affected Keyphasor signals may go invalid while the Manual Threshold is being adjusted. If the connection to the rack is lost during the adjustment process, use this switch to remove the module from Manual Keyphasor Threshold Adjust Mode.

The module switch number is used in the Communication Gateway or Display Interface Module, as follows.

Module Switch Number

Switch Name

1

Configuration Mode

4

Manual Keyphasor Threshold Adjust Mode

CHANNEL SWITCHES These switches affect the Keyphasor Module on an individual channel basis.

Bypass When this switch is enabled, the RPM value for the channel will be rendered invalid and the signal conditioning for the channel will be bypassed.

The channel switch number is used in the Communication Gateway or Display Interface Module, as follows.

Channel Switch Number

Switch Name

4

Bypass

3500/25 Operation and Maintenance 4 I/O Module Description

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4 Keyphasor I/O Module Descriptions

The Keyphasor I/O Modules are full-height rack modules that receive signals from the Keyphasor transducers and route these signals to the Keyphasor Main Module (or Modules). The I/O Modules provide power to the Keyphasor transducers, and have provisions for outputting conditioned Keyphasor signals via their Buffered Output terminals. These buffered outputs are typically used to provide Keyphasor signals to external equipment, such as TDIX or TDXnet.

One or two Keyphasor Main Modules may be installed in any one available "monitoring position" in the rack, occupying the upper and/or lower half-slot(s) of the chosen monitoring position. For paired Keyphasors configuration, the two paired keyphasors must occupy adjacent rack slots. Keyphasors configured for paired operation may be installed in any two consecutively available monitoring positions in the rack, occupying the upper and lower half-slots of the chosen position. One (or two for paired) full-height Keyphasor I/O Module is then installed behind this slot (if installed in a Rack Mount or a Panel Mount rack) or above this slot (if installed in a Bulkhead rack).

There are five different types of Keyphasor I/O Modules available, covering the various options for internal or external terminations, type of terminations, signal isolation or non-isolation, and use of intrinsic safety barriers or not. The following table summarizes the Keyphasor I/O Module options that are available.

Internal Termination* External Termination** Non-Isolated Keyphasor I/O Module Isolated Keyphasor I/O Module Internal Barrier Keyphasor I/O Module

Non-Isolated Keyphasor I/O Module Isolated Keyphasor I/O Module

* All Internal Termination Keyphasor I/O Modules use Euro Style connectors. ** All External Termination Keyphasor I/O Modules use an External Termination Block. External Termination Blocks are available with either Euro Style connectors or Terminal Strip connectors.

This section of the manual describes how to use the connectors on the various Keyphasor I/O Modules. It also lists part numbers of what cables to use, and shows cable signal pin-outs.

The following additional documentation should be referenced to assist with module wiring and mounting details.

The 3500 Field Wiring Diagram Package (part number 130432-01) shows how to connect Keyphasor transducers to the Keyphasor I/O Modules or to External Termination Blocks.

The 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01) shows how to mount External Termination Blocks.

4 I/O Module Description 3500/25 Operation and Maintenance

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4.1 Internal Termination Keyphasor I/O Modules Internal Termination Keyphasor I/O Modules require you to wire each Keyphasor transducer to the I/O Module individually. This section shows what the different Internal Termination Keyphasor I/O Modules look like and how to connect the wires to the Euro Style connectors that are used on all of these modules.

4.1.1 Non-Isolated Internal Termination Keyphasor I/O Module

1) Connect wires here to the Keyphasor transducer associated with Upper Keyphasor Main Module, Channel 1.

2) Connect wires here to external equipment such as TDIX/TDXnet, associated with Upper Keyphasor Main Module, Channels 1 and 2.

3) Connect wires here to the Keyphasor transducer associated with Lower Keyphasor Main Module, Channel 2.

4) Connect wires here to external equipment such as TDIX/TDXnet, associated with Lower Keyphasor Main Module, Channels 1 and 2.




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4.1.2 Isolated Internal Termination Keyphasor I/O Module The Isolated Internal Termination Keyphasor I/O Module provides true isolation for four Keyphasor channels by passing the input signals through transformers. The primary side of each transformer is not referenced to ground and therefore provides isolation that removes potential ground loops present in installations where numerous systems are connected in parallel. The transformer-coupled signals are also given a -10 Vdc offset after passing through the transformers. This improves the range of input signals that can be input to the Keyphasor Main Module without internal clipping. The Isolated I/O module was created specifically for Magnetic Pickup applications, however it will work and provide isolation for proximitor applications as long as an external power supply is provided. It should also be noted that this I/O module was meant to be used primarily to measure shaft speed and not as a phase measurement. It can be used in phase measurements, but it should be noted that this I/O introduces a slightly higher phase shift than the Non-Isolated version. Refer to section 8 (Specifications) for the specific phase shift associated with this I/O at different frequencies.








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4.1.3 Internal Barrier Internal Termination Keyphasor I/O Module The Internal Barrier Internal Termination Keyphasor I/O Module provides four channels of intrinsically safe signal conditioning for Keyphasor transducers. It has two internally mounted zener barrier modules, one for each pair of transducer channels. A 3500 Earthing Module is required for systems that use the Internal Barrier Internal Termination Keyphasor I/O Module to provide an intrinsically safe earth connection. Refer to the 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01) for system requirements when using the Internal Barrier Internal Termination Keyphasor I/O Module.

1) Connect wires here to the Keyphasor transducers associated with Lower Keyphasor Main Module, Channels 1 and 2. Note that these channels are referred to as Channels 3 and 4, respectively, from the point of view of the I/O Module.

2) Connect wires here to external equipment such as TDIX/TDXnet, associated with Lower Keyphasor Main Module Channels 1 and 2.

3) Connect wires here to the Keyphasor transducers associated with Upper Keyphasor Main Module Channels 1 and 2.

4) Connect wires here to external equipment such as TDIX/TDXnet, associated with Upper Keyphasor Main Module Channels 1 and 2.


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4.1.4 Euro Style Connectors It is often easier to wire connections to a Euro Style connector by removing the connector terminal block from its base, making the connections at the terminal block, and then securing the terminal block back to its base. To remove a Euro Style connector terminal block from its base, loosen the screws attaching the terminal block to the base, grip the block firmly and pull. Do not pull the block out by its wires because this could loosen or damage the wires or connector.

Typical I/O Module with Euro Style connectors

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


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

4.2.1 Non-Isolated External Termination Keyphasor I/O Module

1) Connect the 9-pin cable (part number 129530-XXXX-XX) here to the External Termination Block associated with Upper Keyphasor Main Module, Channels 1 and 2.

2) Connect the 9-pin cable (part number 129530-XXXX-XX) here to the External Termination Block associated with Lower Keyphasor Main Module, Channels 1 and 2.




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4.2.2 Isolated External Termination Keyphasor I/O Module The Isolated External Termination Keyphasor I/O Module provides true isolation for four Keyphasor channels by passing the input signals through transformers. The primary side of each transformer is not referenced to ground and therefore provides isolation that removes potential ground loops present in installations where numerous systems are connected in parallel. The transformer-coupled signals are also given a -10 Vdc offset after passing through the transformers. This improves the range of input signals that can be input to the Keyphasor Main Module without internal clipping. The Isolated I/O module was created specifically for Magnetic Pickup applications, however it will work and provide isolation for proximitor applications as long as an external power supply is provided. It should also be noted that this I/O module was meant to be used primarily to measure shaft speed and not as a phase measurement. It can be used in phase measurements, but it should be noted that this I/O introduces a slightly higher phase shift than the Non-Isolated version. Refer to section 8 (Specifications) for the specific phase shift associated with this I/O at different frequencies.

1) Connect the 9-pin cable (part number 129530-XXXX-XX) here to the External Termination Block associated with Upper Keyphasor Main Module, Channels 1 and 2.

2) Connect the 9-pin cable (part number 129530-XXXX-XX) here to the External Termination Block associated with Lower Keyphasor Main Module, Channels 1 and 2.




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4.2.3 External Termination Blocks Two types of External Termination Blocks are used with the External Termination Keyphasor I/O Modules. These are the Keyphasor External Termination Block with Terminal Strip Connectors and the Keyphasor External Termination Block with Euro Style Connectors.

4.2.3.1 Keyphasor External Termination Block With Terminal Strip Connectors

1) Connect wires here to the Keyphasor transducers. 2) Connect the 9-pin cable(s) (part number 129530-XXXX-XX) here to

the External Termination Keyphasor I/O Module. The two cable connectors are labeled Top and Bottom corresponding to the associated Upper and Lower Keyphasor Main Modules, respectively.

3) Use this set of terminals for wiring to Lower Keyphasor Main Module, Channels 1 and 2.

4) Use this set of terminals for wiring to Upper Keyphasor Main Module, Channels 1 and 2.


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4.2.3.2 Keyphasor External Termination Block With Euro Style Connectors

1) Connect wires here to the Keyphasor transducers. 2) Connect the 9-pin cable(s) (part number 129530-XXXX-XX) here to

the External Termination Keyphasor I/O Module. The two cable connectors are labeled Top and Bottom corresponding to the associated Upper and Lower Keyphasor Main Modules, respectively.

3) Use this set of terminals for wiring to Lower Keyphasor Main Module, Channels 1 and 2.

4) Use this set of terminals for wiring to Upper Keyphasor Main Module, Channels 1 and 2.


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4.2.4 External Termination Block Cable Signal Pin Outs

The following shows the signal pin outs used to connect Keyphasor transducer signals from Keyphasor External Termination Blocks to External Termination Keyphasor I/O Modules. The cable is part number 129530-XXXX-XX.

3500/25 Operation and Maintenance 5 Maintenance

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5 Maintenance

The printed circuit boards and components inside of 3500 Modules, including the Keyphasor Module, are not designed to be repaired in the field. Maintaining a 3500 Rack module consists of testing module channels to verify that they are operating correctly, and replacing a faulty module with a spare. This section shows how to verify correct operation of a Keyphasor Module.

When performed properly, the Keyphasor Module may be installed into or removed from the rack while power is applied to the rack. Refer to the 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01) for the proper procedure.

Application Alert

Machinery protection may be lost while Keyphasor Module maintenance operations are being performed.

5.1 Verifying Keyphasor Module Operation The 3500 Monitoring System is a high precision instrument that requires no calibration. The functions of Keyphasor Module channels, however, must be verified at regular intervals. At each maintenance interval, it is recommended that the procedures in this section be exercised to verify the operation of all active channels in the Keyphasor Module.

5.1.1 Choosing A Maintenance Interval Start with an interval of one year and then shorten the interval if any of the

following conditions apply: o The monitored machine is classified as critical. o The 3500 Rack is operating in a harsh environment, such as that of

extreme temperatures, high humidity or corrosive atmospheres.

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

5.1.2 Required Verification Test Equipment Listed below is the equipment needed to conduct module verification testing.

Signal Function Generator Multimeter DC Power Supply Laptop or other Computer running 3500 Rack Configuration Software

5 Maintenance 3500/25 Operation and Maintenance

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5.1.3 Typical Verification Test Setup The following figure shows the typical test setup for verifying a Keyphasor Module. The Signal Function Generator and DC Power Supply are used to simulate the transducer signal and DC bias input to the module. The Multimeter is useful for verifying signal levels. The laptop computer is used to observe the output from the Rack Configuration Software during the tests. It is also used to save the current rack configuration prior to conducting the tests, and to restore the saved configuration afterwards.

General Layout for Maintenance Testing

1) 3500 Rack 2) Signal Generation / Verification Test Equipment 3) RS-232 Communications Cable 4) Laptop Computer running 3500 Rack Configuration

Software


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Transducers can be connected to a 3500 Rack in a variety of ways. Depending on the type of Keyphasor I/O Module being used, connect the test equipment to the Keyphasor transducer input terminals per the following figure.

1) The Keyphasor transducer input terminals are located variously as shown, depending on the Keyphasor I/O Module type:

2) Internal Barrier Internal Termination Keyphasor I/O Module 3) Internal Termination Keyphasor I/O Module (Non-Isolated or Isolated) 4) Keyphasor External Termination Block With Euro Style Connectors (used

with External Termination Keyphasor I/O Modules) 5) Keyphasor External Termination Block With Terminal Strip Connectors

(used with External Termination Keyphasor I/O Modules).


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5.1.4 Using Rack Configuration Software For Verification Testing To perform the test procedures described in this section you must be familiar with the following features of the 3500 Rack Configuration Software:

Uploading, Saving and Downloading of Configuration Files Display of the Verification Utility Screen

The 3500 Monitoring System Rack Configuration and Utilities Guide (part number 129777-01) explains how to perform these operations.

Note It is important to save the original rack configuration before doing any maintenance or troubleshooting procedures, and to restore the rack configuration to its original state afterwards.

The following figure depicts a typical screen view of the 3500 Rack Configuration Software, Verification Utility Screen. This screen may be accessed by selecting Utilities/Verification from the main menu screen of the Rack Configuration Software.

The information displayed on this screen is used in the module channel verification procedure.


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5.1.5 Procedure For Verifying Keyphasor Module Channels

This section shows how to verify correct operation of Keyphasor Module channels. This procedure tests the Threshold, RPM, and OK Status values for each channel of the Keyphasor Module. The values are checked and verified by varying the input Keyphasor signal frequency and DC bias applied and then observing that the correct results are reported in the Rack Configuration Software Verification screen on the test computer. Refer to the following figure.

Keyphasor Module Channel Verification Setup

1) Keyphasor I/O Module test signal connections (Internal Termination type I/O Modules shown; connect test signal equipment in the same manner to the External Termination Block terminals for External Termination type I/O Modules).

2) Multimeter 3) DC Power Supply 4) Signal Function Generator

Note: Test equipment outputs should be floating relative to earth ground.


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5.1.5.1 Set Up The Test Signal Equipment And Verification Display Screen The Keyphasor transducer signal will be simulated by combining the Sync Out signal of the function generator with the output of the dc power supply to drive the Keyphasor I/O Module transducer input.

1. Turn on the function generator and dc power supply, and connect these as shown in the Setup diagram. For now, connect the combined test signal output only to the Multimeter (not to the I/O Module). Set the function generator to an initial frequency of 100 Hz and the power supply to -7.00 Vdc. Use the Multimeter to verify the signal frequency and dc bias level.

2. Run the Rack Configuration Software on the test computer. Save the current configuration now if you have not already done so. Following that, choose Verification from the Utilities menu and choose the proper Slot number and Channel number of the Keyphasor Module Channel to be tested. Then click on the Verify button to open the Verification display screen.

5.1.5.2 Verify Keyphasor Threshold Value The Keyphasor Threshold value is the input voltage level where the Keyphasor signal will turn on. This value can be set automatically or manually. Use the following procedure to verify that the Keyphasor Threshold is working correctly.

1. Disconnect PWR, COM, and KPH wiring from the Channel 1 terminals on the Keyphasor I/O Module or External Termination Block.

2. Connect the test signal to the Keyphasor I/O Module or External Termination Block as shown in the Setup diagram.

3. If the channel is configured for Manual Threshold, adjust the power supply voltage so that it is 2.50 Vdc more negative than the configured Manual Threshold voltage level. Note: Skip this step if the channel is configured for Automatic Threshold.

Example: If the displayed Manual Threshold value is: -10.00 Vdc Then adjust the power supply voltage to: -12.50 Vdc

4. Observe the Keyphasor Module Verification screen and do the following.

Verify that the Channel OK State reads OK Verify that the Keyphasor RPM box displays an RPM value

5. If the Keyphasor channel will not produce an RPM reading, double check the input signal to ensure it is correct. Also, make sure Channel Bypass and Channel Off are showing as Disabled. If the module still does not perform as expected, it may be considered faulty. In this case, proceed to Section 5.1.6.


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5.1.5.3 Verify Keyphasor RPM Value The Keyphasor RPM value is the measured speed in RPM of the Keyphasor input signal. Use the following procedure to verify that the Keyphasor RPM measurement is working correctly.

Note Before following this procedure, verify that the Channel OK State reads OK.

1. Disconnect PWR, COM, and KPH wiring from the Channel 1 terminals on the Keyphasor I/O Module or External Termination Block.

2. Connect the test signal to the Keyphasor I/O Module or External Termination Block as shown in the Setup diagram. Adjust the frequency to 100 Hz.

3. Observe the Keyphasor Module Verification screen and note the number displayed as either the Events Per Rev or the Event Ratio value. This value will be referred to as simply the Event Value in the following step.

4. Use the following equation to determine what the correct nominal displayed RPM value should be:

Displayed RPM = (Frequency x 60) / Event Value

Example 1: Example 2: Input Frequency = 100 Hz Input Frequency = 100 Hz Events Per Rev = 10 Event Ratio = 2.27 Displayed RPM = (100 x 60) / Events Per Rev Displayed RPM = (100 x 60) / Event Ratio = 6000 / 10 = 6000 / 2.27 = 600 = 2643

5. Observe the Keyphasor Module Verification screen and note the type of Rack Signal, displayed as either Non-Processed or Processed. The displayed RPM value accuracy is slightly different for Non-Processed and Processed signals, as noted in the table below. Verify that the displayed Keyphasor RPM is within the specified tolerance. This is specified at +25C (+77F).

Rack Signal Type Input Frequency Displayed RPM Non-Processed 0.017 to 100 Hz

101 to 500 Hz 501 to 20 kHz

Nominal 1 RPM Nominal 8 RPM

1% of Nominal RPM Processed 0.017 to 60 Hz

61 to 150 Hz 151 to 20 kHz

Nominal 1 RPM Nominal 8 RPM

1% of Nominal RPM

6. If the RPM reading does not meet specifications, double check the input signal to ensure it is correct. If the module still does not perform as expected, it may be considered faulty. In this case, proceed to Section 5.1.6.


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5.1.5.4 Verify Channel OK Status The Keyphasor Channel OK Status indicates the overall state of the Keyphasor Channel. There are two states, OK and Not OK. This is shown as the Channel OK State on the Verification screen. The individual Channel OK Statuses also affect the Keyphasor Module OK State, which is indicated on the Keyphasor Main Module front panel OK LED, and on the Verification screen. Use the following procedure to verify the Keyphasor Channel OK Status is valid.

1. Disconnect the wire from the test equipment to the Channel 1 KPH input terminals on the Keyphasor I/O Module or External Termination Block. The OK LED on the front of the Keyphasor Main Module should go off.

2. Observe the Keyphasor Module Verification screen and do the following.

Verify that the Channel OK State reads Not OK Verify that the Keyphasor RPM box display reads Invalid

3. If the above is not observed, double check that there is no input signal to the Keyphasor Module transducer input. If the module still does not perform as expected, it may be considered faulty. In this case, proceed to Section 5.1.6.

4. Disconnect the test equipment and reconnect the PWR, COM, and KPH wiring to the Channel 1 terminals on the Keyphasor I/O Module or External Termination Block.

5.1.5.5 Perform Verification Procedure On Keyphasor Module Channel 2 Repeat the Threshold, RPM and Channel OK Status verification procedure steps for Channel 2 of the Keyphasor Module. Once that is complete, restore the original rack configuration that was saved prior to starting the verification tests.

5.1.6 If A Channel Fails A Verification Test This section describes what to do if a Keyphasor Module fails a Channel Verification test. When handling or replacing circuit boards always be sure to adequately protect against damage from Electrostatic Discharge (ESD). Always wear a proper wrist strap and perform work on a grounded conductive surface.

1. Double check that the configuration for the module has been saved using the Rack Configuration Software.

2. Replace the module with a spare. Refer to the 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01) for details.

3. Download the configuration to the spare module.

4. Verify the operation of the spare module.

5. Return the faulty module to Bently Nevada LLC for repair.


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5.2 Performing Firmware Replacement / Upgrade

Occasionally it may be necessary or desirable to replace the original firmware that is shipped with the 3500/25 Keyphasor Module, to support functional upgrades or changes. This section of the manual describes how to go about doing this. Early versions of the module, including the original Keyphasor Module and some Enhanced Keyphasor Modules, incorporate a socketed, integrated circuit memory device ("Firmware IC") to store the firmware program. This Firmware IC may be replaced as outlined below. Later versions of the Enhanced Keyphasor Module support firmware downloads directly from the 3500 Rack Configuration Software. This allows for easier upgrading or changing of the firmware without requiring the module to be physically removed from the rack. This process is described below as well.

5.2.1 Determine The Firmware Replacement Process To Use The first step in performing a fi

Documents

9770M1 3500 25.pdf