Manuals & Guides: AMS 2600 Machinery Health Expert User Guide-A6560R and A6510 modules
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MHM-97453-PBF-EN, Rev 0
AMS 2600 Machinery Health Expert
A6560R Processor Module and A6510 Signal Input Module
User Guide
May 2017
Copyright
©
2017 by Emerson. 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.
Disclaimer
This manual is provided for informational purposes. EMERSON 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 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. The information in this manual is
not all-inclusive and cannot cover all unique situations.
Trademarks and Servicemarks
See http://www2.emersonprocess.com/siteadmincenter/PM Central Web Documents/marks.pdf
All other marks are property of their respective owners.
Patents
The product(s) described in this manual are covered under existing and pending patents.
Contents
Contents
Chapter 1 AMS 2600 Machinery Health Expert ................................................................................1
1.1 AMS 2600 overview ..................................................................................................................... 1
1.2 References ...................................................................................................................................1
1.3 AMS 2600 and accessories ........................................................................................................... 2
1.4 Data collection requirements .......................................................................................................3
1.5 Precautions ..................................................................................................................................3
1.6 Safety notes .................................................................................................................................4
Chapter 2 Getting started ...............................................................................................................5
2.1 Remove the AMS 2600 from the case .......................................................................................... 5
2.2 AMS 6500 front view ....................................................................................................................7
2.3 Back view and connections .......................................................................................................... 8
2.4 Turn on the AMS 2600 ................................................................................................................. 9
2.5 Turn off the AMS 2600 ................................................................................................................. 9
2.6 System configuration overview ..................................................................................................10
2.7 Data collection overview ............................................................................................................10
2.8 Data recorder modes ................................................................................................................. 11
2.9 AMS 2600 fuse access ................................................................................................................12
2.10 Access the termination board .................................................................................................... 12
2.11 Connectivity .............................................................................................................................. 13
Chapter 3 Hardware configuration ...............................................................................................17
3.1 Hardware configuration: overview .............................................................................................17
3.2 The A6560R and A6510 modules ...............................................................................................18
3.3 AMS 2600 signal inputs ..............................................................................................................26
3.4 Configure the A6560R with a terminal emulator ........................................................................27
Chapter 4 Sensor installation ....................................................................................................... 32
Chapter 5 Software configuration ................................................................................................ 33
5.1 System overview diagram ..........................................................................................................33
5.2 System configuration overview ..................................................................................................34
5.3 Install AMS Machinery Manager ................................................................................................. 35
5.4 Configure the FTP server to download firmware .........................................................................35
5.5 Connect the A6560R CPU to AMS Machinery Manager ...............................................................39
Chapter 6 Data collection and analysis ......................................................................................... 40
6.1 Online database diagram .......................................................................................................... 40
6.2 View or edit IP addresses with the unit ....................................................................................... 42
6.3 Verify or assign a unit IP address to the Online Server in RBM Network Administration ...............43
6.4 Add a unit's IP address to the Online Server in RBM Network Administration ..............................44
6.5 Online database configuration: overview ...................................................................................44
6.6 Online Watch overview ..............................................................................................................48
6.7 Archive management ................................................................................................................ 51
6.8 Create an archive manually ........................................................................................................52
6.9 Disable archive predicates ......................................................................................................... 52
6.10 Stop transient acquisition .......................................................................................................... 53
6.11 Remove an archive from the Transient Archive Status tab ..........................................................53
6.12 Change databases when moving the AMS 2600 to a new machine ............................................ 54
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Contents
Chapter 7 Specifications ...............................................................................................................55
7.1 AMS 6500 Machinery Health™ Monitor specifications ................................................................55
7.2 AMS 2600 product specifications
7.3 Environmental specifications ..................................................................................................... 56
7.4 A6560R Processor module LEDs .................................................................................................57
7.5 A6510 Signal Input module LEDs ............................................................................................... 59
...............................................................................................56
Chapter 8 System calibration ....................................................................................................... 61
8.1 System calibration overview ...................................................................................................... 61
Appendices and reference
Appendix A Data types ....................................................................................................................64
A.1 Gross Scan analysis .................................................................................................................... 64
A.2 Spectral analysis ........................................................................................................................ 65
A.3 Time Waveform analysis ............................................................................................................ 66
A.4 Non-Vibration unit analysis types ...............................................................................................67
A.5 Set DC offset ..............................................................................................................................67
Appendix B Internal wiring of the AMS 2600 ................................................................................... 69
B.1 Rear termination panel .............................................................................................................. 69
B.2 Internal wiring diagram — AMS 2600 ......................................................................................... 72
B.3 Terminal descriptors ..................................................................................................................73
B.4 Rear terminal power connections .............................................................................................. 76
B.5 AMS 2600 DIP switch settings ....................................................................................................76
Appendix C Troubleshooting .......................................................................................................... 77
Index ................................................................................................................................................. 78
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AMS 2600 Machinery Health Expert
1 AMS 2600 Machinery Health Expert
Topics covered in this chapter:
• AMS 2600 overview
• References
• AMS 2600 and accessories
• Data collection requirements
• Precautions
• Safety notes
1.1 AMS 2600 overview
The AMS 2600 is a portable, online analyzer that simultaneously and continuously
monitors and records up to 24 vibration or process channels and up to 4 speed inputs.
The AMS 2600 comes in non-Transient and Transient configurations. This manual
describes the AMS 2600 configured as model A2600T8—a Transient, 24 channel system.
Available models are:
• A2600M7—non-Transient, 12 channel
• A2600M8—non-Transient, 24 channel
• A2600T7—Transient, 12 channel
• A2600T8—Transient, 24 channel
Emerson's AMS Machinery Manager allows you to view data collected by the AMS 2600,
including orbits, shaft center lines, Bode, polar, cascade, waveform, and spectrum plots
live and simultaneously, or to archive for future reference.
The AMS 2600 contains the A6560R CPU module and A6510 Signal Input module.
1.2 References
For instructions regarding the current generation AMS 6500 CPU (A6560R), refer to the
following resources:
• MHM-97125-PBF-EN, "AMS 6500 Machinery Health™ Monitor User Guide: A6560R
CPU and A6510 Signal Input Module"
• MHM-97124, "AMS 6500 Machinery Health™ Monitor Protection Chassis with
A6500-P-RTRM Rear Termination Panel Reference Manual"
• MHM-97402, "AMS Machinery Manager Installation Guide"
• AMS Machinery Manager Help is available from the AMS Machinery Manager menu.
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AMS 2600 Machinery Health Expert
For instructions regarding the previous generation AMS 6500 CPU (A6560), refer to the
following resources:
• MHM-97125, Rev 8, "CSI 6500 Machinery Health™ Monitor Hardware Installation
Guide"
• MHM-97453, Rev 1, "CSI 2600 Machinery Health™ Expert User Guide"
Refer to the following topics and sources for detailed system setup instructions.
Topic Section
Check the version of AMS Machinery Manager.
Add an Online Server.
Add an AMS 6500 to an Online Server.
Start and stop data collection.
Set up data collection for MODBUS data from a AMS
6500 .
Using Online Server (O_Server) and Online Watch (O_
Watch).
Set up Acquisition Parameters (APs) for data collection
for transient channels.
Assign a tachometer a transient channel.
Related procedures and topics in AMS Machinery Manager Help Table 1-1:
Help>Administration
Help>Data Import
Help>Tools>Online Software
Table 1-2:
Related procedures and topics in AMS 6500 Machinery Health™ Monitor
User Guide
Topic Reference
Set up an FTP Server Configure the FTP server to download firmware
Install the firmware Update CSI Machinery Health Monitor firmware
Connect to the unit using a serial port or
Ethernet
Deploy the bootscript Configure boot parameters with a terminal emulator
Configure access to a CSI Machinery Health Monitor
from a computer
1.3 AMS 2600 and accessories
AMS 2600 and accessories
• AMS 2600 and case
• AMS Machinery Manager DVD (contains Firmware)
• AMS Machinery Manager Operating Manuals & Extras DVD
• 1 Ethernet cable
• 1 serial cable
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• 1 package of replacement filters
• 1 standard IEC 320 C13 to NEMA 5-15P power cord
• 1 3-pin screw mount connector plug
• 3-piece international AC adapter kit
Optional accessories
• Sensors
• Mounting pads
• BNC connectors
• Extension cords
Optional firmware
• PeakVue
• Modbus
Optional software
• Object Linking and Embedding for Process Control (OPC)
AMS 2600 Machinery Health Expert
1.4 Data collection requirements
The AMS 2600 must be connected to the sensors on the equipment you want to monitor
and contain an AMS Machinery Manager database that matches the how the sensors on
the equipment are connected to the channels of the AMS 2600.
• AMS 2600 and accessories
• Field wiring to installed sensors
• AC line power wiring
• Connection points (usually a buffered output panel) for cabling to the AMS 2600
• Computer (usually a laptop) with AMS Machinery Manager
1.5 Precautions
Cleaning
The AMS 2600 is dust resistant. Use a damp, clean cloth for cleaning. Do not use cleaning
fluids, abrasives, or aerosols, as they could enter the device, causing damage, fire or
electrical shock.
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AMS 2600 Machinery Health Expert
Avoid water
Avoid direct contact with water, wet surfaces, or condensing humidity. Keep away from
wet locations such as sinks, laundry, wet basements, swimming pools, and so on. If the
device is subjected to these conditions, adverse operation may result. If the surface of the
device becomes wet, allow it to dry thoroughly before operation.
Avoid damage or injury
Follow these guidelines to avoid costly damage or injury:
• Place the device on a solid, stable surface when not in use and do not place any
heavy objects on it.
• Use only accessories recommended by Emerson Process Management.
• Keep liquids and foreign objects away from your AMS 2600.
• Never operate your AMS 2600 if any liquid or foreign object has entered it.
• The enclosure should never be subjected to direct sunlight for long periods of time.
1.6 Safety notes
This document is intended as a guide only. No instructions given here are intended to
supersede any locally issued directions or safety instructions.
WARNING!
Do not operate the AMS 2600 in a hazardous area.
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2 Getting started
Topics covered in this chapter:
• Remove the AMS 2600 from the case
• AMS 6500 front view
• Back view and connections
• Turn on the AMS 2600
• Turn off the AMS 2600
• System configuration overview
• Data collection overview
• Data recorder modes
• AMS 2600 fuse access
• Access the termination board
• Connectivity
Getting started
2.1 Remove the AMS 2600 from the case
CAUTION!
The AMS 2600 should be placed on a dry, level, cool surface where the vents and fans are not
blocked. Avoid hot, wet surfaces and do not block the vents or fans.
Note
The AMS 2600 cannot be used while in the case.
Procedure
Reach down along the top and bottom of the AMS 2600 and extract the device straight up
from its case.
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Getting started
Remove the AMS 2600 from the caseFigure 2-1:
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2.2 AMS 6500 front view
AMS 6500 front view with A6560R and A6510 modulesFigure 2-2:
Getting started
A. Front power switch
B. A6560R Status LEDs
C. A6510 Status LEDs
D.
Module name
E. 2 Ethernet ports — NIC and Hub
F. Serial port
G. Handles
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Getting started
2.3 Back view and connections
Back view and connectionsFigure 2-3:
A. BNC Connectors — Sensor channels, CH 1-24; Tach channels TACH 1-4; Digital relay channels,
RELAY 1-4.
B. Thumbscrews — Access inside of the AMS 2600.
C. Input power switch — Turn power on or off to the AMS 2600.
Fuse access panel — Two 10 A fuses for the power input.
D.
E. Auxiliary -24 VDC power supply — 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 AMS 2600.
8 MHM-97453-PBF-EN, R0
WARNING!
Tachometers should provide 1/rev pulses of >0.5 V pk-pk with tach pulse 2x noise.
The AMS 2600 can accept any sensor type with AC component 10 V pk-pk and DC component <
+/-24 V, AC+DC not to exceed +/-24 V. Accelerometers can be powered by the system’s power
supply. Enable sensor power using the DIP switches on the termination panel, accessible
through the rear panel.
Make sure that the sensor power is disabled when connecting to a protection system with
unbuffered BNC outputs.
2.4 Turn on the AMS 2600
The AMS 2600 has two toggle switches, and both must be toggled in order to turn the unit
on and off.
Prerequisites
WARNING!
Getting started
Ensure that physical contact with unbuffered sensor signals will not interfere with other
monitoring or protection systems.
Procedure
1. Plug the power cord into a standard 120 - 240 VAC input. Attach one of the provided
adapters if necessary.
The unit automatically senses the correct voltage.
2. Press the toggle switch located at the rear of the case to
3. Press the toggle switch located at the front of the case to On.
2.5 Turn off the AMS 2600
Prerequisites
Make sure that the computer has been connected long enough to allow all of the desired
data to be transferred to the computer for storage. Check the time stamps of the data
being reported in Online Watch. Once the times have progressed past the time range
needed, data collection can be stopped and the AMS 2600 can be powered off.
Procedure
On.
1. Turn the toggle switch located on the front of the unit to the Off position.
After a couple seconds, the light will turn off. Wait for the light to turn off before
continuing with the next step.
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Getting started
2. Turn the toggle switch located on the back of the unit to the Off position.
3. Unplug the power cord.
2.6 System configuration overview
The A6560R CPU module communicates through an Ethernet connection. When you are
using the AMS 6500, AMS Machinery Manager is on a server and connected through a
network. When you are using the AMS 2600, the AMS Machinery Manager is on a laptop
and connected directly to the unit.
In order for the unit and the server to successfully communicate, both must have
addresses known to each other. Also, A6560R must contain the IP address of the FTP
server from which to download firmware updates.
1. Set up the computer:
• Set the computer's IP address, as needed.
• Install AMS Machinery Manager on the computer as a Network system.
• Set up an FTP server to host the firmware, as needed.
• Install the A6560R firmware on the FTP server.
2. Set up the unit to communicate with AMS Machinery Manager.
• Connect the computer to the unit with an Ethernet or Serial cable
• Connect to the unit from a computer using a terminal emulator.
• Set the unit's IP address.
• Set the IP address of the FTP server for the unit to obtain firmware updates.
3.
Connect equipment to be monitored to the unit:
a. In AMS Machinery Manager, add an online server to RBM Network
Administration.
b. In Online Configuration, add the unit's IP address, create a database for the
equipment to be monitored, and save it to the unit.
4. Set up the database in AMS Machinery Manager:
a. In AMS Machinery Manager, add an online server to RBM Network
Administration.
b. In Online Configuration, add the unit's IP address, create a database that
matches the configuration of the equipment to be monitored, and save it to the
unit.
2.7 Data collection overview
The AMS 6500 is a continuously monitoring online systems. Once configured, it will collect
both periodic predictive data (Trend, Spectra, and Waveform snapshots, multiplexed two
channels at a time) and Transient measurements (continuous unbroken waveforms for
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Getting started
extended periods on up to all 24 channels). Predictive data can be stored in an AMS
Machinery Manager database. Sections of the transient waveforms can also be extracted
into archives either on-demand or based on alarm events.
For the Transient channels, the waveform measurements are continuously stored on either
the internal drive or an external NAS drive (up to 250 GB). When the drive fills up, the
system will begin overwriting the oldest measurements in a First In First Out (FIFO)
manner.
Data is stored at a rate of approximately 40 MB per hour per channel. The following
method can be used for estimating the amount of time that data can be streamed to the
HDD before it begins to FIFO. First determine the number of channels that will be
commissioned for Transient operation; then use this equation:
Storage Time (in hours) = HDD size / (number of Transient channels x 40 MB/hr).
For example, consider a pump monitoring system which has a total of 14 sensors. This
could include 4 pairs of radial shaft vibration probes, 2 thrust probes, 1 case expansion
sensor, 1 eccentricity sensor, and 2 horizontal accelerometers. In addition to collecting
periodic prediction data, the 8 shaft vibration probes are also commissioned for Transient
data collection.
80,000 MB / (8 channels x 40 MB/hr) = 250 hours (approximately 10 days)
So, the internal HDD will store data for approximately ten days before starting to FIFO.
The AMS 2600 is both a continuous monitoring system and a portable monitoring system.
It can be moved from one piece of equipment to another, with data from each piece
stored in separate databases. See Section 6.12 for more information.
CAUTION!
Changing databases will reinitialize the Transient HDD, which eliminates all stored data.
Extract any data before changing databases.
2.8 Data recorder modes
Data collection to AMS 2600 internal memory
When the AMS 2600 is running and the computer is disconnected, the unit runs in DAT
recorder mode, optimized for turbomachinery transient data. Waveforms from up to 24
channels, including tach striping, are recorded continuously and simultaneously. If all 24
channels are streaming transient data, the internal solid-state drive SSD) will store
approximately 100 hours of data before it begins to FIFO.
With the computer disconnected, the periodic predictive data is also buffered in the AMS
2600’s internal RAM. The amount of time it will take to fill up the AMS 2600’s internal RAM
depends on how periodic predictive data storage settings are configured in the database.
This data will also begin to FIFO when the memory buffer is full.
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Getting started
Data extraction from the AMS 2600
If the computer is reconnected while the AMS 2600 is in DAT recorder mode, any buffered
periodic predictive data that has not been deleted by the FIFO process will automatically
be transferred from internal memory to the database. Transient data will only be written to
the database if a transient alarm event has occurred and the associated data has not been
deleted by the FIFO process. Each transient channel can transfer a configurable amount of
data (up to 30 minutes before and after) when a predefined transient alarm event has
occurred.
When the computer is reconnected, portions of recorded data can be extracted on
demand with AMS Machinery Manager Vibration Analysis. Field-based processing of
multiplexed predictive data continues as usual while Vibration Analysis extracts data.
CAUTION!
If the computer is not connected, data may be lost or overwritten.
2.9 AMS 2600 fuse access
CAUTION!
Turn off the power and unplug the unit before accessing the fuses.
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.
Fuse accessFigure 2-4:
The AC power input is located on the unit's faceplate.
A. Fuse access panel
2.10 Access the termination board
WARNING!
Always turn off and unplug the AMS 2600 before you open the rear panel. Close the rear panel
before powering the AMS 2600.
You can access the termination board through the rear panel of the AMS 2600.
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Getting started
You may need to toggle a DIP switch on the termination board to for enable or disable
sensor power.
Procedure
1. At the bottom of the rear panel, loosen the thumbscrews by hand.
2. To lock the rear panel in the open position, lift the panel to an almost horizontal
position and gently push down near the top center of the panel (as shown).
Termination boardFigure 2-5:
3. Toggle the DIP switch to the left to turn off sensor power, or to the right to turn it
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. Figure B-1 shows the DIP switches.
2.11 Connectivity
The AMS 2600 monitoring unit consists of:
• An AC power connection (110–220 V, 50/60 Hz)
• An Ethernet connection
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Getting started
• 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
2.11.1 Ethernet and serial ports
Use an Ethernet connection to configure the unit or transfer data. Use the NIC port to
connect to a computer over a local area network. Use the Hub port to connect directly to
the computer.
Use the Serial connection directly from a computer to configure the unit without using the
Ethernet port or IP address.
Ethernet and serial ports on the A6560RFigure 2-6:
2.11.2 Power supply
Power input: 120–240 VAC, 50–60 Hz input, auto-sensing.
• AC power connection has an IEC 320 C13 receptacle
• North American 3-prong plug (NEMA 5-15P) is provided
• 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
• 80 W consumption
Note
A 500 W UPS is recommended. The quality of the power provided to the AMS 2600 is very important.
Although the AMS 2600 contains input protection and some degree of line conditioning, it is
important to provide the unit with clean power with ground isolation from the production
equipment.
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2.11.3 4-channel relay inputs and outputs
The AMS 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 @ 0.5 A.
The A6510 Signal Input module connects to the unit's CPU, and allows a combination of
sensor and relay types in one module. Each I/O relay channel on the A6510 Signal Input
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 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 console 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.
Getting started
The shelf-state of the output relays is normally open, meaning that when the power to the
unit is disconnected, the relays are open. During operation of the unit, the relays are
typically closed until activated by an alarm, but they can be configured either way.
The following are usage examples for an online monitoring system:
• (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 AMS 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 AMS 2600 relays are different in that:
• An AMS 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 AMS 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 AMS Machinery Manager Help in the Online Software
section. These are innovations provided by the AMS 2600 system, which have value in
turbo machinery applications.
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Getting started
2.11.4 AMS 2600 field wiring
In addition to predictive monitoring, the AMS 2600 is also a portable transient monitoring
system, which means in most applications it is being connected to already installed
sensors. Portable transient monitoring is different from a fixed, permanently connected
system. For example:
• The portable application includes actions of connecting and disconnecting cables
between the AMS 2600 monitoring unit and installed modules or even junction
boxes. It is critical to ensure that these actions do not interfere with 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 AMS 2600). For
instance, some modules connect to an eddy current sensor which provides a DC
output equivalent to gap voltage (usually about -10 V) and an AC voltage equivalent
to vibration (millivolt signal). 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 – 10 V version of the input.
An analyst must know the sensitivity and offset of signals connected to the AMS 2600,
which may be the same (or different) as signals connected to existing modules. An analyst
must also know if the AMS 2600 connections are to buffered or unbuffered field wiring or
module outputs.
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3 Hardware configuration
Topics covered in this chapter:
• Hardware configuration: overview
• The A6560R and A6510 modules
• AMS 2600 signal inputs
• Configure the A6560R with a terminal emulator
3.1 Hardware configuration: overview
The AMS 6500 Machinery Health™ Monitor (A6560R CPU module, in combination with the
A6510 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 eddy current sensors. 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 an eddy current sensor, 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.
Hardware configuration
Tachometer inputs are used to determine machine speed. These tachometer signals are
typically generated from an eddy current sensor 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.
Discrete inputs represent machine states such as running, off, and starting. These inputs
are used to control or modify the data acquisition based on machine state. Common state
control inputs are relay closures or machine RPM. AC or DC signal levels can also be used
for state control.
3.1.1 Gross Scan monitoring
Gross Scan monitoring includes:
• the acquisition of the overall level of the dynamic AC vibration signal, typically the
RMS value of the signal.
• the DC sensor bias level.
• the measurement of a DC process signal.
All these signal inputs are DC values (the RMS value is a DC value proportional to the
overall energy content of the AC signal). The Gross Scan inputs are multiplexed into a fast
successive approximation ADC controlled by the A6560R CPU module. Gross Scan
monitoring measures all input channels AC+DC twice per second. When the Transient
option is included, true waveform peak-to-peak may be included in Gross Scan
monitoring.
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Hardware configuration
3.1.2 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). Preprogrammed
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.
3.1.3 Transient data capture
Transient data capture is the acquisition of continuous time waveforms of dynamic AC
signals. Transient data is captured in parallel for all channels. Other data stored along with
the Transient data include Gross Scan data captured once per second, tach pulse records,
and acquisition timestamps. The Transient data is stored on hard disk, and is available for
real-time analysis via Ethernet.
3.2 The A6560R and A6510 modules
The AMS6500M has an A6560R Processor module and either one or two A6510 Signal
Input modules.
The AMS6500T has an A6560R Processor module with a solid-state drive and either one or
two A6510 Signal Input modules, each with Transient Filter Boards.
3.2.1 A6560R Processor module
The A6560R Processor module provides all data acquisition, data storage, and data
communication functions for the AMS 6500 system and the AMS 2600 system. The
A6560R is capable of up to 24 simultaneous, 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 and 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.
The Processor module provides four 100 Base-T Ethernet ports and one RS-232 serial port
for system communications and diagnostics. Additional connections are available for the
calibration signal and a dry contact SPDT SysFail relay. This relay is energized when the
Processor CPU successfully boots. On a CPU failure or power loss, the relay will deenergize.
The Processor module may be configured to download its operational firmware via
Ethernet upon boot, or to operate on firmware that has been stored in FLASH memory.
The Processor module has an on-board signal generator capable of producing sinusoidal
and DC signals that are routed to the input modules during system calibration and on
Power On Self Test (POST).
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Hardware configuration
Note
If the unit experiences frequent extreme temperature changes, recalibrate the signal generator
more frequently.
The Processor module automatically detects input module type and configuration, and
only permits database configuration based on the existing channel set.
A6560R Processor moduleFigure 3-1:
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Hardware configuration
Transient capability
The A6560R CPU module, is capable of parallel, continuous time waveform acquisition on
all channels. All collected time waveform data, along with Gross Scan data and up to four
tachometer pulse records, is stored on an internal solid-state drive (SSD). The SSD is
specially rated for industrial operation and provides approximately 100 hours of DCR
(Digital Condition Recorder) transient data. There is also room on the drive to store
transient archives manually and automatically.
Transient data can be streamed 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 processor continuously
calculates the peak-to-peak value of each channel's waveform. When configured, this
value can be used as the Gross Scan instead of the RMS value produced by the A6510
Signal Input module.
A6560R CPU module with and without Transient capabilityFigure 3-2:
An A6560RT with mounted SSD. An A6560R next to the older A6560RT.
A. SSD
Replace the Transient SSD
Only replace the Transient SSD if directed by Emerson Product Support.
CAUTION!
Follow the same safety precautions as replacing a card in the unit. Always power down the
unit.
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Hardware configuration
Procedure
Replace the SSD as directed by Emerson Product Support.
Postrequisites
Format the Transient SSD.
Format the Transient SSD
You must format the new solid-state drive before you can use it.
Procedure
1. Power on the system and ignore any hard drive error messages on the
HyperTerminal monitor.
2. When the system has booted, launch
DHM_III.exe is located at C:\inetpub\ftproot\bin\Tools directory.
3. In DHM, connect to the unit in "Single User" mode.
4. From the main menu, select Transient > Format Hard Drive.
5. When the drive has been formatted, reboot the unit. Ignore any hard drive error
messages.
DHM_III.exe.
When the POST process is complete, the firmware automatically prepares the hard
drive with the Transient File System. This process can take up to 15 minutes.
6. Disconnect DHM.
The unit will reboot automatically.
When the unit boots, there should be no hard drive error messages. If configured,
Transient data collection should begin, indicated by a flashing hard drive indicator on the
A6560R CPU module front panel.
3.2.2 A6510
The A6510 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 A6510 provides 12 channels of vibration or process sensor inputs, 2 channels of
tachometer sensor inputs, and 2 optically-isolated I/O relay channels.
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Hardware configuration
A6510Figure 3-3:
Transient Filter Board for the A6510
The Transient Filter Board provides parallel anti-aliasing filters for the signal channels on
the Signal Input module. Either one or two Transient Filter Boards may be used to
configure either a 12- or 24-channel Transient System.
When installing the Transient Filter Board on the Signal Input module, make sure both
mating connectors are fully engaged, then install all six mounting screws.
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