DynAmp RCEM Installation, Operation And Service Manual

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MODEL RCEM
PORTABLE FLEXIBLE VERSION
RECTIFIER MONITORING SYSTEM
Installation, Operation and Service Manual
Manual Item No. 043756
Rev. G
DynAmp, LLC 3735 Gantz Road Phone +1 614.871.6900 www.dynamp.com
Grove City, Ohio 43123 USA Fax +1 614.871.6910 help@dynamp.com
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DynAmp, LLC WARRANTY
Items and components manufactured by Seller for permanent installation are warranted for two (2) years from the date of shipment.
Items and components manufactured by Seller for portable and temporary use in more than one location are warranted to be free from defects in material and workmanship for a period of eighteen (18) months from the date of shipment.
Items and components not manufactured and resold by Seller are warranted by their manufacturer.
Warranty repair shall be, at DynAmp's option, in the form of repair or replacement of the defective items or components. Concerning warranty repairs, DynAmp will be responsible for DynAmp provided time, material and transportation costs (shipping or travel). Actual method of warranty repair / correction will be determined by DynAmp at DynAmp's sole option. Such warranty repair shall constitute a fulfillment of all DynAmp, LLC liabilities in respect to said items and components. In no event shall DynAmp, LLC be liable for consequential damages.
Information in this document is subject to change without notice.
© 2001, 2003, 2004, 2006, 2011, 2012 DynAmp, LLC. All rights reserved.
Reproduction for purposes other than operation and service without written permission of DynAmp, LLC is strictly forbidden.
This manual includes detailed drawings, installation, operation, service and maintenance. Users should evaluate the information in the manual and their particular application. DynAmp assumes no liability for any incidental, indirect, or consequential damages arising fro the use of this documentation.
While all information presented is believed to be reliable and in accordance with accepted engineering practices, DynAmp makes no warranties as to the completeness of the information.
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VOLTAGE
INSTALLATION
Hazard Warning!
GENERAL
HAZARDOUS
Qualified technicians who are familiar with the warnings and instructions of this manual must perform all installation, maintenance and service.
Disconnect power to the system before servicing or replacing fuses.
Use of the equipment in a manner not specified by the manufacturer can impair the protection provided within.
DynAmp does not assume liability for the customer’s failure to comply with the rules and requirements provided in this manual.
This equipment is designed to be connected to hazardous electric voltages. Ignoring the installation precautions and warnings can result in severe personal injury or equipment damage.
To avoid the risk of electrical shock or fire, the safety instructions and guidelines in this manual must be followed. The electrical specifications must not be exceeded and the unit must be installed according to directions provided.
This equipment is intended for indoor use only. It should be mounted in a well-ventilated area, away from high heat, dust, and corrosive atmosphere.
The ambient temperature must not exceed 55°C.
The laptop computer must be located well away from magnetic fields. Failure to comply may result in damage to the computer.
For mounting considerations that fall outside the recommended specifications provided in this manual, the factory should be contacted for approval.
This unit is rated for installation category III, 300V and pollution degree 2.
Symbol Identification:
General definitions of safety symbols used on equipment and manual.
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Caution/Warning: Refer to accompanying documents for instructions.
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DynAmp, LLC Customer Support
For further assistance, contact DynAmp Customer Support at:
Americas:
Telephone: +1 614.871.6900 Fax: +1 614.871.6910
8:00 AM to 5:00 PM USA Eastern Time
From first Sunday in November to second Sunday in March – 13:00 GMT to 22:00 GMT
From second Sunday in March to first Sunday in November – 12:00 GMT to 21:00 GMT
Europe:
Telephone: +41 22.706.1446 Fax: +41 22.706.1311
8:30 AM to 5:00 PM Central European Time
From last Sunday in October to last Sunday in March – 7:30 GMT to 16:00 GMT
From last Sunday in March to last Sunday in October – 6:30 GMT to 15:00 GMT
After Hours Critical Service Emergency:
Telephone: +1 614.871.6906
5:00 PM to 8:00 AM USA Eastern Time
From first Sunday in November to second Sunday in March – 22:00 GMT to 13:00 GMT
From second Sunday in March to first Sunday in November – 21:00 GMT to 12:00 GMT
Central e-mail:
help@dynamp.com
DynAmp web:
www.dynamp.com
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Page
Rev
Reason For Revision
Date
All
NEW
06/01
23,
A
Add Integrator PC Board calibration procedure and Update
10/01
37
B
Revise Appendix B-2: Minimum Requirements for Laptop
10/03
45-54
C
ECO-3099 - Revise Appendix B: Add Devices/Leg
08/04
45-54
D
Update to DynAmp, LLC, ECO-3102 – Revise Appendix B:
12/04
v, 1, 27,
36
E
Update fuse precautions per ECR 1304
07/06
Intervals / New Manual Format
/Software requirments
REVISION PAGE
37-46
all F
35, 45 G
Appendix B to revised spreadsheets
Computer
Command Button
Add ANSI Rectifier Circuit select
PAR 10245 – Handling & Storage, ECR 1440- Calibration
ECR1683 - Revise Spare Parts List, Table 8.1, Computer
06/11
03/12
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TABLE OF CONTENTS

Par. Title Page
1. SAFETY ____________________________________________________________ 1
1.1 O
VERVIEW ............................................................................................................................. 1
2. HANDLING AND STORAGE ____________________________________________ 3
3. DESCRIPTION _______________________________________________________ 5
3.1 G
3.2 D
3.3 D
3.4 L
3.5 F
3.6 M
ENERAL ............................................................................................................................... 5
EFINITIONS........................................................................................................................... 5
ATA ACQUISITION UNIT ......................................................................................................... 5
APTOP COMPUTER ................................................................................................................ 6
LEXIBLE CURRENT SENSORS ................................................................................................. 6
AGNETIC FIELD STATEMENT .................................................................................................. 6
4. SPECIFICATIONS ____________________________________________________ 7
5. TECHNICAL DESCRIPTION ____________________________________________ 9
5.1 G
5.2 B
5.3 A
5.4 B
5.5 P
5.6 A
5.7 I
5.8 R
5.9 T
5.10 P
5.11
5.12 D
ENERAL ............................................................................................................................... 9
ASIC THEORY OF OPERATION ............................................................................................... 9
NALOG CARD RACK .............................................................................................................. 9
ACKPLANE ......................................................................................................................... 10
OWER CIRCUITS ................................................................................................................. 10
NALOG INPUT CONNECTORS ............................................................................................... 11
NTEGRATOR CARDS ............................................................................................................. 11
ESET SYNC CARDS ............................................................................................................. 12
EST SIGNAL GENERATOR .................................................................................................... 13
ERSONAL DAQ/56 ............................................................................................................... 14
USB EXTENDER RECEIVER .................................................................................................. 15
IGITAL INTERFACE MODULE ................................................................................................. 15
6. PREPARATION FOR USE _____________________________________________ 17
6.1 S
6.2 R
6.3 S
6.4 I
YSTEM CHECKOUT AND PREPARATION ................................................................................. 17
ECTIFIER SHUTDOWN ......................................................................................................... 17
ENSOR MOUNTING AND CONNECTION CONSIDERATIONS ....................................................... 17
NSTALLATION INSTRUCTIONS ................................................................................................ 17
7. MAINTENANCE AND TROUBLESHOOTING ______________________________ 27
7.1 C
7.2 G
7.3 V
7.4 F
7.5 S
7.6 V
7.7 A
7.8 A
7.9 S
7.10 S
7.11 C
7.12 R
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ALIBRATION INTERVALS ....................................................................................................... 27
ENERAL ............................................................................................................................. 27
ERIFYING PROPER OPERATION ............................................................................................ 27
USE REPLACEMENT ............................................................................................................ 28
TATIC PRECAUTIONS WHEN SERVICING ............................................................................... 28
ERIFYING PROPER INTEGRATOR RESET SYNCHRONIZATION .................................................. 29
DJUSTING THE SIGNAL GENERATOR ..................................................................................... 29
DJUSTING THE INTEGRATOR PC BOARDS....................................................................... 30
ENSOR TESTING (CONTINUITY METHOD) .............................................................................. 30
ENSOR DIELECTRIC TESTING - WINDINGS TO SURFACE ........................................................ 31
ONNECTOR CONTAMINATION (INTEGRATOR CARDS) .............................................................. 32
ESET SYNC ERROR OR INCORRECT DATA ............................................................................ 33
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8. SERVICE, PARTS, AND DOCUMENTATION ______________________________ 35
8.1 SERVICE
8.2 S
8.3 S
PARE PARTS ORDERS - ROUTINE OR EMERGENCY ................................................................ 36
PARE PARTS ...................................................................................................................... 36
ASSISTANCE ..................................................................................................... 35
9. DRAWING LIST _____________________________________________________ 37
9.1
REQUIRED DRAWINGS ............................................................................................................. 37
APPENDIX A: ANSI RECTIFIER CIRCUITS __________________________________ 39
APPENDIX B: SOFTWARE _______________________________________________ 45
B.1 P B.2 M B.3 S B.4 S B.5 S B.6 PROGRAMMING B.7 SEL B.8 A B.9 S B.10 A B.11 STARTING B.12 STOPPIN B.13 V B.14 R B.15 CALIBRATE B.16 P
ROVIDED SOFTWARE .......................................................................................................... 45
INIMUM REQUIREMENTS FOR LAPTOP COMPUTER ................................................................ 45
OFTWARE INSTALLATION ..................................................................................................... 45
TARTING THE DATA ACQUISITION PROGRAM ......................................................................... 46
PREADSHEET DESCRIPTION ................................................................................................ 47
THE NUMER OF DEVICES/LEG ............................................................ 48
ECTING THE ANSI RECTIFIER CIRCUIT NUMBER .................................................................. 48
CQUIRING A RECTIFIER DATA SET ........................................................................................ 49
AVING THE RECTIFIER DATA TO A DISK FILE ......................................................................... 49
CTIVATING THE TEST MODE OF OPERATION ......................................................................... 49
THE SCAN MODE OF OPERATION ................................................................ 49
G THE SCAN MODE OF OPERATION ....................................................................... 50
IEWING THE DIODE CURRENT BAR GRAPHS ........................................................................... 50
ECOVERING FROM DAQ ERRORS ......................................................................................... 50
WORKSHEET ................................................................................................ 51
RECAUTIONS ...................................................................................................................... 51
FIGURES
Figure # Title .................................................................................................. Page
Figure 5.1 Analog Card Rack ................................................................................................ 10
Figure 5.2 Reset Pulse Connector Location .......................................................................... 13
Figure 5.3 Reset Pulse Signal Location ................................................................................. 13
Figure 5.4 571A Test Signal Waveform................................................................................. 14
Figure 5.5 Personal Daq/56 .................................................................................................. 14
Figure 5.6 USB Extender Receiver ........................................................................................ 15
Figure 5.7 Digital Interface Module ........................................................................................ 15
Figure 6.1 Flexible Current Sensor Installation Detail ............................................................ 18
Figure 7.1 Device Current Waveform .................................................................................... 29
Figure 7.2 Reset Sync PC Board .......................................................................................... 30
Figure 7.3 Integrator PC Board ............................................................................................. 30
Figure 7.4 Hi-Pot Test Setup ................................................................................................. 32
Figure A.1 ANSI Rectifier Circuit 23 ...................................................................................... 39
Figure A.2 ANSI Rectifier Circuit 24 ...................................................................................... 39
Figure A.3 ANSI Rectifier Circuit 25 ...................................................................................... 40
Figure A.4 ANSI Rectifier Circuit 26 ...................................................................................... 40
Figure A.5 ANSI Rectifier Circuit 31 ...................................................................................... 41
Figure A.6 ANSI Rectifier Circuit 32 ...................................................................................... 41
Figure A.7 ANSI Rectifier Circuit 45 ...................................................................................... 42
Figure A.8 ANSI Rectifier Circuit 46 ...................................................................................... 42
Figure A.9 ANSI Rectifier Circuit 52 ...................................................................................... 43
Figure B.1 6Leg120Ch Spreadsheet ..................................................................................... 52
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Figure B.2 M6Leg120Ch Spreadsheet ................................................................................... 52
Figure B.3 12Leg120Ch Spreadsheet ................................................................................... 53
Figure B.4 1Leg-20ch Spreadsheet ....................................................................................... 53
Figure B.5 Leg 1 Bar Chart ................................................................................................... 54
Figure B.6. Calibrate Worksheet ........................................................................................... 54
TABLES
Table # Title .................................................................................................. Page
Table 4.1 Rectifier Condition Evaluation Monitor Specifications .............................................. 7
Table 4.1 Rectifier Condition Evaluation Monitor Specifications (Continued) ........................... 8
Table 6.1 Transducer Connections, 6-Leg Rectifier (20 Diodes Max.).................................... 19
Table 6.2 Transducer Connections, 6-Leg Rectifier (40 Diodes Max.)................................... 20
Table 6.3 Transducer Connections, Parallel 6-Leg Rectifier (10 Diodes Max) ........................ 21
Table 6.4 Transducer Connections, Parallel 6-Leg Rectifier (20 Diodes Max) ....................... 22
Table 6.5 Transducer Connections, 12-Leg Rectifier (10 Diodes Max.) ................................. 23
Table 6.6 Transducer Connections, 12-Leg Rectifier (20 Diodes Max.) ................................. 24
Table 6.7 Transducer Connections, 1-Leg of a Multi-Leg Rectifier ......................................... 25
Table 8.1 Spare Parts List ..................................................................................................... 36
Table 9.1 Drawing List ........................................................................................................... 37
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1. SAFETY

1.1 OVERVIEW
This equipment is designed to be connected to hazardous electric voltages. Ignoring the installation precautions and warnings can result in severe personal injury or equipment damage. The following are general guidelines that should be followed when installing, operating and servicing the RCEM.
Qualified technicians who are familiar with the warnings and instructions of this manual
must perform all installation, maintenance and service.
Always follow all local and plant safety procedures.
The equipment covers should remain closed at all times during operation to ensure
safety of personnel. Only authorized personnel or technicians should be allowed to open and service the equipment.
Cover #3 (PC Board Cover) may be removed if the operator needs access to the diode
waveform connectors. Use caution whenever the cover is removed.
Only qualified technicians should perform Service. If use of an oscilloscope becomes
necessary during operation or servicing, either the scope must be floating or ungrounded, or differential probe(s) must be used. The equipment is isolated from the mains via the power transformers. If a grounded scope is used, a hazardous condition is created since current will flow through the probe to ground.
Replace fuses with correct type, size and value. Refer to the servicing instructions or
spare parts list for more information on replacement fuses. Do not bypass the fuses or modify the electronics. Disconnect power to the system before replacing fuses. Failure to follow these instructions will result in intermittent operation and premature failure and will void the warranty.
The equipment is not intrinsically safe. Do not place in explosive atmospheres.
The Current Transducers are double insulated to protect the operator from possible
hazardous voltage potentials of the rectifier. The transducers are also protected from heat by a protective sheath.
Make sure the transducer cables and interconnection cables are kept well away from
hazardous voltage potentials and heat sources inside the rectifier.
Keep the electronics enclosure as far as possible away from the hazardous voltage
potentials of the rectifier.
Use of the equipment in a manner not specified by the manufacturer can impair the
protection provided.
DynAmp does not assume liability for the customer’s failure to comply with the rules and requirements provided in this manual.
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2. HANDLING AND STORAGE

DynAmp products are engineered and manufactured for use in industrial environments. However, they contain sensitive electronic and mechanical components which may be damaged and fail if not handled and stored properly. All products must be handled and stored with the same care as any precision measurement instrument. Severe bumps or jolts may damage internal parts and cause malfunction or premature failure. DynAmp products are designed and assembled with conformal coating, shock mounting, and environmental seals, when appropriate or when specified. However, this protection requires that the product must be properly installed and operational before the protection is fully functional. Therefore, adequate protection from humidity, shock, and temperature must be provided during handling and storage prior to installation.
The handling and storage of equipment must be sufficient to meet the storage temperature and humidity specifications of the product and to prevent any condensation or contact with water or any other liquid. The storage location and container or crate must provide adequate protection from precipitation (rain, snow, ice) and direct water contact. Adequate shelter must be provided to prevent the accumulation of precipitation (rain, snow, ice) and water which can lead to the deterioration or failure of shipping containers or crates and cause water ingress. Storage in coastal or industrial areas subject to salt-laden or corrosive air or areas of wind-driven sand or other abrasive dust must be adequate to prevent the deterioration or failure of shipping containers or crates and cause ingress. Frequent inspection of storage areas and storage containers or crates is required to ensure proper storage conditions are being maintained.
If the shipping container or crate is opened and/or the equipment is removed for inspection prior to installation, the equipment must be repackaged in the original undamaged container or crate in the same manner as it was shipped to prevent environmental damage or placed in a storage location that meets the required environmental and storage conditions.
General product storage temperature and humidity requirements:
Storage Temperature: -40 to 70°C
-40 to 158°F Storage Humidity: 85%, non-condensing
DynAmp, LLC does not assume liability for the customer’s failure to comply with handling and storage requirements.
For further assistance, contact DynAmp customer support.
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Channel
Flexible Current Sensor and associated electronic circuitry
DAU
Abbreviation for Data Acquisition Unit; rectifier monitoring system Device
Rectifier semiconductor device (such as a diode or thyristor).
Current Sensor
DynAmp Flexible Current Sensor
I/O
Input/Output device.
Laptop Computer
Portable computer used to display the rectifier data
Leg
Group of rectifier devices connected in parallel. Symbolically
Multiplexer
The binary address that selects one-of-six integrator card leg
USB
Universal Serial Bus
RCEM
DynAmp Rectifier Condition Evaluation Monitor RMS
root mean square – Effective value of a waveform

3. DESCRIPTION

3.1 GENERAL
The DynAmp RECTIFIER MONITORING SYSTEM Model RCEM is designed for isolated measurement of device currents in multiple path power rectifiers.
Model RCEM is a monitoring system composed of a 120 Channel Data Acquisition Unit, a laptop computer, Flexible Current Sensors, and the interconnection cables.
A 240 Channel RCEM is also available. This system consists of two 120 Channel Data Acquisition Units, a laptop computer, LEM~flex Current Transducers, and interconnection cables.
3.2 DEFINITIONS
The following terms are used extensively in this manual:
Address
active electronics hardware
referred to as R or S in ANSI circuit diagrams
output signals.
3.3 DATA ACQUISITION UNIT
The Data Acquisition Unit contains the following elements:
1.) Analog Card Rack containing:
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2.) Backplane
3.) Reset Sync Cards
4.) Integrator Cards
5.) Personal Daq/56 – USB Data Acquisition Module
6.) USB Extender Receiver
7.) Digital Interface Module
3.4 LAPTOP COMPUTER
The laptop computer is connected to the Data Acquisition Unit via the USB Extender Sender and RJ-45 cable. The laptop computer provides a means of displaying the rectifier data. It also allows access to the internal test signal generator. The data is displayed on a spreadsheet program.
3.5 FLEXIBLE CURRENT SENSORS
The 3.625 ID Flexible Current Sensor is the standard sensor supplied with the RCEM. Other Flexible Current Sensor sizes are available from DynAmp, if required. Presently they include inside diameter (I.D.) sizes of 1.000", 1.500", 2.750", 4.250", and 2.875” x 5.500” models. All Flexible Current Sensors have the same output, so they may be interchanged.
3.6 MAGNETIC FIELD STATEMENT
The magnetic field from a high current DC bus may damage or destroy the laptop computer hard disk drive, or floppy disks. To avoid damage the laptop and floppy disks should be kept as far from the DC bus as practicable. Protect floppy disks in a magnetic shielded case. This warning applies at all times.
The destructive effect of a magnetic field on a hard disk drive depends on the orientation of the laptop computer within the field, and the degree of magnetic shielding provided by the hard disk enclosure. Laptop computer and hard disk manufacturers do not provide specifications for maximum magnetic field outside the hard disk enclosure.
It is difficult to accurately specify a maximum safe Gauss level for laptop computer disk drives. Our best estimate is a maximum ambient magnetic field strength of 25 to 50 Gauss for safe laptop computer operation.
This manual provides recommended guidelines for use of the rectifier monitoring system. It is the sole responsibility of the customer to assure safety of equipment and personnel when using this product.
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Physical
Dimensions
Comments:
Data Acquisition Unit
22”W x 23”H x 13.75”D (559 x 584 x 349) mm
Flexible Current Sensor
3.625 ID (92 mm)
Standard Size (other sizes are available)
Sensor cable length
4.5 ft. (1.37 m)
Weight
Data Acquisition Unit
55 lbs. (20.5 kg)
Flexible Current Sensor
0.76 lbs. (0.28 kg)
3.625 ID Flexible Current Sensor
Interconnection Cable
Length
33 ft (10 m)
Data Acquisition Unit(s) to Flexible Current Sensor
USB Cable Length
15 ft (5 m)
Computer to USB Extender Sender
Serial Data Cable Length (Type Category 5E)
150 ft (45.7 m)
USB Extender Sender to Data Acquisition Unit
USB Cable Length
15 ft (5 m)
Data Acquisition Unit #1 to
Channel Systems)
Environmental
Temperature
Comments:
Data Acquisition Unit
0°C to 50°C
Flexible Current Sensor
-20°C to +150°C
Humidity
Data Acquisition Unit
85% RH non-condensing
Flexible Current Sensor
85% RH non-condensing

4. SPECIFICATIONS

The specifications for the Rectifier Condition Evaluation Monitor are listed in Table 4.1.
TABLE 4.1
RECTIFIER CONDITION EVALUATION MONITOR SPECIFICATIONS
Data Acquisition Unit #2 (240
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Electrical
AC Supply
Comments:
Voltage
90 – 135 Vac 175 – 264 Vac
Automatic Selection Frequency
50/60 Hz
Basic Accuracy
3%
Flexible Current Sensors
Measuring Range
Flexible Current Sensor
0…2000A
Data Acquisition Unit
10 to 100%
Output
Analog Output
1V/1kA
Waveform Connectors
Serial Data
USB Port
Laptop Computer
Safety
Isolation
Comments:
Flexible Current Sensor
3000 VAC, 1 Minute @ 60 Hz
Data Acquisition Unit Output to line
Installation Category III @ 300 Volts
Other
Visual Indicators
Comments:
Data Acquisition Unit
+24V LED
TEST A0 – TEST A1 LEDs
Personal Daq/56 Update Rate
4 seconds for 120 channels
TABLE 4.1
RECTIFIER CONDITION EVALUATION MONITOR SPECIFICATIONS (CONTINUED)
MUX A0 – MUX A2 LEDs TEST MODE LED
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DAU Data I/O Connector Variations
DAU Version
Data Port
USB Port
120 Channel
Installed
N/A
240 Channel DAU #1
Installed
USB “A”
240 Channel DAU #2
N/A
USB “B”

5. TECHNICAL DESCRIPTION

5.1 GENERAL
The Data Acquisition Unit (DAU) contains one analog card rack with backplane, reset sync cards, and integrator cards. The Data Acquisition Unit also contains the Personal Daq/56 USB Data Acquisition Module, the USB Extender Receiver, and two power supplies. The Personal Daq/56 accepts a maximum of 120 device data channels. The Data Acquisition Unit #2 in a 240 Channel system does not contain an USB Extender Receiver.
5.2 BASIC THEORY OF OPERATION
Each current sensor is associated with the measurement channel for a specific rectifier element. The signal from each current sensor is conducted to the DAU via an individual 2­conductor cable and a wire pair within the interconnection cable.
The output from a current sensor is a voltage waveform corresponding to the instantaneous change of current in the rectifier device associated with that current sensor. Integrating the output signal of the current sensor returns it to the current waveform being conducted by the rectifier device. The current waveform is converted to a DC voltage proportional to the RMS value of the integrated signal.
The analog card rack contains multiplexer circuits to switch the DC voltage signals into the twenty analog input channels located in the Personal Daq/56. The digital I/O in the Personal Daq/56 controls the multiplexer. The multiplexing scheme can be described as a 6-leg by 20-channel matrix. One of six integrator channels ("legs") is addressed on all 20 integrator cards.
5.3 ANALOG CARD RACK
The analog card rack contains the following elements: one backplane, two reset sync cards, and twenty integrator cards. See Figure 5.1.
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5.4 BACKPLANE
The digital interface circuits to/from the Personal Daq/56 are located on the Data Acquisition Unit backplane. The backplane also contains the reset sync cards connectors, the integrator card connectors, the signal input connectors from the current sensors, and the power circuits.
The backplane also contains the ac zero-crossing detector circuit. This circuit supplies the ac zero-crossing timing pulse to the reset sync pulse generator and the test signal generator circuits located on the Reset Sync Cards.
5.5 POWER CIRCUITS
The power circuits in the Data Acquisition Unit consist of the ac power input circuit, the regulated quad output power supply, the +12V power supply, the + 5V power supply, and the dc power input circuits.
Figure 5.1
Analog Card Rack
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