Emerson CSI 6500 Quick Start Manual

Quick Start Guide

MHM-97465

NC: 6540-90104

Rev.: 1.002

CSI 6500 Machinery Health™Monitor

A6151, Dual Channel Low Frequency Shaft Vibration Monitor

Emerson Process Management

Machinery Health Management

835 Innovation Drive

Knoxville, TN 37932 USA

T 1(865) 675-2400

F 1(865) 218-1401

www.EmersonProcess.com

©2010, Emerson Process Management.

The contents of this publication are presented for informational purposes only, and while every effort has

been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express

or implied, regarding the products or services described herein or their use or applicability. All sales are

governed by our terms and conditions, which are available on request.We reserve the right to modify or

improve the designs or specifications of our products at any time without notice.

All rights reserved. Machinery Health is a mark of one of the Emerson Process Management group of

companies. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are

the property of their respective owners.

GB

Explanation of symbols

!

If this symbol is printed on a device, according to IEC 61010 it means that the
documentation of the device must be completely read and understood before
installation and commissioning of the device. All safety−related instructions
of this document must be observed. These safety−related instructions are
marked by the “STOP” symbol in this document.

If this symbol is printed on a device, according to IEC 61010 it means that this
device must be operated with DC voltage.

i

This symbol identifies text that contains important information.

!

Not following instructions identified with this symbol can result in functional
issues and incorrect measurements without damaging the machine.

STOP

Safety and warning instructions are identified with this symbol.
Failure to observe these instructions can result in material damage or

personal injury.

D

Symbolerklärung

!

Ist dieses Symbol auf einem Gerät angebracht, so sagt dies nach IEC 61010
aus, das es zur Installation und Inbetriebnahme des Gerätes zwingend
erforderlich ist, die Dokumentation des Gerätes vollständig gelesen und
verstanden zu haben. Sicherheitsrelevante Hinweise in dieser
Dokumentation sind unweigerlich zu beachten und im weiteren Verlauf dieser
Dokumentation durch das “STOP” Symbol (siehe unten) gekennzeichnet.

Ist dieses Symbol auf einem Gerät angebracht, so sagt dies nach IEC 61010
aus, dass es mit Gleichspannung betrieben wird.

i

Dieses Symbol kennzeichnet Textstellen, die wichtige Informationen
enthalten.

!

Hinweise, die bei Nichtbeachtung zu Funktionsstörungen und
Fehlmessungen führen, ohne das Gerät zu beschädigen, sind mit diesem
Symbol gekennzeichnet.

STOP

Sicherheits- und Warnhinweise sind mit diesem Symbol gekennzeichnet.
Die Nichtbeachtung solcher Hinweise kann zu Sachbeschädigungen oder

Personenschäden führen.

Product Service Centers

America

Emerson Process Management
835 Innovation Drive
Knoxville, TN 37932
Tel: 865−675−2110
Fax: 865−218−1401

Brazil

Emerson Process Management Ltd.
Av Hollingsworth 325
Sorocaba, SP
BRAZIL 18087−000
Phone: [phone]
Fax: [phone]

Europe, Middle East, Africa

Emerson Process Management
div. ESAD
MHM Repair Center
Piestanska 1202/44
915 28 Nove Mesto nad Vahom
Slowakia
Tel: [phone]
Fax: [phone]

Asia

Emerson Process Management / Asia
Pacific Private Ltd.

3904 Room Central Plaza
18 Harbour Road Wan−Chai
Hong Kong
Tel: 852−2802−9223
Fax: 852−2802−8227

Incoming goods inspection

Check the content of the shipment to ensure that it is
complete; visibly inspect the goods to determine if the
device may possibly have been damaged during
transport. The following parts are included in the scope
of delivery and must be contained in the shipment.

1. A6151

2. Product information

If the contents are incomplete, or if any defects are
observed, a complaint must be filed with the carrier
immediately. Moreover, the responsible Emerson sales
organization must be informed to enable repair or
replacement of the device. Repairs or calibration that
may be required, are only possible at the Emerson
factory.

In this case, a non−detachable tag with customer name,
defect observed and version of the A6910 configuration
software must be attached to the device.

Repair and maintenance

During operation, monitors do not require any mainte­nance.

Repair or calibration of monitors is only possible at
Emerson.

i

The additional PCB (controller board)
is calibrated with the main board and
must not be replaced.

If work with the opened device on−site is
unavoidable, this should only be performed by a
specialist who is familiar with the associated
hazards.

STOP

Capacitors in the device can still be
energized, even if the device has
been disconnected from all power
sources.

If repair or recalibration of a monitor is required, it
must be sent to Emerson. Attach a non−detachable
tag to the monitor with customer name, defect
observed and version of the A6910 configuration
software.

Guidelines for Returning Equipment to the
Product Service Center

If repair or calibration of a monitor is required, it must
be sent to Emerson.
Occasionally, concerns with CSI technology
hardware could arise. Should this happen, customers
under warranty or a current support agreement are
entitled to no−charge repairs.

Follow the checklist below to minimize return time
and ensure proper processing of your equipment.
Before returning any equipment to a Product Support
Center, please review this information:

1. Obtain a Return Materials Authorization (RMA)
number and the address of the appropriate
Product Service Center by calling 865.675.4274*.

Listen to the options for receiving an RMA. You
will be routed to support personnel who will
document your concern and give you an RMA
number if you are under support or warranty. If
your hardware is not under support or warranty,
you must have a Purchase Order for the amount
of the repair service before you can receive an
RMA number. Pricing for your repair can be
obtained from support personnel or by calling
your local sales representative. Once you have
your purchase order, call 865.675.4274* for an
RMA.

2. Once you have received your RMA, send your
hardware to the appropriate product service
center. Your hardware package should include:

G RMA Number (plus Purchase Order if

applicable)

G Description of the hardware

problem

G Return shipping address including a

phone number (No P.O. boxes).

G Any special request regarding the

return shipment.

G A list of the model numbers of each

item(s) being returned, along with
the serial number.

G Your name, address, telephone

number and email address.

G Company Name.

A form for completing this information has
been provided.

Make a copy of the form, complete all lines,
and return a copy in each return shipment.

Out of warranty? Need to get under
support? Get a customized quote for
bringing all your CSI technologies under a
support agreement:
Phone: [phone]*, ext. 2130
Fax: [phone]*
Email:
mhm.supportagreement@emersonproces
s.com

*Customers outside the Americas and
Canada: please refer to the list of service
centers and contact the service center near
you.

All rights are strictly reserved

Reproduction or divulgation in any form
whatsoever is not permitted without written
authority from the copyright owner.

RMA Required Information

RMA number issued by Product
Service Center:

For all items beingreturned, please
list Model / Serial Number:

Are you under warranty or a current
support agreement (circle one)?

Yes No

If you answered no, what is your
purchase order number?

Company Name:

Contact Name:

Contact Address:

Contact Phone:

Contact Fax:

Contact Email:

Please describe the problem you are experiencing:

If we are to send the return shipment to someone other than the
Contact Name/Address above, please provide that address here,
including Contact Name and Phone Number:

Are there any special instructions regarding the return?

Please provide invoice address (if a purchase order was required):

Support customers − your instrument is shipped back to you the same
way that it is sent to our service center. For example, if you ship via
ground transportation, it is shipped back via ground.

Page/Seite 7

Product Information / Produktinformation

A6151

1

GB

Shaft Vibration Monitor 9........................

1.1 Scope of Delivery 9...........................................

1.2 CSA Certification 10...........................................

1.3 CSA − Conditions of acceptability 10............................

1.4 Advice for Installation 10.......................................

1.5 Installation and Mounting 11...................................

1.5.1 Jumper RS 485 11..........................................................

1.5.2 Sensor raw signal 12........................................................

1.5.3 Installation 14..............................................................

1.6 Technical Data 14..............................................

1.6.1 Signal conditioning 14.......................................................

1.6.2 Channel monitoring 18......................................................

1.6.3 Limit value formation and alarms 19...........................................

1.6.4 Communication interfaces 20.................................................

1.6.5 Power supply 21............................................................

1.6.6 Environmental conditions 22.................................................

1.6.7 Mechanical structure 22.....................................................

2

D

Wellenschwingungsmonitor 23....................

2.1 Lieferumfang 23...............................................

2.2 CSA Zertifizierung 24..........................................

2.3 CSA − Akzeptanzkriterien 24....................................

2.4 Hinweis zur Installation 25......................................

2.5 Installation und Montage 25....................................

2.6 Technische Daten 28...........................................

2.6.1 Signalkonditionierung 28.....................................................

2.6.2 Kanalüberwachung 31.......................................................

2.6.3 Grenzwertbildung und Alarme 33.............................................

2.6.4 Kommunikationsschnittstellen 34.............................................

2.6.5 Spannungsversorgung 35....................................................

2.6.6 Umgebungsbedingungen 36..................................................

2.6.7 Mechanischer Aufbau 36....................................................

3 Connection Diagrams and Figures /

Anschlusspläne und Abbildungen 37....................

4 PI Revision List 41.....................................

Page 8

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

1

GB

SHAFT VIBRATION MONITOR

The two−channel Low Frequency Shaft Vibration Monitor A6151 is a module of the A6000
machine monitoring system. The micro−processor controlled monitor is used in conjunction with
two eddy current measuring chains to measure and monitor the relative shaft vibration of hydro
turbines.

The two channels of the monitor can be used as separate channels or they can be linked together
via the configuration. The following operating modes are possible:

• Dual channel operation.

• The calculation and output of the maximum value S

max

.

• The calculation and output of the greater vibration width S

PPmax

The characteristic values can be output via a 0/4 ... 20mA current output per channel

i

In this product information the mounting and electrical connection of the
monitor is described. The configuration of the A6151 is similar to the
configuration of the A6110. Hence additional information concerning
configuration and installation can be found in the operation manual of the
A6110 (order number: 6110−90001) This operating manual is part of the
configuration software CD. All differences in installation and configuration are
described in this product information.

To ensure the safe operation of the monitor and to permit setting of all
functions, it is indispensable to use only the latest versions of configuration
software (version 2.07 Beta 78) and operating manual.

The use of old operating manuals or configuration programs out of date may
lead to malfunctions or limitations of the measuring functions.

1.1 Scope of Delivery

The following parts are included in the scope of delivery and must be contained in the shipment:

• Low Frequency Shaft Vibration Monitor A6151

• This product information

Accessories (not included in delivery):

• MMS ParaKit (order no.: 9510−00027)

If the contents are incomplete or if is there any damage, so directly complain at the bearer. The
competent epro sales agency must be informed also, to enable repair or replacement for the
monitor. Repair or calibration of this instrument may only be made at epro.

Page 9

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

1.2 CSA Certification

STOP

For valid CSA certification, all devices (IMR 6000/xx and A6000 modules)
must be marked with the respective CSA lable.

If no CSA lable is available on the respective device, this device is not CSA
certified!

The respective CSA lable looks as shown in the following picture.

1.3 CSA − Conditions of acceptability

This device must be supplied with safety low voltage SELV LPS (C22.2 60950−1) 24V. The
voltage required for operation must be drawn from a separate power supply.

The system should be placed in a suitable fire enclosure.

The system is evaluated for an ambient Temperature of 0°C to 45°C.

Adequate ventilation space has to be provided so that heat does not build up. The ventilation
space must be at least 1 RU (1

3/4

inch) in all directions. If the ambient temperature of the rack

rises above 45 °C, cool this instrument with a forced air fan, cooler, or similar.

When mounting several IMR units above each other in one cabinet, install cooling fan racks in
between instead of the ventilation space. The necessary specifications for cooling fan racks
result from the environmental and sitting criterions of the cabinet and thus cannot be defined
generally.

1.4 Advice for Installation

STOP

According to the IEC 61010 directive, permanently installed systems must be
equipped with a power disconnect device (e.g. a switch or circuit−breaker
according to IEC60947−1 and IEC60947−3). When using an IMR rack, in
compliance with this directive, such a switch or breaker must be implemented
into the cabinet installation and easily accessible for the user. Furthermore,
each disconnect devices must be labeled in accordance to the associated
system.

Page 10

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

1.5 Installation and Mounting

A prepared 3U slot in a 19” rack, or other Intermas−compatible enclosure, is required for
mounting the A6151 monitor. The slot must be fitted with a 48−pin plug connector (DIN 41612,
design F 48 M). The pin assignment is listed in the following table.

d

b z

2

UN+ (+ 24V) U− (0V/Common) UB+ (+24V, redundant)

2

4

A (RS 485) GND (BP, Common, RS 485) B (RS 485)

4

6

Supply2+ (sensor) Supply1− (sensor) Supply1+ (sensor)

6

8

AIN2− (Input) Supply2− (sensor) AIN1− (Input)

8

10

AIN2+ (Input) GND AIN1+ (Input)

10

12

NGL2 (scaled dc−output) GND NGL1 (scaled dc−output)

12

14

EO1 (voltage output1) EI1 (voltage input1) AC1 (sensor raw signal1)

14

16

EO2 (voltage output2) EI2 (voltage input2) AC2 (sensor raw signal2)

16

18

GWM (limit value) I1− (current output common) I1+ (current output CH1)

18

20

NC I2− (current output common) I2+ (current output CH2)

20

22

KEY−N (key signal input) GND ES (external lock)

22

24

SC−A (oper. principle alert) GND SC−D (oper. principle danger)

24

26

D1−C (danger1 collector) A1−C (alert1 collector) CC1−C (ch. clear1 collector)

26

28

D1−E (danger1 emitter) A1−E (alert1 emitter) CC1−E (ch. clear1 emitter)

28

30

D2−C (danger2 collector) A2−C (alert2 collector) CC2−C (ch. clear2 collector)

30

32

D2−E (danger2 emitter) A2−E (alert2 emitter) CC2−E (ch. clear2 emitter)

32

1.5.1 Jumper RS 485

RS 485 bus operation requires an electrical terminator on the first and last bus device.

This is done with plug−in jumpers, that are on the controller board. The figure shows the position
of the jumpers.

To activate the bus terminator and to place lines “A” and “B” on the references, plug the jumpers
as shown in Fig. b). Fig. a) shows the jumper position for deactivated bus termination and open
references (delivery status).

• Plug−in jumper 1−2 closed: Bus line “B” via pull−down resistor on ground

• Plug−in jumper 3−4 closed: 120 Ω resistor between “A” and “B”

• Plug−in jumper 5−6 closed: Bus line “A” via pull−up resistor on +5 V

Page 11

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

1

35

2

46

1

35

2

46

a)

b)

i

For trouble−free operation of the RS 485 bus, the lines “A” and “B” must be
connected on their references (+5 V, ground) in one monitor. This is only
possible if the bus termination jumper at this monitor has been closed as well.

1.5.2 Sensor raw signal

The raw sensor signal (unfiltered, in−phase output signal of the converter with AC and DC
portion) is applied to the front panel SMB sockets and can be fed to the terminals z14: channel
1 and z16: channel 2 of the connection strip with the jumpers J2. As delivered, the J2 jumpers
are set, that on terminals z14 and z16 the dynamic portion of the sensor signal (scaled to output
range 0 ... 20 Vss) is applied. The controller board must be removed in order to switch the signal
on the connection strip. The following points describe the procedure:

i

The reference point for the raw sensor signal from channel 1 is the connection
strip terminal z6: Supply1(+), and for the raw sensor signal from channel 2 the
terminal d6: Supply2(+). If these terminals are connected with terminal b10,
then the reference point is connected to system ground (GND). In this case
the terninals b22: GND and b24: GND can be used as reference point.

STOP

When working at the monitor, ensure that there is adequate protection against
electrostatic discharge. For example, wear an ESD bracelet to prevent
electrostatic discharge via the monitor electronics.

Page 12

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

3. Use a cross head screwdriver to remove the four cross−headed screws, identified with the
arrows, in the following figure.

4. Carefully pull the controller board off the main board without tilting it. The position of the J2
jumpers on the main bard is identified with a white frame in the following figure.

5. To switch the raw sensor signal to terminals z14 and z16 place the jumpers as shown in b).
If the jumpers are set as shown in a) then the dynamic portion of the sensor signal is applied
on terminals z14 and z16.

J2

z14:

z16:

AC1

AC2

SENS1

SENS2

J2

z14:

z16:

AC1

AC2

SENS1

SENS2

a)

b)

Page 13

Product Information / Produktinformation

A6151

Shaft Vibration Monitor

6. Place the controller board back on the main board and secure it with the four screws. Now,
the raw sensor signal is on the connection strip.

1.5.3 Installation

1. Check the slot wiring prior to installing the monitor.

2. Push the A6151 monitor into the prepared slot and press it with light pressure into the plug
connector.

3. Hand tighten the two anchoring screws on the front panel to secure the monitor.

Any other information, e. g. shielding and grounding, configuration of the monitor, etc., can be
found in the direction for use of the A6110, order number: 6110−90001.

1.6 Technical Data

Only information with tolerances and limit values are considered as binding data. Data without
tolerances or error limits are provided as information only. We reserve the right to make technical
changes − particularly to the software.

All of the following information applies uniformly for channel 1 and channel 2, if not otherwise
specified.

1.6.1 Signal conditioning

Two separate signal inputs for channel 1 and channel 2 with uncoupled signal conditioning.

Measured value inputs

Differential voltage amplification inputs, non−reactive, open−circuit and short−circuit proof.

Channel 1 z8: AIN1 (−); z10: AIN1 (+)

Channel 2 d8: AIN2 (−); d10: AIN2 (+)

Input nominal range −1,0 ... −22.16 V

Limit range 0 ... −30 V DC

Input resistance > 100 kΩ