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CSI 6500
Machinery HealthTM Monitor
Online System Installation and Configuration
2
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3
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4
CSI 6500 Contents
Chapter 1 • Introduction
Special Emphasis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Plant Appointed Project Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Where to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
5
A0322LC with Quick-Connect Mounting Instructions . . . . . . . . . . 4-25
A0322RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
A0322RM Mounting Stud Installation (Stud Mounting Only) . . . . 4-35
Sensor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
V425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Description & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Choosing Proper Actuator (Target) . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Mounting Sensor Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Mounting Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Eddy Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Power Circuit Guidelines for the CSI 6500 enclosure . . . . . . . . . . . . 6-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Recommended Sensor Wiring and Grounding Practices. . . . . . . . . . . 6-12
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
CSI 6500 System Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
7
CSI 6500 Transient Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
General Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Configuring a CSI 6500 with Hyperterminal . . . . . . . . . . . . . . . . . . 8-31
CSI 6560 Processor Module LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
CSI 6510 Signal Input module LEDs . . . . . . . . . . . . . . . . . . . . . . . . 8-41
Backplane/Termination Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Overall Level Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Spectral Scan Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Calibrating the CSI 6500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Test Signal Generator (TSG) Calibration. . . . . . . . . . . . . . . . . . . . . 8-51
Gross Scan (GS) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
DSP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Transient Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Index
8
Chapter 1
Introduction
Preface
Congratulations on your purchase of the CSI 6500 Machinery Health Monitor
online system. Along with your system hardware and software, you have been
provided several manuals to assist in installing, learning, and maintaining your
system. This particular document is the CSI 6500 Machinery Health Monitor -
Installation and Configuration manual. The purpose of this manual is to provide
system installers specific requirements and instructions for the correct installa-
tion and configuration of the CSI 6500 and accessories.
This manual does not attempt to explain the operation or application of the CSI
6500.
1-1
Note
Normal installation for the Model CSI 6500 Machinery Health
Monitor unit is in an orientation such that the front panels are ver-
tical.
CSI 6500
1-2 Introduction
Read This First
Special Emphasis
These conventions are used throughout this manual to call attention to the adja-
cent text:
Note
A note indicates special comments or instructions.
Caution!
A caution indicates actions that may have a major impact on the
system integrity.
Warning!
The Warning paragraph warns you of actions that could cause
serious injury or death.
1-3
How to Use
There are two intended audiences for this manual: the plant appointed project
manager, and the contractor. As such, it is important that each understand how
to make use of this document.
Warning!
All wiring should be installed by a trained and qualified electri-
cian. Wiring must conform to all applicable local codes and regu-
lations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
Warning!
Power to the CSI 6500 Machinery Health Monitor rack must
include a remote disconnect switch or circuit breaker. The switch
or circuit breaker must be in close proximity to the equipment and
within easy reach of the operator.
1-4 Introduction
Plant Appointed Project Manager
The project manager will be involved in budgeting money for the installation
work, setting schedules, procuring bids from contractors, and supervising the
system install. Therefore, it is important that the project manager understand the
scope of work which is involved with an on-line system installation which can
be properly estimated by reviewing each section of this manual. Furthermore,
this manual is divided into sections:
• Pre-Installation Review
• System Documentation
• Install Instrumentation
• Enclosure Mounting
• Cabling Requirements
• Wire Terminations
• System Hardware Configuration.
These sections follow the natural progression of a system installation which
should make it easier for the project manager to estimate schedules and budgets
for the installation. Another important function of the project manager is to pro-
cure bids from contractors. Each contractor should receive a copy of this manual
and use that as a basis for their scope of work. Apart from the installation
manual, all the contractor should need is a copy of the system proposal and any
supplemental information for special purchases. When reviewing bids from
contractors it is very important that each contractor’s scope of work is based on
this installation manual and all exceptions are noted.
Before the contractor begins work, the project manager will have the important
duty of performing an installation review and creating proper system documen-
tation. The installation review, which may include a “Contractor Kickoff
Meeting” attended by a CSI 6500 online project manager, is intended to educate
everyone involved with the installation on requirements, deadlines, procedures,
etc. The installation review also requires the project manager to perform a final
walk-through of the installation site and determine if the purchased hardware is
adequate and if any additional hardware will be required.
Contractor
The contractor will use this manual for two purposes: preparing a bid for the
system installation, and as a guide during the system installation. When pre-
paring a bid for the system installation, it is imperative that the contractor
reviews all parts of the manual that are specific to the installation and list any
exceptions to the manual within the bid. If the contractor takes no exceptions,
then it will be assumed that the bid covers the scope of work as defined in the
installation manual.
As an installation guide, it is not necessary that the installer be familiar with the
entire manual. The manual is written so a contractor when performing a certain
action, such as installing an AO322LC sensor, can turn to that particular section
and have a complete instruction set without referencing any other part of the
manual. This should make it easier when many people are involved with the
installation, each performing a specific function.
1-6 Introduction
Supplemental Information
This installation and configuration manual covers the standard online system
components. For specific customer installations, there will be non-standard
components purchased with the online system. For each of these components,
an installation guide supplement will be prepared by Emerson and included with
the installation guide. If a purchased component cannot be found in the installa-
tion guide, please contact your CSI 6500 Monitor project manager and request
an installation guide supplement.
1-8 Introduction
Chapter 7 Wire Terminations
Improper wiring is often the cause of system failures. Proper wire terminations
within the online system components is critical for a successful system startup.
This chapter covers routing, tagging, preparing, and terminating cables within
the V707, 727, 745 junction boxes and the CSI 6500.
Pre-Installation Review
Description
The pre-installation review is a short but important phase in a successful online
system implementation. Consisting of a “Contractor Kickoff Meeting,” final
walk-through, and a system component review, it is the responsibility of the
plant assigned project manager with the assistance of the CSI 6500 Monitor
online project manager or online system engineer to ensure this phase of the
system installation is completed successfully. The pre-installation review
accomplishes the following:
• Identify and Educate all parties involved in the online system installation
• Makes sure that all parties fully understands the scope of work
• Sets the system installation schedule
• Confirms that system components fit customer’s application
• Confirms that all necessary system components are on site and available.
• Confirms location of system components is appropriate
It is not uncommon for plants to schedule the “Contractor Kickoff Meeting,”
final walk-through, and system component review all in one day. This is espe-
cially beneficial when the CSI 6500 online project manager is attending the
“Contractor Kickoff Meeting” so that they may assist the plant assigned project
manager during the final walk-through and system component review. For this
reason it is also recommended that the online system has been shipped to the
customer site before installation work begins.
2-1
Contractor Kickoff Meeting
Although referred to as the “Contractor Kickoff Meeting,” this meeting brings
together all parties involved with the online system installation. Typically, this
will involve:
• Plant Assigned Project Manager
• CSI Online Project Manager or CSI Online Systems Engineer
• End User(s)
• Contractor Representative(s)
• Information Systems Representative(s).
The purpose of this meeting is to:
• Assign Responsibilities
• Review Scope of Work For Contractors
• Answer Any Installation Related Questions
• Review Customer Expectations of Installed System
• Tentatively Set Schedules for Installation.
Although many contractors will be educated on the system installation during
the bid process by reviewing the installation manual and the system documen-
tation (see Chapter 3). It is important to confirm that they fully understand the
scope of work by reviewing each part of the installation during this meeting. If
the system documentation has not been submitted to the contractors, this is the
time to do so.
System Documentation
Description
Often an overlooked part of the system installation, proper documentation of a
system installation will not only avoid problems during installation but will also
make system maintenance much more efficient. Unfortunately, many system
installations do not have documentation created until after an installation is
completed. A successful installation requires that proper system documentation
be created before a contractor begins working. Proper documentation includes:
system overview drawings showing the on-line system layout within the plant;
system layout drawings showing sensor and enclosure mounting locations; and
tags for all sensors, cables, and enclosures documented in cable administration
charts. This documentation must be given to a contractor before the installation
begins and preferably as part of the bid package. When an installation is fin-
ished, it is important that the documentation which has been maintained by the
plant assigned project manager is distributed to the proper plant personnel and
readily available for system maintenance and troubleshooting. The CSI 6500
data collection unit and junction/switch box enclosures include see-through
pouches for storing the on-line system documentation.
3-1
System Overview Drawings
The system overview drawings illustrate how system components interconnect.
These drawings are normally prepared by a CSI 6500 Online Business Devel-
opment Manager and included in the online system proposal during the sales
process. If these drawings were not part of the proposal or if the system has
changed significantly from the time the proposal was created, it will be neces-
sary for the plant assigned online systems engineer to create or update the draw-
ings. The following system drawings were taken from an on-line system
proposal.
Note
Each IP address should be linked to the corresponding CSI 6500.
Install Instrumentation
4-1
A0322RA Image & Outline Drawing
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5-
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
4-3
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable
connection during wire pulls.
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers.
4-5
Stud Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Note
Mounting location must provide a case thickness exceeding .4". If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1 . . Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2 . . Using wire brush and plant approved cleaner, clean and degrease surface
area.
3 . . Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
4. . .Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
4-7
Proper (left) & Improper Spot Facing
Note
Mounting Location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
4-9
A911 Mounting Stud Installation (Stud Mounting Only)
1 . . Using plant-approved degreaser, remove any lubricating fluid used
during the tapping process.
2 . . Using plant-approved epoxy, rub a small amount of epoxy onto spot face.
3 . . Using 1/4" allen wrench loosely screw A911 into mounting location.
4 . . Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A911 mounting base is not seated against spot face this is an
indication that the tap was not deep enough.
5 . . If sensor is not to be mounted immediately, it is necessary to cover
exposed quick connect threads to prevent contamination. Industrial tape
is recommended.
Note
If not ready to pull cables, it is recommended that sensors not be
mounted to machine. If it is necessary to mount a sensor, then the
bundled cable must be secured to the machine and protected from
damage.
4-11
Mounting Procedure
4-13
A0322LC, A0322DS
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers
Stud Mounting
Note
Mounting location must provide a flat surface 1/2” in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
4 . . Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
Note
Mounting location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Caution!
Do not terminate or secure cable to machine before mounting
sensor.
A0322RM 4-27
Description
The A0322RM is a general purpose accelerometer with 90-degree MIL-2 pin
connection. These sensors are stud mounted or epoxy mounted to machinery
surfaces and transmit vibration data to the on-line monitoring system. The MIL-
2 pin connection joins the sensor housing at a 90-degree angle to provide a low-
profile installation.
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5-
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable
connection during wire pulls.
A0322RM 4-29
A212 Mounting Pad (Epoxy Mounting Only)
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers.
Note
Mounting location must provide a flat surface 1" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Note
Mounting location must provide a case thickness exceeding .4". If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
A0322RM 4-31
Note
If the spot face is not uniform on all sides this is an indication that
the spot face tool was not perpendicular to mounting surface and
will not allow the sensor to be mounted properly.
4 . . Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
A0322RM 4-33
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
A0322RM 4-35
Sensor Mounting
1 . . If necessary, clean A0322RM Quick-Connect threads using plant
approved degreaser/cleaner.
2 . . Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
3 . . Place sensor onto mounting base and hold in desired position to create the
least amount of cable strain and cable exposure. Holding sensor, hand-
tighten 7/8" captive nut and use a torque wrench with 7/8" open end to
finish tightening to 50-60 in-lbs.
4 . . If not ready to pull cables, cover exposed sensor connector threads with
supplied connector cover.
Description
The V425 Passive Magnetic Pickup is an industrial sensor used to measure the
rotational speed of machinery. The sensor is commonly used to sense an actu-
ator (target) on a rotating shaft giving a once per revolution trigger.
Handling
The V425 is unique in that it is the only piece of system instrumentation which
is installed near moving machinery (a rotating shaft typically). Therefore, it is
important to observe clearances between the sensor and the target as well as
observe cable clearances.
Caution!
The V425 can be damaged if proper clearance is not maintained
between sensor and actuator. It is important to follow installation
procedures to set proper clearance.
V425 4-37
Required Tools & Parts
Actuator Dimensions
The V425 is designed to be used with a key meeting the following minimum
specifications:
V425 4-39
If the chosen actuator has a dimension (A) which must be greater than .5 inches
it is necessary to round the edges of the actuator to allow sensor to be as close
as possible to actuator.
Actuator Material
The actuator must be made of a metallic material with a high permeability. Ideal
actuators are soft iron, cold-rolled steel and #400 stainless steel.
V425 Mounting
V425 4-41
Mounting Sensor
1 . . Screw locking nut onto sensor and thread completely onto sensor.
2 . . Screw sensor into mounting bracket until sensor pole piece contacts
actuator.
3 . . Back sensor off 1 full turn and holding sensor in place thread locking nut
against mounting bracket. Torque to 15 ft.-lbs.
4 . . Slowly turn shaft and confirm that actuator is not contacting sensor. If
sensor is contacting shaft then repeat step (3) after loosening up lock nut.
5 . . Run machinery at full speed and confirm that sensor is not contacting
actuator. Let machine reach normal operating temperature and run
through all operational speeds.
6 . . Observe machinery during coastdown and confirm that sensor is not
contacting actuator.
7 . . Cover exposed connector threads with included protective cap to prevent
contamination.
Enclosure Mounting
Description
The junction boxes are NEMA 4X rated enclosures used to terminate the online
instrumentation wiring. The junction boxes consist of a 12- channel version in
a fiberglass or stainless steel enclosure. Box consist of individual 3 lug terminal
blocks mounted on a DIN rail.
The V745 junction/switch box serves the dual purpose of providing a junction
between the instrumentation and the CSI 6500 online system as well as allowing
portable data collectors local data access. The V745 is a 6 or 12 channel box
(fiberglass or stainless steel) with 3 terminal phoenix connections for both the
inputs and outputs.
5-1
Junction box outline drawing
5-3
Required Tools & Parts
Mounting Feet
5-5
Mount the CSI 6500 Rack Chassis
Description
The CSI 6500 rack chassis is either mounted on 19" rack mounting rails in a cab-
inet enclosure (with rear termination panels) or in a stainless steel housing (with
a front termination panel) to protect it from harsh industrial environments.
Note
All CSI 6500 enclosures must be grounded to earth. It is acceptable
to ground enclosure through conduit or mounting structure if
grounded to earth. Otherwise, a bonding wire must be used to con-
nect enclosure to earth ground.
The CSI 6500 chassis has two oblong holes for attaching to the mounting rails
at the left and right sides respectively.
When mounting CSI 6500 units above each other in one cabinet, a cooling fan
rack should be placed between each CSI 6500 unit. This will help maintain the
specified environmental operating conditions for all components. The necessary
requirements for cooling fans depends on the environmental conditions of the
cabinet.
To install a module, line up the guide rails and push the module into the slot until
fully seated, then tighten the mounting screws.
To remove a 3U high module, loosen the mounting screws, then simply pull
from the slot by the handle.
To remove a 6U high module, loosen the mounting screws, push outward on the
handles as shown to eject the module from the backplane connectors, then pull
from the slot by the handle.
Cabling Requirements
Introduction
This chapter covers conduit installation guidelines, network cabling guidelines,
power line specifications, and pulling the online instrumentation cabling as well
as the multipair bundled cable from junction boxes to the CSI 6500.
Warning!
All wiring should be installed by a trained and qualified electri-
cian. Wiring must conform to all applicable local codes and regu-
lations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
6-1
Junction box/CSI 6500 Cable Recommendations
Table 1: Cable pulled in Steel Conduit
9734 V727/ V745 12 pair, 24 AWG, Individual foil shield, PVC jacket
8168 V707 8-pair, 24 AWG, Individual foil shield, PVC jacket, Overall
Braid Shield
8175 V727/V745 15-pair, 24 AWG, Individual foil shield, PVC jacket, Overall
Braid Shield
Note
For cables with overall braided shield, the shield should be
grounded to the CSI 6500 enclosure.
Note
All conduit must be bonded to earth ground and adhere to IEEE
1100 specifications for grounding.
6-3
5 . . Conduit must enter the CSI 6500 enclosure and junction boxes from
bottom of enclosures.
Instrumentation Cables
Installation
Caution!
If pulling in conduit cable pull force should not exceed 25 lbs.
Excessive force will deform twisted pair and degrade performance
of cable.
Note
Wire labels must be placed on each end of cable and have the same
designation. Wire label designations must be documented on
“SENSOR LOCATION CARD” chart included on inside of junc-
tion/switch boxes.
Caution!
Cables must be secured to plant infrastructure in such a manner
that no safety hazards are created from plant personnel tripping on
or catching slack cable on clothing or tool belt, etc.
1. . .If using the A612-I-30 cable, apply a thin coating of dielectric grease to
connector and screw into sensor housing using hand force only.
2. . .Label cable on both ends using plant approved wire labels. Wire label
designation must be the same on both ends of cable.
3. . .Choose a physical path for the sensor cable pull using the following
guidelines:
a) Remain 12" from 110VAC, 2’ from 220VAC and 440VAC power
lines.
Description
The V680 bundled cable is a nine-pair twisted-pair instrumentation grade cable
with individual foil shielding on each pair. The twisted-pair is 24 gauge and
individually color-coded. The V680 is used to extend the on-line instrumenta-
tion wiring from the V707 and V745 junction boxes to the CSI 6500 enclosure.
V680
Installation
1. . .Starting at junction box, pull cable through conduit run. At the CSI 6500
enclosure, blunt cut cable, leaving enough cable inside the enclosure for
routing to terminal connectors.
2. . .Label wire according to project specifications and place label within 6
inches of cable access plate with label facing toward front of enclosure.
3. . .Blunt cut cable at junction box leaving 2 feet inside box for routing.
Pull V680 Bundled Cable from Junction Box to CSI 6500 6-9
Guidelines for Dedicated CSI 6500 Network Segment
Description
The CSI 6500 Processor module communicates with a database server via a
100BaseT connection adhering to the IEEE 802.3 Ethernet protocol. It is recom-
mended that customers run a dedicated physical network segment between the
database server and the CSI 6500. Although it is ultimately the responsibility of
the plant to install and maintain the network, the following guidelines are rec-
ommended:
1 . . Handling & Care Guidelines per EIA/TIA 568/569.
Note
Although EIA/TIA 568/569 only requires CAT5 cabling, it is rec-
ommended that customers run at least CAT5e to be compatible
with future upgrades.
Note
Network Cabling to the CSI 6500 should be in steel conduit.
Description
The CSI 6500 Data Collection Unit is a laboratory grade instrument measuring
millivolt level instrument signals. Therefore, the quality of the power provided
to the CSI 6500 is very important. Although the CSI 6500 contains input protec-
tion and some degree of line conditioning, it is important for the plant to follow
specific guidelines when running power to the CSI 6500 enclosure.
Note
Contractors should adhere to the IEEE 1100 specification for pow-
ering and grounding electronic equipment.
Scope
This section will present some recommended practices to follow when speci-
fying and installing 6500 systems and their related sensor and ground wiring.
Installation Considerations
Signal Quality
The data collected by the CSI 6500 system can only be as good as the signals
presented at the CSI 6500 inputs. The 6500 system is capable of resolving
microvolt level dynamic signal components. Typically, signals from sensors
such as accelerometers mounted on operating machinery are millivolt level sig-
nals. Signals of this low magnitude can easily be overwhelmed by interference
from any number of sources in an industrial environment.
Shielding
The shield termination of each shielded twisted pair cable must be connected as
required by the particular installation. The normal installation is to tie the shield
drain wire only at the 6500 input. However, if the sensor cable shield is
grounded at the sensor side, the cable shield should not be connected at the CSI
6500 input side. The shield connection at the CSI 6500 inputs is connected
directly to the CSI 6500 chassis ground. Therefore, if a grounded shield connec-
tion has also been made at the sensor side, a noise current, typically at line fre-
quency, can flow in the shield conductor. This noise current flow will induce a
noise voltage into the sensor signal lines. This condition is referred to as a
“ground loop”.
Cable Terminations
Cables should be terminated neatly at the CSI 6500 system inputs. The outer
cable coverings should not be stripped back farther than necessary, and the
exposed cable shields should not be allowed to touch from cable to cable. The
shields should be cut back as little as possible so that the minimum of unshielded
signal conductors are exposed.
Cables should be clearly marked at the CSI 6500 inputs with labels indicating
the sensor location.
Note
Unused shield drain wires should not be cut. Unused shield drain
wires should be folded back and taped to allow their use if it should
prove necessary to make a double shield tie to reduce RF or static
interference.
Overall shields in multiple conductor cables must be tied to earth ground at one
end. Unused overall shield drain wires should be folded back and taped to allow
their use if it should prove necessary to make a double shield tie to reduce RF
or static interference.
Junction Boxes
In most installations, sensor cables are routed through junction boxes. In this
case, the cable “+”, ”-“, and shield connections must be maintained from input
to output. Shield connections must not be allowed to touch from cable to cable,
and shields must not be connected to the local junction box earth ground.
System Grounding
For personnel safety and correct system operation, the CSI 6500 system must be
grounded properly. If possible, the CSI 6500 enclosure should be bolted to a
grounded beam or wall. A ground bonding wire must also be connected from the
CSI 6500 enclosure to a nearby earth ground. Use a minimum 14 AWG stranded
cable for grounding.
Inside the CSI 6500 enclosure, verify grounding wires from the CSI 6500
chassis, the CSI power supply, the enclosure frame, the enclosure door, and the
AC power cable ground and have been installed. These should be connected to
the main enclosure earth ground.
Note
The use of a hard drive on the CSI 6500 Transient Daughterboard
places strict temperature limits on the CSI 6500 system. The CSI
6500 Fan Tray (PN B6500FT) must be used in CSI 6500 systems
equipped with Transient Ambient temperature must be limited to
30C. or 86F.
Wire Terminations
Description
The V707 and V745 series junction boxes will have single twisted pair instru-
mentation wire pulled through cable grips on the left side of box and one or more
V680 bundled 9 twisted pair cable pulled through a 1.5" conduit fitting on the
right side of the box. The cables will be routed through the box leaving a service
loop and terminated to 3-lug terminal blocks on the V701 series or industry stan-
dard Phoenix connectors on the V745.
7-1
Required Tools & Parts
• wire labels
• 24 AWG wire strippers
• cable tie down
Caution!
Use correct gauge strippers on individual conductors. Do not strip
more than a 1/4” off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
Note
Shield connections pass through junction boxes and are not
grounded at the box!
1. . .Starting at cord grip pull wire to top of box on left side. Pull service loop
as shown in diagram.
2. . .Strip 1" of polyurethane jacket from cable.
3. . .Carefully pull twisted pair conductors out of braided shield. Do not
remove braided shield.
4. . .Strip 1/4” from each conductor and twist braided shield at end.
5. . .Terminate the wire into the proper terminal block as follows:
a) Connect white wire (sensor positive input) to upper level of the ter-
minal block.
b) Connect black wire (sensor negative input) to middle level of the ter-
minal block.
c) Connect braided shield to lower level of the terminal block.
7-3
Terminal Connections
Caution!
Use 24 AWG gauge strippers on individual conductors. Do not
strip more than a 1/4” off conductor. Do not overtighten connector.
Turn terminal screw clockwise until contact with wire is made then
1/4 turn additional.
1. . .Starting at cord grip, strip cable jacket and braided shield off cable.
2. . .Use the following pair sequence from top to bottom beginning at first
terminal block:
Negative
Terminal Block Positive Conductor Foil Shield
Conductor
7-5
Note
For 16 channel box, start sequence over on terminal block #9.
3 . . Pull individual twisted pair (with foil shield in place) to top of box on
right side. Pull service loop as shown in diagram.
4 . . Pull to terminal block and blunt cut any extra wire.
5 . . Remove 1" of foil shield from twisted pair and seal foil shield using heat
shrink or electrical tape.
6 . . Strip 1/4” from each conductor and terminate to terminal block as
follows:
a) Positive Conductor on upper level of terminal block
b) Negative Conductor on middle level of terminal block
c) Shield Drain on lower level of terminal block.
Description
The CSI 6500 is designed to have sensor cables terminate in three different
ways.
1...Sensors can be terminated directly into the CSI 6510 (12-2-2) modules at a
rear A6500-M-RTRM termination panel.
2...Sensors can be terminated at the inputs on the A6500-P-RTRM termination
panel and then buffered outputs can be routed to the CSI 6510 (12-2-2)
modules with DIP switches.
3. . .Sensors can be terminated directly into the CSI 6510 (12-2-2) modules at
a front A6500-M-FTRM termination panel.
Backplane:
8. . .SysFail relay connector
9. . .DC Power input connector for Prediction Side
10. .HUB network connector
11. .NIC network connector
12. .Chassis Ground lug.
13. .Power On LED
14. .+24V Input LED
15. .Status LED
Note
For the Tach and Relay channels the DIP switches must be left in
the OFF position.
Caution!
Use 24 AWG gauge strippers on individual conductors. Do not
strip more than a 1/4" (0.64 centimeters) off conductor. Do not
overtighten connector. Turn terminal screw clockwise until contact
with wire is made then1/4 turn additional.
Each signal input channel has an associated DIP switch for connecting acceler-
ometer power. (See callout number 5 in photo on page 8.) For accelerometer
channels that require power, set the associated DIP switch to the right (ON posi-
tion). For sensor channels that do not require power from the CSI 6500, set the
associated DIP switch to the left (OFF position).
Note
These functions are duplicated on the front termination panel.
Each channel has 5 terminals. The first two are for the + and - signal inputs. If
the associated DIP switch is set to ON, these terminals will also supply +24V
constant current accelerometer power.
The second two are for the -24V power supply for eddy current probes. These
terminals only supply power if an external -24V power supply is connected to
the J19 power input terminal at the edge of the termination panel.
The last terminal for each channel is a chassis ground for connecting the sensor
cable shield.
DIP switches
Set these switches to the right (ON position) to connect to the respective A6500-
P-RTRM buffered outputs.
Sensor inputs 1-12 on the A6500-M-RTRM panel are connected to buffered out-
puts from monitor positions 1-6 on the A6500-P-RTRM panel (connectors
XR11-XR64).
Caution!
Use correct gauge strippers on individual conductors. Do not strip
more than a 1/4” off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
1. . Pull cable to the I/O Relay channel inputs on the termination panel.
2. . Blunt cut excess wire. Strip 1" from cable jacket and 1/4” from each
conductor.
3. . Terminate as follows, referring to the previous Terminal Panel Pin-Out
table:
a. Relay Excitation Voltage... (SIG +)
b. Voltage Return... (SIG -)
c. Shield Drain... (Shield)
4. . Relabel wire at connector.
5. . After all wires are pulled, bundle wires with Velcro cable wrap. Secure
bundle to side of enclosure.
Note
Load may be placed on either -L2 or +L1.
Caution!
The CSI 6500 +24V power terminals are not wired the same as the
CSI 4500 power terminals. Do not use a connector that was previ-
ously wired for a CSI 4500 without reconfiguring the wiring.
Caution!
The +24V power input for the CSI 6560/6510 requires a +24V
power supply. Do not connect the -24V power supply intended for
Eddy Current Probe power to this input. Verify all power supply
connections are wired and connected properly before powering the
unit.
The +24V power input for the CSI 6560/6510 Prediction modules is located on
the A6500-M-BP backplane (as well as on the A6500-M-FTRM front termina-
tion panel). This connector is isolated from the CSI 6000 Protection modules,
which are powered separately. The use of a separate power supply is recom-
mended for the CSI 6000 Protection modules.
Note
Use of an Uninterruptable Power Supply (UPS) is recommended
for both Prediction and Protection modules.
Power
Caution!
The -24V Eddy Current Probe power input requires a -24V power
supply. Do not connect the +24V power supply intended for the
CSI 6560/6510 power to this input. Verify all power supply connec-
tions are wired and connected properly before powering the unit.
The -24V Eddy Current Probe power input connector is located on the A6500-
M-RTRM rear termination panel, and also on the A6500-M-FTRM front termi-
nation panel.
Note
The CSI 6500 performs an internal test to verify that -24V power
is connected. If a -24V supply is not connected, the “CPU Status”
LEDs on the CPU, and the “Status” LED on the left side of the ter-
mination panel will turn from green to red. If eddy current sensor
power is not required, this internal test can be disabled by installing
a jumper on the termination panel at the pins labeled “-24V Dis-
able”.
Caution!
The SysFail Relay connection is an output for relays only. Do not
connect the +24V power supply intended for the CSI 6560/6510
power or the -24V power supply intended for the Eddy Current
Probe power to this output. Verify all power supply connections are
wired and connected properly before powering the unit.
Note
CSI 6500 MUX (SIG) channels do not provide “loop power” to 4-
20mA devices. A separate source / module is required to provide
loop power.
Note
Eight-position jack pinout should conform to plant standards for
10/100Base-T connections.
Note
The NIC connector is used when connecting to an ethernet hub or
switch. The HUB connector is used when connecting directly to a
PC (i.e. the HUB connector provides the same function as a cross-
over cable).
Note
The network arrangement shown above assumes one of the CSI
6500s is a transient model (CSI 6500T).
Introduction
Description
The CSI 6560 processor module (in combination with the CSI 6510 signal input
module) is a multi-channel, multi-tasking, multi-processor data acquisition
system primarily intended for monitoring heavy industrial rotating machinery.
Typical signal inputs are dynamic AC machine vibration signatures from accel-
erometers, velocity probes, or proximity probes. These signals include two com-
ponents: the dynamic AC component, which represents machine vibration, and
a DC component, which represents the sensor bias level. In the case of a prox-
imity probe, the DC component represents the gap, or average distance between
the probe tip and the machine shaft. Other signal inputs include process signals;
these are DC parameters such as temperature or pressure.
Tachometer inputs are used to determine machine speed. These tachometer sig-
nals are typically generated from a proximity probe or passive magnetic sensor
positioned at a machine shaft keyway or gear, producing a pulse train (not nec-
essarily 1x machine speed) representing the machine phase and running speed.
A final class of inputs are digital inputs which represent machine states, such as
running, off, starting, etc. These inputs are used to control or modify the data
acquisition state. Common state control inputs are relay closures or machine
RPM. AC or DC signal levels can also be used for state control.
Monitoring Methods
The CSI 6560 uses three basic data monitoring methods.
8-1
Overall Level Monitoring
Overall Level Monitoring is defined as (1) the acquisition of the overall level of
the dynamic AC vibration signal, typically the RMS value of the signal, and/or
(2) the DC sensor bias level, or (3) measurement of a DC process signal. Note
that all these signal inputs are DC values (The RMS value is a DC value propor-
tional to the overall energy content of the AC signal). The Overall Level inputs
are multiplexed into a fast successive approximation ADC controlled by the CSI
6500 Processor module. Overall Level Monitoring is a continuous process, with
all input channels AC+DC measured twice every second. When the Transient
option is included, true waveform Peak-to-Peak may be included in Overall
Level Monitoring.
Spectral Scan
Spectral Scan is defined as the acquisition and analysis of dynamic AC signals
only. The signals are acquired, two channels at a time (referred to as CHX and
CHY), with a dual channel delta-sigma ADC controlled by the system DSP. The
DSP performs analysis of the acquired time waveforms and transmits the results
to the CPU host processor. Prep rog rammed groups of Spectral Scan measure-
ment parameters (AP Sets) may be assigned to specific machine state conditions
to tailor data acquisition to specific machine operational states.
Signal Quality
The data collected by the CSI 6560 system can only be as good as the signals
presented at the CSI 6510 inputs. Typically, signals from sensors such as accel-
erometers are of millivolt levels. Signals of this magnitude can easily be over-
whelmed by interference from any number of sources in an industrial
environment.
Note
Distances are reduced if non-standard cable is used.
Junction Boxes
In many installations, sensor cables are connected via junction boxes. In this
case, the cable “+,” “-,” and shield connections must be maintained from input
to output. Shield connections of different cables must not be allowed to touch,
and shields must not be connected to the local junction box ground.
Cables should be terminated in the junction boxes following the recommenda-
tions of the previous section.
System Grounding
For personnel safety and correct system operation, the CSI 6500 system must be
grounded properly.
Inside the CSI 6500 cabinet enclosure, verify grounding wires have been con-
nected from the CSI 6500 chassis to the enclosure ground. Also verify the enclo-
sure doors and side panels are grounded to the enclosure frame. Use a minimum
14 AWG stranded cable for grounding.
Outside, the CSI 6500 cabinet enclosure should be connected to a nearby earth
ground.
Note
Temperatures inside the CSI 6500 enclosures can exceed 140F
when ambient temperatures reach 120F. While the CSI 6500
system has been tested to operate reliably in temperatures this
high, it should be realized that the CSI 6500 electronics would age
at much higher rates than electronics maintained below 100F. It is
therefore recommended that active cooling be employed to keep
the CSI 6500 system electronics below 100F at all times for max-
imum system reliability and longevity.
Environmental
Environmental
Note
The SysFail relay may not be used for other, e.g., vibration moni-
toring, purposes.
The CSI 6560 Processor module may be configured to download its operational
firmware via Ethernet upon every boot, or operate on firmware which has been
stored in FLASH memory.
Caution!
The NIC / HUB connections should not be used to create a daisy
chain connection, as this creates a single point of communication
failure for multiple CSI 6500 units.
Note
AC-relays are not provided.
Note
Emerson provides an industrial rated HDD, capable of 100% duty
cycle. Emerson recommends that an equivalent HDD be utilized.
Connecting
Using a standard serial cable make a connection from the serial port on your PC
to the serial port on the CSI 6560 Processor front panel.
Configure Hyperterminal on your PC to use the serial port (typically COM 1)
with the following settings:
9600 baud
8 data bits
stop bit
no parity
no flow control
Turn power on to the CSI 6500. From here, you can watch the boot process. You
may interrupt boot by pressing the “Space” bar after the VxWorks copyright is
displayed as shown below. By the time “Press any key to stop auto-boot…” is
displayed, most of the time allotted for pressing a key has passed. Interrupting
the boot process will allow the configuration of boot specific parameters.
VxWorks System Boot
Copyright 1984-2002 Wind River Systems, Inc.
If allowed to complete without interruption, the boot process should finish with
a screen similar to this:
/browser/ - Volume is OK
Base Modbus register table size (excluding DCS info): 0xcf8a (53130)
This unit will begin announcing it's availability in 84 seconds
Navigation
The following list is printed to the screen by interrupting boot and typing "?" or
help.
? - print this list
@ - boot (load and go)
p - print boot params
c - change boot params
l - load boot file
g adrs - go to adrs
d adrs[,n] - display memory
Changing configuration
Once the boot process has been interrupted, you should get the prompt
[VxWorks Boot] : At this prompt, type “c” and press enter to configure the unit.
Each parameter in the configuration will be brought up and you can type a new
value and press enter to replace the old value, press enter to accept the old value,
type “.” and press enter to clear the value or type “-” and press enter to go back
to the previous parameter.
Transient Configuration
boot device : shend0
processor number : 0
host name :
file name : bin/6500t
inet on ethernet (e) : 192.168.0.11ffffff00
inet on backplane (b) :
host inet (h) : 192.168.0.1
gateway inet (g) :
user (u) : anonymous
ftp password (pw) (blank = use rsh) : anonymous
flags (f) : 0x1409
target name (tn) :
startup script (s) :
other (o) : (IP Address of WINS server, if configured)
CPU Status
The CPU Status LED indicates the status of the Main Processor board. The four
(4) status conditions are listed below along with their assigned priorities.
Note
It is possible for more than one status condition to be active at one
time. When this happens, the LED will indicate the active status
condition with the highest priority. For example if the module is
both “Uncalibrated” (3) and is also currently “Performing POST”
(1), the LED would indicate “Performing POST.” Additionally, if
the module is both “Uncalibrated” (3) and in “Failure” (2) then the
LED will indicate the “Failure.”
Transient Status
The Transient Status LED indicates the status of the Transient Daughter Board.
The LED is always off when a Transient board is not installed in the system.
System Status
The System Status LED indicates the status of the overall system. It reflects the
worst case state of all boards in the system. For example, if the Test Function
generator on the Main Processor board is uncalibrated, and the first MSIG
module has a power fault, then the LED will show a solid red color to indicate
the worst case of these two which is a “Failure” state.
When all the firmware components are operating as expected, this LED overlays
a “heartbeat” pulse pattern on top of the system status. The heartbeat pattern
occurs in a 4 count cycle. The LED is pulsed off briefly during each of the first
and second counts, and then left on during the 3rd and 4th counts. In practice it
gives the appearance of a human heartbeat. If the heartbeat stops, it indicates a
firmware fault has occurred. Many times the system is capable of recovering
from a missed heartbeat. However, if the system cannot recover quickly it will
automatically reboot itself to clear up the fault and then it will resume moni-
toring.
Modbus Connect
The Modbus Connect LED indicates when a Modbus client, Web Browser, or
Transient Live client are connected. A green color indicates that at least one of
these types of clients has established a connection. If the LED is OFF it indicates
that none of these types of clients are connected. There is no indication of client
data transfer, only the presence of at least one established connection. The red
color is not used with this LED.
HD Active
The HD Active LED indicates when the onboard Transient Hard Drive is being
accessed with read/write activity. The green LED blinks on each time a read or
write activity accesses the Transient hard drive. The more time the LED is
green, the more hard drive activity. This LED is always off if there is no Tran-
sient board installed in the system.
Status LED
The Status LED indicates the overall status of the CSI 6510 module. The four
(4) CSI 6510 module status conditions are listed below along with their assigned
priorities.
Note
It is possible for more than one status condition to be active at one
time. When this happens, the LED will indicate the active status
condition with the highest priority.
If the Status LED is off entirely, it indicates that the CSI 6510 module is being
ignored by the Processor module. This is a special case which should not be
encountered in practice. Modules are only ignored if the addition of the module
would exceed the maximum channel count limits that the Processor module can
support (32 analog, 16 Tach, 16 I/O) as channels are counted starting in the left
most slot and working toward the right.
Note
Some DC Process inputs could provide Pk, Pk-Pk, or other Mea-
surement Units
DC V / E.U. no no DC E.U.
AC V / E.U. no yes RMS E.U.
ACCEL V / 32.2 ft/sec no yes RMS g’s
V / 32.2 ft/sec yes yes RMS in/s
Note
RMS, PK, PK-PK Measurement Units are valid and can be freely
converted.
AC V / E.U. no no no E.U.
ACCEL V / 32.2 ft/sec no no no g’s
V / 32.2 ft/sec no single no in/s
V / 32.2 ft/sec no double no mils
V / 32.2 ft/sec yes no no i/s
V / 32.2 ft/sec yes single no mils
V / 32.2 ft/sec yes no single g’s
V / mm/s no no no mm/s
V / mm/s no single no microns
V / mm/s yes no no microns
V / mm/s no no single g’s
V / mm/s yes no single mm/s
DISP V / mil no no no mil’s
V / mil no no single i/s
V / mil no no double g’s
V / micron no no no micron’s
V / micron no no single mm/s
V / micron no no double g’s
Note
Measurement Unit Type is specific to Analysis Type. No Software
Integration or Differentiation can be performed.
AC V / E.U. no E.U.
ACCEL V / 32.2 ft/sec no g’s
V / 32.2 ft/sec yes in/s
V / mm/s no mm/s
V / mm/s yes microns
V / micron no micron’s
Offset Adjustment
For thrust probes, the CSI 6510 input channel is defined as a DC Process input.
To set the DC offset so that the thrust reading may be zeroed, use a DC voltmeter
(or the DHM program) to measure the DC voltage as seen directly on the CSI
6510 inputs. Enter this value into the offset field in the sensor set up page in
OCONFIG.
It is important to note, from Table 3, that the TSG circuit provides an output
signal, which is used to create all of the other calibration tables. The TSG circuit
has its own calibration table, stored in the CPU board. If a CPU board is
replaced, then the other calibrations need to be rerun for that CSI 6560, since
their (original) calibration tables used the TSG signal from the original CPU
board.
Calibration tables may be copied from each CSI 6560 onto an online server, and
those can be downloaded into the same CSI 6560. Emerson Online Product Sup-
port personnel, and Online Systems Engineers, can assist customers with this
type of operation.
Should it be desirable or necessary to recalibrate an installed system, it is rec-
ommended that this be accomplished with the support of the local Emerson
Online Product Support office, and that it be scheduled during an equipment
outage. Calibrations can be accomplished in less than an hour (per CSI 6500),
but during that time, the units cannot be monitoring rotating equipment.
DSP Calibration
Digital Signal Processing (DSP) calibration
• uses a CPU board’s TSG output signal
• does not require that any wire harnesses be disconnected
• is completed in about 30-40 minutes (per CSI 6500)
• does not require any special cables or test equipment
• uses a special calibration utility program (DHM).
Transient Calibration
The CSI 6500T includes two processing boards; a Main Processor board and a
Transient board. Both boards include separate Digital Signal Processors. The
DSP on the Transient board uses an internal calibration table, in much the same
way that the Main Processor DSP circuit does. However it is calibrated sepa-
rately, it is not calibrated as part of a DSP calibration for a Main Processor.
Transient calibration
• uses a Processor Module’s TSG output signal
• does not require that any wire harnesses be disconnected
• is completed in about 30-40 minutes (per CSI 6500T)
I-1
CSI 6500 Discrete Input/Outputs 5-10 F
CSI 6500 Enclosure 6-9 Final Walk-Through 2-3
CSI 6500 enclosure and junction boxes 6-4 Foil Shield 7-5
CSI 6500 Ethernet Connection 5-9
CSI 6500 Power 5-9 G
CSI 6500 Transient Daughterboard 8-22
General Wiring Notes 8-29
Replacing the Hard Drive 8-25
CSI 6500 Transient Daughterboard
Specifications 8-23 H
CSI 6500 Transient Filter Board 8-27 Handling Instructions 4-3, 4-15, 4-28
CSI 6500 Wiring 7-7
CSI 6510 Signal Input module 8-14 I
CSI 6510 Tachometer Input Module Installation 6-7
Specifications 8-20
CSI 6560 Processor module 8-9
J
CSI 6560 Processor Module Specifications
Jbox 6-2
8-11
M
D
Monitoring Methods
Data Types
Overall Level Monitoring 8-2
Analysis Type
Overall Level 8-44
Spectral Scan 8-2
Spectral 8-45 Transient Data Capture 8-2
Time Waveform 8-47 Mount the IMR 6500xx Rack 5-6
CSI 4500 System Calibration 8-49 Mounting Bracket & Locking Nut 4-38
Non Vibration Unit Analysis Types 8-48 Mounting Sensor 4-42
Offset Adjustment 8-48 Mounting Sensor Bracket 4-41
Overall Level Parameters 8-44 Multi-pair Bundled Cable Pulls 5-9
Spectral Scan Parameters 8-44
Dedicated CSI 6500 Network Segment 6-10 N
Description 4-3, 4-15, 4-28 Negative Conductor 7-5
dielectric grease 6-7
Documentation Storage 3-9
P
PGME07 cord grip 6-8
E Positive Conductor 7-5
EIA/TIA 568/569 6-10 Power Circuit Guidelines 6-11
Epoxy Mounting 4-9, 4-22, 4-34 Prediction Side -- AC Power Specifications
6-11
I-2
Prediction Side -- DC Power Specifications V
6-11 V425 4-37
Prepare the CSI 4500 Cable Access Plate 5-9 V425 Passive Magnetic Pickup 4-37
Project Manager 1-5 V680 Bundled Cable 7-5
Pull Instrumentation Wiring 6-5 V701 and V745 series junction 7-1
V745 junction/switch box 5-1
R
Required Tools & Parts 4-4 W
wire labels 6-7, 6-9, 7-2
S
SENSOR LOCATION CARD 6-7
Sensor Mounting 4-11, 4-36
Signal Quality 8-4
Cable Terminations 8-6
Ethernet Cable Routing 8-5
Grounding and Shielding 8-5
Junction Boxes 8-6
Sensor Cable Routing 8-4
Sensor Cable Type 8-4
System Grounding 8-6
Special 1-3
Spot Face & End Mill Tool 4-29
Spot Face and End Mill Tool 4-4, 4-16
Stud Mounting 4-6, 4-18, 4-31
Surface Preparation 4-5, 4-18, 4-30
System Component Review 2-4
System Overview Drawings
Additonal Information to Keep 3-4
Machine Level Diagram
3-3
Overall System Diagram
3-3
T
terminal block 7-3
7-5
Terminate Network Connection 7-25
Torque Wrench 4-5, 4-18, 4-30
I-3
I-4