6479A1 3500-72 rodrop

Part number 146479-01 Revision A, April 2004

3500/72M Recip Rod Position Monitor

Operation and Maintenance Manual

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Copyright © 2001 - 2004 Bently Nevada, LLC

All Rights Reserved. The information contained in this document is subject to change without notice. The following are trademarks of Bently Nevada, LLC in the United States and other countries:

ACM™, Actionable Information®, Actionable Information to the Right People at the Right Time®, ADRE, Asset Condition Management™, Asset Condition Monitoring™, Bently ALIGN™, Bently BALANCE®, Bently DOCUVIEW™, Bently LUBE™, Bently PERFORMANCE™, Bently Nevada, CableLoc™, ClickLoc™, Data Manager, Decision SupportSM, DemoNet™, Dynamic Data Manager, Engineer Assist™, FieldMonitor™, flexiTIM™, FluidLoc, Helping You Protect and Manage All Your Machinery, HydroScan, HydroView™, Key ∅, Keyphasor, Machine Condition Manager™ 2000, MachineLibrary™, Machine Manager™, MicroPROX, Move Data, Not People, Move Information, Not Data™, NSv™, Prime Spike™, PROXPAC, Proximitor, REBAM, RuleDesk™, SE™, Seismoprobe, Smart Monitor, Snapshot™, System 1™, System Extender™, TDXnet™, TDIXconnX™, TipLoc™, TorXimitor, Transient Data Manager, Trendmaster, TrimLoc™, Velomitor. Bently Nevada’s orbit logo and other logos associated with the trademarks in bold above, are also all trademarks or registered trademarks of Bently Nevada in the United States and other countries

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

Mailing Address 1631 Bently Parkway South Minden, NV 89423 USA

Telephone 1 775 782 3611 1 800 227 5514

Fax 1 775 215 2876 Internet www.bently.com

ii

http://www.bently.com/

Additional Information

Notice: This manual does not contain all the information required to operate and maintain the 3500/72M Recip Rod Position Monitor module. Refer to the Following manuals for other require information. 3500 Monitoring System Rack Installation and Maintenance Manual (129766-01) • general description of a standard system • general description of a Triple Modular redundant (TMR) system • instructions for installing the removing the module from a 3500 rack • drawings for all cables used in the 3500 Monitoring System 3500 Monitoring System Rack Configuration and Utilities Guide ( 129777-01) • guidelines for using the 3500 Rack Configuration software for setting the operating

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

the module are operating properly 3500 Monitoring system Computer Hardware and Software Manual (128158-01) • instructions for connecting the rack to 3500 host computer • procedures for verifying communication • procedures for installing software • guidelines for using Data Acquisition / DDE Server and Operator Display Software • procedures and diagrams for setting up network and remote communications 3500 Field Wiring Diagram Package (130432-01) • diagrams that show how to hook up a particular transducer • lists of recommended wiring

iii


Contents

1. Receiving and Handling .............................................................. 1 1.1 Receiving Inspection........................................................................................... 1 1.2 Handling and Storing Considerations ................................................................. 1 1.3 Disposal Statement............................................................................................. 1

2. General Information..................................................................... 3 2.1 Triple Modular Redundant Description ............................................................... 5 2.2 Available Data..................................................................................................... 5

2.2.1 Statuses .............................................................................................. 5 2.2.2 Proportional Values ............................................................................. 8

2.3 LED Descriptions ................................................................................................ 9

3. Configuration Information......................................................... 11 3.1 Software Configuration Options........................................................................ 11

3.1.1 Recip Rod Position Monitor Configuration Options ........................... 12 3.1.2 Rod Position Single Channel Configuration ...................................... 15 3.1.3 Rod Position Pair Channel Configuration.......................................... 23 3.1.4 Rod Drop Channel Configuration ...................................................... 31 3.1.5 Hyper Channel Configuration ............................................................ 38 3.1.6 Rod Position Transducer Calibration................................................. 44

3.2 Setpoints........................................................................................................... 48 3.3 Software Switches ............................................................................................ 52

4. I/O Module Descriptions ............................................................ 55 4.1 Setting the I/O Jumper...................................................................................... 55 4.2 Prox/Velom I/O Module (Internal Termination) ................................................. 57

4.2.1 Wiring Euro Style Connectors ........................................................... 58 4.3 Barrier Proximitor Internal I/O Module (Internal Termination) ........................... 59 4.4 Prox/Velom I/O Module (External Termination) ................................................ 60

4.4.1 External Termination Blocks.............................................................. 61 4.4.2 Cable Pin Outs .................................................................................. 65

5. Maintenance ............................................................................... 67 5.1 Verifying a 3500 Rack – Recip Rod Position Monitor Module .......................... 67

5.1.1 Choosing a Maintenance Interval...................................................... 68 5.1.2 Required Test Equipment and Setup ................................................ 68 5.1.3 Typical Verification test setup............................................................ 70 5.1.4 Using the Rack Configuration Software ............................................ 71 5.1.5 Rod Position Single Channels........................................................... 74 5.1.6 Rod Position Pair Channels .............................................................. 93 5.1.7 Rod Drop Channels......................................................................... 115 5.1.8 Hyper Channels............................................................................... 125 5.1.9 Verify Recorder Outputs.................................................................. 139 5.1.10 If a Channel Fails a Verification Test............................................... 140

6. Troubleshooting....................................................................... 141 6.1 Self-test........................................................................................................... 141

iv

6.2 LED Fault Conditions ......................................................................................142 6.3 System Event List Messages..........................................................................143 6.4 Alarm Event List Messages ............................................................................154

7. Ordering Information............................................................... 155 7.1 Ordering Considerations .................................................................................155 7.2 List of Options and Part Numbers...................................................................155

7.2.1 Recip Rod Position Monitor .............................................................155 7.2.2 External Termination Blocks............................................................155 7.2.3 3500 Transducer Signal to External Termination Block Cable ........155 7.2.4 3500 Recorder Output to External Termination (ET) Block Cable...156 7.2.5 Spares .............................................................................................156

8. Specifications .......................................................................... 157 8.1 Inputs ..............................................................................................................157 8.2 Outputs ...........................................................................................................157 8.3 Data Values ....................................................................................................157 8.4 Signal Conditioning .........................................................................................158 8.5 Rod Drop:........................................................................................................159 8.6 Hyper-Channel: ...............................................................................................159 8.7 Alarms.............................................................................................................160 8.8 Environmental Limits.......................................................................................160 8.9 CE Mark Directives .........................................................................................161 8.10 Hazardous Approvals......................................................................................161 8.11 Physical...........................................................................................................162

v


vi

Section 1 — Receiving and Handling

1. Receiving and Handling

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

1.2 Handling and Storing Considerations Circuit boards contain devices that are susceptible to damage when exposed to electrostatic charges. Damage caused by obvious mishandling of the board will void the warranty. To avoid damage, observe the following precautions in the order given: Application Alert: Machinery protection will be lost when this module is removed from the rack.

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

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

• Transport and store circuit boards in electrically conductive bags or foil.

• Use extra caution during dry weather. Relative humidity less than 30 % tends to multiply the accumulation of static charges on any surface.

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

1


2

Section 2 — General Information

2. General Information The 3500/72M Recip Rod Position Monitor is a four-channel monitor that accepts input from Proximitor Transducers which measure the position of the reciprocating rod on a rev-to-rev basis. The monitor uses this input to drive alarms for protection and provide waveform data to System 1 for management via 3500 TDI. The monitor can be programmed using the 3500 Rack Configuration Software to perform any of the following functions: Rod Position-Pair, Rod Position-Single, Rod Drop, and Hyper compressor Rod Movement. The monitor can receive input from many types of transducers including the following Bently Nevada transducers:

Proximitor Transducers

3300XL 8mm and 11mm

3300 8mm

7200 8mm, 11mm, and 14mm

3


(1) Main module front view. (2) Status LEDs, refer to Section 2.3. (3) Buffered transducer outputs, provide an unfiltered output for each of the four transducers. All are

short circuit protected. (4) I/O module rear views. (5) Barrier I/O module, Internal Termination. Refer to Section 4.3. (6) I/O module, Internal Termination. Refer to Section 4.2 (7) I/O module, External Termination. Refer to Section 4.4.

4


The primary purpose of the 3500/72M monitor is to provide 1) machinery protection by continuously comparing current machine wear against configured alarm setpoints to drive alarms and, 2) essential machine wear information to both operator and maintenance personnel. Alarm setpoints are configured using the 3500 Rack Configuration Software. Alarm setpoints can be configured for each active proportional value, and danger setpoints can be configured for two of the active proportional values. When shipped from the factory, the 3500/72M is delivered unconfigured. When needed, the 3500/72M can be installed into a 3500 rack and configured to perform the required monitoring function. This lets you stock a single monitor for use as a spare for many different reciprocating compressor applications.

2.1 Triple Modular Redundant Description Not available with this monitor.

2.2 Available Data The Recip Rod Position Monitor returns specific proportional values dependent upon the type of channel configured. This monitor also returns both monitor and channel statuses which are common to all types of channels.

2.2.1 Statuses The following statuses are provided by the Recip Rod Position Monitor. This section describes the available statuses and where they can be found.

2.2.1.1 Monitor Status

Statuses Monitor Front Panel

Communication Gateway Module

Rack Configuration Software

Operator Display Software

Monitor OK X X X

Monitor Alert/Alarm 1 X X

Monitor Danger/Alarm 2 X X

Monitor Bypass X X

Monitor Configuration Fault X X

Monitor Special Alarm Inhibit X

OK This indicates if the monitor is functioning correctly. A NOT OK status is returned under any of the following conditions: - Module Hardware Failure - Node Voltage Failure - Configuration Failure - Transducer Failure

5


- Slot ID Failure - Channel not OK If the Monitor OK status goes not OK, then the system OK Relay on the Rack Interface I/O Module will be driven not OK.

Alert/Alarm 1 This indicates whether the monitor has entered Alert/Alarm 1. A monitor will enter the Alert/Alarm 1 state when any proportional value provided by the monitor exceeds its configured Alert/Alarm 1 setpoint.

Danger/Alarm 2

This indicates whether the monitor has entered Danger/Alarm 2. A monitor will enter the Danger/Alarm 2 state when any proportional value provided by the monitor exceeds its configured Danger/Alarm 2 setpoint.

Bypass This indicates when the monitor has bypassed alarming for one or more proportional values of a channel. When a channel bypass status is set, this monitor bypass status will also be set.

Configuration Fault This indicates if the monitor configuration is valid.

Special Alarm Inhibit This indicates whether all the non-primary Alert/Alarm 1 alarms in the associated monitor are inhibited. The Channel Special Alarm Inhibit function is active when: - The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

(active). - A Channel Special Alarm Inhibit software switch is enabled.

2.2.1.2 Channel Status

Statuses Communication Gateway Module

Rack Configuration Software

Operator Display Software

Management Software

Channel OK X X X X

Channel Alert/Alarm 1 X X X X

Channel Danger/Alarm 2 X X X X

Channel Bypass X X X X

Channel Special Alarm Inhibit

X X X

Channel Off X X X

OK This indicates that no fault has been detected by the associated Recip Rod Position Monitor channel.

6

Section 2 — General Information There are two types of channel OK checking: Transducer Input Voltage and Transducer Supply Voltage A channel OK status will be deactivated if either of the OK types goes not OK.

Alert/Alarm 1 This indicates whether the associated monitor channel has entered Alert/Alarm 1. A channel will enter the Alert/Alarm 1 state when any proportional value provided by the channel exceeds its configured Alert/Alarm 1 setpoint.

Danger/Alarm 2 This indicates whether the associated monitor channel has entered Danger/Alarm 2. A channel will enter the Danger/Alarm 2 state when any proportional value provided by the channel exceeds its configured Danger/Alarm 2 setpoint.

Bypass This indicates that the channel has bypassed alarming for one or more of its proportional values. A channel bypass status may result from the following conditions: - The Keyphasor transducer associated with the channel has gone invalid

causing all proportional values associated with the Keyphasor to be bypassed.

- The monitor has detected a serious internal fault. - A software switch is bypassing any channel alarming function. - The Special Alarm Inhibit is active and causing enabled alarms not to be

processed. Special Alarm Inhibit

This indicates whether all the nonprimary Alert/Alarm 1 alarms in the associated Recip Rod Position Monitor channel are inhibited. This status is active when: - The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

(active). - Software Special Channel Alarm Inhibit is active.

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

7


2.2.2 Proportional Values Proportional Values are measurements used to monitor the machine. The Recip Rod Position Monitor returns Proportional values for the following channel types: Rod Position – Single

Position Magnitude, Position Angle, Crank Angle, Pk-Pk Displacement, Gap, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude

Rod Position – Pair Position Magnitude, Position Angle, Crank Angle, Pk-Pk Displacement, Gap, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude

Rod Drop Average Piston Position, Average Probe Gap, Instantaneous Piston Position, and Instantaneous Probe Gap

Hyper Channel Pk-Pk Displacement, Gap, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude

8


2.3 LED Descriptions The LEDs on the front panel of the Recip Rod Position Monitor indicate the operating status of the module as shown in the following figure. Refer to Section 6.2 for all of the available LED conditions.

(1) OK: Indicates that the Recip Rod Position Monitor and the Prox/Velom I/O module are operating correctly.

(2) TX/RX: Flashes at the rate that messages are received and transmitted. (3) BYPASS: Indicates that some of the monitor functions are temporarily suppressed.

9


10

Section 3 — Configuration Information

3. Configuration Information This section describes how the 3500/72M Recip Rod Position Monitor is configured using the Rack Configuration Software. It also describes any configuration restrictions associated with this module. Refer to the 3500 Monitoring System Rack Configuration and Utilities Guide and the Rack Configuration Software for the details on how to operate the software.

Configuration Overview A series of steps is required to configure the Recip Rod Position Monitor. The basic steps in this process are: 1) Enter channel type and machine parameters into the software configuration screens. 2) Download the incomplete configuration to the 3500 Rack. 3) While the configuration computer is connected to the Rack, use the software Calibrate Channel screen and calibrate the transducer(s) and configure the options for the channel in the Options screen. 4) While in the Options screen, gap the probe at the required position. 5) Adjust the Zero Position or Setup Voltage in the Options screen accordingly. 6) Adjust alarm setpoints to the desired levels in the Setpoint configuration screen. 7) Download the completed channel configuration to the 3500 Rack.

3.1 Software Configuration Options This section shows the configuration screens of the Rack Configuration Software that are associated with the monitor and discusses the configuration considerations. It will show a copy of the software screens and will explain the options that are available.

11


3.1.1 Recip Rod Position Monitor Configuration Options This section describes the options available on the Recip Rod Position Monitor configuration screen.

Reference Information These fields contain information that indicates which module you are configuring.

Slot The location of the monitor in the 3500 rack (2 through 15).

Rack Type The type of Rack Interface Module installed in the rack (Standard or TMR). This field is always set to standard since the Recip Rod Position Monitor can only be installed in a standard rack.

Configuration ID A unique six character identifier which is entered when a configuration is downloaded to the 3500 rack.

Slot Input/Output Module Type The I/O field lets you identify the type of I/O Module that is attached to the monitor (The option selected must agree with the I/O module installed). These choices are:

12


Prox/Velom Internal I/O The transducer field wiring is connected directly to the I/O module.

Prox/Velom External I/O The transducer field wiring is connected to an External Termination Block and then routed from the External Termination Block to the I/O module through a 25-pin cable. The recorder field wiring is connected to an External Termination Block and then routed from the External Termination Block to the I/O module through a 9-pin cable.

Prox/Accel Internal Barrier I/O The transducer field wiring is connected directly to the Internal Barrier I/O Module. Note that selecting the Prox/Accel Internal Barrier I/O option will disable certain transducer type options.

Throw Configuration The fields within these tabs pertain to the monitoring of each individual throw.

Channel Type The type of monitoring which is to be performed by the channel pair. The following Channel types are available in the monitor: - Rod Position Single - Rod Position Pair - Rod Drop - Hyper

Keyphasor® Association

No Keyphasor Can be used when a Keyphasor is not available. If this is marked, then it will restrict data available for each channel type. Rod Position Single and Rod Position Pair channel types will only have Position Magnitude, Position Angle, Pk-Pk, and Gap measurements. Rod Drop will only allow Average measurements. Hyper channels will only have Pk-Pk and Gap available.

Design Speed When the No Keyphasor box is selected for Rod Position Single and Rod Position Pair channel types, the configuration software creates a new box called Design Speed. You are required to enter the designed operating RPM of the system.

Primary The Keyphasor channel selected that is normally used for measurement. When this Keyphasor transducer is marked invalid, the backup Keyphasor will provide the shaft reference information.

Backup The Keyphasor channel selected that will be used if the primary fails. If you do not have a backup Keyphasor, select the same Keyphasor channel as the primary.

13


Piston Angle When the piston hits top dead center, this is the angular measurement between the centerline of the Keyphasor probe to the keyphasor leading edge. This is measured to the left edge (for CCW rotating crankshaft) or to the right edge (for CW rotating crankshaft) of the index notch on the crankshaft position wheel in the direction of crank rotation when the piston is at Top Dead Center.

Channel

Active Select whether the functions of the channel will be turned on ( ) or off ( ).

Channel Selection Use the pull down menu to determine which channel(s) are to be used with the throw. Only one channel is used with Rod Position Single and Rod Drop channel types. For Rod Position Pair and Hyper channel types, you must use dual channels, either 1-2 or 3-4.

Configuration A button used to display the configuration options for the selected channel type.

Barriers Select the MTL 796(-) Zener External option, or Galvanic Isolators if external safety barriers are connected between the monitor and the transducer. If the Prox/Accel Internal Barrier I/O Module is selected for Slot Input/Output Module Type, the Internal option is selected for you. These devices are used to restrict the amount of energy that can flow into a hazardous area.

14


3.1.2 Rod Position Single Channel Configuration This section discusses the Configuration Considerations and the Rack Configuration Software screens associated with the Rod Position Single channel type.

3.1.2.1 Rod Position Single Channel Configuration Considerations Consider the following items before configuring a Rod Position Single Channel:

• Internal Barrier I/O Modules and External barriers are not currently supported with 7200 11 mm or 14 mm.

• When “NO Keyphasor” is selected, the Design Speed is used to calculate Position Magnitude, Position Angle, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude. Differences between the input Design Speed and the actual machine running speed will produce inconsistent data. Crank Angle measurements are not valid.

• If a Keyphasor Channel is selected, a Keyphasor Module must be installed in the rack.

• The full scale options allowed for each proportional value are dependent upon the transducer type and rod material.

• Setpoints may only be set on proportional values which are enabled.

• Monitors must be configured in channel pairs. Channels 1 and 2 must be configured to be the same Channel type. Channels 3 and 4 must be configured to be the same channel type. (Ex: Channels 1 and 2 may be configured as Rod Position Single and Channels 3 and 4 may be configured as Hyper)

• When a full-scale range is modified, the setpoints associated with this proportional value should be readjusted.

• You should run the transducer calibration and download it to the monitor before you do the center position setup.

• The configuration program will not allow you to make a change without checking for proper settings in the options screen.

15


3.1.2.2 Rod Position Single Channel Configuration Screen This section describes the required inputs and options available on the Rod Position Single Channel Configuration screen.

Average Reference Temperature The average temperature of the environment when the piston clearance and cylinder bore measurements were taken.

Average Suction Temperature The average temperature of the suction gas under normal operating conditions.

Average Discharge Temperature The average temperature of the discharge gas under normal operating conditions.

Piston Material The material from which the piston was made. The materials to choose from are iron, steel, or aluminum.

Piston Top Clearance The measurement from the top of the piston to the cylinder internal diameter, taken while the piston is at rest in the cylinder supported by its rider band(s).

16


Piston Bottom Clearance The measurement from the bottom of the piston to the cylinder internal diameter, taken while the piston is at rest in the cylinder supported on its rider band(s).

Direction of Rotation: The direction of the rotation of the crank shaft as viewed from the driver end of the machine. This value will be Clockwise (CW) or Counter Clockwise (CCW).

Stroke The length that the piston travels in one direction.

Cylinder Bore Diameter The measurement of the cylinder internal diameter.

Probe Position The distance from the crosshead pin pivot to the probe when the piston is at Top Dead Center (TDC) at the head end of the cylinder.

Connecting Rod Length The length between the “hole center” to “hole center” on the connecting rod, or length between the center of the connecting rod journal to the center of the crosshead pin.

Piston Rod Length The length from the crosshead pin pivot center to rider band (if only one) or to the center of the rider bands (if two or more).

Channel Transducer Tab For Rod Position Single there will be only one channel transducer tab.

Transducer Type

The following transducer types are available for the Rod Position Single NON-BARRIER I/O modules: - 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm - 7200 – 11mm - 7200 – 14mm

The following transducer types are available for the Rod Position Single BARRIER I/O modules: - 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm

17


Transducer Orientation The physical position of the transducer with respect to the rod. The orientation is specified as 0 to 180 degrees left or right. Zero degrees is defined as follows: For horizontal machines: Stand at the driver end (crankshaft) and look towards the driven end (cylinder). Zero degrees is located at the top (up) of the case; the 180 degree mark is located at the bottom (down). For vertical machines: Stand at the top of the machine and look down. Zero degrees can be associated with any recognizable physical reference point. Typically this might be set to the direction “North”.

Calibrate Channel Button A button to display the transducer calibration screen. See Section 3.1.6 for transducer calibrations. It is always recommended to calibrate all transducers for any rod material.

Note: Calibrate the selected transducer before continuing with the transducer options.

Options Button

A button to display the configuration options for the selected transducer type.

Point Names Button This button allows the user to define and input custom names to each channel.

CP Mod Selecting the CP Mod button Channel Options Dialog Box, allows a Custom channel configuration to be downloaded to the monitor. Custom configuration data is stored in a Custom Products Modification File. Custom Products Modification files follow the naming convention <modification #.mod>. These files must be located in the \3500\Rackcfg\Mods\ directory. When a CP Mod file is selected, a window is displayed which describes the function of the modification. CP Mod files are available through Bently Nevada's Custom Products Division. Contact your local Bently Nevada Sales Representative for details.

18


3.1.2.3 Rod Position Single Channel Options Screen This section describes the options available on the Rod Position Single Channel Transducer Options screen.


Channel

The channel of the monitor being configured.



19


Enabled An enabled proportional value specifies that the value will be provided by the channel ( enabled, disabled).

Position Magnitude

The maximum value of the position vector magnitudes calculated every one degree of crank rotation over one cycle. The position vector magnitudes are the rod center position relative to a zero position representing the piston being concentric to the cylinder bore.

Position Angle The angle made by the vector representation of the maximum position magnitude. Represents where the center of the rod is with respect to the zero position when the position vector is at its maximum magnitude. 0 degrees is defined as vertical with CW being positive rotation viewed from crank end. For Rod Position Single channel types, Position Angle measurements can only be 0 or 180 degrees.

Crank Angle The rotational angle of the crank corresponding to the axial position of the rod (referenced from piston Top Dead Center) when the position vector is at its maximum magnitude. Represents where the rod is located in its stroke when the position vector is at its maximum magnitude. The crank angle is referenced from the piston angle (TDC being 0 degrees) with positive rotation in the direction of crank rotation.

Pk Pk Displacement Data which represents the overall peak to peak vibration. For the Recip Rod Position Monitor the frequency response for Pk Pk displacement is always 1 to 600 Hz or 60 to 36,000 CPM.

Gap A voltage representing the physical distance between the face of a proximity probe tip and the observed surface. Standard polarity convention dictates that a decreasing gap results in an increasing (less negative) output signal.

1X Amplitude In a complex vibration signal, notation for the amplitude component that occurs at the rotative speed frequency.

2X Amplitude In a complex vibration signal, notation for the amplitude component having a frequency equal to two times the shaft rotative speed.

Not 1X Amplitude In a complex vibration signal, notation for the peak to peak amplitude of the wave shape after the rotative speed component is removed.

Full Scale Range Each selectable proportional value provides the ability to set a full scale value. The Full Scale Range selections are dependant upon the transducer calibration. The Full Scale cannot be set larger than the linear range of the transducer. All scales for the Rod Position channel types have a minimum value of 0.

Clamp Value The value that a proportional value goes to when that channel or proportional value is bypassed or defeated (For example when a problem occurs with the transducer).

20

Section 3 — Configuration Information The selected value can be between the minimum and maximum full-scale range values. Only the values available from the Recorder Outputs, Communication Gateway and Display Interface Module are clamped to the specified value when the proportional value is invalid.

Recorder Output The proportional value of a channel that is sent to the 4 to 20 mA recorder. The recorder output is proportional to the measured value over the channel full scale range. An increase in the proportional value that would be indicated as upscale on a bar graph display results in an increase in the current at the recorder output. If the channel is Bypassed, the output will be clamped to the selected clamp value or to 2 mA (if the 2 mA clamp is selected).

Alarm Mode Alert should be the first level alarm that occurs when the transducer signal level exceeds the selected value. Danger should be the second level alarm that occurs when the transducer signal level exceeds the selected value. The Alert and Danger values are set on the Setpoint screen.

Latching Once an alarm is active it will remain active even after the proportional value enters back into the configured non-alarm setpoint level. The channel will remain in alarm until it is reset using one of the following methods: - the reset switch on the front of the Rack Interface Module - the contact on the Rack Interface I/O Module - the Reset button in the Operator Display Software - the reset command through the Communication Gateway Module - the reset command through the Display Interface Module - the reset command in the Rack Configuration Software

Nonlatching When an alarm is active it will go inactive as soon as the proportional value enters back into the configured non-alarm setpoint level.

Delay The time which a proportional value must remain at or above an over alarm level or below an under alarm level before an alarm is declared as active.

Alert First level alarm that occurs when the transducer signal level exceeds the selected Alert/Alarm 1 setpoint. This setpoint can be set on the Setpoint screen. The Alert time delay is adjustable in one second intervals (from 1 to 60) for all available proportional values.

Danger Second level alarm that occurs when the transducer signal level exceeds the selected Danger/Alarm 2 setpoint. This setpoint can be set on the Setpoint screen. 100 ms option The 100 ms (typical) option applies to the Danger time delay only and has the following results:

21

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual If the 100 ms option is off ( ): - The Danger time delay can be set at one second intervals (from 1 to 60). - The Danger time delay can be set for up to two available proportional

values. If the 100 ms option is on ( ): - The Danger time delay is set to 100 ms. - The Danger time delay can only be set for the primary proportional value.

Channel Centered Position Setup

Setup Crank Angle The angular rotation measurement of the crank from when the piston is at top dead center to the point when the Setup Voltage is read.

Current Gap Voltage The current voltage reading from the transducer. A connection with the rack is required and Gap must be currently enabled in the configuration for the monitor for this value to be returned.

Setup Voltage The voltage the channel’s transducer reads when the piston is at the setup crank angle and is at rest in the cylinder on its initial rider band thickness (bottom clearance).

Channel Offset The distance aligned with the channel’s transducer that shows how far from ideal center the rod is during setup when the piston is resting on its bottom rider band thickness. A channel offset AWAY means that the rod is further away from the probe face than when at ideal center. A channel offset TOWARD means that the rod is closer to the probe face than when at ideal center.

Calculated Center Voltage The voltage the channel’s transducer would read if the piston were being held in the center of the cylinder clearance. This centered voltage is calculated using the transducer scale factor, the cylinder I.D., the piston-to-cylinder bottom and top clearances, the calculated thermal growth of the piston, and the CF when the rod is at the setup crank angle specified.

Setup = Gap Button Adjust the Setup voltage to the current transducer gap voltage. When this button is clicked, the current gap voltage is automatically read into the Setup Voltage box. Since this utility provides active feedback from the 3500 rack, a connection with the rack is required.

Timed OK Channel Defeat When enabled, this feature normally suppresses channel alarms and data values when the channel transitions to a Not OK condition. This feature is always disabled in the Recip Rod Position Monitor, so the action taken by the monitor if a channel goes Not OK is: 1) the Not OK will be reported in the channel status, 2) the proportional values will continue to be calculated and reported, and 3) the channel will annunciate

22


and maintain an alarm if the data value in the Not OK condition exceeds the alarm setpoint.

3.1.3 Rod Position Pair Channel Configuration This section discussees the Configuration Considerations and the Rack Configuration Software screens associated with the Rod Position Pair channel type.

3.1.3.1 Rod Position Pair Channel Configuration Considerations Consider the following items before configuring a Rod Position Pair Channel:


• When “NO Keyphasor” is selected, the Design Speed is used to calculate Position Magnitude, Position Angle, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude. Differences between the input Design Speed and the actual machine running speed will produce inconsistent data. Crank Angle measurements are not valid.






• You should run the transducer calibration and download it to the monitor before you do the center position setup.


23


3.1.3.2 Rod Position Pair Channel Configuration Screen This section describes the required inputs and options available on the Rod Position Pair Channel Configuration screen.

Average Reference Temperature The average temperature of the environment when the piston clearance and cylinder bore measurements were taken.

Average Suction Temperature The average temperature of the suction gas under normal operating conditions.

Average Discharge Temperature The average temperature of the discharge gas under normal operating conditions.

Piston Material The material from which the piston was made. The materials to choose from are iron, steel, or aluminum.

Piston Top Clearance The measurement from the top of the piston to the cylinder internal diameter, taken while the piston is at rest in the cylinder supported by its rider band(s).

24


Piston Bottom Clearance The measurement from the bottom of the piston to the cylinder internal diameter, taken while the piston is at rest in the cylinder supported on its rider band(s).

Direction of Rotation: The direction of the rotation of the crank shaft as viewed from the driver end of the machine. This value will be Clockwise (CW) or Counter Clockwise (CCW).


Cylinder Bore Diameter The measurement of the cylinder internal diameter.




Channel Transducer Tab For Rod Position Pair there will be two channel transducer tabs, one for each transducer.

Transducer Type

The following transducer types are available for the Rod Position Pair NON-BARRIER I/O modules: - 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm - 7200 – 11mm - 7200 – 14mm

The following transducer types are available for the Rod Position Pair BARRIER I/O modules:

- 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm

25


Transducer Orientation The physical position of the transducer with respect to the rod. The orientation is specified as 0 to 180 degrees left or right. Zero degrees is defined as follows: For horizontal machines: Stand at the driver end (crankshaft) and look towards the driven end (cylinder). Zero degrees is located at the top (up) of the case; the 180 degree mark is located at the bottom (down). For vertical machines: Stand at the top of the machine and look down. Zero degrees can be associated with any recognizable physical reference point. Typically this might be set to the direction “North”. For Rod Position Pair channel type, transducer probes must be set at an angle apart no less than 75 Degrees and no greater than 105 Degrees. For the best acuracy, probes should be set as close to 90 Degrees apart as possible.



Options Button




26


3.1.3.3 Rod Position Pair Channel Options Screen This section describes the options available on the Rod Position Pair Channel Transducer Options screen.


Channel

The channels of the monitor being configured.



27



Position Magnitude

The maximum value of the position vector magnitudes calculated every one degree of crank rotation over one cycle. The position vector magnitudes are the rod center position relative to a zero position representing the piston being concentric to the cylinder bore.

Position Angle The angle made by the vector representation of the maximum position magnitude. Represents where the center of the rod is with respect to the zero position when the position vector is at its maximum magnitude. 0 degrees is defined as vertical with CW being positive rotation viewed from crank end.

Crank Angle The rotational angle of the crank corresponding to the axial position of the rod (referenced from piston Top Dead Center) when the position vector is at its maximum magnitude. Represents where the rod is located in its stroke when the position vector is at its maximum magnitude. The crank angle is referenced from the piston angle (TDC being 0 degrees) with positive rotation in the direction of crank rotation.

Pk Pk Displacement Data which represents the overall peak to peak vibration. For the Recip Rod Position Monitor the frequency response for Pk Pk displacement is always 1 to 600 Hz or 60 to 36,000 CPM.





Full Scale Range Each selectable proportional value provides the ability to set a full scale value. The Full Scale Range selections are dependant upon the transducer calibration. The Full Scale cannot be set larger than the linear range of the transducer. All scales for the Rod Position channel types have a minimum value of 0.

Clamp Value The value that a proportional value goes to when that channel or proportional value is bypassed or defeated (For example when a problem occurs with the transducer). The selected value can be between the minimum and maximum full-scale range

28

Section 3 — Configuration Information values. Only the values available from the Recorder Outputs, Communication Gateway and Display Interface Module are clamped to the specified value when the proportional value is invalid.

Recorder Output The proportional value of a channel that is sent to the 4 to 20 mA recorder. The recorder output is proportional to the measured value over the channel full scale range. An increase in the proportional value that would be indicated as upscale on a bar graph display results in an increase in the current at the recorder output If the channel is Bypassed, the output will be clamped to the selected clamp value or to 2 mA (if the 2 mA clamp is selected).






Danger Second level alarm that occurs when the transducer signal level exceeds the selected Danger/Alarm 2 setpoint. This setpoint can be set on the Setpoint screen. 100 ms option The 100 ms (typical) option applies to the Danger time delay only and has the following results: If the 100 ms option is off ( ):

29


- The Danger time delay can be set at one second intervals (from 1 to 60). - The Danger time delay can be set for up to two available proportional


Channel Centered Position Setup

Setup Crank Angle The angular rotation measurement of the crank from when the piston is at top dead center to the point when the Setup Voltage is read.

Current Gap Voltage The current voltage reading from the transducer. A connection with the rack is required and Gap must currently be enabled in the configuration of the monitor for this value to be returned.

Setup Voltage The voltage the channel’s transducer reads when the piston is at the setup crank angle and is at rest in the cylinder on its initial rider band thickness (bottom clearance).

Channel Offset The distance aligned with the channel’s transducer that shows how far from ideal center the rod is during setup when the piston is resting on its bottom rider band thickness. A channel offset AWAY means that the rod is further away from the probe face than when at ideal center. A channel offset TOWARD means that the rod is closer to the probe face than when at ideal center.

Calculated Center Voltage The voltage the channel’s transducer would read if the piston were being held in the center of the cylinder clearance. This centered voltage is calculated using the transducer scale factor, the cylinder I.D., the piston-to-cylinder bottom and top clearances, the calculated thermal growth of the piston, and the CF when the rod is at the setup crank angle specified.

Setup = Gap Button Adjust the Setup voltage to the current transducer gap voltage. When this button is clicked, the current gap voltage is automatically read into the Setup Voltage box. Since this utility provides active feedback from the 3500 rack, a connection with the rack is required.

Timed OK Channel Defeat When enabled, this feature normally suppresses channel alarms and data values when the channel transitions to a Not OK condition. This feature is always disabled in the Recip Rod Position Monitor and so the action taken by the monitor if a channel goes Not OK is: Rod Position Pair Channel Types—For the independent data values being reported (those that only use the values from a single channel such as Pk-Pk

30


Displacement, Gap, 1X Amplitude, 2X Amplitude, Not 1X Amplitude): 1) the Not OK will be reported in the channel status, 2) the proportional values will continue to be calculated and reported, and 3) the channel will annunciate and maintain an alarm if the data value in the Not OK condition exceeds the alarm setpoint. For the composite data values (those that use the values from two channels such as Position Magnitude, Position Angle, Crank Angle): if either channel goes Not OK; 1) the appropriate channel status will be reported as Not OK, 2) the composite data values will be reported as invalid, and.3) the channel pair will defeat an alarm for the composite data values.

3.1.4 Rod Drop Channel Configuration This section discussees the Configuration Considerations and the Rack Configuration Software screens associated with the Rod Drop channel type.

3.1.4.1 Rod Drop Channel Configuration Considerations Consider the following items before configuring a Rod Drop Channel:



• When “NO Keyphasor” is selected Instantaneous Gap and Position measurements will not be available. Also, Instantaneous Correction Factor will not be used.






31


3.1.4.2 Rod Drop Channel Configuration Screen This section describes the required inputs and options available on the Rod Drop Channel Configuration screen.



Trigger Angle The angular measurement of the crankshaft rotation in the direction of rotation from the piston Top Dead Center (TDC) to the position at which the instantaneous measurement will be taken. This is only applicable to Rod Drop channel type configurations that have a Keyphasor.

32




Channel Transducer Tab For Rod Drop channel types, there will be only one channel transducer tab.

Transducer Type

The following transducer types are available for the Rod Drop NON-BARRIER I/O modules: - 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm - 7200 – 11mm - 7200 – 14mm

The following transducer types are available for the Rod Drop BARRIER I/O modules:

- 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm

Transducer Orientation The physical position of the transducer with respect to the rod. The orientation is specified as 0 to 180 degrees left or right. Zero degrees is defined as follows: For horizontal machines:

33

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual Stand at the driver end (crankshaft) and look towards the driven end (cylinder). Zero degrees is located at the top (up) of the case; the 180 degree mark is located at the bottom (down). For vertical machines: Stand at the top of the machine and look down. Zero degrees can be associated with any recognizable physical reference point. Typically this might be set to the direction “North”.



Options Button




34


3.1.4.3 Rod Drop Channel Options Screen This section describes the options available on the Rod Drop Channel Transducer Options screen.


Channel





Average Correction Factor

The Piston Rod Length divided by the calculated average Probe Position throughout the stroke --displayed for information only.

Instantaneous Correction Factor

35

The Piston Rod Length divided by the calculated instantaneous Probe Position set by the Trigger Angle—displayed for information only.


Average Piston Position The time average (over the complete stroke) of the physical distance between the face of the proximity probe tip and the observed rod with respect to the zero position times the average correction factor.

Average Probe Gap The time average of a voltage representing the physical distance between the face of the proximity probe tip and the observed rod.

Instantaneous Piston Position The physical distance between the face of the proximity probe tip and the observed rod with respect to the zero position times the instantaneous correction factor when the rod is in its stroke position described by the configured trigger angle position.

Instantaneous Probe Gap A voltage representing the physical distance between the face of the proximity probe tip and the observed rod when it is in its stroke position described by the configured trigger angle position.

Full Scale Range Each selectable proportional value provides the ability to set a full scale value. The Full Scale Range selections are dependant upon the transducer calibration cannot be set larger than the linear range of the transducer.

Clamp Value The value that a proportional value goes to when that channel or proportional value is bypassed or defeated (For example when a problem occurs with the transducer). The selected value can be between the minimum and maximum full-scale range values. Only the values available from the Recorder Outputs, Communication Gateway and Display Interface Module are clamped to the specified value when the proportional value is invalid.


Zero Position The volts corresponding to the nominal DC shaft position. This voltage will be shown on the user display.

Adjust Button Adjust the Zero Position voltage. When this button is clicked, the current gap voltage is automatically read into the Zero Position box. Since this utility provides active feedback from the 3500 rack, a connection with the rack is required.

Current Gap Voltage The current voltage reading from the transducer. A connection with the rack is required for this value to be returned.

36







Danger Second level alarm that occurs when the transducer signal level exceeds the selected Danger/Alarm 2 setpoint. This setpoint can be set on the Setpoint screen. 100 ms option The 100 ms (typical) option applies to the Danger time delay only and has the following results: If the 100 ms option is off ( ): - The Danger time delay can be set at one second intervals (from 1 to 60). - The Danger time delay can be set for up to two available proportional


37


Timed OK Channel Defeat When enabled, this feature normally suppresses channel alarms and data values when the channel transitions to a Not OK condition. This feature is always disabled in the Recip Rod Position Monitor and so the action taken by the monitor if a channel goes Not OK is: Rod Drop Channel Types - 1) the Not OK will be reported in the channel status, 2) the data values will continue to be calculated and reported, and 3) the channel will annunciate and maintain an alarm if the data value in the Not OK condition exceeds the alarm setpoint.

3.1.5 Hyper Channel Configuration This section discusses the Configuration Considerations and the Rack Configuration Software screens associated with the Hyper channel type.

3.1.5.1 Hyper Channel Configuration Considerations Consider the following items before configuring a Hyper Channel:


• When “NO Keyphasor” is selected, 1X Amplitude, 2X Amplitude, and Not 1X Amplitude are not available.







38


3.1.5.2 Hyper Channel Configuration Screen This section describes the options available on the Hyper Channel Configuration screen.

Channel Transducer Tab For Rod Position Single and Rod Drop channel types, there will be only one channel transducer tab. For Rod Position Pair and Hyper channel types, there will be two channel transducer tabs, one for each transducer.

Transducer Type

The following transducer types are available for the Hyper NON-BARRIER I/O modules: - 3300 – 8mm - 3300XL – 8mm - 3300XL – 11mm - 7200 – 8mm - 7200 – 11mm - 7200 – 14mm

The following transducer types are available for the Hyper BARRIER I/O modules:

- 3300 – 8mm - 3300XL – 8mm

39


- 3300XL – 11mm - 7200 – 8mm

Transducer Orientation The physical position of the transducer with respect to the rod. The orientation is specified as 0 to 180 degrees left or right. Zero degrees is defined as follows: For horizontal machines: Stand at the driver end (crankshaft) and look towards the driven end (cylinder). Zero degrees is located at the top (up) of the case; the 180 degree mark is located at the bottom (down). For vertical machines: Stand at the top of the machine and look down. Zero degrees can be associated with any recognizable physical reference point. Typically this might be set to the direction “North”.



Options Button




40


3.1.5.3 Hyper Channel Options Screen This section describes the options available on the Hyper Channel Transducer Options screen.


Channel





Pk Pk Displacement

Data which represents the overall peak to peak vibration. For the Recip Rod Position Monitor the frequency response for Pk Pk displacement is always 1 to 600 Hz or 60 to 36,000 CPM.

41






Full Scale Range Each selectable proportional value provides the ability to set a full scale value. The Full Scale Range selections are dependant upon the transducer calibration cannot be set larger than the linear range of the transducer. All scales for the Hyper channel types are zero based.

Clamp Value The value that a proportional value goes to when that channel or proportional value is bypassed or defeated (For example when a problem occurs with the transducer). The selected value can be between the minimum and maximum full-scale range values. Only the values available from the Recorder Outputs, Communication Gateway and Display Interface Module are clamped to the specified value when the proportional value is invalid.



Note: If both channels of a Hyper channel pair go Not OK, all enabled alarms configured for Danger/Alarm 2 will become active.

Latching

Once an alarm is active it will remain active even after the proportional value enters back into the configured non-alarm setpoint level. The channel will remain in alarm until it is reset using one of the following methods: - the reset switch on the front of the Rack Interface Module - the contact on the Rack Interface I/O Module - the Reset button in the Operator Display Software

42


- the reset command through the Communication Gateway Module - the reset command through the Display Interface Module - the reset command in the Rack Configuration Software




Danger Second level alarm that occurs when the transducer signal level exceeds the selected Danger/Alarm 2 setpoint. This setpoint can be set on the Setpoint screen. 100 ms option The 100 ms (typical) option applies to the Danger time delay only and has the following results: If the 100 ms option is off ( ): - The Danger time delay can be set at one second intervals (from 1 to 60). - The Danger time delay can be set for up to two available proportional


Note: When both channels in a Hyper pair become Not OK, all configured Danger/Alarm 2 alarms become active.

Timed OK Channel Defeat When enabled, this feature normally suppresses channel alarms and data values when the channel transitions to a Not OK condition. This feature is always disabled in the Recip Rod Position Monitor and so the action taken by the monitor if a channel goes Not OK is: Hyper Channel Types— 1) the Not OK will be reported in the channel status, 2) the data values will continue to be calculated and reported, and 3) the channel will annunciate and maintain an alarm if the data value in the Not OK condition exceeds the alarm setpoint.

43


3.1.6 Rod Position Transducer Calibration This section describes the options available on the Recip Rod Position Monitor Transducer Calibration Screens. A rod transducer calibration is necessary to determine the useable linear range of the transducer when viewing the piston rod material.

The shaft calibrator kit, p/n 330186, is one tool used to temporarily mount a spindle micrometer to the piston rod so that the transducer curve can be generated. The kit includes a spindle micrometer, strap, 4140 target button for system verification with a collet for alignment, eight probe adapters to accommodate most Bently Nevada proximity probes, and an instruction card. A proximity probe is mounted so that the probe face is flush with the piston rod (mechanical zero). It is then backed out in small increments where the voltages are recorded for each gap. The usable linear range can then be calculated using the recorded voltages. The default linear range and gap mil increments are determined by the transducer selected in the previous screen.

44


The gap voltage values may be recorded with conventional methods and directly entered into the calibration screen. Blue values are determined by the software to be outside the useable linear range of the selected transducer. Note: If internal or external barriers are being used, it is critical that the gap voltage be measured on the safe side of the barrier or errors will result in the monitor setup.

Adjust Button The Adjust button next to each voltage may be used to read values directly from the transducer into the calibration screen. This feature requires that the computer used for configuring be connected to the 3500 rack and all wiring be correct within the system. You must also have the configuration on the previous screen downloaded to the rack and the Gap must have been enabled in the Options screen and downloaded using the 3500 Config software. When connected to the 3500 rack a current Gap measurement is shown in the lower right hand corner.

Note: The Adjust Button reads the current voltage value of the system. Proper care must be taken to match up the correct physical gap of the probe with the corresponding voltage.

After the probe has been backed out to a new gap, wait a period of 10 to 15 seconds before taking the Adjust Button reading from the Current Gap Voltage. This accounts for the gap voltage filter setting time.

It is important to run the calibration with the probe viewing an area of the piston rod actually viewed during normal operation of the compressor.

Calculated Values As voltage values are entered for increasing gap values, the Incremental Scale Factors are determined automatically.

Channel Setup

Total Linear Range The Total Linear Range is calculated by the software using the values recorded in the transducer curve. It is defined as the range over which the variation between each Incremental Scale Factor and the Average Scale Factor are less than or equal to 10%. This range can also be identified by the change in colors seen in the transducer curve data.

Lower Gap The Lower Gap is determined by picking the least negative voltage within the linear range. It is the lower value in the range to be used, defines one end of the bar graph, and defines one setpoint limit.

Upper Gap The Upper Gap is determined by picking the most negative voltage within the linear range. It is the upper value in the range to be used, defines one end of the bar graph, and defines one setpoint limit.

Note: The user must set the Upper and Lower Gaps after entering all the transducer curve data. The upper and lower gaps must be within the linear range of the transducer.

45


Scale Factor The calculated average scale factor within the chosen Upper and Lower Gaps. This is the change in output per change in input (sensitivity) of a transducer.

OK Limits The upper and lower OK limit voltages are displayed for reference.

Current Gap Voltage Displays the current voltage of the transducer channel. This value can be “read” into the curve data fields by using the adjust buttons.

Calibration Data

Save Button Calibration data will be saved for the channel as a text file that can be used for later retrieval.

Load Button Calibration data will be loaded for the channel from a saved calibration file.

To use data from a calibration file the transducer, barrier, and unit data must be consistent with the current configured parameters.

46


3.1.6.1 Sample Transducer Calibration The following calibration was made using a Tungsten Carbide target material. The system included a 3300XL 8mm Proximitor and 5m probe combination. The 3500 rack was also connected to the software.

1. After the shaft calibrator kit was installed, the probe was backed out to 5 mils

of Gap. This value, -0.92 V, was input into the 5 mil voltage block using the Adjust Button and reading from the Current Gap Voltage in the lower right hand corner. Remember, the BLUE values are not used in linear range calculations, but are only for reference.

2. The probe was then backed out to a 10 mil gap. Again, the Adjust Button read the Current Gap Voltage and input the reading into the Voltage box.

3. The gap voltage was recorded in 5 mil increments until the voltage values failed to change. This occurred at 85 mils of gap.

Note: Be sure to fill in all voltage spaces down to the bottom of the screen.

4. The ISF for every Gap Increment was calculated by the software along with the percentage of deviation. The software automatically calculates the useable linear range to be 55 mils. The useable linear range is defined as

47


values with less than 10% deviation to its ISF and is within the OK limits of the transducer. This is shown by the Black colored voltage values (10 to 65 mils).

5. The Lower Gap can be set to 10 mils (Least negative voltage inside the linear range).

6. The Upper Gap can be set to 65 mils (Most negative voltage inside the linear range).

3.2 Setpoints This section specifies the available setpoints for each type of channel. A setpoint is the level within the full-scale range that determines when an alarm occurs. The 3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for every proportional value on each channel. The channel will drive an Alert/Alarm 1 indication if one or more of the channel proportional values exceeds its setpoints. The 3500 Monitoring System also allows up to four Danger/Alarm 2 setpoints (two over setpoints and two under setpoints) to be set for up to two of the proportional values. You may select any two of the available proportional values for the channel. Note: The setpoint over and under limits can only be placed within the upper and lower gap values of the specified transducer.

Use the following screen in the Rack Configuration Software to adjust Alert/Alarm 1 and Danger/Alarm 2 setpoints. This screen will vary depending upon the type of channel.

48


The following table lists the Alert/Alarm 1 and Danger/Alarm 2 setpoints available for each channel pair type. The setpoint number is used in the Communication Gateway and Display Interface Modules.

49


SetpointNumber

Rod Position Single and Pair

Rod Drop

Hyper

Over Position Magnitude

Under Average Piston Position

Over Pk-Pk Displacement

Over Pk Pk Displacement

Under Instantaneous Piston Position

Over Gap

Over Gap

Danger (Configurable)

Under Gap

Under Gap


Over 1X Amplitude

Over 1X Amplitude

Under 1X Amplitude

Over 2X Amplitude

Over 2X Amplitude

Over Not 1X Amplitude

Under 2X Amplitude


Over Not 1X Amplitude








All the Alert/Alarm 1 setpoints are provided first, followed by the configured danger setpoints.

Example 1: Rod Position Single with the Danger/Alarm 2 Over Gap setpoint and the Danger/Alarm 2 Under Gap setpoint selected.

Alert/Alarm 1 setpoints: setpoints 1 through 7 Danger/Alarm 2 setpoints: setpoint 8 is Over Gap (Danger)

50

Section 3 — Configuration Information Setpoint 9 is Under Gap (Danger)

Example 2: Rod Drop with the Danger/Alarm 2 Over Instantaneous Piston Position setpoint selected.

Alert/Alarm 1 setpoints: setpoints 1 through 2 Danger/Alarm 2 setpoint: setpoint 3 is Over Instantaneous Piston

Position (Danger)

Notes: The alarming hysteresis for all channel configurations for a 72M Monitor is 1/64 of Full Scale. When a channel exceeds an alarm setpoint, it must fall back below the setpoint less the hysteresis before it can go out of alarm. For example, consider a channel configuration with a 0–10 mils full scale and an alarm setpoint at 6 mils as illustrated below:

The hysteresis = 10 mils/64 = 0.16 mils. The channel input must fall below 6 mils - 0.16 mils (5.84 mils) before the channel is out of alarm.

51


3.3 Software Switches The Recip Rod Position Monitor supports two module software switches and four channel software switches. These switches let you temporarily bypass or inhibit monitor and channel functions. Set these switches on the Software Switches screen under the Utilities Option on the main screen of the Rack Configuration Software.

No changes will take effect until the Set button is pressed.

Module Switches (Screen Not Shown)

Configuration Mode A switch that allows the monitor to be configured. To configure the monitor, enable ()this switch and set the key switch on the front of the Rack Interface Module in the PROGRAM position. When downloading a configuration from the Rack Configuration Software, this switch will automatically be enabled and disabled by the Rack Configuration Software. If the connection to the rack is lost during the configuration process, use this switch to remove the module from Configuration Mode.

52


Monitor Alarm Bypass When enabled, the monitor does not perform alarming functions. All proportional values are still provided. The monitor switch number is used in the Communication Gateway and Display Interface Modules.

Monitor Switch Number Switch Name

1

Configuration Mode

3

Monitor Alarm Bypass

Channel Switches

Alert Bypass When enabled, the channel does not perform Alert alarming functions.

Danger Bypass When enabled, the channel does not perform Danger alarming functions.

Special Alarm Inhibit When enabled, all nonprimary Alert alarms are inhibited.

Bypass When enabled, the channel provides no alarming functions and supplies no proportional values.

The channel switch number is used in the Communication Gateway and Display Interface Modules.

Channel Switch Number Switch Name

1

Alert Bypass

2

Danger Bypass

3

Special Alarm Inhibit

4

Bypass

53


54

Section 4 — I/O Module Descriptions

4. I/O Module Descriptions The Recip Rod Position Monitor will use Prox/Velom I/O Modules and the Barrier Proximitor I/O Module, which receive signals from the transducers and routes the signals to the monitor. The I/O module also supplies power to the transducers. The I/O module provides a 4 to 20mA recorder output for each transducer input channels. Only one I/O module can be installed at any one time and must be installed behind the Recip Rod Position Monitor (in a Rack Mount or Panel Mount rack) or above the Recip Rod Position Monitor (in a Bulkhead rack). In addition, Internal Barrier I/O Modules provide four channels of intrinsically safe signal conditioning for Proximitor transducers. There are two internally mounted zener barrier modules, one for each pair of transducer channels. This section describes how to use the connectors on the I/O modules, lists what cables to use, and shows the pin outs of the cables. The 3500 Field Wiring Diagram Package (part number 130432-01) shows how to connect transducers to the I/O module or the External Termination Block.

4.1 Setting the I/O Jumper The I/O jumper on the Prox/Velom I/O Module is used to identify the type of transducer connected to the I/O module. However, the Recip Rod Position Monitor only uses Proximitor type transducer inputs. The jumper must always be set to the Prox/Accl position. Note: The connector shunt must be installed vertically on the top or bottom 8 terminal posts to select the corresponding transducer type.

WARNING- The connector shunt must be placed over the terminal posts for which the channel pair is configured, even when the channel pair is inactivated.

55


PROX/ACCL (Proximitor/Accelerometer): The eight-pin connector shunt must be installed on the top eight terminal posts.

56


4.2 Prox/Velom I/O Module (Internal Termination) Internal Termination I/O modules require you to wire each transducer and recorder to the I/O module individually. This section shows what this Internal Termination I/O module looks like and how to connect the wires to the Euro Style connector.

(1) Connect the wire from the transducers associated with Channel 1 and 2. (2) The jumper must be set to Prox/Accl transducer type for Channel 1 and 2. (3) Connect the wire from the transducers associated with Channel 3 and 4. (4) The jumper must be set to Prox/Accl transducer type for Channel 3 and 4. (5) INHB/RET: Connect to an external switch. Used to inhibit all non-primary Alert/Alarm 1 functions

for all four channels. (6) COM/REC: Connect each channel of the I/O module to a recorder.

57


4.2.1 Wiring Euro Style Connectors To remove a terminal block from its base, loosen the screws attaching the terminal block to the base, grip the block firmly and pull. Do not pull the block out by its wires because this could loosen or damage the wires or connector.

Figure 4-1 Typical I/O module Refer to the 3500 Field Wiring Diagram Package for the recommended wiring. Do not remove more than 6mm (0.25 in) of insulation from the wires.

58


4.3 Barrier Proximitor Internal I/O Module (Internal Termination) Internal Barrier I/O modules require you to wire each transducer to the I/O module individually. This section shows what this Internal Termination Barrier I/O module looks like and where to connect the wires to the Euro Style connectors.

(1) Connect the wire from the transducers associated with Channel 1 and 2. (2) Connect the wire from the transducers associated with Channel 3 and 4. (3) INHB/RET: Connect to an external switch. Used to inhibit all nonprimary Alert/Alarm 1 functions

for all four channels. (4) COM/REC: Connect each channel of the I/O module to a recorder.

59


4.4 Prox/Velom I/O Module (External Termination) External Termination I/O modules let you simplify the wiring to the I/O modules in a 3500 rack by using a 25-pin cable to route the signals from the four transducers and a nine pin cable to route the signals from the recorders to the I/O module. This section describes and shows the External Termination I/O module, the External Termination Blocks, and the pin outs for the cables that go between the External Termination I/O module and the External Termination Blocks.

(1) Connect the Prox/Velom I/O Module to the Proximitor External Termination Block using cable

129525-XXXX-XX. (2) The jumper must be set to Prox/Accl transducer type for Channel 1 and 2. (3) The jumper must be set to Prox/Accl transducer type for Channel 3 and 4. (4) Connect the I/O module to the Recorder External Termination Block using Cable 129529-XXXX-

XX.

60


4.4.1 External Termination Blocks The two types of External Termination Blocks used with a Prox/Velom I/O Module are the Prox/Velom External Termination Blocks and the Recorder External Termination Blocks. Each type comes with either Terminal Strip or Euro Style connectors.

4.4.1.1 Prox/Velom External Termination Block (Terminal Strip connectors)

(1) Connect the wire from the transducers associated with Channel 1, 2, 3, and 4 to the External

Termination Block. INHB/RET: Connect to an external switch. (2) Connect the I/O module to the External Termination Block using cable 129525-XXXX-XX (3) Channel 1 and Channel 2 (4) Channel 3 and Channel 4

61


4.4.1.2 Prox/Velom External Termination Block (Euro Style connectors)

(1) Connect the wire from the transducers associated with Channel 1, 2, 3, and 4 to the External

Termination Block. INHB/RET: Connect to an external switch. (2) Connect the I/O module to the External Termination Block using cable 129525-XXXX-XX (3) Channel 1 and Channel 2 (4) Channel 3 and Channel 4

62


4.4.1.3 Recorder External Termination Block (Terminal Strip connectors)

(1) Connect the recorders associated with Channel 1, 2, 3, and 4 to the Recorder External Termination

Block. (2) Connect the I/O module to the Recorder External Termination Block using cable 129529-XXXX-

XX. (3) Channel 1 and Channel 2 (4) Channel 3 and Channel 4

63


4.4.1.4 Recorder External Termination Block (Euro Style connectors)

(1) Connect the recorders associated with Channel 1, 2, 3, and 4 to the Recorder External Termination

Block. (2) Connect the I/O module to the Recorder External Termination Block using cable 129529-XXXX-

XX. (3) Channel 1 and Channel 2 (4) Channel 3 and Channel 4

64


4.4.2 Cable Pin Outs Cable Number 129525-XXXX-XX 3500 Transducer Signal to External Termination Block Cable

65


Cable Number 129529-XXXX-XX 3500 Recorder Output to External Termination Block Cable

66

Section 5 — Maintenance

5. Maintenance The boards and components inside of 3500 modules cannot be repaired in the field. Maintaining a 3500 rack consists of testing module channels to verify that they are operating correctly. Modules that are not operating correctly should be replaced with a spare. This section shows how to verify the operation of channels in a Recip Rod Position Monitor.

5.1 Verifying a 3500 Rack – Recip Rod Position Monitor Module The 3500 Monitoring System is a high precision instrument that requires no calibration. The functions of monitor channels, however, must be verified at regular intervals. At each maintenance interval, we recommend that you use the procedures in this section to verify the operation of all active channels in the monitor. It is only necessary to verify the alarms and accuracy of channel proportional values that are active.

Section

Number

Topic

5.1.1 Choosing a Maintenance Interval

5.1.2 Required Test Equipment

5.1.3 Typical Verification test setup

5.1.4 Using the Rack Configuration Software

5.1.5 Rod Position Single Channels

5.1.6 Rod Position Pair Channels

5.1.7 Rod Drop Channels

5.1.8 Hyper Channels

5.1.9 Verify Recorder Outputs

5.1.10 If a Channel Fails a Verification Test

67


5.1.1 Choosing a Maintenance Interval Use the following approach to choose a maintenance interval:

• Start with an interval of one year and then shorten the interval if any of the following conditions apply: - The monitored machine is classified as critical - The 3500 rack is operating in a harsh environment such as in extreme

temperature, high humidity, or in a corrosive atmosphere.

• At each interval, use the results of the previous verifications and ISO Procedure 10012-1 to adjust the interval.

5.1.2 Required Test Equipment and Setup The verification procedures in this section require the following test equipment and setup.

All Recip Rod Position Monitor Channels • Power Supply (single channel)

• Multimeter – 4 ½ digits

• Function Generator

• 100 µF capacitor

• 40 kΩ resistor

• Bently Nevada Corporation TK 16 Keyphasor Multiplier/Divider or equivalent (Instructions in this manual refer to the TK 16)

• Additional –18 Vdc Supply for use with the TK 16

• 2 channel Oscilloscope

WARNING High Voltage Present. Contact could cause shock, burns, or death. Do not touch exposed wires or terminals.

Application Alert: Tests will exceed alarm setpoint levels causing alarms to activate. This could result in a relay contact state change. Disconnecting the field wiring will cause a Not OK condition.

68


Figure 5-1 Recip Rod Position Monitor Test Setup The Test Equipment outputs should be floating relative to earth ground. For external termination I/O modules, the test setup is identical except that the test equipment outputs connect to the external termination block.

69


The equipment shown in the dashed box is required for Crank Angle, 1X Amplitude, 2X Amplitude, Not 1X Amplitude, Instantaneous Piston Position, and Instantaneous Gap. 1. Keyphasor Signal 2. Keyphasor I/O Module

3. 40 KΩ Resistor 4. 100 µF Capacitor 5. Keyphasor Multiplier/Divider 6. Input Signal 7. Multimeter 8. Proximitor I/O Module 9. Function Generator 10. Power Supply

5.1.3 Typical Verification test setup The following figure shows the typical test setup for verifying a Recip Rod Position Monitor. The test equipment is used to simulate the transducer signal and the laptop computer is used to observe the output from the rack.

Figure 5-2 General layout for Maintenance Transducers can be connected to a 3500 rack in a variety of ways. Depending on the wiring option for the I/O module of the monitor, connect the test equipment to the monitor using one of the following methods.

70


(1) Connect test equipment here. (2) Proximitor I/O Module (Internal Termination) (3) External Termination Block (Euro Style Connectors) (4) External Termination Block (Terminal Strip Connectors)

5.1.4 Using the Rack Configuration Software The laptop computer that is part of the test setup uses the Rack Configuration Software to display output from the rack and to reset certain operating parameters in the rack. To perform the test procedures in this section you must be familiar with the following features of the Rack Configuration Software:

• upload, download, and save configuration files

• enable and disable channels and alarms

• bypass channels and alarms

• display the Verification screen The Rack Configuration and Test Utilities Guide explains how to perform these operations. Note: It is important to save the original rack configuration before doing any Maintenance or Troubleshooting Procedures. It may be necessary during these procedures to change setpoints, etc. which must be restored to their original values at the conclusion of the procedures. At that time the original configuration should be downloaded to the rack.

The Keyphasor module must not be configured for the Recip Multi-Event Wheel to do the verification.

71


The following figures show how the Verification screen displays output from a 3500 rack:

Alarm Verification Fields:

(1) These fields display output for verifying channel alarms. Alert/Alarm 1 alarms are displayed in yellow in the bar graph and with the word “Alarm” under the current value box. Danger/Alarm 2 alarms are displayed in red in the bar graph and with the word “Alarm” under the current value box.

(2) Current Value: The current proportional value is displayed in this box. Setpoints are indicated by lines on the bargraph display

• Danger/Alarm 2 Over = Solid Red Line

• Alert/Alarm 1 Over = Solid Yellow Line

• Alert/Alarm 1 Under = Dashed Yellow Line

• Danger/Alarm 2 Under = Dashed Red Line

72

The Zero Position Voltage is the voltage input that will cause the reading on the bar graph display and current value box to be zero. The Zero Position Volts value is displayed in the Zero Position Volts box above each channel value bar graph.


OK Limit Verification Fields These fields display output for verifying OK limits.

Current Value Verification Fields: These fields display output for verifying channel output.

73


5.1.5 Rod Position Single Channels The following sections describe how to test alarms, verify channels, and test OK limits for channels configured as Rod Position Single. The output values and alarm setpoints are verified by varying the input signal levels and observing that the correct results are reported in the Verification screen on the test computer. Rod Position Single channels can be configured for the following channel values and alarms:

Channel Values Alarms

Over Under

Position Magnitude

X

Position Angle

Crank Angle

Pk Pk Displacement

X

Gap

X

X

1X Amplitude

X

2X Amplitude

X

Not 1X Amplitude

X

5.1.5.1 Test Equipment and Software Setup – Rod Position Single The following test equipment and software set up can be used as the initial setup needed for all the Rod Position Single channel verification procedures (Test Alarms, Verify Channels, and Test OK Limits).


74



Test Equipment Setup – Rod Position Single Simulate the transducer signal by connecting the power supply, function generator, and multimeter to COM and SIG of channel 1 with polarity as shown in Section 5.1.2, Recip Rod Position Monitor Test Setup Figure. Set the test equipment as specified below:

Power Supply Function Generator Keyphasor Multiplier/Divider

-7.00 Vdc

Wave Form: sinewave

DC Volts: 0 Vdc

Frequency: 15 Hz

Amplitude Level: Minimum (above zero)

Multiply Switch: 001

Divide Switch: 001

Verification Screen Setup – Rod Position Single Run the Rack Configuration Software on the test computer. Choose Verification from the Utilities menu and choose the proper Slot number and Channel number then click on the Verify button. The following table directs you to the starting page of each maintenance section associated with the Rod Position Single Channels: Section Number

Topic

5.1.5.2 Test Alarms – Position Magnitude

5.1.5.2 Test Alarms – Pk Pk Displacement

5.1.5.2 Test Alarms –Gap

5.1.5.2 Test Alarms – 1X Amplitude


5.1.5.2 Test Alarms – Not 1X Amplitude

5.1.5.3 Verify Channel Values – Position Magnitude

5.1.5.3 Verify Channel Values – Position Angle

5.1.5.3 Verify Channel Values – Crank Angle

5.1.5.3 Verify Channel Values – Pk Pk Displacement

5.1.5.3 Verify Channel Values – Gap

5.1.5.3 Verify Channel Values – 1 X Amplitude

5.1.5.3 Verify Channel Values – 2X Amplitude

5.1.5.3 Verify Channel Values – Not 1X Amplitude

5.1.5.4 Test OK Limits

75


5.1.5.2 Test Alarms – Rod Position Single The general approach for testing alarm setpoints is to simulate the position and Keyphasor® signals with a function generator. The alarm levels are tested by varying this input signal and observing that the correct results are reported in the Verification screen on the test computer. It is only necessary to test those alarm parameters that are configured and being used. The general test procedure to verify current alarm operation will include simulating a transducer input signal and varying this signal: 1. to exceed Over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and 2. to drop below any Under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and 3. to produce a non-alarm condition. When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis must be considered. Adjust the signal well below the alarm setpoint for the alarm to clear.

Position Magnitude Note: The Calculated Center Voltage value can be seen in the verification screen.

1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on the I/O module.

2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup. Set the function generator to have Sine wave output.

3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. Turn down the Amplitude on the function generator to have the minimum possible value and adjust the power supply DC voltage level to produce a gap reading that results in a Position Magnitude that is above (more negative than) the Calculated Center Voltage level and below (less negative than) the Position Magnitude setpoint levels on the bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bar graph indicator for Position Magnitude is green, and the Current Value field contains no alarm indication.

5. Increase (more negative) the power supply voltage such that the signal just exceeds the Position Magnitude Over Alert/Alarm 1 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the RIM. Verify that the bar graph indicator for Position Magnitude remains yellow and that the Current Field still indicates an Alarm.

7. Increase (more negative) the power supply such that the signal just exceeds the Position Magnitude Over Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph

76


indicator for Position Magnitude changes color from yellow to red and that the Current Value Field indicates an Alarm.

8. Press the RESET switch on the RIM. Verify that the bar graph indicator for Position Magnitude remains red and that the Current Value Field still indicates an Alarm.

9. Decrease (less negative) the power supply voltage such that the gap signal reads above the Calculated Center Voltage level and below the Over Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Position Magnitude changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the RIM to reset latching alarms.

10. Press the RESET switch on the RIM. Verify that the OK LED is on, the bar graph indicator for Position Magnitude is green, and the Current Value field contains no alarm indication.

11. Adjust the power supply level to produce a gap reading that is below (less negative than) the Calculated Center Voltage level and results in a Position Magnitude that is below (more negative than) the Position Magnitude setpoint levels on the bar graph display of the Verification screen.

Note: The Position Magnitude value will always be positive. Notice when the power supply voltage level crosses the Calculated Center Voltage level, the Position Angle value changes by 180 degrees. This is the angle of the Position Magnitude vector. This is always 0 or 180 only for Rod Position Single channel types.


13. Decrease (less negative) the power supply voltage such that the signal just exceeds the Position Magnitude Over Alert/Alarm 1 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from green to yellow and that the Current Value Field indicates an Alarm.


15. Decrease (less negative) the power supply such that the signal just exceeds the Position Magnitude Over Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from yellow to red and that the Current Value Field indicates an Alarm.


17. Increase (more negative) the power supply voltage such that the signal reads below the Over Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Position Magnitude changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the RIM to reset latching alarms.

77


18. If you cannot verify any configured alarm, recheck the configured setpoints. If the monitor still does not alarm properly or fails any other part of this test, go to Section 5.1.10 (If a Channel Fails a Verification Test).

19. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press the RESET button on the RIM to reset the OK LED.

20. Repeat steps 1 through 19 for all configured channels.

Pk Pk Displacement 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on

the I/O module. 2. Connect test equipment and run software as described in Section 5.1.2,

Required Test Equipment and Setup. Set the function generator to have Sine wave output.

3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. Adjust the function generator amplitude to produce a reading that is below the Pk-Pk Displacement setpoint level on the bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bargraph indicator for Pk-Pk Displacement is green, and the Current Value field contains no alarm indication.

5. Adjust the function generator amplitude such that the signal just exceeds the Pk-Pk Displacement Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Pk-Pk Displacement changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the RIM. Verify that the bar graph indicator for Pk-Pk Displacement remains yellow and that the Current Value Field still indicates an Alarm.

7. Adjust the function generator amplitude such that the signal just exceeds the Pk-Pk Displacement Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Pk-Pk Displacement changes color from yellow to red and that the Current value Field indicates an Alarm.

8. Press the RESET switch on the RIM. Verify that the bar graph indicator for Pk-Pk Displacement remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the function generator amplitude such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe that the bar graph indicator for Pk-Pk Displacement changes color to green and that the Current Value Box contains no indication of Alarms. Press the RESET switch on the RIM to reset latching alarms.

10. If you can not verify any configured alarm, recheck the configured setpoints. If the monitor still does not alarm properly or fails any other part of this test, go to Section 5.1.10 (If a Channel Fails a Verification Test).

78


11. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press the RESET button on the RIM to reset the OK LED.


Gap 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on



3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. With minimal Amplitude level on the function generator, adjust the power supply to produce a voltage that is within the Gap setpoint levels on the Gap bar graph display of the Verification Screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bargraph indicator for Gap is green and the Current Value Field contains no alarm indication.

5. Adjust the power supply voltage such that the signal just exceeds the Gap Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Gap changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the RIM. Verify that the OK LED is on, the bargraph indicator for Gap is yellow and the Current Value Field indicates an alarm.

7. Adjust the power supply voltage such that the signal just exceeds the Gap Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Gap changes color from yellow to red and that the Current Value Field indicates an Alarm.

8. Press the RESET switch on the RIM. Verify that the bar graph indicator for Gap remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the power supply voltage such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe that the bar graph indicator for Gap changes color to green and that the Current Value Box contains no idication of Alarms. Press the RESET switch on the RIM to reset latching alarms.

10. Repeat steps 5 through 9 to test the Under Alert/Alarm 1 and Under Danger/Alarm 2 setpoints by adjusting the power supply to exceed the Under Alarm setpoint levels.

11. If you can’t verify any configured alarm, recheck the configured setpoints. If the monitor still does not alarm properly or fails any other part of this test, go to Section 5.1.10 (If a Channel Fails a Verification Test).

12. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED

79


comes on and the OK relay energizes. Press the RESET switch on the RIM to reset the OK LED.


1X Amplitude Note: The Keyphasor must be triggering and have a valid rpm value to check this parameter.



3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. Adjust the function generator amplitude to produce a reading that is within the 1X Ampl setpoint levels on the 1X Ampl bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bargraph indicator for 1X Ampl is green and the Current Value Field contains no alarm indication.

5. Adjust the function generator amplitude such that the signal just exceeds the 1X Ampl Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for 1X Ampl changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the RIM. Verify that the bar graph indicator for 1X Ampl remains yellow and that the Current Value Field still indicates an alarm.

7. Adjust the function generator amplitude such that the signal just exceeds the 1X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for 1X Ampl changes color from yellow to red and that the Current Value Field indicates an Alarm.

8. Press the RESET switch on the RIM. Verify that the bar graph indicator for 1X Ampl remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the function generator amplitude such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe that the bar graph indicator for 1X Ampl changes color to green and that the Current Value Box contains no indication of Alarms. Press the RESET switch on the RIM to reset latching alarms.


11. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press the RESET switch on the RIM to reset the OK LED.

80






3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is two. Adjust the function generator amplitude to produce a reading that is within the 2X Ampl setpoint levels on the 2X Ampl bar graph display of the Verification screen.




7. Adjust the function generator amplitude such that the signal just exceeds the 2X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for 2X Ampl changes color from yellow to red and that the Current Value Field indicates an Alarm.






81


Not 1X Amplitude Note: The Keyphasor must be triggering and have a valid rpm value to check this parameter.



3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is two. Adjust the function generator amplitude to produce a reading that is within the Not 1X setpoint levels on the Not 1X bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bargraph indicator for Not 1X is green and the Current Value Field contains no alarm indication.

5. Adjust the function generator amplitude such that the signal just exceeds the Not 1X Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Not 1X changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the RIM. Verify that the bar graph indicator for Not 1X remains yellow and that the Current Value Field still indicates an alarm.

7. Adjust the function generator amplitude such that the signal just exceeds the Not 1X Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Not 1X changes color from yellow to red and that the Current Value Field indicates an Alarm.

8. Press the RESET switch on the RIM. Verify that the bar graph indicator for Not 1X remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the function generator amplitude such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe that the bar graph indicator for Not 1X changes color to green and that the Current Value Box contains no indication of Alarms. Press the RESET switch on the RIM to reset latching alarms.



Repeat steps 1 through 11 for all configured channels.

82


5.1.5.3 Verify Channel Values – Rod Position Single The general approach for testing channel values is to simulate the position and Keyphasor input signals with a function generator and power supply. The output values are verified by varying the input signal level and observing that the correct results are reported in the Verification screen on the test computer. Note: These parameters have an accuracy specification of ±1% of full scale for amplitude.

Position Magnitude – Position Angle 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals

on the I/O module. 2. Connect test equipment and run software as described in Section 5.1.2,


3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one.

4. Calculate the Full scale voltage according to the equation and examples shown below.

Full Scale Voltage = Calculated Center Voltage - (Position Magnitude Top Scale x Transducer Scale Factor) Note: Use the Calculated Center Voltage and the Transducer Scale Factor displayed on the Verification Screen.

Example 1: Calculated Center Voltage = -10.250 Vdc Position Magnitude Meter Top Scale = 40 mil Transducer Scale Factor = 200mV/mil Full Scale = -10.250 - (40 X 0.200) = -18.250 Vdc Example 2: Calculated Center Voltage = -10.25 Vdc Position Magnitude Meter Top Scale = 800µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = -10.25 - (800 X 0.007874) = -16.5492 Vdc

5. Turn down the Amplitude on the function generator to have the minimum

possible value and adjust the power supply DC voltage level to the calculated Full Scale voltage.

6. Verify that the Position Magnitude bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

7. Verify the Position Angle bar graph display and Current Value Box is reading correctly. If the Transducer Orientation is configured as 0°, the Position Angle should read 180°. If the Transducer Orientation is configured as 180°, the Position Angle should read 0°. If the recorder output is configured, refer

83


to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

8. Set the power supply input voltage equal to the Calculated Center Voltage. Verify that the Position Magnitude bar graph display and Current Value Box is reading aproximately Zero. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

9. Calculate the Opposite Full scale voltage according to the equation and examples shown below.

Note: The Opposite Full scale voltage will result in a full scale reading on the bar graph display and Current Value Box reading.

Opposite Full Scale Voltage = Calculated Center Voltage + (Position Magnitude Top Scale x Transducer Scale Factor) Note: Use the Calculated Center Voltage and the Transducer Scale Factor displayed on the Verification Screen.

Example 1: Calculated Center Voltage = -10.250 Vdc Position Magnitude Meter Top Scale = 40 mil Transducer Scale Factor = 200mV/mil Opposite Full Scale = -10.250 + (40 X 0.200) = -2.250 Vdc Example 2: Calculated Center Voltage = -10.25 Vdc Position Magnitude Meter Top Scale = 800µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Opposite Full Scale = -10.25 + (800 X 0.007874) = -3.9508 Vdc

10. Turn down the Amplitude on the function generator to have the minimum

possible value and adjust the power supply DC voltage level to the calculated Full Scale voltage.

11. Verify that the Position Magnitude bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

12. Verify the Position Angle bar graph display and Current Value Box is reading correctly. If the Transducer Orientation is at 0°, the Position Angle should read 0°. If the Transducer Orientation is at 180°, the Position Angle should read 180°. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

13. If the reading does not meet specifications, check that the input signal is correct. If the monitor still does not meet specifications of fails any other part of this test, go to section 5.1.10 (If a Channel Fails a Verification Test).

14. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press RESET switch on the Rack Interface Module to reset the OK LED.


84


Crank Angle Note: The Keyphasor must be triggering and have a valid rpm value to check this parameter.

1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals on the I/O module.

2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup. Set the function generator to Triangle wave output.

3. Using a 2-Channel oscilloscope, look at the triangle wave at the input to the monitor on one channel and look at the input to the keyphasor module on the other channel. Be sure to look at the keyphasor signal on the I/O side of the capacitor.

4. Set both channels of the oscilloscope to be DC coupled. Note: Due to the low frequencies, making this measurement with the scope AC coupled will introduce error in the Sync_Offset.

5. Measure and calculate the Crank Angle using the following instructions and referencing the drawing below:

• Turn down the DC offset to minimum level with out clipping the signal on the triangle wave input channel so that it can be seen on the scope. Adjust the vertical scale on the scope on the Keyphasor channel so that the Keyphasor pulse can be seen.

Note: This may cause the channel to go Not OK and the proportional value to go Invalid, but it will be reset after calculating the crank angle.

• Measure the time of the full Keyphasor_Cycle_Time (6) as shown.

• Calculate the Piston_Angle_Time using the following equation (The time from the Keyphasor leading edge to the Piston Top Dead Center). Refer to the monitor Configuration Options screen to get the Piston Angle value.

Piston_Angle_Time = (Piston Angle / 360°) X Keyphasor_Cycle_Time

• Mark the Piston_Angle_Time (7) on the scope.

• Measure the time from the Piston_Angle_Time to the next Positive_Peak_Value_Time (8) on the oscilloscope as shown.

• Calculate the Crank Angle using the following equation:

Crank Angle = (Positive_Peak_Value_Time / Keyphasor_Cycle_Time) X 360°

• Adjust the DC offset of the triangle wave input such that the signal is in the OK voltage range.

85


(1) Sync’d Triangle wave input (2) Keyphasor Notch Signal (3) Keyphasor Projection Signal (4) Time Scale (5) Leading edge of the Keyphasor (6) One Crank Shaft Revolution = Keyphasor_Cycle_Time (7) Piston_Angle_Time (time from Keyphasor to Top Dead Center) (8) Positive_Peak_Value_Time (Crank Angle)

6. Verify that the Crank Angle bar graph display and Current Value Box is

reading approximately what was calculated above. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

7. If the reading does not meet specifications, check that the input signal is correct. If the monitor still does not meet specifications or fails any other part of this test, go to section 5.1.10 (If a Channel Fails a Verification Test).

8. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press the RESET button on the Rack Interface Module (RIM) to reset the OK LED.


Pk Pk Displacement 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals

on the I/O module.

86


2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup. Set the function generator to Sine wave output.

3. Calculate the full scale voltage according to the equation and examples shown below. Adjust the amplitude of the function generator to the calculated Full Scale voltage.

Full Scale Voltage = Pk-Pk Displacement Meter Top Scale x Transducer Scale Factor Note: Use the Transducer Scale Factor displayed in the Scale Factor Box on the Verification Screen.

Example 1: Direct Meter Top Scale = 40 mil Transducer Scale Factor = 200mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input Vrms = (.0707/2) X (8) Vrms = 2.828 Vrms Example 2: Direct Meter Top Scale = 800µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms

4. Set the Keyphasor multiplier/divider so that the multiply setting is one and the

divide setting is one. Verify that the Pk-Pk Displacement bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.




Gap 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals

on the I/O module.

87



3. Adjust the power supply to produce a voltage equal to –18.00 Vdc on the Volt Meter. Verify that the Gap bar graph display and Current Value Box is reading –18.00 Vdc ±1% of Full Scale. If the recorder output is configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

4. Adjust the power supply to produce a voltage equal to mid-scale on the Volt Meter. Verify that the Gap bar graph display and Current Value Box is reading the mid-scale value ±1% of Full Scale. If the recorder output is configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.







3. Calculate the full-scale voltage according to the equation and examples shown below. Adjust the function generator amplitude to the calculated Full Scale voltage.

Full Scale Voltage = 1X Ampl Meter Top Scale X Transducer Scale Factor Note: Use the Transducer Scale Factor displayed in the Scale Factor Box on the Verification Screen.

Example 1: 1X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8) Vrms = 2.828 Vrms

88

Section 5 — Maintenance Example 2: 1X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268


divide setting is one. Verify that the 1X Ampl bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.









Example 1: 2X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8) Vrms = 2.828 Vrms

89

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual Example 2: 2X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms


divide setting is two. Verify that the 2X Ampl bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.








Full Scale Voltage = Not 1X Ampl Meter Top Scale X Transducer Scale Factor Note: Use the Transducer Scale Factor displayed in the Scale Factor Box on the Verification Screen.

Example 1: Not 1X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8)

90

Section 5 — Maintenance Vrms = 2.828 Vrms Example 2: Not 1X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms


divide setting is two. Verify that the Not 1X Ampl bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.




5.1.5.4 Test OK Limits – Rod Position Single The general approach for testing OK limits is to input a DC voltage and adjust it above the Upper OK limit and below the Lower OK limit. This will cause a channel not OK condition and the OK Relay to change state (de-energize). The Upper and Lower OK limits are displayed in the Verification screen on the test computer. 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on

the Rod Position I/O Module. 2. Connect test equipment and run software as described in Section 5.1.2,

Required Test Equipment and Setup. Set the function generator to Sine wave output. Set the input to only DC signal into the monitor by adjusting the amplitude of the function generator to approximately zero.

3. Bypass all other configured channels. 4. Adjust the power supply voltage to -7.00 Vdc. 5. Press the RESET switch on the Rack Interface Module (RIM). Verify that the

monitor OK LED is on and that the Channel OK State line in the Channel Status box of the Verification screen reads OK.

91


Note: If the Danger Bypass has been activated, then the BYPASS LED will be on. All other channels in the rack must be OK or bypassed for the relay to be energized.

6. Verify that the OK relay on the Rack Interface I/O Module indicates OK

(energized). See 3500/20 Rack Interface Module Operation and Maintenance Manual.

7. Increase the power supply voltage (more negative) until the OK LED just goes off (upper limit). Verify that the Channel OK State line in the Channel Status box reads not OK and that the OK Relay indicates not OK. Verify that the Upper OK limit voltage displayed on the Verification screen is equal to or more positive than the input voltage.

8. Decrease the power supply voltage (less negative) to -7.00 Vdc. 9. Press the RESET switch on the Rack Interface Module. Verify that the OK

LED comes back on and the OK relay energizes. Verify that the Channel OK State line in the Channel Status box reads OK.

10. Gradually decrease the power supply voltage (less negative) until the OK LED just goes off (lower limit). Verify that the Channel OK State line in the Channel Status box reads not OK and that the OK Relay indicates not OK. Verify that the Lower OK limit voltage displayed on the Verification screen is equal to or more negative than the input voltage.

11. Increase the power supply voltage (more negative) to -7.00 Vdc. 12. Press the RESET switch on the Rack Interface Module. Verify that the OK

LED comes back on, the OK relay energizes, and that the Channel OK State line in the Channel Status box reads OK.

13. If you cannot verify any configured OK limit, go to Section 5.1.10 (If a Channel Fails a Verification Test).

14. Disconnect the test equipment and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the Monitor I/O Module. Press the RESET switch on the Rack Interface Module and verify that the OK LED comes on and the OK relay energizes.

15. Repeat steps 1 through 14 for all configured channels. 16. Return the bypass switch for all configured channels to their original setting.

Table 5-1 Rod Position Single Default OK Limits Table Transducer Lower OK Limit (Volts) Upper OK Limit (Volts) 3300 8 mm w/ Galvanic Isolation

-1.1 -18.2

3300 8 mm w/ External barriers

-1.1 -18.2

3300 8 mm w/ Internal barriers -1.28 -18.2 3300 8 mm w/o barriers -1.28 -19.04 3300XL 8 mm w/ Galvanic Isolation

-1.1 -18.2

3300XL 8 mm w/ External barriers

-1.1 -18.2

3300XL 8 mm w/ Internal barriers

-1.28 -18.2

3300XL 8 mm w/o barriers -1.28 -19.04

92


Transducer Lower OK Limit (Volts) Upper OK Limit (Volts) 3300XL 11 mm w/ Galvanic Isolation

-1.1 -18.2

3300XL 11 mm w/ External barriers

-1.1 -18.2

3300XL 11 mm w/ Internal barriers

-1.28 -18.2

3300XL 11 mm w/o barriers -1.28 -19.04 7200 8 mm w/ Galvanic Isolation

-1.1 -18.2

7200 8 mm w/ External barriers

-1.1 -18.2

7200 8 mm w/ Internal barriers -1.28 -18.2 7200 8 mm w/o barriers -1.28 -19.04 7200 11 mm w/o barriers -3.55 -20.39 7200 14 mm w/o barriers -1.65 -18.05

Note: Assume 50 mV accuracy for check tolerance.

5.1.6 Rod Position Pair Channels The following sections describe how to test alarms, verify channels, and test OK limits for channels configured as Rod Position Pair. The output values and alarm setpoints are verified by varying the input signal levels and observing that the correct results are reported in the Verification screen on the test computer. Rod Position Pair channels can be configured for the following channel values and alarms:


Over

Under

Position Magnitude

X

Piston Angle

Crank Angle

Pk Pk Displacement

X

Gap

X

X

1X Amplitude

X

2X Amplitude

X

Not 1X Amplitude

X

93


5.1.6.1 Test Equipment and Software Setup – Rod Position Pair The following test equipment and software set up can be used as the initial set up needed for all the Rod Position Pair channel verification procedures (Test Alarms, Verify Channels, and Test OK Limits).



94


Test Equipment Setup – Rod Position Pair Simulate the transducer signal by connecting the power supply, function generator, and multimeter to COM and SIG of channel 1 with polarity as shown in Section 5.1.2, Recip Rod Position Monitor Test Setup Figure. Set the test equipment as specified below: Power Supply Function Generator Keyphasor Multiplier/Divider -7.00 Vdc

Wave Form: sinewave DC Volts: 0 Vdc Frequency: 15 Hz Amplitude Level: Minimum (above zero)

Multiply Switch: 001 Divide Switch: 001

Connect the input from Channel 1 to the Channel 2 inputs at the I/O Module as shown. Note: Rod Position Pair Channel Types require input to two channels. This is accomplished with one function generator by giving the same input to both channels.

Note: When using the Software Verification screens for Rod Position Pair, the screen for the first channel of the pair displays the Position Magnitude, Position Angle, and Crank Angle proportional values. These are common/composite proportional values, with all others being independent.

Verification Screen Setup – Rod Position Pair Run the Rack Configuration Software on the test computer. Choose Verification from the Utilities menu and choose the proper Slot number and Channel number then click on the Verify button. The following table directs you to the starting page of each maintenance section associated with the Rod Position Pair Channels:

95


Section Number

Topic

5.1.6.2 Test Alarms – Position Magnitude

5.1.6.2 Test Alarms – Pk Pk Displacement

5.1.6.2 Test Alarms –Gap




5.1.6.3 Verify Channel Values – Position Magnitude

5.1.6.3 Verify Channel Values – Position Angle

5.1.6.3 Verify Channel Values – Crank Angle

5.1.6.3 Verify Channel Values – Pk Pk Displacement

5.1.6.3 Verify Channel Values – Gap

5.1.6.3 Verify Channel Values – 1 X Amplitude

5.1.6.3 Verify Channel Values – 2X Amplitude



5.1.6.2 Test Alarms – Rod Position Pair The general approach for testing alarm setpoints is to simulate the position and Keyphasor® signals with a function generator. The alarm levels are tested by varying the this input signal and observing that the correct results are reported in the Verification screen on the test computer. It is only necessary to test those alarm parameters that are configured and being used. The general test procedure to verify current alarm operation will include simulating a transducer input signal and varying this signal: 1. to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and 2. to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and 3. to produce a non-alarm condition. When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis must be considered. Adjust the signal well below the alarm setpoint for the alarm to clear.

Position Magnitude Note: The Calculated Center Voltage value can be seen in the verification screen.


2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment

96


and Software Setup – Rod Position Pair. Set the function generator to Sine wave output.

Note: When using the Software Verification screens for Rod Position Pair, the screen for the first channel of the pair displays the Position Magnitude, Position Angle, and Crank Angle values. These are common/composite values between the two channels, with all others being independent.

3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. Turn down the Amplitude on the function generator to have the minimum possible value and adjust the power supply DC voltage level to produce a gap reading that results in a Position Magnitude that is above (more negative than) the Calculated Center Voltage level and below (less negative than) the Position Magnitude setpoint levels on the bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bar graph indicator for Position Magnitude is green, and the Current Value field contains no alarm indication.

5. Increase (more negative) the power supply voltage such that the signal just exceeds the Position Magnitude Over Alert/Alarm 1 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from green to yellow and that the Current Value Field indicates an Alarm.


7. Increase (more negative) the power supply such that the signal just exceeds the Position Magnitude Over Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from yellow to red and that the Current Value Field indicates an Alarm.


9. Decrease (less negative) the power supply voltage such that the gap signal reads above (more negative) the Calculated Center Voltage level and below (less negative) the Over Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Position Magnitude changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the RIM to reset latching alarms.


11. Adjust the power supply level to produce a gap reading that is below (less negative) the Calculated Center Voltage level and results in a Position Magnitude that is below (more negative than) the Position Magnitude setpoint levels on the bar graph display of the Verification screen.

Note: The Position Magnitude value will always be positive.

97



13. Decrease (less negative) the power supply voltage such that the signal just exceeds the Position Magnitude Over Alert/Alarm 1 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from green to yellow and that the Current Value Field indicates an Alarm.


15. Decrease (less negative) the power supply such that the signal just exceeds the Position Magnitude Over Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Position Magnitude changes color from yellow to red and that the Current Value Field indicates an Alarm.


17. Increase (more negative) the power supply voltage such that the signal reads below (more negative) the Over Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Position Magnitude changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the RIM to reset latching alarms.

18. If you cannot verify any configured alarm, recheck the configured setpoints. If the monitor still does not alarm properly or fails any other part of this test, go to Section 5.1.10 (If a Channel Fails a Verification Test).

19. Disconnect the test equipment and channel jumpers and reconnect the PWR, COM, and SIG field wiring to the channel terminals on the I/O module. Verify that the OK LED comes on and the OK relay energizes. Press the RESET button on the RIM to reset the OK LED.


Pk Pk Displacement 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on


Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment and Software Setup – Rod Position Pair. Set the function generator to Sine wave output.


98














3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. With minimal Amplitude level on the function generator, adjust the power supply to produce a voltage that is within the Gap setpoint levels on the Gap bar graph display of the Verification Screen.


99













2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment and Software Setup – Rod Position Pair. Set the function generator to Sine wave output.


100





7. Adjust the function generator amplitude such that the signal just exceeds the 1X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for 1X Ampl changes color from yellow to red and that the Current value Field indicates an Alarm.










101















102





7. Adjust the function generator amplitude such that the signal just exceeds the Not 1X Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Not 1X changes color from yellow to red and that the Current value Field indicates an Alarm.






5.1.6.3 Verify Channel Values – Rod Position Pair The general approach for testing channel values is to simulate the position and Keyphasor input signals with a function generator and power supply. The output values are verified by varying the input signal level and observing that the correct results are reported in the Verification screen on the test computer.

Position Magnitude – Position Angle 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals



103


3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. Set the Amplitude level on the function generator for a 1 Vpp Sine wave and adjust the power supply DC voltage level to produce a gap reading that is at least two volts less negative than the Calculated Center Voltage level.

Note: The Pk_Pk voltage cannot cross the Calculated Center Voltage level.

4. Record the transducer orientation angles from the monitor Options screen. These angles are to be between 0° and 359° with 0° being vertical or opposing gravity and going in the CW direction as viewed from the driver end. These angles will be α1 and α2 for Channels 1 and 2 respectively.

Example: α 1 = 10° Left (options screen) = 350° α 2 = 85° Right (options screen) = 85°

5. Calculate β (the angle between the probes) with the following equation:

β = α1 – α2 Example: α1 = 350° α2 = 85° β = α1 – α2 = 350° - 85° = 265°

6. Calculate x’ and y’ (translated orthogonal probe gaps) with the following

equations: x’ (mils) = (P1 – ZP1) / SF1

y’ (mils) = [(P2 – ZP2) / SF2 – x’Cosβ] / Sinβ Example: DC Offset = -5.00 Vdc Sine wave Amplitude = 1 Vpp β = 265° ZP1 = ZP2 = -10.50 Vdc SF1 = SF2 = 200 mV/mil = .200 V/mil P1 = P2 = -5.00 + .50 = -4.5 Volts x’ = [-4.50 – (-10.50)] / .200 x’ = 6.00 / .200 = 30.0 mil y’ = [ [-4.50 – (-10.5)] / .200 – (30*Cos265°) ] / Sin265° y’ = [ 6 / .200 – (-2.61) ] / (-.996) y’ = -32.7 mils

P1 and P2 are the DC offset Voltage value plus ½ of the Vpp Voltage value. Note: Since the same input signal is going into Channel 1 and 2, the values of P1 and P2 will be the same.

ZP1 and ZP2 are the Calculated Center Voltage levels given on the Software Verification Screens. These values will most likely be different for each channel.

104


SF1 and SF2 are the probe Scale Factors for each channel given on the Software Verification Screens. 7. Calculate the Position Magnitude vector value with the following equation: Position Magnitude (mils) = Sqrt(x’^2 + y’^2)

Example: x’ = 30.0 mils y’ = -32.7 mils Position Magnitude = Sqrt [(30)^2 + (-32.7)^2] Position Magnitude = Sqrt [900 + 1069] Position Magnitude = 44.4 mils

8. Verify that the Position Magnitude bar graph display and Current Value Box is

reading of the calculated value ±1% of Full Scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.

9. Transform the coordinates to the actual X and Y values of the position vector with the following equations:

Φ = 90° - α1

x = x’CosΦ – y’SinΦ

y = x’SinΦ + y’CosΦ Example: Φ = 90° - 350° Φ = -260° x = 30.0*Cos(-260°) – (-32.7)*Sin(-260°) x = -5.21 + 32.20 x = 26.99 mils y = 30.0*Sin(-260°) + (-32.7)*Cos(-260°) y = 29.54 + 5.68 y = 35.22 mils

10. Determine the Position Angle with the following rules and equations:

For y = 0 If x > 0 - Position Angle = 90° If x < 0 - Position Angle = 270° If x = 0 - Position Angle = 0° For y > 0 If x >= 0 - Position Angle = arctan (x/y) If x < 0 - Position Angle = arctan (x/y) + 360° For y < 0 - Position Angle = arctan (x/y) + 180° Example: x = 26.99 mils y = 35.22 mils y > 0

105

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual x >= 0 Position Angle = arctan(26.99/35.22) Position Angle = 37.5°

11. Verify that the Position Angle bar graph display and Current Value Box is

reading of the calculated value ±1% of Full Scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.




Crank Angle Note: The Keyphasor must be triggering and have a valid rpm value to check this parameter.


2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment and Software Setup – Rod Position Pair. Set the function generator to Triangle wave output.

3. Using a 2-Channel oscilloscope, look at the triangle wave at the input to the monitor on one channel and look at the input to the keyphasor module on the other channel. Be sure to look at the keyphasor signal on the I/O side of the capacitor.


5. Measure and calculate the Crank Angle using the following instructions and referencing the drawing below: - Turn down the DC offset to minimum level with out clipping the signal on

the triangle wave input channel so that it can be seen on the scope. Adjust the vertical scale on the scope on the keyphasor channel so that the keyphasor pulse can be seen.


- Measure the time of the full Keyphasor_Cycle_Time (6) as shown. - Calculate the Piston_Angle_Time using the following equation (The time

from the Keyphasor leading edge to the Piston Top Dead Center). Refer to the monitor Configuration Options screen to get the Piston Angle value.

106


Piston_Angle_Time = (Piston Angle / 360°) X Keyphasor_Cycle_Time

- Mark the Piston_Angle_Time (7) on the scope. - Measure the time from the Piston_Angle_Time to the next

Positive_Peak_Value_Time (8) on the oscilloscope as shown. - Calculate the Crank Angle with the following equation:

Crank Angle = (Positive_Peak_Value_Time / Keyphasor_Cycle_Time) X 360°

- Adjust the DC offset of the triangle wave input such that the signal is in the OK voltage range.

(1) Sync’d Triangle wave input (2) Keyphasor Notch Signal (3) Keyphasor Projection Signal (4) Time Scale (5) Leading edge of the Keyphasor (6) One Crank Shaft Revolution = Keyphasor_Cycle_Time (7) Piston_Angle_Time (time from Keyphasor to Top Dead Center) (8) Positive_Peak_Value_Time (Crank Angle)

6. Verify that the Crank Angle bar graph display and Current Value Box is

reading approximately what was calculated above. If the recorder output is

107


configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.




Pk Pk Displacement 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals



3. Calculate the Full Scale voltage according to the equation and examples shown below. Adjust the amplitude of the function generator to the calculated voltage.


Example 1: Direct Meter Top Scale = 40 mil Transducer Scale Factor = 200mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input Vrms = (.0707/2) X (8) Vrms = 2.828 Vrms Example 2: Direct Meter Top Scale = 800µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms


divide setting is one. Verify that the Pk-Pk Displacement bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is

108


configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.















109


3. Calculate the full-scale voltage according to the equation and examples shown below. Adjust the function generator amplitude to the calculated voltage with sinewave output.


Example 1: 1X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8) Vrms = 2.828 Vrms Example 2: 1X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268








2. Connect test equipment and run software as described in Section 5.1.2, Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment

110


and Software Setup – Rod Position Pair. Set the function generator to Sine wave output.



Example 1: 2X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8) Vrms = 2.828 Vrms Example 2: 2X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms





7. Repeat steps 1 through 6 for all configured channels



111





Example 1: Not 1X Ampl Meter Top Scale = 40 mil Transducer Scale Factor = 200 mV/mil Full Scale = (40 X 0.200) = 8.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (8) Vrms = 2.828 Vrms Example 2: Not 1X Ampl Meter Top Scale = 800 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (800 X 0.007874) = 6.2992 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (6.2992) Vrms = 2.2268 Vrms






5.1.6.4 Test OK Limits – Rod Position Pair The general approach for testing OK limits is to input a DC voltage and adjust it above the Upper OK limit and below the Lower OK limit. This will cause a channel not OK condition and the OK Relay to change state (de-energize). The

112


Upper and Lower OK limits are displayed in the Verification screen on the test computer. 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on


Required Test Equipment and Setup. Set the function generator to Sine wave output. Set the input to only DC signal into the monitor by adjusting the amplitude of the function generator to approximately zero.

3. Bypass all other configured channels. 4. Adjust the power supply voltage to -7.00 Vdc. 5. Press the RESET switch on the Rack Interface Module (RIM). Verify that the













113



Table 5-2 Rod Position Pair Default OK Limits Table Transducer Lower OK Limit (Volts) Upper OK Limit (Volts) 3300 8 mm w/ Galvanic Isolation -1.1 -18.2 3300 8 mm w/ External barriers -1.1 -18.2 3300 8 mm w/ Internal barriers -1.28 -18.2 3300 8 mm w/o barriers -1.28 -19.04 3300XL 8 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 8 mm w/ External barriers -1.1 -18.2 3300XL 8 mm w/ Internal barriers -1.28 -18.2 3300XL 8 mm w/o barriers -1.28 -19.04 3300XL 11 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 11 mm w/ External barriers -1.1 -18.2 3300XL 11 mm w/ Internal barriers -1.28 -18.2 3300XL 11 mm w/o barriers -1.28 -19.04 7200 8 mm w/ Galvanic Isolation -1.1 -18.2 7200 8 mm w/ External barriers -1.1 -18.2 7200 8 mm w/ Internal barriers -1.28 -18.2 7200 8 mm w/o barriers -1.28 -19.04 7200 11 mm w/o barriers -3.55 -20.39 7200 14 mm w/o barriers -1.65 -18.05

Assume 50 mV accuracy for check tolerance.

114


5.1.7 Rod Drop Channels The following sections describe how to test alarms, verify channels, and test OK limits for channels configured as Rod Drop. The output values and alarm setpoints are verified by varying the input signal levels and observing that the correct results are reported in the Verification screen on the test computer. Rod Drop channels can be configured for the following channel values and alarms:


Over

Under

Average Piston Position

X

Average Gap

Instantaneous Piston Position

X

Instantaneous Gap

5.1.7.1 Test Equipment and Software Setup – Rod Drop The following test equipment and software setup can be used as the initial setup needed for all the Rod Drop channel verification procedures (Test Alarms, Verify Channels, and Test OK Limits).



115


Test Equipment Setup – Rod Drop Simulate the transducer signal by connecting the power supply, function generator, and multimeter to COM and SIG of channel 1 with polarity as shown in Section 5.1.2, Recip Rod Position Monitor Test Setup Figure. Set the test equipment as specified below: Power Supply Function Generator Keyphasor Multiplier/Divider -7.00 Vdc



Verification Screen Setup – Rod Drop Run the Rack Configuration Software on the test computer. Choose Verification from the Utilities menu and choose the proper Slot number and Channel number then click on the Verify button. The following table directs you to the starting page of each maintenance section associated with the Rod Drop Channels: Section Number

Topic

5.1.7.2 Test Alarms – Average Gap

5.1.7.2 Test Alarms – Average Piston Position

5.1.7.2 Test Alarms – Instantaneous Gap

5.1.7.2 Test Alarms – Instantaneous Piston Position

5.1.7.3 Verify Channel Values – Average Gap and Piston Position

5.1.7.3 Verify Channel Values – Instantaneous Gap and Piston Position


116


5.1.7.2 Test Alarms – Rod Drop The general approach for testing alarm setpoints is to simulate the position and Keyphasor® input signals with a function generator and power supply. The alarm levels are tested by varying the input signals and observing that the correct results are reported in the Verification screen on the test computer. It is only necessary to test those alarm parameters that are configured and being used. The general test procedure to verify current alarm operation will include simulating a transducer input signal and varying this signal: 1. to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and 2. to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and 3. to produce a non-alarm condition. When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis must be considered. Adjust the signal well below the alarm setpoint for the alarm to clear.

Average Piston Position 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on


Required Test Equipment and Setup. Set the function generator to Sine wave output.

3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. With minimal Amplitude level on the function generator, adjust the DC power supply level to produce a reading that is above the Average Piston Position setpoint level on the bar graph display of the Verification screen.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bar graph indicator for Average Piston Position is green, and the Current Value field contains no alarm indication.

5. Adjust the power supply voltage such that the signal just exceeds the Average Piston Position Under Alert/Alarm 1 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Average Piston Position changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the Rack Interface Module (RIM). Verify that the bar graph indicator for Average Gap remains yellow and that the Current Field still indicates an Alarm.

7. Adjust the power supply such that the signal just exceeds the Average Piston Position Under Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Average Piston Position changes color from yellow to red and that the Current Value Field indicates an Alarm.

117


8. Press the RESET switch on the Rack Interface Module (RIM). Verify that the bar graph indicator for Average Piston Position remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the power supply voltage such that the signal reads above the Under Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Average Piston Position changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the Rack Interface Module (RIM) to reset latching alarms.




Instantaneous Piston Position 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on



3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the divide setting is one. With minimal Amplitude level on the function generator, adjust the DC power supply to produce a reading that is above the Instantaneous Piston Position setpoint levels on the Instantaneous Piston Position bar graph display of the Verification screen. Be sure to set the DC Voltage levels such that all Sine wave values are still above the setpoint level.

4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the OK LED is on, the bar graph indicator for Instantaneous Gap is green, and the Current Value field contains no alarm indication.

5. Adjust the DC power supply output such that the signal just exceeds the Instantaneous Piston Position Under Alert/Alarm 1 setpoint level. Be sure to set the DC Voltage level such that all Sine wave values are still below the setpoint level (and above the Danger/Alarm 2 setpoint level). Wait until 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Instantaneous Gap changes color from green to yellow and that the Current Value Field indicates an Alarm.

6. Press the RESET switch on the Rack Interface Module (RIM). Verify that the bar graph indicator for Instantaneous Gap remains yellow and that the Current Field still indicates an Alarm.

7. Adjust the power supply output such that the signal just exceeds the Instantaneous Piston Position Under Danger/Alarm 2 setpoint level. Be sure to set the DC Voltage level such that all Sine wave values are still below the setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires

118


and verify that the bar graph indicator for Instantaneous Piston Position changes color from yellow to red and that the Current Value Field indicates an Alarm.

8. Press the RESET switch on the Rack Interface Module (RIM). Verify that the bar graph indicator for Instantaneous Gap remains red and that the Current Value Field still indicates an Alarm.

9. Adjust the power supply output such that the signal reads below the Over Alarm setpoint levels. If the non-latching option is configured, observe that the bar graph indicator for Instantaneous Piston Position changes color to green and that the Current Value Box contains no indication of alarms. Press the RESET switch on the Rack Interface Module (RIM) to reset latching alarms.

10. If you can not verify any configured alarm, recheck the configured setpoints. If the monitor still does not alarm properly or fails any other part of this test, go to Section 5.1.10 (If a Channel Fails a Self Test).



5.1.7.3 Verify Channel Values – Rod Drop The general approach for testing channel values is to simulate the position and Keyphasor input signals with a function generator and power supply. The output values are verified by varying the input signal level and observing that the correct results are reported in the Verification screen on the test computer.

Average Gap – Average Piston Position 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on



3. Adjust the DC power supply to produce a voltage equal to -18.00 Vdc on the voltmeter display. Verify that the Average Gap bar graph display, and Current Value Box, is reading -18.00 Vdc ±1% of Full Scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

4. Using the equation shown below, calculate the Average Piston Position. Verify that the Average Piston Position bar graph display, and Current Value Box, is reading the calculated value ±1% of Full Scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

Average Piston Position = (Average Gap – ZP) / SF * ACF

Example:

119

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual Average Gap = -18.0 Vdc ZP = -8.59 Vdc SF = 200mV/mil = .200 V/mil ACF = 2.05 Average Piston Position = [ (-18.0) – (-8.59) ] / .200 * 2.05 Average Piston Position = -9.41 / .200 * 2.05 Average Piston Position = 96.5 mils

Note: Use the Scale Factor (SF), Zero Position (ZP), and Average Correction Factor (ACF) displayed on the Verification Screen.




Instantaneous Gap – Instantaneous Piston Position Note: The Keyphasor must be triggering and have a valid rpm value to check this parameter.



3. Using a 2-Channel oscilloscope, look at the Sine wave at the input to the monitor on one channel and look at the input to the keyphasor module on the other channel. Be sure to look at the keyphasor signal on the I/O side of the capacitor.


5. Measure and calculate the Sync_Offset_Angle using the following instructions and referencing the drawing below: - Turn down the DC offset to minimum level with out clipping the signal on

the Sine wave input channel so that it can be seen on the scope. Adjust the vertical scale on the scope on the keyphasor channel so that the keyphasor pulse can be seen.


- Center the signal vertically about an axis on the scope. This makes it easier to see the zero crossing.

- Measure the time of the full Keyphasor_Cycle_Time (6) as shown.

120


- Measure the time of the Sync_Offset_Time as shown (7). Calculate the Sync_Offset_Angle:

Sync_Offset_Angle = (Sync_Offset_Time / Keyphasor_Cycle_Time) X 360° Example: Keyphasor_Cycle_Time = 66.4 ms Sync_Offset_Time = 32.4 ms Sync_Offset_Angle = (32.4 / 66.4) X 360° Sync_Offset_Angle = 175°

- Using the following equation and configured machine parameters,

calculate the Instantaneous Gap: Instantaneous Gap = Vp * Sin(PA + TA – Sync_Offset_Angle) + DC Offset

Example: Sync_Offset_Angle = 175° Vpp = 2 Volt, Vp = 1 Volt P.A. = 60° T.A. = 55° DC_Offset = -7.00 Volt I.G. = 1.0V * Sin(60° + 55° - 175°) –7.00V I.G. = 1.0V * Sin(-60°) – 7.00V I.G. = 1.0V * (-.866) – 7.00V I.G. = -7.87 Vdc

- Vp is input peak amplitude (NOT peak to peak). - DC Offset is the DC offset of the input sine wave in negative volts. - PA is the machine parameter Piston Angle. TA is the maching parameter

Trigger Angle. These values are available in the monitor options screen. - Sync_Offset_Angle is the value in degrees from the falling edge

keyphasor signal to the next zero value of the Sine wave heading in the positive direction.

121


(1) Sync’d Sine wave input (2) Keyphasor Notch Signal (3) Keyphasor Projection Signal (4) Time Scale. (5) Leading edge of the Keyphasor (6) One Crank Shaft Revolution = Keyphasor_Cycle_Time (7) Sync_Offset

6. Verify that the Instantaneous Gap bar graph display, and Current Value Box,

is reading approximately what was calculated above. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

7. Using the equations shown below, calculate the Instantaneous Piston Position. Verify that the Instantaneous Piston Position bar graph display, and Current Value Box, is reading the calculated value ±1% of Full Scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder output.

If Transducer Orientation (from monitor Options screen) is 0°: Instantaneous Piston Position = ICF * (Instantaneous Gap – ZP) / SF

If Transducer Orientation (from monitor Options screen) is 180°: Instantaneous Piston Position = -1 * ICF * (Instantaneous Gap – ZP) / SF

Example: Transducer Orientation = 180°

122

Section 5 — Maintenance I.G. = -7.87 Volts ZP = -10.00 Volts SF = 200 mV/mil = .200 V/mil ICF = 1.84 I.P.P. = -1*[(-7.87 + 10.00) / .200 * 1.84] I.P.P. = -1*[10.65 * 1.84] I.P.P. = -19.6

Note: Use the Scale Factor, Zero Position, and Instantaneous Correction Factor displayed on the Verification Screen.

8. If the reading does not meet specifications, check that the input signal is

correct. If the monitor still does not meet specifications or fails any other part of this test, go to section 5.1.10 (If a Channel Fails a Verification Test).



5.1.7.4 Test OK Limits – Rod Drop The general approach for testing OK limits is to input a DC voltage and adjust it above the Upper OK limit and below the Lower OK limit. This will cause a channel not OK condition and the OK Relay to change state (de-energize). The Upper and Lower OK limits are displayed in the Verification screen on the test computer. 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on


Required Test Equipment and Setup. 3. Bypass all other configured channels. 4. Adjust the power supply voltage to -7.00 Vdc. 5. Press the RESET switch on the Rack Interface Module (RIM). Verify that the





123


7. Increase the power supply voltage (more negative) until the OK LED just goes off (upper limit). Verify that the Channel OK State line in the Channel Status box reads Not OK and that the OK Relay indicates not OK. Verify that the Upper OK limit voltage displayed on the Verification screen is equal to or more positive than the input voltage.



10. Gradually decrease the power supply voltage (less negative) until the OK LED just goes off (lower limit). Verify that the Channel OK State line in the Channel Status box reads Not OK and that the OK Relay indicates not OK. Verify that the Lower OK limit voltage displayed on the Verification screen is equal to or more negative than the input voltage.






Table 5-3 Rod Drop Default OK Limits Table Transducer Lower OK Limit (Volts) Upper OK Limit (Volts) 3300 8 mm w/ Galvanic Isolation -1.1 -18.2 3300 8 mm w/ External barriers -1.1 -18.2 3300 8 mm w/ Internal barriers -1.28 -18.2 3300 8 mm w/o barriers -1.28 -19.04 3300XL 8 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 8 mm w/ External barriers -1.1 -18.2 3300XL 8 mm w/ Internal barriers -1.28 -18.2 3300XL 8 mm w/o barriers -1.28 -19.04 3300XL 11 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 11 mm w/ External barriers -1.1 -18.2 3300XL 11 mm w/ Internal barriers -1.28 -18.2 3300XL 11 mm w/o barriers -1.28 -19.04 7200 8 mm w/ Galvanic Isolation -1.1 -18.2 7200 8 mm w/ External barriers -1.1 -18.2 7200 8 mm w/ Internal barriers -1.28 -18.2 7200 8 mm w/o barriers -1.28 -19.04 7200 11 mm w/o barriers -3.55 -20.39 7200 14 mm w/o barriers -1.65 -18.05

Note: Assume 50 mV accuracy for check tolerance.

124


5.1.8 Hyper Channels The following sections describe how to test alarms, verify channels, and test OK limits for channels configured as Hyper. The output values and alarm setpoints are verified by varying the input signal levels and observing that the correct results are reported in the Verification screen on the test computer. Hyper channels can be configured for the following channel values and alarms:


Over

Under

Pk Pk Displacement

X

Gap

X

X

1X Amplitude

X

X

2X Amplitude

X

X

Not 1X Amplitude

X

5.1.8.1 Test Equipment and Software Setup – Hyper The following test equipment and software setup can be used as the initial setup needed for all the Hyper channel verification procedures (Test Alarms, Verify Channels, and Test OK Limits).



125


Test Equipment Setup – Hyper Simulate the transducer signal by connecting the power supply, function generator, and multimeter to COM and SIG of channel 1 with polarity as shown in Section 5.1.2, Recip Rod Position Monitor Test Setup Figure. Set the test equipment as specified below: Power Supply Function Generator Keyphasor Multiplier/Divider -7.00 Vdc



Verification Screen Setup – Hyper Run the Rack Configuration Software on the test computer. Choose Verification from the Utilities menu and choose the proper Slot number and Channel number then click on the Verify button. The following table directs you to the starting page of each maintenance section associated with the Hyper Channels: Section Number

Topic

5.1.8.2 Test Alarms – Pk-Pk Displacment

5.1.8.2 Test Alarms – Gap




5.1.8.3 Verify Channel Values – Pk-Pk Displacment

5.1.8.3 Verify Channel Values –Gap

5.1.8.3 Verify Channel Values –1X Amplitude

5.1.8.3 Verify Channel Values –2X Amplitude



126


5.1.8.2 Test Alarms – Hyper The general approach for testing alarm setpoints is to simulate the position and Keyphasor® input signals with a function generator and power supply. The alarm levels are tested by varying the input signals and observing that the correct results are reported in the Verification screen on the test computer. It is only necessary to test those alarm parameters that are configured and being used. The general test procedure to verify current alarm operation will include simulating a transducer input signal and varying this signal: 1. to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and 2. to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and 3. to produce a non-alarm condition. When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis must be considered. Adjust the signal well below the alarm setpoint for the alarm to clear.

Pk – Pk Displacement 1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on









127









3. Adjust the power supply to produce a voltage that is within the Gap setpoint levels on the Gap bar graph display of the Verification Screen.







128















9. Adjust the function generator amplitude such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe that the bar graph indicator for 1X Ampl changes color to green and that the

129


Current Value Box contains no indication of Alarms. Press the RESET switch on the RIM to reset latching alarms.

10. Repeat steps 3 through 9 to test the Under Alert/Alarm 1 and Under Danger/Alarm 2 setpoints by adjusting the function generator amplitude to exceed the Under Alarm setpoint levels.













9. Adjust the function generator amplitude such that the signal reads below the Over Alarm setpoint levels. If the nonlatching option is configured, observe

130


that the bar graph indicator for 2X Ampl changes color to green and that the Current Value Box contains no indication of Alarms. Press the RESET switch on the RIM to reset latching alarms.

10. Repeat steps 3 through 9 to test the Under Alert/Alarm 1 and Under Danger/Alarm 2 setpoints by adjusting the function generator amplitude to exceed the Under Alarm setpoint levels.











7. Adjust the function generator amplitude such that the signal just exceeds the Not 1X Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the bar graph indicator for Not 1X changes color from yellow to red and that the Current value Field indicates an Alarm.


131






5.1.8.3 Verify Channel Values – Hyper The general approach for testing channel values is to simulate the position and Keyphasor input signals with a function generator and power supply. The output values are verified by varying the input signal level and observing that the correct results are reported in the Verification screen on the test computer. Note: These parameters have an accuracy specification of ±1% of full scale for amplitude.

Pk – Pk Displacement 1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals



3. Calculate the full scale voltage according to the equation and examples shown below. Adjust the amplitude of the function generator to the calculated voltage.


Example 1: Direct Meter Top Scale = 10 mil Transducer Scale Factor = 200mV/mil = .200 V/mil Full Scale = (10 X 0.200) = 2.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input = (.0707/2) X (2) = 0.707 Vrms Example 2: Direct Meter Top Scale = 200µm

132

Section 5 — Maintenance Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (200 X 0.007874) = 1.5748 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for sinewave input = (.0707/2) X (1.574) = 0.5566 Vrms


divide setting is one. Verify that the Pk-Pk Displacement bar graph display and Current Value Box is reading ±1% of full scale. If the recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.












133





3. Calculate the full-scale voltage according to the equation and examples shown below. Adjust the function generator amplitude to the calculated voltage.


Example 1: 1X Ampl Meter Top Scale = 10 mil Transducer Scale Factor = 200 mV/mil Full Scale = (10 X 0.200) = 2.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (2) Vrms = 0.707 Example 2: 1X Ampl Meter Top Scale = 200 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (200 X 0.007874) = 1.5748 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (1.5748) Vrms = 0.5566






134







Example 1: 2X Ampl Meter Top Scale = 10 mil Transducer Scale Factor = 200 mV/mil Full Scale = (10 X 0.200) = 2.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (2) Vrms = 0.707 Example 2: 2X Ampl Meter Top Scale = 200 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (200 X 0.007874) = 1.5748 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (1.5748) Vrms = 0.5566






135







Example 1: Not 1X Ampl Meter Top Scale = 10 mil Transducer Scale Factor = 200 mV/mil Full Scale = (10 X 0.200) = 2.000 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (2) Vrms = 0.707 Example 2: Not 1X Ampl Meter Top Scale = 200 µm Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/µm Full Scale = (200 X 0.007874) = 1.5748 Vpp For Vrms input: Vrms = (0.707/2) X (Vpp), for a sinewave input Vrms = (0.707/2) X (1.5748) Vrms = 0.5566






136


5.1.8.4 Test OK Limits - Hyper The general approach for testing OK limits is to input a DC voltage and adjust it above the Upper OK limit and below the Lower OK limit. This will cause a channel not OK condition and the OK Relay to change state (de-energize). The Upper and Lower OK limits are displayed in the Verification screen on the test computer. Note: If both channels of a Hyper channel pair go Not OK, all enabled alarms configured for Danger/Alarm 2 will become active.

1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on


Required Test Equipment and Setup. 3. Bypass all other configured channels. 4. Adjust the power supply voltage to -7.00 Vdc. 5. Press the RESET switch on the Rack Interface Module (RIM). Verify that the




(energized). See 3500 Rack Interface Module Operation and Maintenance Manual.


8. Decrease the power supply voltage (less negative) to -7.00 Vdc. 9. Press the RESET switch on the RIM. Verify that the OK LED comes back on

and the OK relay energizes. Verify that the Channel OK State line in the Channel Status box reads OK.


11. Increase the power supply voltage (more negative) to -7.00 Vdc. 12. Press the RESET switch on the RIM. Verify that the OK LED comes back on,

the OK relay energizes, and that the Channel OK State line in the Channel Status box reads OK.

137





Table 5-4 Hyper Default OK Limits Table Transducer Lower OK Limit

(Volts) Upper OK Limit (Volts)

3300 8 mm w/ Galvanic Isolation -1.1 -18.2 3300 8 mm w/ External barriers -1.1 -18.2 3300 8 mm w/ Internal barriers -1.28 -18.2 3300 8 mm w/o barriers -1.28 -19.04 3300XL 8 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 8 mm w/ External barriers -1.1 -18.2 3300XL 8 mm w/ Internal barriers -1.28 -18.2 3300XL 8 mm w/o barriers -1.28 -19.04 3300XL 11 mm w/ Galvanic Isolation -1.1 -18.2 3300XL 11 mm w/ External barriers -1.1 -18.2 3300XL 11 mm w/ Internal barriers -1.28 -18.2 3300XL 11 mm w/o barriers -1.28 -19.04 7200 8 mm w/ Galvanic Isolation -1.1 -18.2 7200 8 mm w/ External barriers -1.1 -18.2 7200 8 mm w/ Internal barriers -1.28 -18.2 7200 8 mm w/o barriers -1.28 -19.04 7200 11 mm w/o barriers -3.55 -20.39 7200 14 mm w/o barriers -1.65 -18.05

138


5.1.9 Verify Recorder Outputs The following test equipment and procedure should be used in the verification of the recorder outputs. Recorder outputs for the 3500/72M Recip Rod Position Monitor Module are 4 to 20 mA.

(1) Connect test equipment here. (2) Prox/Velom I/O Module (Internal Termination) (3) Recorder External Termination Block (Euro Style Connectors) (4) Recorder External Termination Block (Terminal Strip Connectors)

1. Disconnect the COM and REC field wiring from the channel terminals on the

I/O module. 2. Connect a multimeter to the COM and REC outputs of the I/O module. The

multimeter should have the capability to measure 4 to 20 mA. 3. If the proportional value is not Gap: Set the proportional value that the

recorder is configured for to full-scale (refer to the proportional value of the channel pair type you are testing in the Verify Channel Values portion of this manual). Verify that the recorder output is reading 20 mA ±1%. Go to step 5.

4. If the proportional value is Gap: Set the Gap proportional value to –18.00 Vdc (Refer to the proportional value of the channel pair type you are testing in the Verify Channel Values portion of this manual). Verify that the recorder output is reading 16 mA ±1%.

5. Set the proportional value that the recorder is configured for to mid-scale. Verify that the recorder output is reading 12 mA ±1%.

6. Set the proportional value that the recorder is configured for to bottom-scale. Verify that the recorder output is reading 4 mA ±1%.

139


7. Disconnect transducer input and verify that the recorder output matches the set monitor clamp value ±1%.

8. If you can not verify the recorder output, the recorder configuration and connections should be checked. If the monitor recorder output still does not verify properly, go to Section 5.1.10 (If a Channel Fails a Verification Test).

9. Disconnect the multimeter and reconnect the COM and REC field wiring to the channel terminals on the I/O module.

10. Repeat steps 1 through 9 for all configured recorder channels.

5.1.10 If a Channel Fails a Verification Test When handling or replacing circuit boards, always be sure to adequately protect against damage from Electrostatic Discharge (ESD). Always wear a proper wrist strap and work on a grounded conductive work surface. 1. Save the configuration for the module using the Rack Configuration Software. 2. Replace the module with a spare. Refer to the installation section in the 3500

Monitoring System Rack Installation and Maintenance Manual. 3. Return the faulty board to Bently Nevada Corporation for repair. 4. Download the configuration for the spare module using the Rack

Configuration Software. 5. Verify the operation of the spare.

140

Section 6 — Troubleshooting

6. Troubleshooting This section describes how to troubleshoot a problem with the Recip Rod Position Monitor or the I/O module by using the information provided by the self-test, the LED’s, the System Event List, and the Alarm Event List.

6.1 Self-test To perform the Recip Rod Position Monitor self-test: 1. Connect a computer running the Rack Configuration Software to the 3500

rack (if needed). 2. Select Utilities from the main screen of the Rack Configuration Software. 3. Select System Events/Module Self-test from the Utilities menu. 4. Press the Module Self-test button on the System Events screen. Application Alert: Machinery protection will be lost while the self-test is being performed

5. Select the slot that contains the Recip Rod Position Monitor and press the OK button. The Recip Rod Position Monitor will perform a full self-test and the System Events screen will be displayed. The list will not contain the results of the self-test.

6. Wait 30 seconds for the module to run a full self-test. 7. Press the Latest Events button. The System Events screen will be updated

to include the results of the Recip Rod Position Monitor self-test. 8. Verify if the Recip Rod Position Monitor passed the self-test. If the monitor

failed the self-test, refer to Section 7.3.

141


6.2 LED Fault Conditions The following table shows how to use the LEDs to diagnose and correct problems.

OK Led

TX/RX

BYPASS

Condition

Solution

1 Hz

1 Hz

<<>>

Monitor is not configured, is in Configuration Mode, or in Calibration Mode.

Reconfigure the Monitor, or exit Configuration, or Calibration Mode.

5 Hz

<<>>

<<>>

Monitor error

Check the System Event List for severity.

ON

Flashing

<<>>

Module is operating correctly

No action required.

OFF

<<>>

<<>>

Monitor is not operating correctly or the transducer has faulted and has stopped providing a valid signal.

Check the System Event List and the Alarm Event List.

2 Hz

<<>>

<<>>

Monitor is configured for Timed OK Channel Defeat and has been not OK since the last time the RESET button was pressed.

Press the Reset button on the Rack Interface Module. Check the System Event List.

<<>>

Not flashing

<<>>

Monitor is not operating correctly.

Monitor is not executing alarming functions. Replace immediately.

<<>>

<<>>

OFF

Alarm Enabled

No action required.

<<>>

<<>>

ON

Some or all Alarming Disabled

No action required.

<<>> = Behavior of the LED is not related to the condition.

142


6.3 System Event List Messages This section describes the System Event List Messages that are entered by the Recip Rod Position Monitor and gives an example of one. Example of a System Event List Message:

Sequence

Number

Event

Information

Event

Number

Class

Event

Date

DDMMYY

Event

Time

Event

Specific

Slot

0000000123

Device Not Communicating

32

1

02/01/90

12:24:31:99

5L

Sequence Number: The number of the event in the System Event List (for example 123).

Event Information: The name of the event (for example Device Not Communicating).

Event Number: Identifies a specific event.

Class: Used to display the severity of the event. The following classes are available:

Class Value

Classification

0

1

2

3

Severe/Fatal Event

Potential Problem Event

Typical logged Event

Reserved

Event Date:

The date the event occurred. Event Time:

The time the event occurred. Event Specific:

It provides additional information for the events that use this field. Slot:

Identifies the module that the event is associated with. If a half-height module is installed in the upper slot or a full-height module is installed, the field will be 0 to 15. If a half-height module is installed in the lower slot, then the field will be 0L to 15L. For example, a module installed in the lower position in slot 5 would be 5L.

143


The following System Event List Messages may be placed in the list by the Recip Rod Position Monitor and are listed in numerical order. If an event marked with a star (*) occurs the Recip Rod Position Monitor will stop alarming. If you are unable to solve any problems contact your nearest Bently Nevada Corporation office.

Flash Memory Failure Event Number: 11 Event Classification: Severe / Fatal Event Action: Replace the Monitor Module as soon as possible.

EEPROM Memory Failure Event Number: 13 Event Classification: Potential Problem or Severe / Fatal Event Action: Replace the Monitor Module as soon as possible.

Device Not Communicating Event Number: 32 Event Classification: Potential Problem Action: Check to see if one of the following components is faulty: - the Monitor Module - the rack backplane

Device Is Communicating Event Number: 33 Event Classification: Potential Problem Action: Check to see if one of the following components is faulty: - the Monitor Module - the rack backplane

* Neuron Failure Event Number: 34 Event Classification: Severe / Fatal Event Action: Replace the Monitor Module immediately. Monitor Module will stop alarming.

* I/O Module Mismatch Event Number: 62 Event Classification: Severe / Fatal Event Action: Verify that the type of I/O module installed matches what was selected in the software. If the correct I/O module is installed, there may be a fault with the Monitor Module or the Monitor I/O module. Monitor Module will stop alarming.

144


I/O Module Compatible Event Number: 63 Event Classification: Severe / Fatal Event Action: Verify that the type of I/O module installed matches what was selected in the software. If the correct I/O module is installed, there may be a fault with the Monitor Module or the Monitor I/O module.

* Fail I/O Jumper Check Event Number: 64 Event Classification: Severe / Fatal Event Action: Verify that the type of I/O module installed matches what was selected in the software. If the correct I/O module is installed, there may be a fault with the Monitor Module or the Monitor I/O module. Monitor Module will stop alarming.

Pass I/O Jumper Check Event Number: 65 Event Classification: Severe / Fatal Event Action: Verify that the type of I/O module installed matches what was selected in the software. If the correct I/O module is installed, there may be a fault with the Monitor Module or the Monitor I/O module.

Fail Main Board +5V-A (Fail Main Board +5V - upper Power Supply) Event Number: 100 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

Pass Main Board +5V-A (Pass Main Board +5V - upper Power Supply) Event Number: 101 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

Fail Main Board +5V-B (Fail Main Board +5V - lower Power Supply) Event Number: 102 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

145


Pass Main Board +5V-B (Pass Main Board +5V - lower Power Supply) Event Number: 103 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

Fail Main Board +5V-AB (Fail Main Board +5V - upper and lower Power Supplies) Event Number: 104 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot Monitor Module will stop alarming.

Pass Main Board +5V-AB (Pass Main Board +5V - upper and lower Power Supplies) Event Number: 105 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot

Fail Main Board +15V-A (Fail Main Board +15V - upper Power Supply) Event Number: 106 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

Pass Main Board +15V-A (Pass Main Board +15V - upper Power Supply) Event Number: 107 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

146


Fail Main Board +15V-B (Fail Main Board +15V - lower Power Supply) Event Number: 108 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

Pass Main Board +15V-B (Pass Main Board +15V - lower Power Supply) Event Number: 109 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

Fail Main Board +15V-AB (Fail Main Board +15V - upper and lower Power Supplies) Event Number: 110 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot Monitor Module will stop alarming.

Pass Main Board +15V-AB (Pass Main Board +15V - upper and lower Power Supplies) Event Number: 111 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot

Fail Main Board -24V-A (Fail Main Board -24V - upper Power Supply) Event Number: 112 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

147


Pass Main Board -24V-A (Pass Main Board -24V - upper Power Supply) Event Number: 113 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot

Fail Main Board -24V-B (Fail Main Board -24V - lower Power Supply) Event Number: 114 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

Pass Main Board -24V-B (Pass Main Board -24V - lower Power Supply) Event Number: 115 Event Classification: Potential Problem Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the lower slot

Fail Main Board -24V-AB (Fail Main Board -24V - upper and lower Power Supplies) Event Number: 116 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot Monitor Module will stop alarming.

Pass Main Board -24V-AB (Pass Main Board -24V - upper and lower Power Supplies) Event Number: 117 Event Classification: Severe/Fatal Event Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, check to see if one of the following components is faulty: - the Monitor Module - the Power Supply installed in the upper slot - the Power Supply installed in the lower slot

148


* Configuration Failure Event Number: 301 Event Classification: Severe/Fatal Event Action: Download a new configuration to the Monitor Module. If the problem still exists replace the Monitor Module immediately. Monitor Module will stop alarming.

Configuration Failure Event Number: 301 Event Classification: Potential Problem Action: Download a new configuration to the Monitor Module. If the problem still exists replace the Monitor Module as soon as possible.

Module Entered Cfg Mode (Module Entered Configuration Mode) Event Number: 302 Event Classification: Typical Logged Event Action: No action required. Monitor Module will stop alarming.

Software Switches Reset Event Number: 305 Event Classification: Potential Problem Action: Download the software switches to the Monitor Module. If the software switches are not correct, replace the Monitor Module as soon as possible.

Internal Cal Reset (Internal Calibration Reset) Event Number: 307 Event Classification: Severe/Fatal Event Event Specific: Ch pair x Action: Replace Monitor Module immediately.

Monitor TMR PPL Failed (Monitor TMR Proportional value Failed) Event Number: 310 Event Classification: Potential Problem Action: Replace the Monitor Module.

Monitor TMR PPL Passed (Monitor TMR Proportional value Passed) Event Number: 311 Event Classification: Potential Problem Action: Replace the Monitor Module.

Module Reboot Event Number: 320 Event Classification: Typical Logged Event Action: No action required.

149


* Module Removed from Rack Event Number: 325 Event Classification: Typical Logged Event Action: No action required. Monitor Module will stop alarming.

Module Inserted in Rack Event Number: 326 Event Classification: Typical Logged Event Action: No action required.

Device Events Lost Event Number: 355 Event Classification: Typical Logged Event Action: No action required. This may be due to the removal of the Rack Interface Module for an extended period of time.

Module Alarms Lost Event Number: 356 Event Classification: Typical Logged Event Action: No action required. This may be due to the removal of the Rack Interface Module for an extended period of time.

Module Entered Calibr. (Module Entered Calibration Mode) Event Number: 365 Event Classification: Typical Logged Event Action: No action required. Monitor Module will stop alarming.

Module Exited Calibr. (Module Exited Calibration Mode) Event Number: 366 Event Classification: Typical Logged Event Action: No action required.

Pass Module Self-test Event Number: 410 Event Classification: Typical Logged Event Action: No action required.

Enabled Ch Bypass (Enabled Channel Bypass) Event Number: 416 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Alarming has been inhibited by this action.

150


Disabled Ch Bypass (Disabled Channel Bypass) Event Number: 417 Event Classification: Typical logged event Event Specific: Ch x Action: No action required.

* Enabled Alert Bypass Event Number: 420 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Alarming has been inhibited by this action.

Disabled Alert Bypass Event Number: 421 Event Classification: Typical logged event Event Specific: Ch x Action: No action required.

* Enabled Danger Bypass Event Number: 422 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Alarming has been inhibited by this action.

Disabled Danger Bypass Event Number: 423 Event Classification: Typical logged event Event Specific: Ch x Action: No action required.

Enabled Special Inh (Enabled Special Inhibit) Event Number: 424 Event Classification: Typical logged event Event Specific: Ch x Action: No action required. Alarming has been inhibited by this action.

Disabled Special Inh (Disabled Special Inhibit) Event Number: 425 Event Classification: Typical logged event Event Specific: Ch x Action: No action required.

151


Enabled Mon Alarm Byp (Enabled Monitor Alarm Bypass) Event Number: 426 Event Classification: Typical logged event Action: No action required. Monitor Module will stop alarming.

Disabled Mon Alarm Byp (Disabled Monitor Alarm Bypass) Event Number: 427 Event Classification: Typical logged event Action: No action required.

* Fail Slot Id Test Event Number: 461 Event Classification: Severe/Fatal Event Action: Verify that the Monitor Module is fully inserted in the rack. If the Monitor Module is installed correctly, check to see if one of the following components is faulty: - the Monitor Module - the rack backplane Monitor Module will stop alarming.

Pass Slot Id Test Event Number: 462 Event Classification: Severe/Fatal Event Action: Verify that the Monitor Module is fully inserted in the rack. If the Monitor Module is installed correctly, check to see if one of the following components is faulty: - the Monitor Module - the rack backplane

* Enabled Test Signal Event Number: 481 Event Classification: Typical logged event Action: No action required. Monitor Module will stop alarming.

Disabled Test Signal Event Number: 482 Event Classification: Typical logged event Action: No action required.

Switch To Primary Kph Event Number: 491 Event Classification: Potential Problem Event Specific: Ch pair x Action: Check to see if one of the following is faulty: - the secondary Keyphasor® transducer on the machine - the Monitor Module

152


Switch To Backup Kph Event Number: 492 Event Classification: Potential Problem Event Specific: Ch pair x Action: Check to see if one of the following is faulty: - the primary Keyphasor transducer on the machine - the Monitor Module

* Kph Lost Event Number: 493 Event Classification: Potential Problem Event Specific: Ch pair x Action: Check to see if one of the following is faulty: - both Keyphasor transducers on the machine - the Monitor Module - the Keyphasor Module For vector and Keyphasor based, alarms the Monitor Module will stop alarming.

DSP Reset Attempted Event Number: 501 Event Classification: Severe / Fatal Event Event Specific: Ch pair x Action: If the message is seen repeatedly in the System Event List, then replace the Monitor Module immediately.

* DSP Self-test Failure Event Number: 502 Event Classification: Severe / Fatal Event Event Specific: Ch pair x Action: Replace the Monitor Module immediately. Monitor Module will stop alarming.

153


6.4 Alarm Event List Messages The following Alarm Event List Messages are returned by the Recip Rod Position Monitor. Alarm Event List Message

When the message will occur

Entered Alert / Alarm 1 A proportional value in the channel has entered Alert / Alarm 1 and changed the channel Alert / Alarm 1 status

Left Alert / Alarm 1 A proportional value in the channel has left Alert / Alarm 1 and changed the channel Alert / Alarm 1 status

Entered Danger / Alarm 2 A proportional value in the channel has entered Danger / Alarm 2 and changed the channel Danger / Alarm 2 status

Left Danger / Alarm 2 A proportional value in the channel has left Danger / Alarm 2 and changed the channel Danger / Alarm 2 status

Entered not OK module went not OK

Left not OK module returned to the OK state

154

Section 7 — Ordering Information

7. Ordering Information

7.1 Ordering Considerations When ordering I/O Modules with External Terminations the External Termination Blocks and Cable must be ordered separately for each I/O Module. The 3500 Internal Barrier Specification sheet should be consulted if the Internal Barrier Option is selected. Version 3.20 or higher of the 3500 Rack Configuration Software is required.

7.2 List of Options and Part Numbers 7.2.1 Recip Rod Position Monitor

3500/72M-AXX-BXX A: I/O Module Type

0 1 I/O Module with Internal Terminations 0 2 I/O Module with External Terminations 0 3 I/O Module with Internal Barriers and Internal

Terminations B: Agency Approval Option

0 0 None 0 1 CSA/NRTL/C

7.2.2 External Termination Blocks 125808-08

Proximitor / Velomitor External Termination Block (Euro Style connectors).

128015-08 Proximitor / Velomitor External Termination Block (Terminal Strip connectors).

128702-01 Recorder External Termination Block (Euro Style connectors)

128710-01 Recorder External Termination Block (Terminal Strip connectors)

7.2.3 3500 Transducer Signal to External Termination Block Cable 129525 -AXXXX-BXX A: Cable Length

0 0 0 5 5 feet (1.5 metres) 0 0 0 7 7 feet (2.1 metres) 0 0 1 0 10 feet (3 metres) 0 0 2 5 25 feet (7.5 metres) 0 0 5 0 50 feet (15 metres)

155

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual 0 1 0 0 100 feet (30.5 metres)

B: Assembly Instructions 0 1 Not Assembled 0 2 Assembled

7.2.4 3500 Recorder Output to External Termination (ET) Block Cable 129529 -AXXXX-BXX A: Cable Length

0 0 0 5 5 feet (1.5 metres) 0 0 0 7 7 feet (2.1 metres) 0 0 1 0 10 feet (3 metres) 0 0 2 5 25 feet (7.5 metres) 0 0 5 0 50 feet (15 metres) 0 1 0 0 100 feet (30.5 metres)

B: Assembly Instructions 0 1 Not Assembled 0 2 Assembled

7.2.5 Spares 140734-08

3500/72M Recip Rod Position Monitor 140471-01

I/O Module with Internal Terminations 140482-01

I/O Module with External Terminations 135489-01

I/O Module with Internal Barriers and Internal Terminations 146479-01

3500/72M Rod Position Manual 00580434

Internal I/O Module connector header, Euro Style, 8-pin, green. Used on I/O modules 140471-01

00580441 Internal I/O Module connector header, Euro Style, 3-pin, green. Used on I/O modules 135489-01 and 140471-01

00502133 Internal I/O Module connector header, Euro Style, 12-pin, blue. Used on I/O modules 135489-01

156

Section 8 — Specifications

8. Specifications

8.1 Inputs Signal:

Accepts from 1 to 4 proximity probe signals. Input Impedance:

10 kΩ Nominal Scale Factor:

Rod Position:

3.94 mV/µm (100 mV/mil) or 7.87 mV/µm (200 mV/mil)

Rod Drop: 3.94 mV/µm (100 mV/mil) or 7.87 mV/µm (200 mV/mil)

Hyper-Compressor: 3.94 mV/µm (100 mV/mil) or 7.87 mV/µm (200 mV/mil)

Note: Configuration allows a wide range of adjustment to accommodate transducer sensitivity for different rod materials.

Power Consumption: Nominal Consumption of 7.7 watts

8.2 Outputs Front Panel LED’s:

OK LED:

Indicates when the 3500/72M is operating properly. TX/RX LED:

Indicates when the 3500/72M is communicating with other modules in the 3500 rack.

Bypass LED: Indicates when the 3500/72M is in Bypass Mode.

Buffered Transducer Outputs The front of each monitor has one coaxial connector for each channel. Each connector is short-circuit protected.

Output Impedance: 550 Ω

Transducer Power Supply: -24 Vdc

8.3 Data Values

The Recip Rod Position Monitor returns the following data values from measurements used to monitor the machine:

157


Rod Position – Single Position Magnitude, Position Angle, Crank Angle, Pk-Pk Amplitude, Gap, 1X Amplitude, Not 1X Amplitude, and 2X Amplitude

Rod Position – Pair Position Magnitude, Position Angle, Crank Angle, Pk-Pk Amplitude, Gap, 1X Amplitude, Not 1X Amplitude, and 2X Amplitude

Rod Drop Average Piston Position, Average Probe Gap, Instantaneous Piston Position, and Instantaneous Probe Gap

Hyper Channel Pk-Pk Displacement, Gap, 1X Amplitude, Not 1X Amplitude, and 2X Amplitude

8.4 Signal Conditioning Specified at +25° C (77° F) Rod Position – Single & Pair:

Frequency Response: Note: 1X and 2X vector and Not 1X parameters are valid for machine operation of 60 cpm to 2000 cpm.

Peak-Peak Filter: Fixed 1 Hz to 600 Hz

Gap Filter: -3 dB at 0.09 Hz

Not 1X Filter: Constant Q notch filter with minimum rejection in stop-band of 34.9 dB over frequency range of 60 cpm to 15.8 times running speed.

1X Vector Filter: Constant Q filter with minimum rejection in stop-band of 57.7 dB


Accuracy

Position Magnitude (direct):

Within ±0.33% of full scale typical, ±1.0% maximum Gap:

Within ±0.33% of full scale typical, ±1.0% maximum 1X Amplitude:


Within ±0.33% of full scale typical, ±1.0% maximum Pk-Pk Amplitude:

Within ±0.33% of full scale typical, ±1.0% maximum

158

Section 8 — Specifications Not 1X Amplitude:

Within ±3.0% of full scale typical Position Crank Angle:

Within ±1° typical, ±3° maximum Rod Position Angle (paired only):

Within ±1° typical, ±3° maximum

8.5 Rod Drop: Frequency Response:

Average Piston Position (direct):

Fixed 1 Hz to 600 Hz Average Gap:

-3 dB at 0.09 Hz Accuracy

Average Piston Position (direct):

Within ±0.33% of full scale typical, ±1.0% maximum Average Gap:

Within ±0.33% of full scale typical, ±1.0% maximum Instantaneous Piston Position:

Within ±0.33% of full scale typical, ±1.0% maximum Instantaneous Probe Gap:

Within ±0.33% of full scale typical, ±1.0% maximum

8.6 Hyper-Channel: Frequency Response: Note: 1X and 2X vector and Not 1X parameters are valid for machine operation of 60 cpm to 2,000 cpm.

Peak-Peak Filter: Fixed 1 Hz to 600 Hz

Gap Filter: -3 dB at 0.09 Hz

Not 1X Filter: Constant Q notch filter with minimum rejection in stop-band of 34.9 dB over frequency range of 60 cpm to 15.8 times running speed.



159

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual Accuracy

Peak-Peak Magnitude (direct):

Within ±0.33% of full scale typical, ±1.0% maximum Gap:



Within ±0.33% of full scale typical, ±1.0% maximum Not 1X Amplitude:

Within ±3.0% of full scale typical

8.7 Alarms Alarm Setpoint Values:

Alert levels can be set for each value measured by the monitor. In addition, Danger setpoint values can be set for any two of the values measured by the monitor. All alarm setpoint values are set using software configuration. Alarms are adjustable and can be set from 0 to 100% of full-scale for each measured value. Accuracy of an alarm setpoint is to within 0.13% of the desired value.

Alarm Time Delays: Alarm delays can be programmed using software, and can be set as follows:

Alert: From 1 to 60 seconds in 1 second intervals.

Danger: From 1 to 60 seconds in 1 second intervals or 0.1 seconds (nominal)

Timed OK Channel Defeat:

Ok Channel defeat is disabled for all rod position configurations. When used as a hyper-compressor monitor the action of both transducers going not OK will cause the immediate issue of a danger alarm.

8.8 Environmental Limits Operating Temperature:

-30°C to +65°C (-22°F to +150°F) when used with Internal/External Termination Proximitor/Seismic I/O Module

Operating Temperature: 0°C to +65°C (32°F to +150°F) when used with Proximitor/Seismic Internal Barrier I/O Module (Internal Termination)

Storage Temperature: -40°C to +85°C (-40°F to +185°F)

160

Section 8 — Specifications Humidity

95%, non-condensing

8.9 CE Mark Directives EMC Directives

EN50081-2

Radiated Emissions

EN 55011, Class A Conducted Emissions

EN 55011, Class A EN50082-2

Electrostatic Discharge

EN 61000-4-2, Criteria B Radiated Susceptibility

ENV 50140, Criteria A Conducted Susceptibility

ENV 50141, Criteria A Electrical Fast Transient

EN 61000-4-4, Criteria B Surge Capability

EN 61000-4-5, Criteria B Magnetic Field

EN 61000-4-8, Criteria A Power Supply Dip

EN 61000-4-11, Criteria B Radio Telephone

ENV 50204, Criteria B CE Mark Low Voltage Directives

EN 61010-1

Safety Requirements

8.10 Hazardous Approvals CSA/NRTL/C:

When used with Internal/External Termination I/O Module: Class I, Division 2, Groups A through D When used with Internal Barrier I/O Module, refer to specification sheet 141495-01 for approvals information.

161


162

8.11 Physical Monitor Module Dimensions (Height x Width x Depth)

241.3 mm x 24.4 mm x 241.8 mm (9.50 in x 0.96 in x 9.52 in)

Weight 0.91 kg (2.0 lbs.).

I/O Modules (non-barrier) Dimensions (Height x Width x Depth)

241.3 mm x 24.4 mm x 99.1 mm (9.50 in x 0.96 in x 3.90 in) Weight

0.20 kg (0.44 lb.). I/O Modules (barrier)

Dimensions (Height x Width x Depth)

241.3 mm x 24.4 mm x 163.1 mm (9.50 in x 0.96 in x 6.42 in)

Weight 0.46 kg (1.01 lbs.).

Rack Space Requirements

Monitor Module 1 full-height front slot

I/O Modules 1 full-height rear slot

6479A1 3500-72 rodrop

Documents

bently lube

bently performance

bently docuview

bently balance

software manual

system extender

actionable information

bently parkway south