HI5500

SIGNAL CONDITIONER5500 SERIES

OPERATION AND INSTALLATIONMANUAL

Corporate Headquarters 3860 Calle Fortunada San Diego, CA 92123-1825 Phone: (858) 278-2900FAX: (858) 278-6700Web-Site: http://www.hardyinstruments.com

Hardy Instruments Document Number: 0296-0026-01 Rev ECopyright November 2000 Hardy Instruments, Inc. All Rights Reserved. Printed in the U.S.A. (941028)

Table of Contents

Table of Contents

TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - I

TABLE OF ILLUSTRATIONS- - - - - - - - - - - - - - - - - - - - I

OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-1A Brief Description of Chapter 1 - - - - - - - - - - - - - - - - - - -1-1About Hardy Manuals - - - - - - - - - - - - - - - - - - - - - - - -1-2Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-3Industries- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-3Applications - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-4Options- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-4

HI 5500PS Power Supply - - - - - - - - - - - - - - - - - - - -1-4Transducers - - - - - - - - - - - - - - - - - - - - - - - - - -1-5NEMA Enclosures - - - - - - - - - - - - - - - - - - - - - - -1-5

Back Plate/Not Wired - - - - - - - - - - - - - - - - - - - -1-5Back Plate/Wired - - - - - - - - - - - - - - - - - - - - - -1-5

CHAPTER 2 - SPECIFICATIONS- - - - - - - - - - - - - - - - - -2-1A Brief Description of Chapter 2 - - - - - - - - - - - - - - - - - - -2-1Specifications for a Standard HI 5000 Series Signal

Conditioning Module - - - - - - - - - - - - - - - - - - - - - - -2-1Electrical Characteristics - - - - - - - - - - - - - - - - - - - -2-1

Input Sensor Sensitivity - - - - - - - - - - - - - - - - - - -2-1Sensor Excitation Current- - - - - - - - - - - - - - - - - -2-1Current Output - - - - - - - - - - - - - - - - - - - - - - -2-1Voltage Output - - - - - - - - - - - - - - - - - - - - - - -2-1Maximum Load Resistance - - - - - - - - - - - - - - - - -2-1Frequency Range (3 dB) - - - - - - - - - - - - - - - - -2-1Vibration Range - - - - - - - - - - - - - - - - - - - - - -2-1Sensor Fault - - - - - - - - - - - - - - - - - - - - - - - -2-2

Power Requirements - - - - - - - - - - - - - - - - - - - - - -2-2Physical Characteristics - - - - - - - - - - - - - - - - - - - -2-2

Mounting - - - - - - - - - - - - - - - - - - - - - - - - - -2-2Physical Dimensions - - - - - - - - - - - - - - - - - - - -2-2

Length - - - - - - - - - - - - - - - - - - - - - - - - -2-2Width - - - - - - - - - - - - - - - - - - - - - - - - -2-2Height - - - - - - - - - - - - - - - - - - - - - - - - -2-2

Weight - - - - - - - - - - - - - - - - - - - - - - - - - - -2-2Environmental Characteristics - - - - - - - - - - - - - - - - -2-3

Temperature Range - - - - - - - - - - - - - - - - - - - -2-3i

Operating - - - - - - - - - - - - - - - - - - - - - - -2-3

HI 5500 SERIES SIGNAL CONDITIONERS

Storage - - - - - - - - - - - - - - - - - - - - - - - -2-3Humidity - - - - - - - - - - - - - - - - - - - - - - - - - -2-3

Ordering Information for the HI 5501 - - - - - - - - - - - - - - - -2-3Ordering Information for the HI 5502 - - - - - - - - - - - - - - - -2-4HI 5501E (Only) - - - - - - - - - - - - - - - - - - - - - - - - - -2-4

Temperature Range - - - - - - - - - - - - - - - - - - - - - -2-4Operating - - - - - - - - - - - - - - - - - - - - - - - - -2-4

Humidity - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4Enclosure Requirements - - - - - - - - - - - - - - - - - - - -2-4Approvals - - - - - - - - - - - - - - - - - - - - - - - - - - -2-4

Optional Equipment- - - - - - - - - - - - - - - - - - - - - - - - -2-5HI 5500PS Power Supply - - - - - - - - - - - - - - - - - - - -2-5

Regulation - - - - - - - - - - - - - - - - - - - - - - - - -2-5Environmental - - - - - - - - - - - - - - - - - - - - - - -2-5

Operating - - - - - - - - - - - - - - - - - - - - - - -2-5Storage - - - - - - - - - - - - - - - - - - - - - - - -2-5Temperature Coefficient - - - - - - - - - - - - - - - -2-5

Dimensions- - - - - - - - - - - - - - - - - - - - - - - - -2-5Physical - - - - - - - - - - - - - - - - - - - - - - - -2-5Weight - - - - - - - - - - - - - - - - - - - - - - - - -2-5

Output Power- - - - - - - - - - - - - - - - - - - - - - - -2-5Options- - - - - - - - - - - - - - - - - - - - - - - - - - -2-5HI 5532 - - - - - - - - - - - - - - - - - - - - - - - - - -2-5HI 5533 - - - - - - - - - - - - - - - - - - - - - - - - - -2-5

CHAPTER 3 - INSTALLATION - - - - - - - - - - - - - - - - - - -3-1A Brief Description of Chapter 3 - - - - - - - - - - - - - - - - - - -3-1Unpacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1Pre-Installation Engineering Procedures- - - - - - - - - - - - - - -3-2Electrical Wiring Precautions - - - - - - - - - - - - - - - - - - - -3-3Installing the HI 5500 Standard Module Onto a DIN Rail - - - - - - -3-4Electrical Installation Procedures - - - - - - - - - - - - - - - - - -3-5

LED OK Indicator - - - - - - - - - - - - - - - - - - - - - - - -3-6BNC Connector- - - - - - - - - - - - - - - - - - - - - - - - -3-7Terminal Assignments - - - - - - - - - - - - - - - - - - - - -3-7

TB2-1,2 - - - - - - - - - - - - - - - - - - - - - - - - - -3-7TB2-3,4 - - - - - - - - - - - - - - - - - - - - - - - - - -3-7TB2-5,6 - - - - - - - - - - - - - - - - - - - - - - - - - -3-7TB1-1 - - - - - - - - - - - - - - - - - - - - - - - - - - -3-7TB1-2 - - - - - - - - - - - - - - - - - - - - - - - - - - -3-8TB1-3 - - - - - - - - - - - - - - - - - - - - - - - - - - -3-8TB1-4 - - - - - - - - - - - - - - - - - - - - - - - - - - -3-8TB1-5 - - - - - - - - - - - - - - - - - - - - - - - - - - -3-8ii

Table of Contents

Installing modules in an Enclosure (See Fig. 3-5) - - - - - - - - - -3-8Pump Monitoring with Transducers and HI 5500 Series Module - - -3-9

Threaded Stud - - - - - - - - - - - - - - - - - - - - - - -3-10Cementing Pad- - - - - - - - - - - - - - - - - - - - - - -3-10

Wiring Diagram Example for 5501/55032/5533 with no Power Supply - - - - - - - - - - - - - - - - - - - - - - - - - -3-12

Wiring Diagram for Acceleration and Velocity Monitoring System with Alarm and Danger Relays - - - - - - - - - - - - - -3-13

CHAPTER 4 - SETUP - - - - - - - - - - - - - - - - - - - - - - -4-1A Brief Description of Chapter 4 - - - - - - - - - - - - - - - - - - -4-1Test Equipment and Tools Required - - - - - - - - - - - - - - - -4-1Quick Calibration Check Using An HI 813 Portable Shaker

Calibration System - - - - - - - - - - - - - - - - - - - - - - - -4-2Calibration Setup Procedures Using a Frequency

Generator and Power Supply - - - - - - - - - - - - - - - - - - -4-4Full Scale and Zero Scale Adjustment - - - - - - - - - - - - - - - -4-6Input Sensitivity Selection- - - - - - - - - - - - - - - - - - - - - -4-9Monitoring System Configuration - - - - - - - - - - - - - - - - - -4-10

Reference Voltage Jumper Setting Procedures - - - - - - - - -4-10

CHAPTER 5 - CALIBRATION - - - - - - - - - - - - - - - - - - -5-1A Brief Description of Chapter 5 - - - - - - - - - - - - - - - - - - -5-1Full Scale Output/Span Adjustment - - - - - - - - - - - - - - - - -5-1

Bench Calibration Using the Hardy HI 813 Portable Shaker System - - - - - - - - - - - - - - - - - - - - - - - -5-1

Bench Calibration Using a Frequency Generator and Power Supply - - - - - - - - - - - - - - - - - - - - - - - -5-5

Current Limit Test - - - - - - - - - - - - - - - - - - - - - - -5-6Final Check - - - - - - - - - - - - - - - - - - - - - - - - - -5-6

Calculation of HI 5501/5502 Full Scale Calibration voltage - - - - - -5-7Acceleration or Velocity - - - - - - - - - - - - - - - - - - - - -5-7Accelerometer or Velocity Input with Signal Integration - - - - -5-7

Log Mid-Frequency - - - - - - - - - - - - - - - - - - - - -5-8Convert Output EUs F.S. to Input EUs for Three

Different HI 5501/HI 5502 Configurations - - - - - - - - -5-8Three Examples Based on Part Numbers - - - - - - - - - -5-8

CHAPTER 6 - TROUBLESHOOTING- - - - - - - - - - - - - - - -6-1A Brief Description of Chapter 6 - - - - - - - - - - - - - - - - - - -6-1Problem: Green Light Not Illuminated - - - - - - - - - - - - - - - -6-1Check Output Amperage - - - - - - - - - - - - - - - - - - - - - -6-1iii

HI 5500 SERIES SIGNAL CONDITIONERSiv

Table of Illustrations

Table of Illustrations

OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - -1-1

FIG. 1-1 STANDARD HI 5500 SIGNAL CONDITIONER MODULE -1-1FIG. 1-2 HI 5500PS +24VDC POWER SUPPLY - - - - - - - - - -1-4

CHAPTER 2 - SPECIFICATIONS- - - - - - - - - - - - - - - - - -2-1

FIG. 2-1 SPECIAL PRODUCT CONFIGURATION MENU - HI 55012-3FIG. 2-2 SPECIAL PRODUCT CONFIGURATION MENU - HI 55022-4

CHAPTER 3 - INSTALLATION - - - - - - - - - - - - - - - - - - -3-1

FIG. 3-1 INSTALLING THE MODULE ONTO A DIN RAIL - - - - -3-4FIG. 3-2 MOUNTING LATCH HIGHLIGHTED - - - - - - - - - - -3-5FIG. 3-3 MODULES INSTALLED ON DIN RAIL - - - - - - - - - -3-5FIG. 3-4 FUNCTIONAL BLOCK DIAGRAM FOR HI 5501/HI 5502 -3-6FIG. 3-5 CONNECTIONS/5501 - - - - - - - - - - - - - - - - - -3-6FIG. 3-6 INSTALLING THE MODULES IN AN ENCLOSURE - - -3-9FIG. 3-7 PUMP MONITORING - - - - - - - - - - - - - - - - - -3-9FIG. 3-8 CEMENTING PAD INSTALLATION - - - - - - - - - - -3-11FIG. 3-9 WIRING DIAGRAM FOR 5501/5532/5533 WITH

NO POWER SUPPLY - - - - - - - - - - - - - - - - -3-12FIG. 3-10 WIRING DIAGRAM FOR MONITORING SYSTEM

WITH ALARM AND DANGER RELAYS - - - - - - - - -3-13

CHAPTER 4 - SETUP - - - - - - - - - - - - - - - - - - - - - - -4-1

FIG. 4-1 FIELD CHECKOUT USING HI 813 CALIBRATION SHAKER - - - - - - - - - - - - - - - - - - - - - - - -4-3

FIG. 4-2 CONNECTING TRANSDUCER LEADS TO HI 5501 MODULE - - - - - - - - - - - - - - - - - - -4-3

FIG. 4-3 CALIBRATION EQUIPMENT SETUP- - - - - - - - - - -4-5FIG. 4-4 HI 5500 SERIES SIGNAL CONDITIONER

CIRCUIT BOARDS - - - - - - - - - - - - - - - - - - -4-6FIG. 4-5 REMOVING THE MODULE COVER - - - - - - - - - - -4-7FIG. 4-6 J4 SENSITIVITY JUMPER SETTINGS - - - - - - - - - -4-10FIG. 4-7 JUMPER SETTINGS FOR REFERENCE VOLTAGE - - -4-11

CHAPTER 5 - CALIBRATION - - - - - - - - - - - - - - - - - - -5-1I

FIG. 5-1 REMOVE PHILLIPS PAN HEAD SCREWS- - - - - - - -5-4

HI 5532/5533 MODULESII

Chapter 1 - Overview

CHAPTER 1 - OVERVIEW

A BRIEF DESCRIPTION OF CHAPTER 1

This manual provides the user and service personnel with a description of the specifications, installation, setup, configuration, operation, communication, maintenance, and troubleshooting procedures for the Hardy Instruments HI 5500 Series Signal Condition-ers. The HI 5500 Series Signal Conditioner provides a modular and versatile solution to predictive mainte-nance of machinery. Modules can be configured as a stand alone monitoring system with shutdown capa-bility or as a simple signal conditioner feeding vibra-tion information to a plants control computer (PLC or DCS). The modules process vibration signals and allow plant computers or recording devices to monitor the overall vibration levels on important production machinery. Machinery vibration monitoring is a cost effective way to implement predictive maintenance for sustained machine reliability.

FIG. 1-1 STANDARD HI 5500 SIGNAL CONDITIONER MODULE

The modules can be used on a variety of machine types. Each HI 5500 module contains the circuitry to condition and convert the dynamic signal produced by 1-1


the vibration transducer (HI 111, HI 113) to a cali-brated 4-20mA current output. The 4-20mA output is proportional to the measured vibration amplitude for trending by a PLC or DCS. The HI 5500 Series can be used with either a set point module (HI 5532) and a relay module (HI 5533) to provide a monitoring sys-tem (HI 5500 MS) with alarm and/or shut down capa-bilities. The HI 5500 Series conditioning monitoring system detects machine problems early so that cata-strophic failure can be minimized and any problems can be repaired during scheduled downtime. The HI 5500 Series Signal Conditioner Modules are essential for successful predictive maintenance.

To get the maximum service life from this product, users should operate this module in accordance with recommended practices either implied or expressed in this manual. Before using the HI 5500 Signal Condi-tioning modules, all users and maintenance personnel should read and understand all cautions, warnings, and safety procedures, either referenced or explicitly stated in this manual, to ensure the safe operation of the module. Hardy Instruments appreciates your busi-ness. Should you not understand any information in this manual or experience any problems with the product, please contact our Customer Support Depart-ment at:

Phone: (858) 278-2900FAX: (858) 278-6700e-mail: [email protected] Address: http://www.hardyinstruments.com

ABOUT HARDY MANUALS

Every Hardy Installation and Operation manual is organized into easily referenced chapters, that are almost always the same:

Chapter 1 - Provides an introduction to the instrument and an Overview of the equipment and its capabilities.

Chapter 2 - Provides a complete list of Specifi-cations.1-2


Chapter 3 - Contains complete instructions needed to install the HI 5500 Series Vibration Signal Conditioners.

Chapter 4 - Provides complete hardware Con-figuration instructions for setting dip switches and jumpers.

Chapter 5 - Pertains to the firmware/software Setup and preparation procedures to calibrate and operate the instrument.

Chapter 6 - Provides all Calibration instruc-tions.

Chapter 7 - Pertains to the Operating Proce-dures of the HI 5500 Series Vibration Signal Conditioners.

Chapter 8 - Pertains to the Troubleshooting procedures for repair of the instrument.

Hardy Instruments hopes that this manual meets your needs for installation and operation. All corrections or suggestions for improvements of this manual are wel-come and can be sent to the Technical Publications Department or Customer Support Department at Hardy Instruments Inc.

DESCRIPTION The Hardy Instruments DI 5500 Series Signal Condi-tioning Modules are specifically designed to:

Continuously monitor the condition rotating machinery vibration.

Monitor machine vibration in a plant computer using 4-20 milliamp and 0-5 VDC outputs.

Set off an alarm to alert maintenance personnel of excessive vibration.

Provide vibration analysts the raw vibration sig-nal for diagnosing machine vibration essential for predictive maintenance.

INDUSTRIES Petroleum Chemical Power Pulp and Paper Food/Beverage Metal Fabrication1-3

Transportation


APPLICATIONS Pumps Fans/Blowers Motors Chillers Compressors Machine Tools

OPTIONS

HI 5500PS Power Supply

The Hardy HI 5500PS is a compact power source that converts 110VAC to 24VDC to provide power for Hardys HI 5500 Series Signal Conditioners. It is rug-gedly constructed and designed to withstand substan-tial overloads or short circuits for reasonable lengths of time. The power supply can be connected to a type C or D style mounting rail for easy installation. Rec-ognized by Underwriters Laboratories (UL)(See Fig. 1-2)

FIG. 1-2 HI 5500PS +24VDC POWER SUPPLY1-4


Transducers HI 111 (General Purpose) Accelerometer - 100 mV/g, 250 F Service, 2-Pin MS connector, Case

Isolated. HI 113 (Premium) Accelerometer - 100 mV/g,

250 F Service, 2-Pin MS connector Case Iso-lated.

HI 113SM Accelerometer, 100 mV/g, 250 F Ser-vice, 2-Pin MS Connector, Case Isolated, Side Mount.

NEMA Enclosures Enclosures constructed of Fiberglass, Mild Steel or Stainless Steel without back plate.

Back Plate/Not Wired

Aluminum back plate with Type C Din Rail(s) and two rail stops to mount HI 5500 Series modules. Wir-ing of modules is not included.

Back Plate/Wired

Aluminum back plate with Type C Din Rail(s) and two rail stops to mount HI 5500 Series modules. Wired per customer configuration. Also includes AC input terminal and fuse block.1-5

HI 5500 SERIES SIGNAL CONDITIONERS1-6

Chapter 2 - Specifications

CHAPTER 2 - SPECIFICATIONS

A Brief Description of Chapter 2

Chapter 2 lists the specifications for the HI 5000 Series Signal Conditioning Module. Specifications are listed for the standard instrument and for optional equipment. The specifications listed are designed to assist in the installation, operation and troubleshoot-ing of the instrument. All service personnel should be familiar with this section before attempting an instal-lation or repair of this instrument.

Specifications for a Standard HI 5000 Series Signal Conditioning Module

Electrical Characteristics

Input Sensor Sensitivity

10, 100, 500 mV/g User Selectable

Sensor Excitation Current

+24 VDC @ 4 mA

Current Output 4-20mA 10%

Voltage Output 0-5 VDC 10%

Maximum Load Resistance

1.2 KOhms

Frequency Range (3 dB)

See Table 2-1

Vibration Range

See Table 2-12-1


NOTE: *Special Orders are available at various Frequency and Vibration Ranges.

Sensor Fault 0mA output in Fault Condition

Power Requirements

Nominal: +24 VDCRange: +22 to +28 VDC

Physical Characteristics

Mounting DIN Rail (35mm x 15mm)

Physical Dimensions

Length Approx. 4.00 (102mm)Width Approx. 1.9 (48mm)Height Approx. 3.25 (80mm)

Table 2-1: Frequency Range

Standard Models

Frequency Range( 3dB)

Vibration Range

HI 5501 - ASTD 2 - 10 KHz 0 - 10 g

HI 5501 - VSTD 2 - 10 KHz 0 - 1 ips

HI 5501 - VLF 2 - 1 KHz 0 - 1 ips

HI 5502 - STD 2 - 10 KHz 0 - 1 ips

Hazardous Models

Frequency Range( 3dB)

Vibration Range

HI 5501E - ASTD 2 - 10 KHz 0 - 10 g

HI 5501E - SPEC ACCEL, VEL, DISPLACE Special Order*

HI 5501E - VLF 2 - 1 KHz 0 - 1 ips

HI 5501E - VSTD 2 - 10 KHz 0 - 1 ips2-2

Weight Approx. 4.6 oz. (131 grams)


Environmental Characteristics

Temperature Range

Operating 0-70 C (32-158 F)Storage 0-85 C (32-185 F)

Humidity 0-95% Non-Condensing

Ordering Information for the HI 5501

FIG. 2-1 SPECIAL PRODUCT CONFIGURATION MENU - HI 5501

NOTE: AR pertains to Active Reference, and IR to Inac-tive Reference. Active Reference designates an HI 5501/5502 module as the master module when it is used with multiple modules in an auctioneering (or group) mode. For example, if one sensor is used with two HI 5501 modules of provide acceleration and velocity measurements, one of the two modules must be configured for AR and the other module for IR. Similarly, if multiple modules (each with their own sensor) are grouped together in an auctioneering mode (AM), the module must be configured for AR and the remaining modules for IR.2-3


Ordering Information for the HI 5502

FIG. 2-2 SPECIAL PRODUCT CONFIGURATION MENU - HI 5502

NOTE: These menus are for standard product configurations only. Special product configurations can be provided. Contact your local Hardy Representative for more information.

HI 5501E (Only)

Temperature Range

Operating -40 to +85 C (-40 - 185 F)Humidity 0-95% Non-Condensing

Enclosure Requirements

These devices are intended to be installed within an enclosure rated to at least IP54/NEMA 3 or 3S

Approvals UL CUL This equipment is suitable for use in Class I,

Division 2, Groups A,B,C and D Hazardous loca-tions.

This equipment is suitable fore use in Class I, Zone 2, Ex nL IIC T4 X, AEx nC IIC T42-4


Optional Equipment

HI 5500PS Power Supply

The HI 5500PS Power Supply is a compact power source for HI 5500 Series Signal Conditioners. Rug-ged and designed to withstand substantial overloads or short circuits for reasonable periods of time. The HI 5500PS can be connected to a Type C or D style mounting rail for easy installation. Recognized by Underwriters Laboratories. UL

Regulation 0.1% load 0.5% line Impedance: 0.07 ohms at 1kHz

0.20 ohms at 10 kHz

Environmental

Operating -20 to +71 C (-4 to +160 F)

Storage -55 to +85 C (-67 to +185 F)

Temperature Coefficient

-.015%/ C

Dimensions

Physical 4.0L x 2.875W x 3.375H (101.6mmL x 73.0mmW x 85.72mmH)

Weight 2 lbs, 1 oz. (.48Kgs)

Output Power .6 AmpsProvides power for up to 12 Signal Conditioner Mod-ules

Options 5500PS-1: 210-250 Volt Input, 47 to 420 Hz

HI 5532 Dual Alarm Setpoint Module

HI 5533 Relay Module, DPDT2-5

Chapter 3 - Installation

CHAPTER 3 - INSTALLATION


All information contained in Chapter 3 pertains to unpacking, cabling, interconnecting, configuration and installing the HI 5000 Series Signal Conditioning Module. Alternatives to any procedures contained or implied in this chapter are not recommended. It is very important that the user and service personnel be familiar with the procedures contained in this chapter, before installing or operating the HI 5500 Series mod-ule. Hardy Instruments appreciates your business. Should you experience any problems installing this equipment, contact Hardy Instruments Inc., Customer Support for assistance.

Unpacking Step 1. Before signing the packing slip, inspect the packing for damage of any kind.

Step 2. Report any damage to the carrier company immediately.

Step 3. Check to see that everything in the pack-age matches the bill of lading.

Step 4. Write down the Model(s) and Serial num-ber(s) of the module(s). Store this informa-tion in a convenient location for reference when contacting The Customer Support Department for parts or service.

WARNING ELECTROSTATIC DISCHARGE MAY DAM-AGE SEMICONDUCTOR COMPONENTS IN THE MODULE. DO NOT TOUCH THE CON-NECTOR PINS. PLEASE OBSERVE THE FOL-LOWING HANDLING PRECAUTIONS:

Wear an approved wrist-strap grounding device when handling the module.

Touch a grounded object or sur-face to rid yourself of any elec-trostatic discharge prior to handling the module.

Only Handle the module by grasping the DIN Rail Mount.3-1


Pre-Installation Engineering Procedures

Step 1. Always check the hazardous area classifi-cation of the site where you are going to install the modules. Make absolutely sure that the module meets the hazardous area classification before installation. If you dont know the hazardous classification, check with the Site or Consulting Engi-neer.

WARNING DO NOT INSTALL THE MODULES IN HAZ-ARDOUS AREAS WHERE THE MODULE DOES NOT MEET THE HAZARDOUS AREA CLASSIFICATION.

Step 2. Choose a location in where the tempera-ture and humidity meets the limits speci-fied for the HI 5500 Series signal conditioners (See Chapter 2). Always keep the modules dry and try to maintain a con-stant temperature. Temperature recycling can lead to moisture build-up inside the module.

Step 3. The HI 5500 Series terminal blocks permit solderless and lugless connections of 16 to 22 GA stranded wiring. Strip back the insulation.25 to.30 before making con-nections to make sure there is a good con-nection.

Step 4. Always use rigid metal conduit whenever possible for field wiring transducers to the HI 5500 Conditioners.

Step 5. Make sure to separate the low level vibra-tion signal cabling from other instrument and control signals.

WARNING NEVER RUN THE TWISTED, SHIELDED OR COAXIAL CABLES CONTAINING LOW LEVEL VIBRATION SIGNALS IN THE SAME CON-DUIT WITH AC WIRING.

Step 6. Shielding must be pulled back from the transducer wire in order to terminate them. Unshielded wire is susceptible to Radio 3-2


Frequency Interference (Walkie Talkie, 2-Way Radios etc.) Always locate the DI-5500 Series units in a metal enclosure to shield unshielded wires.

Step 7. It is important to know the machine or mounting position resonant frequency (at running speed) in order to achieve accu-rate measurements. Your machinery sup-plier can provide you with this information. Mounting resonance can give a false indication of high frequency machinery faults such as gear mesh and bearing problems. In some cases the mounting resonance can cause sensor overload if it is excited by a machinery fault. An accelerometers region and linear frequency response generally extends well above and below running speed of most rotating machinery.

Step 8. Make sure that all covers, fittings and accessories are tightly fastened to the machine. Readings are corrupted by vibrating loose parts and degrade the qual-ity of the measurement.

Step 9. After completing the field installation and system commissioning, set up a schedule for regular calibration and maintenance. This will make sure the results from the instrument are reliable so that others in your facility can rely on the information. For calibration we recommend the Hardy HI 803, HI 813, HI 823 Transducer Cali-bration Systems. Contact your local Hardy Instruments Dealer for more information.

Electrical Wiring Precautions

1. Never route the cable along side high voltage power lines and only cross high voltage power lines at right angles. For example, if a power line is 440 volts and 60 Hz and the signals from the sensor are at the milli and microvolt levels any cross talk can severely corrupt the data.

2. Cable and Shielding should be grounded at one end only preferably at the controller.3-3


3. Shield and Common wires must be wired to earth ground.

Installing the HI 5500 Standard Module Onto a DIN Rail

Step 1. Hold the module with the DIN Rail Mounting facing down and what appears to be a spring type mounting latch. (See Figs. 3-1 & 3-2)

Step 2. Tilt the front of the module and mount slightly down about 30 degrees.

Step 3. Slide the mounting latch over the edge of the DIN Rail until the rail edge touches the bottom of the DIN Mount frame.

Step 4. Slide the mount back until it stops.Step 5. Gently push the back of the mount down

until the mount snaps onto the DIN Rail. (See Fig. 3-3)

FIG. 3-1 INSTALLING THE MODULE ONTO A DIN RAIL3-4


FIG. 3-2 MOUNTING LATCH HIGHLIGHTED

FIG. 3-3 MODULES INSTALLED ON DIN RAIL

Step 6. Now wire the module to the transducer and the power supply.

Electrical Installation Procedures

The following describes the electrical components of a module and terminal assignments. A block diagram 3-5


is provided to assist in installation. (See Figs. 3-4 & 3-5)

FIG. 3-4 FUNCTIONAL BLOCK DIAGRAM FOR HI 5501/HI 5502

FIG. 3-5 CONNECTIONS/5501

LED OK Indicator A green LED illuminates when the sensor connection and power is OK. The LED goes off when a circuit fault exists.3-6


BNC Connector The vibration signal can be accesses at the BNC con-nector or at the Terminal Connector. The Vibration signal can be accessed in either the filtered or unfil-tered form.

WARNING DO NOT REMOVE OR REPLACE WHILE CIR-CUIT IS LIVE UNLESS THE AREA IS KNOWN TO BE FREE OF IGNITABLE CONCENTRA-TIONS OF FLAMMABLE GASES OR VAPORS.

Terminal Assignments

TB2-1,2 Power supply input terminals - The voltage measured between TB2-1 and TB2-2 should be within the range of +22 to +28VDC. Nominal voltage should be +24VDC.

TB2-3,4 Output current (4-20mA) proportional to the mea-sured vibration is available between terminals TB2-3 (4-20) and TB2-4 (common) This is the output to be connected to the plant DCS or data acquisition system for tending analysis. The 4-20mA output is clamped to approximately 0mA whenever the green OK LED is out (Transducer Fault Condition).

TB2-5,6 Voltage output (0-5VDC) proportional to the mea-sured vibration is available between terminals TB2-5 and TB2-6. This 0-5VDC output is driven to a nega-tive voltage whenever the green OK LED is out. The 0-5VDC output is intended primarily as an input signal to the HI-5532 Setpoint Module for communi-cating the vibration level measured by the HI-5501/5502.

TB1-1 Connect the shield from the transducer cable to this terminal if the shield is isolated from ground at the truncates end. If the shield is common to the trans-ducer case, the shield must be tied back to the cable and NOT connected to the HI 5501/5502 shield termi-nal.3-7


TB1-2 The output signal from the field mounted sensor is connected to this terminal. Power to accelerometers is provide via this terminal.

TB1-3 Connect the common terminal from the transducer to this terminal. This terminal could be called signal return.

TB1-4 The voltage at this terminal is the internal circuit ref-erence. This terminal is used when connecting the HI 5532 Setpoint and HI 5533 Relay modules to the HI 5501/5502 Signal Conditioners and are to provide relay outputs for annunciation or shutdown. Self-gen-erating velocity pickups (no external voltage applied) will require the low side or return wire to be con-nected to this terminal. No connection will terminate at TB1-3 in this case. For example:

When one transducer is connected to several 5501 modules, you make one module the Active Reference Voltage (AR) by setting the jumper at JP1. The remaining modules you set for Inactive Reference voltage (IR) by setting the jumpers for IR.

Another example is when you have several individual modules connected to individual sensors and you want to use the Auctioneering mode to check each.

TB1-5 This is an optional buffered signal out connection in case you dont have a cable with a BNC connector.

Installing modules in an Enclosure (See Fig. 3-5)

Step 1. Mount the DIN Rail(s) (Standard 35mm DIN RAIL) onto the back plate of the enclosure. The center distance between the installed DIN Rails should be no less than 5.5 (139.7mm) to allow for proper wiring of the modules.

Step 2. Mount the modules onto the DIN Rail. See Installing the HI 5500 Standard Module onto a DIN Rail above.

Step 3. It is recommended that you install a DIN Rail Stop or Stops to prevent the modules from accidentally sliding off the DIN Rail.3-8

Step 4. Its that easy.


FIG. 3-6 INSTALLING THE MODULES IN AN ENCLOSURE

Pump Monitoring with Transducers and HI 5500 Series Module

FIG. 3-7 PUMP MONITORING

Step 1. Select a sensor mounting location that minimizes the vibration transmission route through the machine. Avoid mounting the sensor on thin sections or vibration-free areas.3-9


Step 2. Select the mounting configuration based on whether the mount is permanent or temporary. In most cases the mounting configuration is permanent and you should use a stud mount or cementing pad.

Step 3. Install the sensor according to the chosen mounting configuration and sensor sup-plier instructions. See instructions below:

Threaded Stud Stud mounting requires a tapped hole drilled directly into the structure. A threaded stud provides electrical and mechanical connection between the sensor and the pump bearing housing. The sensor requires a flat surface perpendicular to the tapped hole. The spot face must be 1.1 times larger than the diameter of the sensor housing to ensure flush mounting. For mea-surements above 1,000Hz (60,000cpm), the surface should be flat within 1 mil and have surface texture no greater than 32 microinches. Make sure that burrs between the sensor and the pump bearing housing are removed.The center line of the tapped hole must be perpendic-ular to within 1 of the mounting surface to ensure no gaps are present between the base of the sensor and the bearing housing structure.

Cementing Pad

Cementing pads eliminate drilling/tapping into the structure, but provide high frequency capability approaching stud mounts. Select the appropriate cementing pad for the application. Check with your sensor supplier for the correct cementing pad and instructions for installation. Here are some general guidelines for installation:

Bore a spot face 1.1 times larger than the diameter of the cement-ing pad to be installed on the bearing housing. Allow the machine tool to groove and abrade the surface to prepare for the adhesive bonding. Do not use cutting fluids as they may con-taminate the bonding area.3-10


Apply the primer with a brush and let dry for 5 minutes.

Mix the Bi-pack thoroughly by removing the clip and working the epoxy and catalyst into each other.

Apply a generous amount to the spot face and set the Cementing pad with a turning motion.

Filet the adhesive around the sides of the pad to increase shear strength and assist electrical iso-lation. The working time is usu-ally 5 minutes but may vary depending the on the ambient temperature. (See Fig. 3-8) Do not get epoxy in the sensor mounting surface.

FIG. 3-8 CEMENTING PAD INSTALLATION

Test the electrical isolation from the pad to the machine with an ohmmeter.

Apply a service removable threadlock such as Loctite 242 blue to the tapped hole in the sen-sor.

Torque the sensor to the manu-facturers specifications.

Step 4. Connect the Sensor Waveform lead to the In Connection (TB1-2) on the HI 5500 3-11

Series Signal Conditioning Module.


Step 5. Connect the ground lead to the Common Connection (TB1-3) on the HI 5500 Series Signal Conditioning Module. (See Fig. 3-9)

Wiring Diagram Example for 5501/55032/5533 with no Power Supply

FIG. 3-9 WIRING DIAGRAM FOR 5501/5532/5533 WITH NO POWER SUPPLY

+ 24CVDC

COM

RESET

ACK

INPUT #1

REF

INPUT #2

DUALSETPOINTMODULEHI 5532

ALARM #1 READ#1

AUX1

OUT1A

OUT1B

READ#2

AUX 2

OUT 2A

OUT 2B

TB1 TB2

ADJ.

ADJ.

ALARM #2

+ 24VDC

COM

4-20MA

COM

DCOUT

REF

OUTPUT SIGNALCONDITIONER

OK

SHD

IN

COM

REF

SIGH I 5 5 0 1 - 0 0 0 0 5 - 9 9 9 9 9

L 1 0 K - 0 1 . 0 V - 1 0 0 - P K

TB2

TB1

+ 24CVDC

COM

DISABLE

INPUT

REFRELAY CONTACTS AREDPDT 3 AMPS SUPPRESSED(MAYBE PROGRAMMED FORFAIL SAFE. SEE MANUAL)

N.C.

COM

N.O.

TB1

TB2

RELAY MODULEHI 5533

SET

#1

N.C.

COM

N.O.

SET

#2

CO

NTA

CT

CO

NTA

CT

RELAY CONTACTS

TRANSDUCER SIGNAL (+)TRANSDUCER SIGNAL (-)

+ 24 VDCCOMMON

4-20 mA Output

+ 24 VDCDC CommonAlarm Reset

+ 24 VDCDC Common

N.C.CommonN.O.N.C.CommonN.O.

CABLE SHIELD

Relay Inhibit3-12


Wiring Diagram for Acceleration and Velocity Monitoring System with Alarm and Danger Relays

FIG. 3-10 WIRING DIAGRAM FOR MONITORING SYSTEM WITH

+ 24VD C

COM

4-20MA

COM

DCOUT

RE F

OUTPUT SIGNA LCOND ITIONER

OK

SHD

IN

COM

RE F

SIGH I 5 5 0 1 - 0 0 0 0 5 - 9 9 9 9 9

L 1 0 K - 0 1 . 0 V - 1 0 0 - P K

TB2

TB1

+ 24C VD C

COM

RE SET

AC K

INPUT # 1

RE F

INPUT # 2

DUA LSETPOINTMODULEHI 5532

ALA RM #1 RE AD #1

AUX 1

OUT1A

OUT1B

RE AD #2

AUX 2

OUT 2A

OUT 2B

TB1 TB2

AD J.

AD J.

ALA RM #2

+ 24C VD C

COM

DISAB LE

INPUT

RE FRE LAY C ONTAC TS AR EDP DT 3 A MPS SUPPR ESSED(MAYB E PROGRA MMED FORFAIL SAFE. SEE MA NUA L)

N.C.

COM

N.O.

TB1

TB2

RE LAY MODULEHI 5533

SET

#1

N .C.

COM

N.O.

SET

#2

CO

NTA

CT

CO

NTA

CT

ALARM RELAY CONTACTS

+ 24VD C

COM

4-20MA

COM

DCOUT

RE F

OUTPUT SIGNA LCOND ITIONER

OK

SHD

IN

COM

RE F

SIGH I 5 5 0 1 - 0 0 0 0 5 - 9 9 9 9 9

L 1 0 K - 0 1 . 0 V - 1 0 0 - P K

TB2

TB1

+ 24C VD C

COM

DISAB LE

INPUT

RE FRE LAY C ONTAC TS AR EDP DT 3 A MPS SUPPR ESSED(MAYB E PROGRA MMED FORFAIL SAFE. SEE MA NUA L)

N.C.

COM

N.O.

TB1

TB2

RE LAY MODULEHI 5533

SET

#1

N .C.

COM

N.O.

SET

#2

CO

NTA

CT

CO

NTA

CT

DANGER RELAYCONTACTS

AC

AC

Mod

el 5

500P

S54

EB60

AC

TO

DC

PO

WE

R S

UPP

LY

DC COMMON

+24 VDC

InputPower

TRANSDUCER SIGNAL (+) WHITETRANSDUCER SIGNAL (-) BLACK

+ 24 VDCInputPowerRecorderOutput

COMMON4-20 mA Output

COMMON

+ 24 VDCInputPowerRecorderOutput

COMMON4-20 mA Output

COMMON

+ 24 VDCDC CommonAlarm Reset

InputPower

+ 24 VDCDC Common

InputPower

+ 24 VDCDC Common

N.C.CommonN.O.

N.C.CommonN.O.N.C.CommonN.O.3-13

ALARM AND DANGER RELAYS

Chapter 4 - Setup

CHAPTER 4 - SETUP


All information contained in Chapter 4 pertains to set-ting up for a Bench Check and Calibration of the HI 5501/HI 5502 Signal Conditioner Modules. All Ser-vice Personnel should read this chapter before attempting to calibrate or perform a bench check of any 5500 Series Module. Alternatives to any proce-dures explicit or implied in this chapter are not recom-mended. Be sure to have on hand, all the equipment necessary to perform these tests. All safety precau-tions should be taken when performing a calibration or bench check.

NOTE: The HI 5500 Series Signal Conditioners are shipped from the factory with the jumpers set for default Auc-tioneering (or group) mode unless specified at time or order and Active Reference Voltage. When setting up a Monitoring system or any system where more than one Signal conditioner is connected to Input #1 or Input #2 on one HI 5532 Dual Set Point Control. See the Monitoring System Setup Procedures below before setup of the Monitoring System.

Test Equipment and Tools Required

Phillips screw driver - #0 or #1 tip. Small Flat Head screw driver for HI 5501 or HI

5502 terminals and potentiometers. Digital Multi-Meter

Must read DC milliamps Must be Broadband Must be capable of accurate measure-

ments over the expected frequency ranges.

NOTE: Not all Digital Volt Meters are accurate below 50-60Hz. Check your multi-meter specification sheet to verify that the instrument accuracy is adequate below 50-60Hz. If the accuracy of the meter is not adequate below 50-60Hz the calibration or calibration check of the HI 5500 Module is not very accurate. A rule of thumb for calibration is that the instrument you are using to calibrate or check calibration should be 4 4-1


times more accurate than the instrument being cali-brated.

Variable voltage DC Power supply - 0 to +30VDC at 250mA.

HI 813 Portable Shaker System (Desirable but not Mandatory)

Assorted test leads and connectors. Signal generator with variable DC positive offset

capability (0 to +20VDC), required to calibrate the HI 5501 or HI 5502

NOTE: If a signal generator with 0-20VDC offset capability is not available, a second DC power supply is required to produce the DC offset voltage required to simulate accelerometer bias voltage (a 9VDC battery is sufficient).

Frequency Counter - Resolution to 0.1 Hz mini-mum

Oscilloscope

Quick Calibration Check Using An HI 813 Portable Shaker Calibration System

Step 1. Make sure the transducer you are going to use is calibrated.

Step 2. Make sure the HI 813 Portable Shaker is calibrated.

Step 3. Do not connect any equipment to the HI 813 Portable Shaker unless it is OFF.

Step 4. Place the HI 813 Portable Shaker on a sur-face that is free from any measurable vibration. If the shaker is placed on a sur-face that is vibrating, the zero adjustment of the 4-20mA output might be set artifi-cially high.

Step 5. Install transducer and cable assembly that is the same type that will be used with the field installed HI 5500 Series Signal Con-ditioners, onto the adapter head of the HI 813 Portable Shaker System for Calibra-tion. (See Fig. 4-1)

Step 6. Connect the accelerometer cable, power/signal and common leads or velocity trans-ducer signal and common leads to the ter-4-2

Chapter 4 - Setup

minals marked IN and COM which are printed on the HI5501/HI 5502 top cover assembly. (See Fig. 4-2)

FIG. 4-1 FIELD CHECKOUT USING HI 813 CALIBRATION SHAKER

FIG. 4-2 CONNECTING TRANSDUCER LEADS TO HI 5501 MODULE

Step 7. Make sure the power supply is off. Step 8. Connect the +24VDC Power Supply to the

TB2-1 and TB2-2 terminals on the HI 4-3


5501/HI 5502. Do not apply power to the module yet. (See Fig. 4-1)

Step 9. Connect the Ammeter to the4-20mA and Com terminals. (See Fig. 4-1)

Step 10. Using the +24VDC Power Supply apply power to the TB2-1 and TB2-2 terminals on HI 5501/HI 5502.

Step 11. Apply the +24VDC power to the module. Step 12. Turn ON the HI 813 Portable Shaker. Step 13. On the shaker set the Amplitude to the full

scale Gs that the 5501 or 5502 you are checking is rated for. For example: If you bought an HI 5501 with a full scale rating of 10 Gs, set the amplitude for 10Gs.

Step 14. Check the ammeter. If the ammeter is reading 20mA (within a tolerance range of 19.5 to 20.5mA), the HI 5500 Series Mod-ule is in calibration.

Step 15. Set the Amplitude to 0Gs. If the ammeter is reading 4mA ( 5%), the HI 5500 Series module is in calibration.

Step 16. If the reading is outside the tolerance range, check to be sure the cables are securely fastened and the transducer is securely fastened to the shaker.

Step 17. If the reading continues to be outside the tolerance range, calibrate the HI 5500 Series Module.

Calibration Setup Procedures Using a Frequency Generator and Power Supply

It is important to note that the Frequency Generator creates a known input frequency and the power sup-ply generates a know input voltage thereby simulating the output from a transducer.

Step 1. Connect the Frequency Generator output to the HI 5501/HI 5502s transducer input terminals marked IN+ and COM-. The IN terminal is positive and the COM ter-minal is negative. (See Fig. 4-3)

NOTE: If you do not have a 10VDC Power Supply you can use a 9VDC battery in its place.4-4

Chapter 4 - Setup

FIG. 4-3 CALIBRATION EQUIPMENT SETUP

Step 2. Set the Frequency Generators DC offset to +10VDC.

NOTE: The AC (sinewave) output from the frequency genera-tor remains OFF until an input signal is required.

Step 3. Using the +24VDC Power Supply apply power to the TB2-1 and TB2-2 terminals on HI 5501/HI 5502. (See Fig. 4-3)

Step 4. The Green LED on the cover should illu-minate indicating that the circuitry senses an acceptable bias voltage at the trans-ducer input terminals.

Step 5. If the LED does not light up turn off the power to the system and check all the con-nections to be sure they are securely fas-tened.

Step 6. Apply power to the system again. If the LED lights up the system is ready for test-ing.4-5


Step 7. If the LEd still does not light up, contact the Hardy Customer Support Department for assistance.

Step 8. Go to Chapter 5 - Calibration.

Full Scale and Zero Scale Adjustment

This adjustment is required if you find the milliamp output at full scale or zero scale is not stable. This adjustment is performed by adjusting potentiometer R14 located on the Top Circuit board (Prt. # 0235-0106-01) and potentiometers R24, R25 located on the Bottom circuit board (Prt. # 0235-0105-01). (See Fig. 4-4)

FIG. 4-4 HI 5500 SERIES SIGNAL CONDITIONER CIRCUIT BOARDS

Step 1. Make sure that you have completed the Calibration setup and have all the equip-ment installed correctly. (See Chapter 4 - Setup/Calibration Setup Procedures)

Step 2. Check to be sure the +24VDC Input Power Supply is OFF.4-6

Chapter 4 - Setup

Step 3. Use a phillips head screw driver and remove the two phillips pan head screws that fasten the cover to the two standoffs. (See Fig. 4-5)

FIG. 4-5 REMOVING THE MODULE COVER

Step 4. Lift off the cover and move it to the side. Be careful not to damage the attached wires.

Step 5. Turn ON the +24VDC Input Power Sup-ply.

NOTE: The HI 5500 Series Signal Conditioners are cali-brated using a +24VDC Power input.

Step 6. Set the frequency to full scale of the HI 5501/HI 5502 you are going to calibrate and the frequency generator power supply to 10VDC.

NOTE: It is a good idea if you have two multimeters to install them both. One to read output amperage (4-20mA) connected to terminals TB2-3 and TB2-4 as in the diagram. One to read voltage connected to terminals TB2-5 and TB2-6. (See Fig. 4-4)

Step 7. Set the multimeter to read volts and con-nect the multimeter to terminals TB2-5+ 4-7


and TB2-6- on the input side of the HI 5501/HI 5502 module. (See Fig. 4-4)

Step 8. Use the small flat head screw driver and adjust the R14 potentiometer until the voltmeter reads 5.0VDC.

Step 9. Set the multimeter to read milliamps. Con-nect the multimeter leads back to terminals TB1-3+ and TB1-4-.If the milliamp read-ing is 20.0mA you are done.

Step 10. If the milliamp reading is more than 5% of 20.0mA go to Step 11.

Step 11. Use the small flat head screw driver to adjust the R24 potentiometer until the meter reads 20mA.

Step 12. Set the frequency to 0 output. Step 13. Set the multimeter to voltage. Connect the

leads to terminals TB2-5 and TB2-6. See if the output voltage reading is 0 volts.

Step 14. Set the multimeter to read milliamps. Con-nect the leads to terminals TB1-3 and TB1-4. The reading should be within 5% of 4.0mA. If it is you are done and ready to calibrate.

Step 15. If the milliamp reading is above 5% of 4.0mA go to Step 16

Step 16. Use the small flat head screw driver to adjust the R25 potentiometer until the multimeter reads 4.0mA.

Step 17. Set the frequency to full scale again. Step 18. Again check the voltage and milliamp

readings and set them as close to 5VDC and 20mA as possible by adjusting the R24 potentiometer. (See Fig. 4-4)

Step 19. Continue going through this adjustment process by going from full scale frequency to zero scale frequency until you have a 5VDC reading @ 20mA and a 0VDC reading @ 4mA 5%. Do the adjustment process a few times. If you cannot get the voltage or amperage readings within toler-ance, contact Hardy Instruments Customer Support for further assistance. 4-8

Chapter 4 - Setup

CAUTION: NEVER ALLOW THE POWER SUPPLY VOLT-AGE TO EXCEED +30VDC.

Step 20. Turn off the +24VDC power supply. Step 21. Place the cover on the standoffs. Step 22. Use the phillips head screw driver and

replace the two phillips pan head screws that fasten the cover to the standoffs.

Input Sensitivity Selection

The Input Sensitivity of the HI 5501 & HI 5502 can be halved or doubled relative to a HI 5501/5502s as delivered configuration by changing the J4 jumpers. (See Fig. 4-6) The table below shows the effect the J4 jumpers have on the full scale amplitude for all HI 5501/5502. However, the voltage input column is valid for this example and for the HI 5501 or HI 5502 calibrated for 1.0 EU full scale and a transducer sensi-tivity of 100 mV/EU.

Examples:

X 1.0 - with J4 pins 2 to 3 jumpered. An HI 5501 or HI 5502 calibrated for 1.0 IPS full scale, will produce 20mA at the 4-20mA output terminal when the vibration input is 1.0 IPS.

X 2.0 - with J4 pins 1 to 2 jumpered. An HI 5501 or HI 5502 will produce 20mA output with a vibration input of 0.5 IPS 0-pk or 35.35mVrms.

X 0.5 - with jumpers at J4 removed entirely, the HI 5501 or HI 5502 will produce 20mA output with a vibration input of 2.0 IPS 0-pk. This in effect halves the sensitivity.

Pins Jumpered Full Scale MultiplierVoltage Input

Current Output

1 to 2 X2.0 35.35mVrms 20mA

2 to 3 X1.0 70.70mVrms 20mA

None X.5 141.4mVrms 20mA4-9


This capability is designed to make it possible under some circumstances to half or double the HI 5501 or HI 5502 full scale range without the necessity for a complete re-calibration. After changing jumpers we suggest a field checkout to confirm the HI 5501/02 accuracy was maintained. A change in jumper posi-tion should maintain the calibration and should not cause a shift in calibration greater than 2%.

FIG. 4-6 J4 SENSITIVITY JUMPER SETTINGS

Monitoring System Configuration

If no HI 5532 Dual Set Point Module is being used, or if one (1) Set Point Module is being used per HI 5500 Series Signal Conditioner, no jumper changes are required to the Signal Conditioners. The factory set Default Modes are AM (Auctioneering Mode) and AR (Active Reference Voltage) for individually shipped modules.

Reference Voltage Jumper Setting Procedures

You need to set jumper (JP1) to Inactive Reference Mode when more than one Signal Conditioner is con-nected to one HI 5532 Set Point Module and if the modules are being powered with a +24VDC Power Supply. (See Fig. 4-6) One module must be set for AR (the master module) in group mode.4-10

Chapter 4 - Setup

Step 1. Turn the +24VDC Input Power Supply OFF.



Step 4. Jumper JP1 is located on the Bottom board and can be removed without taking off the Top board. (See Fig. 4-6)

FIG. 4-7 JUMPER SETTINGS FOR REFERENCE VOLTAGE

Step 5. To set the module Reference Voltage to Inactive.

Use a small needle nose pliers and gently lift the jumper off the pins.

Step 6. To set the module Reference Voltage to Active.

Use a small needle nose pliers and gently press the jumper on the pins.4-11

Chapter 5 - Calibration

CHAPTER 5 - CALIBRATION


Chapter 5 pertains to the calibration procedures for the HI 5500 Series Signal Conditioners. Alternatives to any procedures either implied or explicitly con-tained in this chapter are not recommended. In order for the signal conditioners to work properly, it must be calibrated prior to operation. It is recommended that the module be re-calibrated periodically or when not in use for extended periods of time. Be sure to fol-low all the procedures in this chapter completely to insure that the module is accurate. It is very important that the user and service personnel be familiar with the procedures contained in this chapter, before installing or operating the HI 5500 Series Signal Con-ditioners.

Full Scale Output/Span Adjustment

The HI 5501/HI 5502 full scale output may be set with an accelerometer or velocity transducer mounted on a Hardy HI 813 Portable Shaker System or by using the signal generator to produce the AC and DC voltages required to represent the transducer output. You must perform the setup (See Chapter 4) before calibration.

Bench Calibration Using the Hardy HI 813 Portable Shaker System

NOTE: See Chapter 4 for the Setup using the HI 813 Portable Shaker System.

Step 1. Calculate the Log Mid-Frequency by using the following formula:

NOTE: See the calibration example below. This is one exam-ple only, do not use these values for all transducers.

The HP Frequency = 00002 Hz The LP Frequency = 02000 Hz5-1


Log Mid Frequency = AntiLog ((Log HP Freq + Log LP Freq) 2)

CALCULATION EXAMPLE FOR HI 5501 (MODEL #5501-00002-02000-1.0V-100):

Log Mid Frequency = 10x ((Log2 + Log 2,000) 2)

Log Mid Frequency = 10x ((.3 + 3.3) 2)

Log Mid Frequency = 10x ((3.6) 2)

Log Mid Frequency = 10x (1.80)

The Log Mid Frequency for calibrating this HI 5501 = 63.09 Hz

HP Frequency is the corner frequency in Hz of the HP (Highpass) filter.LP Frequency is the corner frequency in Hz of the LP (Lowpass) filter.

Low Pass Frequency

High Pass Frequency

Log Mid Frequency

2 Hz 1 KHz 44.7 Hz

2 KHz 63.1 Hz

3 KHz 79.4 Hz

5 KHz 100 Hz

10 KHz 141.3 Hz

30 KHz 251.2 Hz

5 Hz 1 KHz 70.8 Hz

2 KHz 100 Hz

3 KHz 125.9 Hz

5 KHz 158.5 Hz

Table 5-1: Log Mid Frequency Table5-2


Step 2. Turn the HI 813 Shaker amplitude knob to counter-clockwise until it stops. This is the minimum frequency.

Step 3. Set the HI 813 Shaker Function Display Switch to Acc, Vel, or Disp to match the HI 5501/HI 5502 output mode. In our example the HI 813 switch is set to Vel to match the V (velocity) output mode of the HI 5501 model 5501-00002-02000-1.0V-100

Step 4. Set the HI 813 power switch to ON. Step 5. Adjust the HI 813 vibration amplitude to

the desired full scale amplitude which is shown in the display. In our example the HI 5501 is calibrated for a full scale of 1.0 IPS, indicated by the 1.0V in the model number. Set the shaker amplitude to 1.0 for our example by turning the amplitude knob clockwise until 1.0 appears in the display.

Step 6. Adjust the HI 813 vibration frequency to the Log Mid Frequency from the Log Mid Frequency Table 5-1or as calculated using

10 KHz 223.9 Hz

30 KHz 398.1 Hz

10 Hz 1 KHz 100 Hz

2 KHz 141.3 Hz

3 KHz 177.8 Hz

5 KHz 223.9 Hz

10 KHz 316.2 Hz

30 KHz 562.3 Hz

Low Pass Frequency

High Pass Frequency

Log Mid Frequency

Table 5-1: Log Mid Frequency Table5-3


the formula provided. The Log Mid Fre-quency in our example is 63.09Hz.

Step 7. Verify the Analog output reading to be 20 mA 5%.

Step 8. Check to be sure the +24VDC Input Power Supply is OFF.


FIG. 5-1 REMOVE PHILLIPS PAN HEAD SCREWS



Step 12. If necessary use a small flat head screw driver to adjust the R14 potentiometer until the multimeter is reading 20.0mA 5%.

Step 13. This completes the calibration of an HI 5501 Signal Conditioner that contains a 2Hz HP filter, a 2,000Hz LP filter and one stage of integration with 20.0mA output when the vibration input is 1.0 inches per second.5-4


Step 14. This completes the span or full scale cali-bration using the HI 813 Portable Shaker System to the full scale amplitude.

Step 15. Shut OFF the +24VDC power supply. Step 16. Place the cover on the standoffs. Step 17. Use the phillips head screw driver and


Step 18. Using the formula above and the fre-quency range to be monitored by the HI 5500 Series Signal Condition Monitor, calculate the Log Mid-Frequency for each HI 5500 Series Monitor in your system.

Bench Calibration Using a Frequency Generator and Power Supply

NOTE: See Chapter 4 for the Setup using the Frequency Gen-erator and Power Supply.

Step 1. Set the Frequency Generators DC Offset to +10VDC.

Step 2. Make sure the Green OK light is on. Step 3. Adjust the frequency generators AC sine-

wave output to the voltage the vibration transducer would produce when set to the full scale output for the HI 5501/HI 5502 module you are calibrating. For example:

To calibrate an HI 5501 for 20mA at 2 Gs of acceleration when connected to a 100mV per G accelerometer, the frequency generators sinewave out-put would be set to 200mV 0-pk or 141.1mV RMS.

Step 4. Check the milliamp reading. Step 5. Check to be sure the +24VDC Input Power

Supply is OFF. Step 6. Use a phillips head screw driver and

remove the two phillips pan head screws 5-5


that fasten the cover to the two standoffs. (See Fig. 4-5)



Step 9. Use a small flat head screw driver to adjust the R14 potentiometer until the multimeter is reading 20.0mA 5%.

Step 10. This completes the calibration of an HI 5501 Signal Conditioner that contains a 2Hz HP filter, a 2,000Hz LP filter and one stage of integration with 20.0mA output when the vibration input is 1.0 inch per second.

Step 11. This completes the span or full scale cali-bration using the Frequency Generator to duplicate the full scale amplitude.

Current Limit Test The Current Limit Test insures the 4-20mA circuitry is properly limiting the output current to approxi-mately 34mA.

Step 1. With the Frequency Generator apply 100Hz sinewave of 100mV RMS ampli-tude to the HI 5501 transducer input termi-nals with the DC Offset set to +10VDC.

Step 2. Increase the AC input voltage to approxi-mately 2V RMS while observing the 4-20mA current output. Current limiting should begin to occur when the input volt-age gets to about 1.875V RMS, and limit the output current to approximately 30 to 40mA.

Step 3. Shut off the +24VDC Input Power Supply. Step 4. Place the cover on the standoffs. Step 5. Use the phillips head screw driver and


Final Check Step 1. Turn ON the +24VDC Input Power Sup-ply.5-6


Step 2. Check the OK light and the full scale output again to make sure no wiring was shorted on reassembly.

This completes the bench calibration of the HI 5501 or HI 5502 Signal Conditioner. The mod-ule(s) is fully calibrated and ready for field instal-lation.

Calculation of HI 5501/5502 Full Scale Calibration voltage

Acceleration or Velocity

When the connected transducers output matches the HI 5501/HI 5502/s output mode, no signal integration is required. For this condition, full scale calibration voltage is derived by multiplying the number of EUs full scale by the transducers milli-volt per EU Sensi-tivity.

For example:

HI 5501 w/Accel IN - Accel OUT:

HI 5501-00010-02000-5.0G-100 - Pk

= Calibration Voltage = EUs Full Scale * milli-volts per EU

= 5.0 * 100mV = Calibration Voltage = 500mV

HI 5502 w/ Vel IN - Vel OUT:

HI 5502-00002-01500-2.0V-400

= Calibration Voltage = EUs Full Scale * milli-volts per EU

= 2.0 * 400mV = Calibration Voltage = 800mV

Accelerometer or Velocity Input with

When the transducer input signal must be single or double integrated to provide the desired vibration 5-7

Signal Integration parameter, the Hardy HI 5500 Signal Condition can


contain one or two stages of integration. With integra-tion installed, the transducer input voltage required to produce the HI 5501/HI 5502s integrated full scale output must be calculated and used as the input volt-age when calibrating the 4-20mA output.

There are three Procedures to follow when deriving the full scale calibration voltage for HI 5500 Series Signal Conditioners containing one or two stages of signal integration.

1. Calculate the Log Mid-Frequency (See proce-dures above)

2. Convert Output Eus F.S. to Input EUs F.S at f (Log Mid-Freq).

3. Convert derived Input Eus F.S. to Volts for the specific transducer.

Log Mid-Frequency

Get from Table 5-1.

Convert Output EUs F.S. to Input EUs for Three Different HI 5501/HI 5502 Configurations

1. HI 5501 with Accel to Vel Single Integration requires Vel to Accel conversion:

Accel = 0.0162 * Vel EUs F.S. * f (Log Mid-Freq)

Three Examples Based on Part Numbers

Prt. # HI-5501-00005-01500-2.0V-100 Covers the Accel to Velocity Configuration:

Accel = 0.0162 * V (Vel EUs F.S.) * f (Log-Mid-Freq)Accel = 0.0162 * 2.0 * 86.6Accel = 2.8064-20mA F.S. Calibration Voltage = 281mV pk.

This example covers an HI 5501, acceleration input signal, which requires double integration to displace-ment.

Prt. # HI 5501-00003-01000-5.0D-100 Covers the 5-8

Accel to Displacement Configurations:


Log Mid-Freq = 54.77 HzAccel =.0511 * f2 (Log Mid-Freq2 * Disp EUs F.S. (inches)Accel =.0511 * (54.77)2 *.005Accel =.7664-20mA F.S. Calibration Voltage = 76.6 mV pk.5-9

Chapter 6 - Troubleshooting

CHAPTER 6 - TROUBLESHOOTING


All the information in Chapter 6 pertains to the trou-bleshooting and resolution of operating problems that may occur. All maintenance personnel and users should be familiar with Chapter 6 before attempting to repair an HI 5500 Series Signal Conditioner Mod-ule.

Problem: Green Light Not Illuminated

Step 1. Use a Volt meter and check the Loop Power (Terminals TB2-1 & 2) to see if you have +24VDC to the board. If the voltage is not +24VDC there is a problem with the circuit board or the power source.

Step 2. Use a Volt meter and check terminals TB2-5&6 to see if you have 5VDC. If the voltage is not 5VDC there is a problem with the circuit board. Go to Step 7.

Step 3. Turn the Power from your +24VDC Source OFF.

Step 4. Remove the Cover and check the BNC and LED connectors to see if they are con-nected to the proper pins or completed seated on the pins. Note: There is a white dot on the connector which should match the position of the dot on the circuit board. If they do not match up, re-connect the connector(s) so they do.

Step 5. After each Step, check to see if the green OK light comes on. If it does not got to another step until you have found the problem.

Step 6. If the green OK light still does not come on after going through all the steps. Con-tact Hardy Instruments, Customer Support Department for assistance.

Check Output Amperage

Step 1. Use an ammeter and check terminals TB2-3&4 to see if you have 20mA. If the amperage is not 20mA there is a problem with the circuit board.

Step 2. Check to be sure that the 4-20mA output is suppressed to 0mA whenever the DC bias 6-1


voltage is outside of the normal +3VDC to +18 VDC OK range. If the 4-20mA is not suppressed to 0mA when the DC bias voltage is outside of the normal range there is a problem with the circuit board.6-2

SIGNAL CONDITIONER5500 SERIESTable of ContentsTable of IllustrationsChapter 1 - OverviewA Brief Description of Chapter 1About Hardy ManualsDescriptionIndustriesApplicationsOptionsHI 5500PS Power SupplyTransducersNEMA EnclosuresBack Plate/Not WiredBack Plate/ Wired

Chapter 2 - SpecificationsA Brief Description of Chapter 2Specifications for a Standard HI 5000 Series Signal Conditioning ModuleElectrical CharacteristicsInput Sensor SensitivitySensor Excitation CurrentCurrent OutputVoltage OutputMaximum Load ResistanceFrequency Range (3 dB)Vibration RangeSensor Fault

Power RequirementsPhysical CharacteristicsMountingPhysical DimensionsLengthWidthHeight

Weight

Environmental CharacteristicsTemperature RangeOperatingStorage

Humidity

Ordering Information for the HI 5501Ordering Information for the HI 5502HI 5501E (Only)Temperature RangeOperating

HumidityEnclosure RequirementsApprovals

Optional EquipmentHI 5500PS Power SupplyRegulationEnvironmentalOperatingStorageTemperature Coefficient

DimensionsPhysicalWeight

Output PowerOptionsHI 5532HI 5533

Chapter 3 - InstallationA Brief Description of Chapter 3UnpackingPre-Installation Engineering ProceduresElectrical Wiring PrecautionsInstalling the HI 5500 Standard Module Onto a DIN RailElectrical Installation ProceduresLED OK IndicatorBNC ConnectorTerminal AssignmentsTB2-1,2TB2-3,4TB2-5,6TB1-1TB1-2TB1-3TB1-4TB1-5

Installing modules in an Enclosure (See Fig. 3-5)Pump Monitoring with Transducers and HI 5500 Series ModuleThreaded StudCementing Pad

Wiring Diagram Example for 5501/ 55032/5533 with no Power SupplyWiring Diagram for Acceleration and Velocity Monitoring System with Alarm and Danger Relays

Chapter 4 - SetupA Brief Description of Chapter 4Test Equipment and Tools RequiredQuick Calibration Check Using An HI 813 Portable Shaker Calibration SystemCalibration Setup Procedures Using a Frequency Generator and Power SupplyFull Scale and Zero Scale AdjustmentInput Sensitivity SelectionMonitoring System ConfigurationReference Voltage Jumper Setting Procedures

Chapter 5 - CalibrationA Brief Description of Chapter 5Full Scale Output/ Span AdjustmentBench Calibration Using the Hardy HI 813 Portable Shaker SystemBench Calibration Using a Frequency Generator and Power SupplyCurrent Limit TestFinal Check

Calculation of HI 5501/ 5502 Full Scale Calibration voltageAcceleration or VelocityAccelerometer or Velocity Input with Signal IntegrationLog Mid- FrequencyConvert Output EUs F.S. to Input EUs for Three Different HI 5501/HI 5502 ConfigurationsThree Examples Based on Part Numbers

Chapter 6 - TroubleshootingA Brief Description of Chapter 6Problem: Green Light Not IlluminatedCheck Output Amperage

HI5500

Documents

standard hi

brief description of

physical characteristics

hardy instruments

ordering information

sensor excitation current

frequency range

sensor fault