Prepared By WASIT

IED Unit





WASIT Gas
Plant
Bently Nevada
3500 Booklet
for
Maintenance
PCS Technicians

3500 Monitoring System
Installation and
Operation

WASIT Gas Plant



Table of Contents:
1- Introduction of WASIT Project VMS
2- What is Vibration?
3- 3500 Monitoring System Overview
4- 3500 System Hardware
5- Monitor Modules
6- Operating the system
7- Abbreviations
8- Common maintenance procedures
9-






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3500 MONITORING SYSTEM OVERVIEW
The 3500 is a state of the art machinery monitoring system that can collect machinery data from a variety of
transducers. It is a dedicated hardware platform designed and built to help manage critical machinery.
























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1- 3500 System Hardware


1-1 Rack

Rack is available in panel mount; rack mount and bulkhead mount versions. The Power Supplies and Rack Interface
Module must be installed in the far left positions. The remaining 14 rack positions are available for any
combination of modules.














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1-2 Power Supply



Power Supply is a half-height 120Vac module. Two power supplies are installed in the rack. Each power supply has
the capacity to power a fully loaded rack.
Removing or inserting a power supply module will not disrupt operation of the rack as long as a backup supply is
installed.
The supply in the lower slot acts as the primary supply and the supply in the upper slot acts as the backup supply. If
the primary supply fails, the backup supply will provide power to the rack without interrupting rack operation.
Each supply provides power on an independent power distribution network. This ensures that any failure in one
power distribution network (e.g., a short in +5 volt supply) will not affect the other supply.
If the system detects a problem with a power supply or that you have removed or installed a power supply, the
system will enter one of the following messages in the System Event List:
Message Description
Supply OK/Installed A Power Supply has been installed or it has been gone from a Not OK condition to
an OK condition
Supply Faulted/Removed A Power Supply has been removed or a Power Supply has gone Not OK

Single-Point Ground
To avoid ground loops, the system must provide a single point ground. The Power Input Modules provide a switch
that lets you control where your system is grounded. As the rack uses 2 power supplies then both switches must
set to the same position.
A CLOSED switch grounds the system through the GND terminal on the terminal strip connector. If the system is
grounded at another location, such as internal/external barriers, the switch on each Power Input Module must set
to OPENED.
The Supply OK LED on the front of each power supply module indicates
if all of the output voltages from that supply are within specification.


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Most racks the switch will be set to CLOSED at the factory.










When the switch is moved to this side (toward the rack) the switch is in the CLOSED position
When the switch is moved to this side (away from the rack) the switch is in the OPENED position
Grounding switch. Could be located directly above or below the input connector

Troubleshooting
If the Power Supply OK LED is off, check the following items:
1. Verify that the supply voltage to the Power Input Module is correct.
Danger
High voltages are present on power input lines. High
voltages can result in shock, burns, or death. Remove
power and avoid contact with power input terminals while
servicing the power supply and Power Input Module
1
3
2
1
2
3

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2. Verify that the installed Power Input Module type matches the installed power supply (e.g., you are using an AC
Power Input Module with the ac version of the power supply).
3. Determine whether the fuse on the Power Input Module is blown. If the fuse is blown, replace it. A blown fuse
may be due to a severe overvoltage on the Power Input Module or a fault within the 3500 Power Supply.
4. If steps 1 through 3 do not solve the problem, install a new Power Supply. If the Power Supply OK LED comes on,
the original Power Supply is faulty.
5. If the problem persists, the Power Input Module may be damaged.





















Danger
High voltages may persist on the ac and dc power supplies
for several minutes after you remove the module from the
rack. High voltages may cause shock, burns, or death.
Always wait several minutes after removing power
supplies before attempting to handle them.


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1-2 Rack Interface TDI Module


The 3500 Transient Data Interface (TDI) is the interface between the 3500 monitoring system and Bently Nevadas
System 1 machinery management software. TDI operates in the RIM slot of a 3500 Rack in conjunction with the M
series Monitors (3500/40M, 3500/42M etc.) to continuously collect steady state and transient waveform data and
pass this data through an Ethernet link to the host software. Rack Interface TDI Module is a full-height module. It
also maintains System Event List and Alarm Event List.




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2- Monitor Modules
The Monitor Modules are full-height modules that can collect data from a variety of vibration, position and
temperature transducers. Any combination of Monitor Modules can be installed in the 3500 rack.
Not OK Status
This indicates whether the monitor is functioning correctly. The monitor returns a
Not OK status under any of the following conditions:
Module Hardware Failure
Node Voltage Failure
Configuration Failure
Transducer Failure
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.









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2-1 Proximity Module (3500/40M) Radial / Axial


The 4 channel 3500/40M Proximitor Module conditions the input signals from transducers to make radial vibration
and position measurements (only), and compares the measured signals with user-programmable alarms.
Alert/Alarm 1 Status
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 set point.
Danger/Alarm 2 Status
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 set point.

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Bypass Status
This indicates when the monitor has bypassed alarming for 1 or more proportional values at a channel. A condition
that sets the channel bypass status will also set this monitor bypass status.
Configuration Fault Status
This indicates whether the monitor configuration is valid.

-Proximity/Seismic Module (3500/42M) Acceleration / Velocity

The 4 channel 3500/42M Proximitor Seismic Module conditions the input signals from transducers to make radial
vibration, accelerometer, velocity and position measurements, and compares the measured signals with user-
programmable alarms.







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-Keyphasor Module (3500/25)

The 3500/25 Keyphasor Module is a half-height, 2-channel module used to provide Keyphasor signals to the
monitor modules in a 3500 rack. The module receives input signals from proximity probes or magnetic pickups and
converts the signals to digital Keyphasor signals that indicate when the Keyphasor mark on the shaft coincides with
the Keyphasor transducer. The 3500 Machinery Protection System can accept up to four Keyphasor signals. A
Keyphasor signal is a once-per-turn pulse from a rotating shaft used to provide a precise timing measurement. This
allows 3500 monitor modules and external diagnostic equipment to measure shaft rotative speed and vector
parameters such as 1X vibration amplitude and phase.






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-Temperature Module (3500/60 and 65)

The 3500/60 module provides six channels of temperature monitoring and accepts both Resistance Temperature
Detector (RTD) and Thermocouple (TC) temperature inputs. The modules condition these inputs and compare
them against user-programmable alarm set points.





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Temperature Module (3500/65)

The 3500/65 module provides sixteen channels of temperature monitoring and accepts both Resistance
Temperature Detector (RTD) and Thermocouple (TC) temperature inputs. The modules condition these inputs and
compare them against user programmable alarm set points.
























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-Channel Relay Module (3500/33)

The 16 SPDT Channel relay module (3500/33) is full-height module that operates in a standard (or non-redundant)
monitoring system. Its function is to provide relay outputs. Each relay, utilized on these Relay Modules, includes
"Alarm Drive Logic". The Alarm Drive Logic is programmed using AND/OR logic and can utilize alarming inputs
(alerts and dangers) from any monitor channel or any combination of monitor channels in the rack. This Alarm
Drive Logic is programmed using the Rack Configuration Software to meet the specific needs for the application.
In Wasit Gas Plant, the relay output will be configured as Normally Energized that is the contact will be closed
during normal operation and open when losing power or reaching a danger condition.









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-Communication Module (3500/92)

The monitoring system provides a communication module utilizing the Modbus protocol to communicate to other
systems such as the DCS. This module has redundant communication ports one as Ethernet and the other as serial
RS485. The system also has the ability to accommodate redundant communication modules in one rack. The
communication module provides two-way communication capability. Monitoring information is available to other
systems via the Modbus protocol. Further, these other systems are able to access rack set points, alarm event lists,
and be able to set trip multiply, rack reset, and alarm inhibiting. All available monitoring parameters are available
through the Modbus link. Depending on monitor type, this will include gap, 1X amplitude and phase and 2X
amplitude and phase. The communications module has the ability to time and date stamps all information. This
module allows the rack time to be synchronized with the DCS.









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6- Operating the system
This section shows how to use the various indicators and connections of a 3500 rack to control
operation and collect data.
The section is divided into the following parts:
6-1 Verifying configuration
6-2 Operating switches
6-3 Reading LEDs
6-4 Collecting data from output terminals

6-1 Verifying configuration
A 3500 rack can contain a variety of modules that can be set up to operate different ways. The process
of setting system, module, and channel options so that all the modules in the 3500 rack work together is
called configuration.
After power is applied to the rack, the configuration LED (CONFIG OK) indicates that the rack contains a
complete and correct configuration.
If the configuration LED is not ON, contact your local Bently Nevada representative.
6-2 Operating switches
Hardware switches let you control the operation of the rack as follows:
Reset switch: clears latched alarms and resets Timed OK Channel Defeat indications. If the Configuration
LED is blinking at 5 Hz, it will be stopped. This switch performs the same function as the Rack Reset
contact on the Rack Interface I/O Module.
Key switch: prevents unauthorized changes to the configuration settings. When the switch is in the RUN position,
the 3500 rack cannot be configured. When the switch is in the PROGRAM position, the 3500 rack can be configured
and the rack continues to operate normally. By removing the key, you can lock the Rack Interface Module in the
RUN or PROGRAM position.


6-3 System contacts

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System contacts provide additional control by connecting external contacts to the rack.
Trip multiply (TM) temporarily increases the alarm (Alert and Danger) set point values by a specific multiple
(usually two or three). This function is normally applied by manual (operator) action during start-up to allow a
machine to pass through high vibration speed ranges without monitor alarm indications.
Rack alarm inhibit (INHB) prevents an alarm from being declared on any monitor or relay in the 3500 rack. This is
typically used when performing maintenance functions.
Reset (RST) Same function as pressing in the RESET switch on the front of the rack.

6-4 Reading the LEDs
The LEDs on the front panel of 3500 modules indicate the operating status of the module

3500 Module LED Label Description Detail
3500/15 Power Supply Supply OK all of the output voltages
from the supply are within
specification

Most 3500 modules OK



TX/RX



Bypass
The module and I/O
module are operating
correctly

Flashes at the rate that
messages are sent from
the module

Some of the monitor
functions are temporarily
suppressed

3500/20 RIM Module TM



CONFIG OK
Indicates whether the
rack is in Trip Multiply
mode

The configuration of the
rack is correct.

3500/32 and 34 Relay CHn ALARM An alarm condition has
occurred with this relay.
(Where n is the channel
number 1 through 4)


If the Power Supply OK LED is off, check the following items:
Verify that the correct voltage is connected to the Power Input Module (refer to Table 1-2 Power Supply I/O
Modules on page 10).
Check to see if the fuse on the Power Input Module has blown. If the fuse is blown, replace it.

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A blown fuse may be due to:
-Severe over voltage on the Power Input Module
-A fault within the 3500 Power Supply

3500 Software
Rack Configuration Software. This package configures all 3500 modules.
All 3500 software is Microsoft Windows based and can operate across a network using Windows 2003 Server
or Windows XP Professional operating systems.