Professional Documents
Culture Documents
CSI 4500
Machinery Health™ Monitor
Online System Installation and Configuration
ii
License Agreement year from the date of purchase, and thereafter on an annual
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iii
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Hardware Technical Help
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iv
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v
vi
Contents
Chapter 1 • Introduction
Special Emphasis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Plant Appointed Project Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Where to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
vii
A0322LC, A0322DS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
AO322LC Sensor Mounting (without Quick-Connect) . . . . . . . . . . 3-23
A0322LC with Quick-Connect Mounting Instructions . . . . . . . . . . 3-25
A0322RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
A0322RM Mounting Stud Installation (Stud Mounting Only) . . . . 3-35
Sensor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
V425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Description & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Choosing Proper Actuator (Target) . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Mounting Sensor Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Mounting Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
viii
Pull V680 Bundled Cable from Junction Box/CSI 4500 . . . . . . . . . . . . . . 5-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Required Tools & Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CSI 4500 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Guidelines for Dedicated CSI 4500 Network Segment . . . . . . . . . . . . . . 5-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Power Circuit Guidelines for the CSI 4500 enclosure . . . . . . . . . . . . . . . 5-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
ix
Replacing the CSI 4500 Transient Daughterboard Hard Drive . . . . 7-60
CSI 4500 Transient Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
General Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Configuring a 4500 with Hyperterminal . . . . . . . . . . . . . . . . . . . . . 7-72
4500 G2 Processor Card LCD navigation screens . . . . . . . . . . . . . . 7-78
Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Overall Level Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Spectral Scan Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Calibrating the CSI 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Test Signal Generator (TSG) Calibration. . . . . . . . . . . . . . . . . . . . . 7-96
Gross Scan (GS) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
DSP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Transient Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
x
Index
xi
xii
Chapter 1
Introduction
Preface
Congratulations on your purchase of the CSI 4500 Machinery Health Monitor
online system. Along with your system hardware and software, you have been
provided several manuals to assist in installing, learning, and maintaining your
system. This particular document is the AMS Suite: Machinery Health Manager
Online Installation and Configuration. The purpose of this manual is to provide
system installers specific requirements and instructions for the correct installa-
tion and configuration of the CSI 4500 Machinery Health Monitor online
system and accessories.
This manual does not attempt to explain the operation or application of the CSI
4500 Machinery Health Monitor online system nor does it cover hardware or
software specifications.
Note
Normal installation for the Model CSI 4500 Machinery Health
Monitor unit is in an orientation such that the front panels are ver-
tical.
1-1
Read This First
Special Emphasis
These conventions are used throughout this manual to call attention to the adja-
cent text:
Note
A note indicates special comments or instructions.
Caution!
A caution indicates actions that may have a major impact on the
system integrity.
Warning!
The Warning paragraph warns you of actions that could cause
serious injury or death.
1-2 Introduction
How to Use
There are two intended audiences for this manual: the plant appointed project
manager, and the contractor. As such, it is important that each understand how
to make use of this document.
Warning!
All wiring should be installed by a trained and qualified electri-
cian. Wiring must conform to all applicable local codes and regu-
lations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
Warning!
Power to the CSI 4500 Machinery Health Monitor power converter
PCB must include a remote disconnect switch or circuit breaker.
The switch or circuit breaker must be in close proximity to the
equipment and within easy reach of the operator.
Caution!
Use of the CSI 4500 Machinery Health Monitor AC-DC Power
converter in a manner not specified by Emerson may impair pro-
tection offered by the equipment.
1-4 Introduction
Contractor
The contractor will use this manual for two purposes: preparing a bid for the
system installation, and as a guide during the system installation. When pre-
paring a bid for the system installation, it is imperative that the contractor
reviews all parts of the manual that are specific to the installation and list any
exceptions to the manual within the bid. If the contractor takes no exceptions,
then it will be assumed that the bid covers the scope of work as defined in the
installation manual.
As an installation guide, it is not necessary that the installer be familiar with the
entire manual. The manual is written so a contractor when performing a certain
action, such as installing an AO322LC sensor, can turn to that particular section
and have a complete instruction set without referencing any other part of the
manual. This should make it easier when many people are involved with the
installation, each performing a specific function.
1-6 Introduction
Where to Start
The chapters in this manual are intended to follow the natural progression of a
system installation. The plant assigned project manager needs to pay particular
attention to Chapter 2 “Pre-Installation Review” and Chapter 3 “System Docu-
mentation.” Contractors need to review Chapters 4-8 to fully understand the
scope of work involved in the online system installation. The following is a brief
summary of each chapter.
1-8 Introduction
Chapter 2
Pre-Installation Review
Description
The pre-installation review is a short but important phase in a successful online
system implementation. Consisting of a “Contractor Kickoff Meeting,” final
walk-through, and a system component review, it is the responsibility of the
plant assigned project manager with the assistance of the CSI 4500 Monitor
online project manager or online system engineer to ensure this phase of the
system installation is completed successfully. The pre-installation review
accomplishes the following:
• Identify and Educate all parties involved in the online system installation
• Makes sure that all parties fully understands the scope of work
• Sets the system installation schedule
• Confirms that system components fit customer’s application
• Confirms that all necessary system components are on site and available.
• Confirms location of system components is appropriate
It is not uncommon for plants to schedule the “Contractor Kickoff Meeting,”
final walk-through, and system component review all in one day. This is espe-
cially beneficial when the CSI 4500 online project manager is attending the
“Contractor Kickoff Meeting” so that they may assist the plant assigned project
manager during the final walk-through and system component review. For this
reason it is also recommended that the online system has been shipped to the
customer site before installation work begins.
2-1
Contractor Kickoff Meeting
Although referred to as the “Contractor Kickoff Meeting,” this meeting brings
together all parties involved with the online system installation. Typically, this
will involve:
• Plant Assigned Project Manager
• CSI Online Project Manager or CSI Online Systems Engineer
• End User(s)
• Contractor Representative(s)
• Information Systems Representative(s).
The purpose of this meeting is to:
• Assign Responsibilities
• Review Scope of Work For Contractors
• Answer Any Installation Related Questions
• Review Customer Expectations of Installed System
• Tentatively Set Schedules for Installation.
Although many contractors will be educated on the system installation during
the bid process by reviewing the installation manual and the system documen-
tation (see Chapter 3). It is important to confirm that they fully understand the
scope of work by reviewing each part of the installation during this meeting. If
the system documentation has not been submitted to the contractors, this is the
time to do so.
System Documentation
Description
Often an overlooked part of the system installation, proper documentation of a
system installation will not only avoid problems during installation but will also
make system maintenance much more efficient. Unfortunately, many system
installations do not have documentation created until after an installation is
completed. A successful installation requires that proper system documentation
be created before a contractor begins working. Proper documentation includes:
system overview drawings showing the on-line system layout within the plant;
system layout drawings showing sensor and enclosure mounting locations; and
tags for all sensors, cables, and enclosures documented in cable administration
charts. This documentation must be given to a contractor before the installation
begins and preferably as part of the bid package. When an installation is fin-
ished, it is important that the documentation which has been maintained by the
plant assigned project manager is distributed to the proper plant personnel and
readily available for system maintenance and troubleshooting. The CSI 4500
data collection unit and junction/switch box enclosures include see-through
pouches for storing the on-line system documentation.
2-1
System Overview Drawings
The system overview drawings illustrate how system components interconnect.
These drawings are normally prepared by a CSI 4500 Online Business Devel-
opment Manager and included in the online system proposal during the sales
process. If these drawings were not part of the proposal or if the system has
changed significantly from the time the proposal was created, it will be neces-
sary for the plant assigned online systems engineer to create or update the draw-
ings. The following system drawings were taken from an on-line system
proposal.
Note
Each IP address should be linked to the corresponding CSI 4500.
Install Instrumentation
3-1
A0322RA Image & Outline Drawing
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5-
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
3-3
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable
connection during wire pulls.
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers.
3-5
Stud Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Note
Mounting location must provide a case thickness exceeding .4". If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1 . . Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2 . . Using wire brush and plant approved cleaner, clean and degrease surface
area.
3 . . Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
4. . .Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
3-7
Proper (left) & Improper Spot Facing
Note
Mounting Location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
3-9
A911 Mounting Stud Installation (Stud Mounting Only)
1 . . Using plant-approved degreaser, remove any lubricating fluid used
during the tapping process.
2 . . Using plant-approved epoxy, rub a small amount of epoxy onto spot face.
3 . . Using 1/4" allen wrench loosely screw A911 into mounting location.
4 . . Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A911 mounting base is not seated against spot face this is an
indication that the tap was not deep enough.
5 . . If sensor is not to be mounted immediately, it is necessary to cover
exposed quick connect threads to prevent contamination. Industrial tape
is recommended.
Note
If not ready to pull cables, it is recommended that sensors not be
mounted to machine. If it is necessary to mount a sensor, then the
bundled cable must be secured to the machine and protected from
damage.
3-11
Mounting Procedure
3-13
A0322LC, A0322DS
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers
Stud Mounting
Note
Mounting location must provide a flat surface 1/2” in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
4 . . Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
Note
Mounting location must provide a flat surface 1/2" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Caution!
Do not terminate or secure cable to machine before mounting
sensor.
A0322RM 3-27
Description
The A0322RM is a general purpose accelerometer with 90-degree MIL-2 pin
connection. These sensors are stud mounted or epoxy mounted to machinery
surfaces and transmit vibration data to the on-line monitoring system. The MIL-
2 pin connection joins the sensor housing at a 90-degree angle to provide a low-
profile installation.
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and there-
fore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after instal-
lation. Mechanical shock loads of over 5000 g’s will damage sensor and void
manufacturer’s warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
Caution!
Do not exceed specified torque when tightening stud-mounted
accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5-
lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor instal-
lation if possible.
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable
connection during wire pulls.
A0322RM 3-29
A212 Mounting Pad (Epoxy Mounting Only)
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
Surface Preparation
There are several ways to mount your accelerators. This section discusses those
ways and what you need to do to successfully mount your accelerators
Note
Mounting location must provide a flat surface 1" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Note
Mounting location must provide a case thickness exceeding .4". If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
A0322RM 3-31
Note
If the spot face is not uniform on all sides this is an indication that
the spot face tool was not perpendicular to mounting surface and
will not allow the sensor to be mounted properly.
4 . . Using 1/4"–28 tap set, tap pilot hole a minimum depth of .25".
A0322RM 3-33
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1" in diameter. If
this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
A0322RM 3-35
Sensor Mounting
1 . . If necessary, clean A0322RM Quick-Connect threads using plant
approved degreaser/cleaner.
2 . . Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
3 . . Place sensor onto mounting base and hold in desired position to create the
least amount of cable strain and cable exposure. Holding sensor, hand-
tighten 7/8" captive nut and use a torque wrench with 7/8" open end to
finish tightening to 50-60 in-lbs.
4 . . If not ready to pull cables, cover exposed sensor connector threads with
supplied connector cover.
Description
The V425 Passive Magnetic Pickup is an industrial sensor used to measure the
rotational speed of machinery. The sensor is commonly used to sense an actu-
ator (target) on a rotating shaft giving a once per revolution trigger.
Handling
The V425 is unique in that it is the only piece of system instrumentation which
is installed near moving machinery (a rotating shaft typically). Therefore, it is
important to observe clearances between the sensor and the target as well as
observe cable clearances.
Caution!
The V425 can be damaged if proper clearance is not maintained
between sensor and actuator. It is important to follow installation
procedures to set proper clearance.
V425 3-37
Required Tools & Parts
Actuator Dimensions
The V425 is designed to be used with a key meeting the following minimum
specifications:
V425 3-39
If the chosen actuator has a dimension (A) which must be greater than .5 inches
it is necessary to round the edges of the actuator to allow sensor to be as close
as possible to actuator.
Actuator Material
The actuator must be made of a metallic material with a high permeability. Ideal
actuators are soft iron, cold-rolled steel and #400 stainless steel.
V425 Mounting
V425 3-41
Mounting Sensor
1 . . Screw locking nut onto sensor and thread completely onto sensor.
2 . . Screw sensor into mounting bracket until sensor pole piece contacts
actuator.
3 . . Back sensor off 1 full turn and holding sensor in place thread locking nut
against mounting bracket. Torque to 15 ft.-lbs.
4 . . Slowly turn shaft and confirm that actuator is not contacting sensor. If
sensor is contacting shaft then repeat step (3) after loosening up lock nut.
5 . . Run machinery at full speed and confirm that sensor is not contacting
actuator. Let machine reach normal operating temperature and run
through all operational speeds.
6 . . Observe machinery during coastdown and confirm that sensor is not
contacting actuator.
7 . . Cover exposed connector threads with included protective cap to prevent
contamination.
Enclosure Mounting
Description
The junction boxes are NEMA 4X rated enclosures used to terminate the online
instrumentation wiring. The junction boxes consist of a 12- channel version in
a fiberglass or stainless steel enclosure. Box consist of individual 3 lug terminal
blocks mounted on a DIN rail.
The V745 junction/switch box serves the dual purpose of providing a junction
between the instrumentation and the CSI 4500 online system as well as allowing
portable data collectors local data access. The V745 is a 6 or 12 channel box
(fiberglass or stainless steel) with 3 terminal phoenix connections for both the
inputs and outputs.
Note
Normal installation for the CSI 4500 Monitor unit is in an orienta-
tion such that the front panels are vertical.
4-1
Junction box outline drawing
4-3
Required Tools & Parts
Mounting Feet
4-5
Mount the CSI 4500 Data Collection Units
Description
The CSI 4500 is an online data acquisition system used for predictive mainte-
nance of plant machinery. Low-voltage instrumentation is terminated into the
CSI 4500 and is processed, analyzed, compressed, and output via an Ethernet
connection to a database server. The CSI 4500 is enclosed in a stainless steel
enclosure which is intended to protect it from harsh industrial environments.
The enclosure includes a power supply (if powered by 110VAC), a duplex outlet
receptacle for auxiliary power, a sub-panel for mounting accessories, a punch
plate for pulling wire through, and cable management pathways along the sides
and top of the enclosure.
Note
All CSI 4500 enclosures must be grounded to earth. It is acceptable
to ground enclosure through conduit or mounting structure if
grounded to earth. Otherwise, a bonding wire must be used to con-
nect enclosure to earth ground
Description
The CSI 4500 enclosure is designed to have all cables enter from the bottom of
the enclosure. For this reason, a removable cable access plate was built into the
bottom of the enclosure to allow contractors to remove the plate and prepare the
access holes. The stainless steel plate is mounted to the box using 12 machine
screws and a foam gasket to preserve a NEMA 4X rating.
Cabling Requirements
Introduction
This chapter covers conduit installation guidelines, network cabling guidelines,
power line specifications, and pulling the online instrumentation cabling as well
as the multipair bundled cable from junction boxes to the CSI 4500
Warning!
All wiring should be installed by a trained and qualified electri-
cian. Wiring must conform to all applicable local codes and regu-
lations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
5-1
Jbox/CSI 4500 Cable Recommendations
Table 1: Cable pulled in Steel Conduit
9734 V727/ V745 12 pair, 24 AWG, Individual foil shield, PVC jacket
8168 V707 8-pair, 24 AWG, Individual foil shield, PVC jacket, Overall
Braid Shield
8175 V727/V745 15-pair, 24 AWG, Individual foil shield, PVC jacket, Overall
Braid Shield
Note
For cables with overall braided shield, the shield should be
grounded to the CSI 4500 enclosure via the grounding stud
included on the CSI 4500 enclosure’s subpanel assembly.
Note
All conduit must be bonded to earth ground and adhere to IEEE
1100 specifications for grounding.
5-3
5 ···· Conduit must enter the CSI 4500 and junction boxes from bottom of
enclosures.
Instrumentation Cables
Installation
Caution!
If pulling in conduit cable pull force should not exceed 25 lbs.
Excessive force will deform twisted pair and degrade performance
of cable.
Note
Wire labels must be placed on each end of cable and have the same
designation. Wire label designations must be documented on
“SENSOR LOCATION CARD” chart included on inside of junc-
tion/switch boxes.
Caution!
Cables must be secured to plant infrastructure in such a manner
that no safety hazards are created from plant personnel tripping on
or catching slack cable on clothing or tool belt, etc.
1·····If using the A612-I-30 cable, apply a thin coating of dielectric grease to
connector and screw into sensor housing using hand force only.
2·····Label cable on both ends using plant approved wire labels. Wire label
designation must be the same on both ends of cable.
3·····Choose a physical path for the sensor cable pull using the following
guidelines:
a) Remain 12" from 110VAC, 2’ from 220VAC and 440VAC power
lines.
Description
The V680 bundled cable is a nine twisted pair instrumentation grade cable with
individual foil shielding on each pair. The twisted pair is 24 gauge and individ-
ually color-coded. The V680 is used to extend the on-line instrumentation
wiring from the V707 and V745 junction boxes to the CSI 4500 data collection
unit.
V680
Installation
1·····Starting at junction box, pull cable through conduit run. At the CSI 4500
enclosure, blunt cut cable leaving 4 feet inside box for routing.
2·····Label wire according to project specifications and place label within 6
inches of cable access plate with label facing toward front of enclosure.
3·····Blunt cut cable at junction box leaving 2 feet inside box for routing.
Description
The CSI 4500 Data Collection Unit communicates with a database server via a
10BaseT-network (for CSI 4500R and CSI 4500S) or 100BaseT (for CSI
4500M, CSI 4500T and CSI 4500Q) connection adhering to the IEEE 802.3
Ethernet protocol. It is recommended that customers run a dedicated physical
network segment between the database server and the CSI 4500. Although it is
ultimately the responsibility of the plant to install and maintain the network, the
following guidelines are recommended:
1 ···· Handling & Care Guidelines per EIA/TIA 568/569.
Note
Although EIA/TIA 568/569 only requires CAT5 cabling, it is rec-
ommended that customers run at least CAT5e to be compatible
with future upgrades.
Note
Network Cabling to the CSI 4500 should be in steel conduit.
Description
The CSI 4500 Data Collection Unit is a laboratory grade instrument measuring
millivolt level instrument signals. Therefore, the quality of the power provided
to the CSI 4500 is very important. Although the CSI 4500 contains input protec-
tion and some degree of line conditioning, it is important for the plant to follow
specific guidelines when running power to the CSI 4500 enclosure.
Note
Contractors should adhere to the IEEE 1100 specification for pow-
ering and grounding electronic equipment.
DC Power Specifications:
• Nominal input voltage range:12v to 24v DC
• Absolute input voltage range:10v to 36v DC
• Maximum Current Draw3.5 Amps
• Nominal Current Draw1.5 Amps
• Minimum wire gauge:16AWG
• Cable:shielded twisted pair.
AC Power Specifications:
• Nominal voltage:110VAC
• Circuit Breaker:10 Amps (with duplex receptacle)
• Power ground:Isolated (from production equipment)
Wire Terminations
Description
The V707 and V745 series junction boxes will have single twisted pair instru-
mentation wire pulled through cable grips on the left side of box and one or more
V680 bundled 9 twisted pair cable pulled through a 1.5" conduit fitting on the
right side of the box. The cables will be routed through the box leaving a service
loop and terminated to 3-lug terminal blocks on the V701 series or industry stan-
dard Phoenix connectors on the V745.
6-1
Required Tools & Parts
• wire labels
• 24 AWG wire strippers
• cable tie down
Caution!
Use correct gauge strippers on individual conductors. Do not strip
more than a 1/4" off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
Note
Shield connections pass through junction boxes and are not
grounded at the box!
1. . .Starting at cord grip pull wire to top of box on left side. Pull service loop
as shown in diagram.
2. . .Strip 1" of polyurethane jacket from cable.
3. . .Carefully pull twisted pair conductors out of braided shield. Do not
remove braided shield.
4. . .Strip 1/4" from each conductor and twist braided shield at end.
5. . .Terminate the wire into the proper terminal block as follows:
a) Connect white wire (sensor positive input) to upper level of the ter-
minal block.
b) Connect black wire (sensor negative input) to middle level of the ter-
minal block.
c) Connect braided shield to lower level of the terminal block.
6-3
Terminal Connections
Caution!
Use 24 AWG gauge strippers on individual conductors. Do not
strip more than a 1/4" off conductor. Do not overtighten connector.
Turn terminal screw clockwise until contact with wire is made then
1/4 turn additional.
1. . .Starting at cord grip, strip cable jacket and braided shield off cable.
2. . .Use the following pair sequence from top to bottom beginning at first
terminal block:
Negative
Terminal Block Positive Conductor Foil Shield
Conductor
6-5
Note
For 16 channel box, start sequence over on terminal block #9.
3 . . Pull individual twisted pair (with foil shield in place) to top of box on
right side. Pull service loop as shown in diagram.
4 . . Pull to terminal block and blunt cut any extra wire.
5 . . Remove 1" of foil shield from twisted pair and seal foil shield using heat
shrink or electrical tape.
6 . . Strip 1/4" from each conductor and terminate to terminal block as
follows:
a) Positive Conductor on upper level of terminal block
b) Negative Conductor on middle level of terminal block
c) Shield Drain on lower level of terminal block.
Description
The CSI 4500 enclosure was designed to have cables enter from the bottom
through a stainless steel removable access plate. The access plate will have con-
duit fittings/cord grips for instrumentation wiring, control wiring (discrete
input/outputs), power, and a network connection. Instrumentation wiring is
routed along the left side of the enclosure while control, power, and the network
connection is routed along the right side of the enclosure. The CSI 4500 enclo-
sure also includes a 110V duplex receptacle for auxiliary power.
Terminate Power
Phoenix Connection
Caution!
Use correct gauge strippers on individual conductors. Do not strip
more than a 1/4" off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
Note
Eight-position jack pinout should conform to plant standards for
10/100Base-T connections.
Caution!
Use 24 AWG gauge strippers on individual conductors. Do not
strip more than a 1/4" off conductor. Do not overtighten connector.
Turn terminal screw clockwise until contact with wire is made
then1/4 turn additional.
1 . . Pull cable up left side of enclosure and over top of CSI 4500.
2 . . Secure cable to left side of enclosure with cable tie down.
3 . . Remove cable jacket beginning where cable crosses over top of CSI 4500.
4 . . Pull individual pairs down to proper channel on CSI 4500 unit.
5 . . Blunt cut excess wire.
6 . . Remove 1" of foil shield and place wire label around end of foil shield.
Introduction
Description
The CSI 4500 Machinery Health Monitor is a multi-channel, multi-tasking,
multi-processor data acquisition system primarily intended for monitoring
heavy industrial rotating machinery. Typical signal inputs are dynamic AC
machine vibration signatures from accelerometers, velocity probes, or prox-
imity probes. These signals include two components: the dynamic AC compo-
nent, which represents machine vibration, and a DC component, which
represents the sensor bias level. In the case of a proximity probe, the DC com-
ponent represents the gap, or average distance between the probe tip and the
machine shaft. Other signal inputs include process signals; these are DC param-
eters such as temperature or pressure.
Tachometer inputs are used to determine machine speed. These tachometer sig-
nals are typically generated from a proximity probe or passive magnetic sensor
positioned at a machine shaft keyway or gear, producing a pulse train (not nec-
essarily 1x machine speed) representing the machine phase and running speed.
A final class of inputs are digital inputs which represent machine states, such as
running, off, starting, etc. These inputs are used to control or modify the data
acquisition state. Common state control inputs are relay closures or machine
RPM. AC or DC signal levels can also be used for state control.
Monitoring Methods
The CSI 4500 uses three basic data monitoring methods.
8-1
Overall Level Monitoring
Overall Level Monitoring is defined as (1) the acquisition of the overall level of
the dynamic AC vibration signal, typically the RMS value of the signal, and/or
(2) the DC sensor bias level, or (3) measurement of a DC process signal. Note
that all these signal inputs are DC values (The RMS value is a DC value propor-
tional to the overall energy content of the AC signal). The Overall Level inputs
are multiplexed into a fast successive approximation ADC controlled by the CSI
4500 DCM. Overall Level Monitoring is a continuous process, with all input
channels AC+DC measured twice every second. When the Transient option is
included, true waveform Peak-to-Peak may be included in Overall Level Mon-
itoring.
Spectral Scan
Spectral Scan is defined as the acquisition and analysis of dynamic AC signals
only. The signals are acquired, two channels at a time (referred to as CHX and
CHY), with a dual channel delta-sigma ADC controlled by the system DSP. The
DSP performs analysis of the acquired time waveforms and transmits the results
to the CPU host processor. Preprogrammed groups of Spectral Scan measure-
ment parameters (AP Sets) may be assigned to specific machine state conditions
to tailor data acquisition to specific machine operational states.
SI 4500 Syste
Signal Quality
The data collected by the CSI 4500 system can only be as good as the signals
presented at the CSI 4500 inputs. Typically, signals from sensors such as accel-
erometers are of millivolt levels. Signals of this magnitude can easily be over-
whelmed by interference from any number of sources in an industrial
environment.
Note
Distances are reduced if non-standard cable is used.
Junction Boxes
In many installations, sensor cables are connected via junction boxes. In this
case, the cable “+,” “-,” and shield connections must be maintained from input
to output. Shield connections must not be allowed to touch from cable to cable,
and shields must not be connected to the local junction box ground.
Cables should be terminated in the junction boxes following the recommenda-
tions of the previous section.
System Grounding
For personnel safety and correct system operation, the CSI 4500 system must be
grounded properly. The CSI 4500 enclosure should be bolted to a grounded
beam or wall. A grounding wire must also be connected from the CSI 4500
enclosure to a nearby earth ground. Use a minimum 14 AWG stranded cable for
grounding.
Inside the CSI 4500 enclosure, verify grounding wires from the CSI 4500
chassis to the enclosure frame, and from the enclosure door to the enclosure
frame have been installed.
Note
Temperatures inside the CSI 4500 enclosures can exceed 140F
when ambient temperatures reach 120F. While the CSI 4500
system has been tested to operate reliably in temperatures this
high, it should be realized that the CSI 4500 electronics would age
at much higher rates than electronics maintained below 100F. It is
therefore recommended that active cooling be employed to keep
the CSI 4500 system electronics below 100F at all times for max-
imum system reliability and longevity.
Note
The use of a hard drive on the CSI 4500 Transient Daughterboard
places strict temperature limits on the CSI 4500 system. The CSI
4500 Fan Tray (PN B4500FT) must be used. Ambient temperature
must be limited to 30C, 86F.
Note
Sysfail relay may not be used for other, e.g., vibration monitoring,
purposes.
The CSI 4500 G2 Processor Module may be configured to download its opera-
tional firmware via Ethernet upon every boot, or operate on firmware which has
been stored in FLASH memory.
Note
Tachometers used for 4500 transient signal operation must be
(physically) connected to tachometer card inputs 13, 14, 15, or 16.
Tachometers at these connections may be used (simultaneously)
for normal and transient operation.
Note
CSI does not provide AC-relay product versions. If a customer
chooses to replace relays with AC-type, local electrical and
product safety regulations must be observed for the AC voltage
connections.
Caution!
Remove input power from the CSI 4500 DC PS Module before
removing the module from the CSI 4500 rack. Failure to do so may
result in damage to the unit. Make sure the input power switch in
the “OFF” position before connecting input power to avoid
arcing.
The CSI 4500PS must be installed in the rightmost slot in the CSI 4500 System
Chassis.
Warning!
Remove input power from the CSI 4500 AC PS (PN B4500AC)
Module before removing the module from the CSI 4500 rack. Haz-
ardous voltages are present on the PC board.
Failure to remove input power before removing the CSI 4500 AC PS Module
(PN B4500AC) may result in damage to the unit. Make sure the input power
switch in the “OFF” position before connecting input power to avoid arcing.
The CSI 4500PS (PN B4500AC) must be installed in the rightmost slot in the
CSI 4500 System Chassis.
Note
The use of a hard drive on the CSI 4500 Transient Daughterboard
places strict temperature limits on the CSI 4500 system. The CSI
4500 Fan Tray must be used. Ambient temperature must be limited
to 30C, 86F.
When installing the CSI 4500 Transient Daughterboard on the CSI 4500 G2
Processor Module, make sure all five mating connectors are fully engaged, and
then install all six mounting screws.
Note
CSI provides an industrial rated HDD, capable of 100% duty cycle.
CSI recommends that an equivalent HDD be utilized.
Connecting
Using a Null_Modem Cable make a connection from the serial port on your PC
typically to the COM 2 on the CSI 4500 G1.
Configure Hyperterminal on your PC to use the serial port (typically COM 1)
with the following settings:
9600 baud
8 data bits
stop bit
no parity
no flow control
Turn power on to 4500 Unit. From here, you should be able to watch the boot
process. You may interrupt boot by pressing the “Space” bar after the VxWorks
copyright is displayed as shown below. By the time “Press any key to stop auto-
boot…” is displayed, most of the time alloted for pressing a key has passed.
Interrupting the boot process will allow the configuration of boot specific
parameters.
VxWorks System Boot
Copyright 1984-1997 Wind River Systems, Inc.
Navigation
The following list is printed to the screen by interrupting boot and typing "?" or
help.
? - print this list
@ - boot (load and go)
p - print boot params
c - change boot params
l - load boot file
g adrs - go to adrs
d adrs[,n] - display memory
Changing configuration
Once the boot process has been interrupted, you should get the prompt
[VxWorks Boot] : At this prompt, type “c” and press enter to configure the unit.
Each parameter in the configuration will be brought up and you can type a new
value and press enter to replace the old value, press enter to accept the old value,
type “.” and press enter to clear the value or type “-” and press enter to go back
to the previous parameter.
Note
DCMI is another term for CSI 4500 G1 Processor. DCMII is
another term for CSI 4500 G2 Processor.
For CSI 4500 G2 Processor and Transient systems, the “BootROM update” fea-
ture is not implemented yet (0x0200 ignored).
For Transient systems, if redirect is used, do not connect internal transient board
com port to PC since all output will be directed to the external com port.
Subnet Masks
The subnet mask on a 4500 defaults to 255.255.255.0 (ffffff00) and should be
specified when configuring the 4500. The subnet mask should also match the
subnet mask used on the server. If they do not match, network communication
failure is possible. To specify a subnet maks, enter it on the configuration labled
“inet on ethernet.” The IP address of the unit should be entered first, followed
by a colon and then the subnet mask in hexadecimal.
The subnet mask is presented in Windows as a set of four decimal numbers, each
of which can have a value from 0 to 255, seperated by periods (i.e.
255.255.248.0). In the 4500, the subnet mask is represented as a series of four
hexadecimal pairs with no seperation (i.e. fffff800). A hexadecimal conversion
table can be used to convert the numbers. The calculator in Windows' Accesso-
ries can also be used for conversion when set to scientific mode.
In the LCD screen, below the menu options, there are four boxes that may or
may not contain icons.
The first or left most icon shows three boxes connected by lines to show that the
4500 has established a connection to the online server. A two box connection
will appear when the 4500 has a connection to DHM (a troubleshooting and
diagnostic tool used primarily for support purposes).
The second icon (a set of wavy lines) will appear next to the unit connection
during a “Live” data connection with a transient unit.
The fourth or right most icon is a heart shape which indicates that the
unit has booted without any errors. This icon should flash or fade on and
off at a regular pace once the unit has fully booted.
If the heartbeat is displayed as being broken, it indicates that one or more POST
(Power On Self Test) failures occurred during the unit bootup.
Pressing the up and down arrows from this screen will allow you to page
through several screens of information about the 4500.
The next screen displays versions for some of the internal components of the
4500. This information is used for troubleshooting purposes only.
The next screen displays the total amount of onboard system memory as well as
the IP address and Subnet Mask that the CSI 4500 G2 Processor board is cur-
rently using.
The next screen displays the 4500 IP address, Subnet Mask and Host IP address
used by the CSI 4500 G2 Processor . The Subnet Mask and Host IP address set-
tings should be identical to the settings for the Transient board. The IP address,
however, will always be different.
The next screen displays the name of the startup script used by the CSI 4500 G2
Processor board if one is in use or a blank (as shown) if not. Startup scripts
allow some changes to the behavior of the 4500 and will generally be set up
during system commissioning.
The final screen displays the FTP User name and FTP User Password used to
connect to the server to download firmware for the CSI 4500 G2 Processor
board. The Bootflags setting is shown as well. These are set during commis-
sioning and generally will not need to be changed.
The next screen displays the DSP PLD version, Transient Main revision, Tran-
sient Diagnostic revision and Hard Drive Size of the Transient board. The hard
drive size is the total size in megabytes. With the initial release of the 4500T,
60GB is the standard drive size installed in the system.
The next screen shows the IP address and MAC address of the Transient board.
The second screen displays the IP address, Subnet Mask and Host IP address
used by the Transient board. The Subnet Mask and Host IP address settings
should be identical to the settings for the CSI 4500 G2 Processor board. The IP
address, however, will always be different.
The next screen displays the name of the startup script used by the Transient
board if one is in use or a blank (as shown) if not. Startup scripts allow some
changes to the behavior of the 4500 and will generally be set up during system
commissioning.
The final screen displays the FTP User name and FTP User Password used to
connect to the server to download firmware for the Transient board. Also dis-
played is the Bootflags setting which is set during commissioning and should
not need changed thereafter. The “Oth” field should contain the IP address of the
WINS server on the network.
Note
Some DC Process inputs could provide Pk, Pk-Pk, or other Mea-
surement Units
Note
RMS, PK, PK-PK Measurement Units are valid and can be freely
converted.
V / mm/s no no no mm/s
V / mm/s no single no microns
V / mm/s yes no no microns
V / mm/s no no single g’s
V / mm/s yes no single mm/s
DISP V / mil no no no mil’s
V / mil no no single i/s
V / mil no no double g’s
V / micron no no no micron’s
V / micron no no single mm/s
V / micron no no double g’s
Note
Measurement Unit Type is specific to Analysis Type. No Software
Integration or Differentiation can be performed.
V / mm/s no mm/s
V / mm/s yes microns
V / micron no micron’s
Modifying the CSI 4500 Input Ratio to Accept DC Process Signals Greater Than
+/- 10 VDC
Note
This is only necessary for AMS: Machinery Manager version 4.9x
and earlier. For version 5.x this won’t be necessary.
The CSI 4500 is capable of monitoring signals with +/- 10V peak AC or DC
signal ranges and +/- 24V DC bias ranges. In certain cases, such as a proximity
probe thrust measurement, the signal range is greater than +/- 10V. In this case
the input must be rescaled to allow the signal to be correctly measured.
Two equal value resistors are added in series, one with the positive signal wire,
and one with the negative signal wire between the proximity probe amplifier
output and the CSI 4500 Signal Input Module or 4500 MSIG channel input.
These resistors are sized to reduce the input voltage as required so that the max-
imum voltage seen at the CSI 4500 inputs is less then +/- 10V peak. The value
of the sensor sensitivity is adjusted in OCONFIG to correct the measured value
based on the resistor scaling.
Note
These resistors are not required for proximity probe vibration mea-
surements, only for thrust or other DC probes.
For example, with a +/- 24V input range, the resistor sum is 1598 k ohms or
1.598 Megohms and the sensor sensitivity correction factor is 0.416.
The actual resistor values to be added to each input wire are 1.598Megohms / 2
or 800Kohms
In some cases the choice of resistors will be limited. In this case, the input range
and sensor sensitivity may be calculated based on the available resistor as fol-
lows:
For example, if two 500Kohm (1Megohm total) resistors are used, the input
range would be +/-18.75V pk. The sensor sensitivity would be multiplied by
0.533.
Note
In older versions of this procedure a single correction resistor was
calculated to be added to the positive sensor wire. It has been deter-
mined that this can cause incorrect results in certain situations,
depending on the location of the sensor amplifier ground.
Using a balanced, two resistor solution should result in correct operation in all
cases.
It is important to note, from Table 3, that the TSG circuit provides an output
signal, which is used to create all of the other calibration tables. The TSG circuit
has its own calibration table, stored in the CPU board. If a CPU board is
replaced, then the other calibrations need to be rerun for that CSI 4500, since
their (original) calibration tables used the TSG signal from the original CPU
board.
Calibration tables may be copied from each CSI 4500 onto an online server, and
those can be downloaded into the same CSI 4500. Emerson Online Product Sup-
port personnel, and Online Systems Engineers, can assist customers with this
type of operation.
DVM Cable
(connected to rear)
G2 TSG Connections
DVM Cable
(connected to rear)
G1 TSG Connections
DSP Calibration
Digital Signal Processing (DSP) calibration
• uses a CPU board's TSG output signal
• does not require that any wire harnesses be disconnected
• is completed in about 30-40 minutes (per CSI 4500)
• does not require any special cables or test equipment
• uses a special calibration utility program (DHM)
Transient Calibration
The CSI 4500T includes two processing boards; a CPU board and a Transient
board. Both boards include separate Digital Signal Processors. The DSP on the
Transient board uses an internal calibration table, in much the same way that the
CPU board DSP circuit does. However it is calibrated separately, it is not cali-
brated as part of a DSP calibration for a CPU board.
Transient calibration
• uses a CPU board's TSG output signal
• does not require that any wire harnesses be disconnected
Note
The network arrange shown above assumes one of the CSI 4500s
is a transient model (CSI 4500T).
A-1
A-2 CSI 4500 Default Network Addressing Schema
Appendix B
Introduction
On the following pages are additional connections that may help you in setting
up the CSI 4500.
B-1
CSI 4500 Proximity Probe Interconnetion Diagram
Note
CSI 4500 MUX (SIG) channels provide “loop power” to 4-20mA
devices. A separate source / module is required to provide loop
ower.
Introduction
The AC-DC Converter is the power center of the CSI 4500 unit. If it is not
installed and maintained properly, the CSI 4500 unit may not function properly
or in the manner desired.
Warning!
All wiring should be installed by a trained and qualified electri-
cian. Wiring must conform to all applicable local codes and regu-
lations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
Warning!
Power to the CSI 4500 AC-DC power converter PCB must include
a remote disconnect switch or circuit breaker. The switch or circuit
breaker must be in close proximity to the equipment and within
easy reach of the operator.
Caution!
Installation and use of the CSI 4500 AC-DC Power Converter in a
manner not specified by Emerson may impair protection offered by
the equipment.
C-1
Connecting and Maintaining the CSI 4500
General points to remember when installing the CSI 4500 and connecting power
to it:
• The CSI 4500 AC-DC Power converter PCB is connected to the mains
supply through the AC Power Input terminal block located near the
bottom of the panel.
• All wiring should be installed by a trained and qualified electrician.
• Wiring must conform to all applicable local codes and regulations.
• Normal installation of the CSI 4500 is in an orientation such that the front
panels are vertical.
• Operators should use normal caution when cleaning surfaces of the CSI
4500 front panels. Abrasive cleaners or instruments should not be used.
Wipe off with a clan damp cloth.
• Replacement fuses should be 2A 250V Slo-Blow type (250V 2A T).
• Fuses should be replaced by qualified personnel only.
Note
No configuration setup of the unit is required to change operating
voltage.
LED Indicators
Eleven individual LEDs indicate the condition of internal and external
voltage signals. Ten are green and when “on” (illuminated) indicate that the
corresponding voltage signal is at is “active” level. One LED is red and
when “on” (illuminated) indicates that power has failed. The LEDs are
listed in the following table:
Fail Red
3.3V Green
5V Green
+12V Green
–12V Green
+24V Green
AUI Green
AUX24V Green
Fan24 Green
Power On Green
AC Power Green
Connection Parameters
Note
This equipment is only suitable to use in Class I, Division 2,
Groups C and D or non-hazardous locations.
Warning!
Explosion Hazard. Do not remove or replace lamps or fuses unless
you have disconnected the power or you are in a non-hazardous
area.
Warning!
Explosion Hazard. Do not disconnect equipment unless you are in
a non-hazardous area.
D-1
Specifications for equipment that supplies and receives energy:
Tach Board:
I/O Board:
A C
A0322 Quick-Connect 3-11, 3-35 cable tie down 6-2
A0322DR 3-1 cable tie downs 5-7
A0322DS 3-14 Cable Variations 5-6
A0322LC 3-14 Chapter 2 Pre-Installation Review 1-7
A0322LC with Quick-Connect 3-25 Chapter 3 System Documentation 1-7
A0322LC-NT 3-15 Chapter 4 Instrumentation Installation 1-7
A0322LC-NT Quick Release SS Nut & Chapter 5 Enclosure Mounting 1-7
Threaded Base 3-17 Chapter 6 Cabling Requirements 1-7
A0322LC-NT Quick-Connect 3-22, 3-25 Chapter 7 Wire Terminations 1-8
A0322RA 3-1 Chapter 8 System Hardware Configuration
A0322RI 3-1 1-8
A0322RM 3-27, 3-35 conduit
A0322RM Quick-Connect 3-36 steel 5-2
A212 Mounting Pad 3-17, 3-30 tray or aluminum 5-2
A212 mounting pad 3-22 Configuring a 4500 with Hyperterminal 7-72
A612-I-30 cable 5-7 Connecting 7-72
A680 Bundled Cable 6-16 General Boot Flag Notes 7-77
A901-1 mounting pad 3-9 Navigation 7-73
A911 3-10 Configuring a CSI 4500 with Hyperterminal
A911 Quick-Connect 3-10 Subnet Masks 7-78
A92016 2-part epoxy 3-9, 3-22, 3-34 Connecting and Maintaining the 4500R or
A92106 3-5, 3-17 4500S unit C-2
A92106 Loctite Depend Mounting Pad Epoxy Connection Parameters D-1
(Epoxy Mounting Only) 3-30 Contractor Kickoff Meeting 2-2
I-1
CSI 4500 5-11 CSI 4500 Signal Input Module Specifications
Enclosure 2-7 7-19
CSI 4500 4-20ma Current Loop CSI 4500 Tachometer Input Module 7-23
Interconnection B-3 CSI 4500 Tachometer Input Module
CSI 4500 AC Power Supply 7-47, 7-52 Specifications 7-24
CSI 4500 AC Power Supply (PN A4532AC) CSI 4500 Transient Daughterboard 7-56
SPECIFICATIONS 7-52 Replacing the Hard Drive 7-60
CSI 4500 AC Power Supply (PN B4500AC) CSI 4500 Transient Daughterboard
Specifications 7-48 Specifications 7-57
CSI 4500 and junction boxes 5-4 CSI 4500 Transient Filter Board 7-62
CSI 4500 DC Power Supply 7-42 CSI 4500 Transient Filter Board
CSI 4500 DC Power Supply Specifications Specifications 7-62
7-42 CSI 4500 Wiring 6-7
Startup Current Characteristics 7-43 CSI 4500M G2 Processor Card 7-10
CSI 4500 dedicated network segment cables CSI 4500S Enclosure 2-11
5-3
CSI 4500 Discrete Input/Outputs 4-12 D
CSI 4500 Enclosure 5-9 Data Types
CSI 4500 Ethernet Connection 4-12 Analysis Type
CSI 4500 G1 Processor Module 7-37 Overall Level 7-87
CSI 4500 G2 Processor Card LCD navigation Spectral 7-88
screens 7-78 Time Waveform 7-90
Adjusting Contrast 7-80 CSI 4500 System Calibration 7-94
Gross Scan Data 7-80 Modifying the CSI 4500 Input Ratio 7-91
Online Boot Parameters 7-82 Non Vibration Unit Analysis Types 7-91
Online POST Information 7-81 Offset Adjustment 7-93
System Status Menu 7-80 Overall Level Parameters 7-87
Transient Boot Parameters 7-85 Spectral Scan Parameters 7-87
Transient POST 7-84 DC (with Fan Tray) 6-8
CSI 4500 G2 Processor Module Specifications DC (without Fan Tray) 6-9
7-12 DC Power Specifications
CSI 4500 MSIG Module 7-32 5-11
CSI 4500 MSIG Module Specifications 7-33 Dedicated CSI 4500 Network Segment 5-10
CSI 4500 Power 4-12 Description 3-3, 3-15, 3-28
CSI 4500 Power Supply 6-9 dielectric grease 5-7
CSI 4500 Proximity Probe Interconnetion Documentation Storage 2-13
Diagram B-2
CSI 4500 Relay Module 7-28
CSI 4500 Signal Input Module 7-17
I-2
E Mounting Bracket & Locking Nut 3-38
EIA/TIA 568/569 5-10 Mounting Sensor 3-42
Epoxy Mounting 3-9, 3-22, 3-34 Mounting Sensor Bracket 3-41
Equipment Multi-pair Bundled Cable Pulls 4-12
warnings, uses and specifications D-1 Mux or Signal Board D-2
F N
Final Walk-Through 2-3 Negative Conductor 6-5
Foil Shield 6-5
O
G output connections
G1 Processor Module Specifications 7-38 auxiliary sensor C-5
General Wiring Notes 7-65 fan C-5
H P
Handling Instructions 3-3, 3-15, 3-28 PGME07 cord grip 5-8
phoenix connector 6-8, 6-12
I Positive Conductor 6-5
Power Circuit Guidelines 5-11
I/O Board D-2
Prepare the CSI 4500 Cable Access Plate 4-11
Indicators C-4
Project Manager 1-3
LED C-6
Pull Instrumentation Wiring 5-5
Power Output Connectors C-5
auxillary sensor C-5
fan output C-6 R
Installation 5-7 Required Tools & Parts 3-4
RJ45 CAT5 connector 6-8, 6-14
J
Jbox 5-2 S
Junction Box 6-17 SENSOR LOCATION CARD 5-7
Sensor Mounting 3-11, 3-36
M Signal Quality 7-5
Monitoring Methods Cable Terminations 7-7
Overall Level Monitoring 7-2 Ethernet Cable Routing 7-6
Spectral Scan 7-2 Grounding and Shielding 7-6
Transient Data Capture 7-2 Junction Boxes 7-7
Mount the CSI 4500 and 4500S Data Sensor Cable Routing 7-5
Collection Units 4-6 Sensor Cable Type 7-5
I-3
System Grounding 7-7
Special 1-2
Spot Face & End Mill Tool 3-29
Spot Face and End Mill Tool 3-4, 3-16
Stud Mounting 3-6, 3-18, 3-31
Surface Preparation 3-5, 3-18, 3-30
System Component Review 2-4
System Overview Drawings
Additonal Information to Keep 2-4
Machine Level Diagram
2-3
Overall System Diagram
2-3
T
Tach Board D-2
terminal block 6-3
6-5
Terminate Discrete Input/Outputs 6-12
Terminate Network Connection 6-14
Torque Wrench 3-5, 3-18, 3-30
V
V425 3-37
V425 Passive Magnetic Pickup 3-37
V4500 power supply card 6-14
V680 Bundled Cable 6-5
V701 and V745 series junction 6-1
V745 junction/switch box 4-1
Velcro cable tie downs 6-8
W
wire labels 5-7, 5-9, 6-2
I-4