Machinery Condition Monitoring MCM800. Product Description

Transcription

1 Machinery Condition Monitoring MCM800 Product Description

2 NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. Copyright 2007 ABB All rights reserved. Release: September 2007 Document number: 9A63010 Rev D (Preliminary) This product is protected by the following patents: Patent No. 6,414,495 Patent No. 6,546,361 Patent No. 6,668,234 Disclosure number: US (patent pending) TRADEMARKS Registrations and trademarks used in this document include: Windows Registered trademark of Microsoft Corporation. PROFIBUS-DP Trademark of Profibus International (P.I.).

3 About This Book TABLE OF CONTENTS 0.1 Overview Use of Warnings, Caution, Information, and Tip Icons Terminology Related Documentation Introduction 1.1 Product Overview MPM810 Overview TBU850 Overview MCM800 Details Termination Base Unit (TBU850) MPM810 Module Prerequisites and Requirements Product Features Field I/O Capabilities Communication Installation 2.1 Installing Termination Base Unit (TBU850) Termination Base Unit Connections Installing Module (MPM810) Module Interconnection Configuration 3.1 Before You Start Termination Base Units Signal Input Configuration Relay Output Configuration Event Marker Input Configuration DIP Switch Configuration Profibus/Modbus Dipswitch Profibus/Modbus Address Profibus/Modbus Address Option Dipswitch Operating Mode Configuration Retention Module Output Mode MPM MCM800 Configuration via Profibus & Ethernet Module Specific Parameters sent to MCM Channel Specific Parameters sent to MCM Active Data Sent To the MCM Active Data Reported By the MCM Operation 4.1 General Description I/O Conditioning Functions Signal Inputs Event Marker Inputs Relay Outputs Functions

4 4.3.1 Vibration Eccentricity Thrust (Rotor) Position Differential Expansion Case Expansion Dual Probe SMAX Complementary Position Waveform Capture Settings Maintenance 5.1 Preventive Maintenance Hardware Indicators MPM810 I/O Module LEDs Troubleshooting Module Replacement General Replacement Returning a Module Firmware Upgrade Specifications 6.1 MCM800 Product Specifications

5 About This Book 0.1 Overview This book provides a description of the MCM800 I/O modules and termination units. It provides instructions for installation, start-up, and information regarding capacity and performance. This book is not intended to be the sole source of instruction for the MCM800 I/O system. This section provides introductory and background information including guidelines about how to find information in the manual related documentation. The Introduction section provides a product and functional overview. The Installation section provides installation guidance. The Configuration section provides details for customizing the units to meet the requirements of individual applications. The main information is structured as follows: Design considerations and guidelines. Capacity and performance. The Operation section describes the various start modes and operating modes available for each installation. The Maintenance section focuses on detecting faults using built-in diagnostics. It explains system status displays in operator stations and LEDs on I/O modules. In the Specifications section you will find a data sheet that lists the capacities of all of the components of the MCM800 module. 4

6 0.2 Use of Warnings, Caution, Information, and Tip Icons This publication includes Warning, Caution, and Information statements where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows: An electrical warning icon indicates the presence of a hazard, which could result in electrical shock. A warning icon indicates the presence of a hazard, which could result in personal injury. A caution icon indicates important information or a warning related to the concept discussed in the text. It might indicate the presence of a hazard, which could result in corruption of software or damage to equipment/property. An information icon alerts the reader to pertinent facts and conditions. A tip icon indicates advice on, for example, how to design your project or how to use a certain function. 0.3 Terminology The following is a list of terms associated with the MCM800 that you should be familiar with. The list contains terms and abbreviations that are unique to ABB or have a usage or definition that is different from standard industry usage. Term I/O device I/O module MCM TBU DTM EU Description A complete I/O device consists of one TBU and one I/O module. An I/O module is an active, electronic and signal conditioning unit. It can be a part of an I/O device. Machinery Condition Monitoring The Termination Base Unit is a passive base unit containing process terminals. Device Type Manager Engineering Unit 5

7 0.4 Related Documentation The following is a listing of all documentation related to the I/O system. Title MCMDSS MCM Client MCM Configuration Tool Analyst User s Guide Release Notes Description MCM800 Data Source Service MCM800 Client MCM800 Ethernet Configuration Tool Analyst TM User s Guide Release Notes for latest product version 6

8 1 Introduction The Machinery Condition Monitoring Module MCM800 provides a complete set of functions for comprehensive Turbine Supervisory Instrumentation. These functions include: Vibration Monitoring Eccentricity Thrust (Rotor) Position Differential Expansion Case Expansion The MCM800 system is part of a distributed modular I/O system. The MCM800 components provide easy installation and reliable performance using advanced control technology. 1.1 Product Overview MPM810 Overview TBU850 Overview The MCM800 is comprised of a Termination Mounting Unit (TBU850) and a Processing Module (MPM810). Its main function is to provide rotating machinery monitoring and protection capability independent from any master DCS or PLC. This independence results in higher reliability and faster response time. The MCM800 system implements widely used monitoring and protection algorithms available in the industry. Each function also has a set of software configuration parameters. The MCM800 system has a built-in Profibus-DP Communication Interface to facilitate integration with external control systems or other Profibus compatible devices. The Processor Module (MPM810) plugs into the slot of the Termination Base Unit (TBU850). The MPM810 performs these functions: Executes the selected functions of the MCM800 system. Communicates to the control system via Profibus DP. The TBU850 contains terminals for power, field connections, and communication. It houses the MPM810 module. 7

9 1.2 MCM800 Details Termination Base Unit (TBU850) MPM810 Module The Termination Base Unit (TBU850) is an active base unit that receives and conditions the analog signals, and then digitizes the signal for use by the MPM810. It contains the power and field I/O terminals, Profibus communication connectors, serial interface ports, and relay output terminals. The TBU850 can be mounted on a standard DIN rail. It has a mechanical latch to lock the TBU850 to the DIN rail. The latch can be released with a screwdriver. The MPM810 resides in an open ventilated plastic enclosure. On the front of the MPM810 module there are eleven LEDs indicating the module and I/O status. Refer to Section for the status indication of the LEDs. MPM810 module can be easily replaced in a fully operational I/O station. The design of the module and TBUs protect the module from being damaged by excessive voltage or current. 1.3 Prerequisites and Requirements Before operation a complete set of parameters must be downloaded using Profibus DP and the MCM800 DTM or the MCMDSS and the Ethernet Configuration tool. The Profibus master must configure the module before operation can occur. 8

10 1.4 Product Features Field I/O Capabilities Power Input Analog Inputs Channels 1-4 Event Marker Input +24VDC, -24VDC, Common Parallel terminals for use in daisy-chaining modules System Power: +24VDC, -24VDC, or +15VDC current limited to 30mA. Constant current 4.7mA available for +24VDC System Power: -24 VDC current limited to 30mA Relay Outputs Alert Dry Contact (Form C) 24 VDC / VAC (resistive load) Normally deenergized/energized selectable Danger Dry Contact (Form C) 24 VDC / VAC (resistive load) DIP Switches Profibus Address Option Switch Normally deenergized/energized selectable Seven switches for address selection; one for mode selection Used for calibration, startup mode, diagnostics, and power option. Profibus termination Two switches for termination of Profibus line A and line B Communication RS-485 Profibus DP V1 Modbus Ethernet Configuration, Control, and Reporting Values Reporting Values 10/100 BaseT TCP/IP Configuration, Control, and Reporting Values. Firmware Upgrades. RS-232 Debug Note: a special cable is required. Debugging and Firmware Upgrades. 9

11 2 Installation 2.1 Installing Termination Base Unit (TBU850) The Termination Base Unit (TBU850) is designed to connect to a standard 35mm DIN rail. First verify that the locking mechanism is set to the unlocked position. Use a flat head screwdriver if necessary to set the locking mechanism to the unlocked position. Figure 2-1 TBU850 Locking Mechanism Then insert the edge of the DIN rail into the angled tabs located on the metal base. Once inserted, apply pressure on the TBU850 so the metal cover lies flat against the DIN rail. While holding in place, use the flat head screwdriver to set the locking mechanism to the sliding position by turning the device clockwise 90 degrees. Position the TBU850 to the desired location and set the locking mechanism to the locked position by turning another 90 degrees. Although the locking mechanism is in the locked position, it is possible that the unit may slide given enough force, especially if mounted on a vertical DIN rail. To further secure the modules, it is recommended to install a DIN rail end-bracket, or place machine screws through the secure tabs on the TBU Termination Base Unit Connections A TBU850 provides a slot for the MPM810 module. Two DSUB9 connectors are located on the right and left side of the TBU for Profibus and Modbus communication. A standard Profibus or Modbus connector for line A is connected on the left side of the unit and line B on the right side. The TBUs are designed to connect together passing the communication through the system and out the opposite port. The RJ-45 connector on the front of the unit provides proprietary Ethernet communication using TCP/IP protocol. The serial communication port can be used to: Download new firmware. An interface port for debugging 10

12 2.3 Installing Module (MPM810) Install module by aligning the connectors of the TBU and module, and then pushing the units together. Ensure that the module is fully engaged into the TBU. Partial engagement may produce unexpected results After connection to the TBU, lock the I/O module in place using the I/O Module Locking device. 2.4 Module Interconnection On each side of the TBU are two DSBU9 connectors. The TBU is designed to plug together. Place the TBUs on the DIN rail and slide the TBUs together until they are fully engaged. Use a screwdriver to turn the latch to secure the TBUs in place. Figure 2-2 MCM800 Module Interconnection 11

13 3 Configuration 3.1 Before You Start Read this manual thoroughly before landing wires to the Termination Unit and applying power to the modules. 3.2 Termination Base Units The terminals of the TBU850 provide the connections for power and all of the field I/O signals of the MCM800. Table 3-1 through Table 3-5 lists the terminals used by the MCM800 and the signals for connection. Terminal Description 1 +24VDC Power (in) 2 Power Common (in) 3-24VDC Power (in) 4 +24VDC Power (out) 5 Power Common (out) 6-24VDC Power (out) Table 3-1 TBU850 Power Terminals Figure 3-1 Typical Power Connection 12

14 Terminal Description 1 Transducer Power (+) (out) 2 Constant Current (4.7mA) 3 Transducer Common 4 Transducer Signal 5 Transducer Power (-) (out) 6 Earth Ground (Shield) Table 3-2 TBU850 Signal Terminals Channels 1-4 Terminal Description 1 EM Out (+) TTL 2 EM Out (-) TTL 3 Transducer Common 4 EM Common (out) 5 EM Signal (out) 6 EM Common (in) 7 EM Signal (in) 8 Transducer Power (-) (out) 9 Earth Ground (Shield) Table 3-3 TBU850 Event Marker Terminals 13

15 Terminal Description 1 Alert Normally Closed 2 Alert Common 3 Alert Normally Open 4 Danger Normally Closed 5 Danger Common 6 Danger Normally Open Table 3-4 TBU850 Relay Contacts Terminal PA1 PB1 PA2 PB2 1 RS-232 Com NC NC NC 2 RS-232 TXD NC NC NC 3 Profi A+ (in) Profi B+ (out) Profi A+ (out) Profi B+ (in) 4 RS-232 RXD NC NC NC 5 NC NC NC NC 6 NC NC NC NC 7 NC NC NC NC 8 Profi A (in) Profi B (out) Profi A (out) Profi B (in) 9 NC NC NC NC Case Earth Ground Earth Ground Earth Ground Earth Ground (Shield) (Shield) (Shield) (Shield) Table 3-5 TBU850 D-SUB9 (Profibus) Connector 14

16 3.2.1 Signal Input Configuration The MCM800 signal input channels terminals are designed to interface to a variety of transducers. Figures 3-2 through 3-5 show the differenttbu850 wiring configurations associated with the different type of transducers. Figure 3-2 Eddy Current Probe Configuration Figure 3-3 Piezoelectric velocity probes and accelerometers Figure 3-4 Moving Element Velocity Probes 15

17 3.2.2 Relay Output Configuration Figure 3-5 DC LVDT s The MCM800 relay output terminals are designed to interface directly to low power switching configurations or high power switching devices using inter-opposing relays. Figure 3-6 shows the TBU850 configuration for the on-board relay contacts. Figure 3-6 Relay Terminal Connections 16

18 3.2.3 Event Marker Input Configuration The TBU850 has an Event Marker input which typically is used to interface to eddy current probe. Figures 3-7 and 3-8 show the TBU850 wiring configurations associated with these probes. Figure 3-7 Event Marker with single TBU850 Figure 3-8 Event Marker with multiple TBU850 s 17

19 3.3 DIP Switch Configuration The TBU850 requires proper Dipswitch setting prior to operation Profibus/Modbus Dipswitch Profibus/Modbus Address Switch Determine the Profibus/Modbus address of the module and set Dipswitch S1 to the proper address. Valid Profibus addresses range from 0 to 125; however addresses 0 & 1 are reserved for the Profibus Master. Therefore, valid MCM800 addresses range from 2 to 125. Note: System Redundancy requires a slave backup address to be n+64; therefore the highest possible primary address with System Redundancy enabled is 61 for a backup address of 125. Table 3-6 shows the switch settings for addresses The switch settings for addresses correspond to the first 63 settings in the table, with switch 2 (S1) set to the 1 position. Profibus Address Switch Profibus Address Switch Profibus Address Switch Profibus Address A 1 corresponds to the switch position labeled ON or CLOSED Table 3-6 Profibus/Modbus Address Selection 18

20 3.3.2 Profibus/Modbus Address Figure 3-9 Address and Option Dipswitch Switch 1 of Dipswitch S1 is used to determine the Profibus redundancy format used by the MCM800. Setting Description 0 System Redundancy Disabled 1 System Redundancy Enabled Option Dipswitch Operating Mode Switches 1&2 of Dipswitch S2 set the start-up and operating mode of the MCM800. Switch 1 Switch 2 Description 0 0 Normal Mode 0 1 Diagnostic Mode 1 0 Low Speed Mode 1 1 Calibration Mode Configuration Retention Switch 3 determines if the MCM800 retains its configuration on restart or resets all configurations to the default settings. Switch 3 Description 0 Use and store Default settings at start-up. 1 Store configuration and use at start-up. 19

21 Module Output Mode MPM810 Switch 4 determines the output protocol for ports PA1&2 and PB1&2. Switch 4 Description 0 Modbus RTU protocol. 1 Profibus DP-V1 protocol. There are no configurable settings on this board. 3.4 MCM800 Configuration via Profibus & Ethernet The MCM800 system uses Profibus DP for communication with the control system. For an 800 xa system a CI854A (or similar) Profibus master is used to communicate to the module. Refer to the Profibus Users Guide for more information Module Specific Parameters sent to MCM800 Description Range Units Type IP Address NNN.xxx.xxx.xxx 0 to 255 None I IP Address xxx.nnn.xxx.xxx 0 to 255 None I IP Address xxx.xxx.nnn.xxx 0 to 255 None I IP Address xxx.xxx. xxx.nnn 0 to 255 None I Subnet Mask NNN.xxx.xxx.xxx 0 to 255 None I Subnet Mask xxx.nnn.xxx.xxx 0 to 255 None I Subnet Mask xxx.xxx.nnn.xxx 0 to 255 None I Subnet Mask xxx.xxx. xxx.nnn 0 to 255 None I English/Metric EU 0, 1 None B Angular Position of Event Marker probe -360 to 360 Degrees I Event Marker Detect Voltage 0 to 15 Volts I Normal Alert relay state 0,1 None B Normal Danger relay state 0,1 None B IP Address and Subnet Mask The IP Address and Subnet Mask is required for the module to communicate over Ethernet. It is a unique address for a specific network. The default values are and The configuration tools will allow a new address to be set. Once set the user must switch to the new address for proper communication. English/Metric Set this value to a 0 if the engineering units are English and a 1 if they are in metric. Angular Position of Event Marker probe This value is the angular position of the Event Marker from a fixed reference point, typically vertical. Event Marker Detect Voltage This value is the minimum pulse height (pk-pk) of the Event Marker pulse. Normal Alert/Danger relay state Set to 0 for Normally Deenergized (energize to activate relay), and 1 for Energized (deenergize to activate relay). 20

22 3.4.2 Channel Specific Parameters sent to MCM800 Description Range Units Type Channel type 0 to 10 None I Block output select 0 to 5 None I Probe type 0 to 8 None I Probe Sensitivity Full mv/eu R Integration 0 to 2 None I Angular Position of Probe -360 to 360 Degrees I Ramp Angle 0 to 90 Degrees R Probe DC Voltage High Failure Threshold -24 to +24 Volts R Probe DC Voltage Low Failure Threshold -24 to +24 Volts R N for Nth Order 3 to 10 None I Dual Vote Enable 0,1 None B Non-linear Correction: X1 Full EU R For Future Use Non-linear Correction: Y1 Full EU R For Future Use Non-linear Correction: X2 Full EU R For Future Use Non-linear Correction: Y2 Full EU R For Future Use Non-linear Correction: X3 Full EU R For Future Use Non-linear Correction: Y3 Full EU R For Future Use Non-linear Correction: X4 Full EU R For Future Use Non-linear Correction: Y4 Full EU R For Future Use Non-linear Correction: X5 Full EU R For Future Use Non-linear Correction: Y5 Full EU R For Future Use Channel type This value specifies the operation of the channel. 0 = None (Valid for all channels) 1 = Vibration (Channels 1-4 only) 2 = Eccentricity (Channels 1-4 only) 3 = Thrust (Rotor) Position (Channels 1-4 only) 4 = Differential Expansion (Channels 1-4 only) 5 = Case Expansion (Channels 1-4 only) 6 = Dual Probe - Relative (Channels 1 & 3 only) 7 = Dual Probe Seismic (Channels 2 & 4 only) 8 = Dual Probe Absolute (Channels 5 & 6 only) For channel 5, channel 1 must be set to Relative (6), and channel 2 must be set to Seismic (7). For channel 6, channel 3 must be set to Relative (6), and channel 4 must be set to Seismic (7). 9 = SMAX (Channels 5-7only) For channel 5, channel 1 & 2 must be set to Vibration (1) and Probe Type must be Eddy Current (1) for channels 1 & 2. For channel 6, channel 3 & 4 must be set to Vibration (1) and Probe Type must be Eddy Current (1) for channels 1 & 2. For channel 7, channels 5 & 6 must be set to Dual Probe Absolute. 10 = Complementary Position (Channels 5 & 6 only) For channel 5, channel 1 & 2 must be set to Thrust (3) or Differential Expansion (4). For channel 6, channel 3 & 4 must be set to Thrust (3) or Differential Expansion (4). 21

23 Output Select This value specifies value of the output (valid for all channels). 0 = Peak-to-peak 1 = Peak 2 = RMS 3 = Average 4 = Calculated peak-to-peak 5 = Calculated peak Probe Type This value specifies type of probe (valid for channels 1-4 only). 0 = None 1 = Proximity Probe 2 = DC LVDT 3 = Accelerometer 4 = Moving Element velocity probe 5 = Piezoelectric velocity probe 6 = Complementary proximity probe 7 = Ramped proximity probe 8 = Ramped complementary proximity probe Probe Sensitivity This value specifies sensitivity of the probe in mv/eu (valid for channels 1-4 only). Integration This value sets the type of integration (valid for channels 1-4 only). 0 = None 1 = Velocity to displacement (velocity probes only) 2 = Acceleration to velocity (accelerometers only) Angular Position of probe This value is the angular position of the probe from a fixed reference point, typically vertical. Ramp Angle This value specifies the ramp angle for ramped differential expansion. Probe DC Voltage High/Low Failure Thresholds This value is the voltage beyond which the module will report bad quality for that channel. N for Nth Order This value is specifies a user defined order calculation from 3 to 10. Non-linear Correction These are (x,y) pairs of values used to correct for non-linearity effects of probes. (Note: For Future Use Only) Active Data Sent To the MCM800 Description Range Units Type Shaft Rotational Direction 0,1 None B Set Alert Relay 0,1 None B Set Danger Relay 0,1 None B Reset Diagnostic Function 0,1 None B High Danger Threshold Full EU R High Alert Threshold Full EU R Low Alert Threshold Full EU R Low Danger Threshold Full EU R Alert Delay 0.1 to 300 Seconds R Danger Delay 0.1 to 300 Seconds R Alert Enable 0,1 None B Danger Enable 0,1 None B Filter Low Cutoff Frequency 1 to 1,000 Hz I Filter High Cutoff Frequency 30 to 15,000 Hz I Null Position in Engineering Units Full EU R Null Position Voltage -24 to +24 Volts R 22

24 Description Range Units Type Set Null Position Voltage 0,1 None B Waveform Capture 0,1 None B Run-up Capture 0,1 None B Rundown Capture 0,1 None B Event Capture 0,1 None B Shaft Rotational Direction The value indicates the rotation of the shaft. 0 = Clockwise 1 = Counter-clockwise Set Alert / Danger Relay These values will force the relay to the active state. 0 = Normal operation 1 = Force relay active. Reset Diagnostic Function A transition from 0 to 1 forces a reset of the Ethernet communication interface. 0 = Normal Operation 1 = Forces Ethernet Network close and restart. High Alert / Danger Threshold These values determine the point above which the corresponding action will occur. (Valid for all channels). Low Alert / Danger Threshold These values determine the point below which the corresponding action will occur. (Valid for all channels). Alert / Danger Delay These values determine the delay in seconds the condition must exist before activating Alert or Danger status. Note: If the value exceeds the Danger setpoint before the Alert delay expires, the module will immediately set the Alert status. (Valid for all channels). Alert / Danger Enable These values enable the alert and danger action. (Valid for all channels). 0 = Action disabled 1 = Action enabled Filter Low / High Cutoff Frequency These values set the cutoff frequency above or below which the signal is attenuated. The value specified is the -3dB point of a 4-pole Butterworth filter. (Valid for channels 1-4, Vibration, Relative, or Seismic channel types). Null Position in Engineering Units This value is the null or zero point of a position measurement. It is a known starting point of the shaft from which the shaft will deviate either from thermal growth or load conditions. Typically it is determined when the shaft is cold or a no load condition. This value can be set to zero or some measured value. (Valid for channels 1-4, Thrust, Differential or Case Expansion channel types). Null Position Voltage This value is the voltage of the null or zero point of a position measurement describe above. When the voltage measured by the probe is equal to this value the output will display the Null Position set in Engineering Units. When the voltage changes the output value will change based on the Sensitivity parameter. (Valid for channels 1-4, Thrust, Differential or Case Expansion channel types). Set Null Position Voltage This value forces the MCM to set the internal NVRAM to correspond to the Null Position EU and Voltage. (The MCM uses the locally stored values to determine position.) 0 = Normal operation 1 = Set Null Position Waveform, Run-up, Rundown, Event Capture When these values changes from 0 to 1 the specific waveform file will be captured for analysis. Refer to the Waveform Historian manual for more information. 23

25 3.4.4 Active Data Reported By the MCM800 Description Range Units Type Module Alert 0,1 None B Module Danger 0,1 None B Dual Vote Alert Ch 1&2 0,1 None B Dual Vote Danger Ch 1&2 0,1 None B Dual Vote Alert Ch 3&4 0,1 None B Dual Vote Danger Ch 3&4 0,1 None B Dual Vote Alert Ch 5&6 0,1 None B Dual Vote Danger Ch5&6 0,1 None B MCM Mode 0,1 None B Calibration Active 0,1 None B Diagnostic Error 0,1 None B Orders Active 0,1 None B Event Marker Status 0,1 None B Zero Speed Indicator 0,1 None B Invalid IP Address 0,1 None B Profibus Active 0,1 None B Software Version Major 0 to 255 None I Software Version Minor 0 to 255 None I Software Version Revision 0 to 255 None I Software Version Pre-Release 0 to 255 None I Speed 0 to 30,000 RPM R Overall Output Full EU R DC Voltage -24 to +24 Volts R DC Relative Gap Full EU R Ethernet Only Order 0.5x Amplitude Full EU R Order 0.5x Phase 0 to 359 Degrees R Order 1x Amplitude Full EU R Order 1x Phase 0 to 359 Degrees R Order 2x Amplitude Full EU R Order 2x Phase 0 to 359 Degrees R Order Nx Amplitude Full EU R Order Nx Phase 0 to 359 Degrees R Order Not1x Amplitude Full EU R N for Nth Order 0 to 359 Degrees R Critical Error 0,1 None B Configuration Error 0,1 None B Probe Voltage Error 0,1 None B Bad Data 0,1 None B Suspect Data 0,1 None B Alert Active 0,1 None B Alert Low Active 0,1 None B Alert High Active 0,1 None B Danger Active 0,1 None B Danger Low Active 0,1 None B Danger High Active 0,1 None B Time Waveform Buffer Full 0,1 None B Time Waveform Capture Complete 0,1 None B Time Waveform Runup Active 0,1 None B Time Waveform Rundown Active 0,1 None B Time Waveform Event Log Active 0,1 None B 24

26 Module Alert / Danger These values indicate the Alert / Danger alarm status. 0 = Normal 1 = Alert / Danger Active Dual Vote Alert / Danger These values indicate if both channels are active when Dual Voting is enabled. 0 = Normal 1 = Alert / Danger Active (Both channels) MCM Mode These values reflect the operational mode of the MCM800 based on Dipswitch S2. 0 = Normal 1 = Low Speed Calibration Active This value indicates the calibration status. 0 = Not calibrating (Normal) 1 = Module is calibrating Diagnostic Error This value indicates the diagnostic status. 0 = Diagnostics successfully passed 1 = Diagnostics failed Orders Active This value indicates orders are being calculated. 0 = Orders are not being calculated 1 = Orders are being calculated Event Marker Status This value indicates Event Marker Status. 0 = Event Marker Failed 1 = Event Marker OK Zero Speed Indicator This value indicates if shaft has stopped. 0 = Speed is >= 1 RPM or bad quality (Event Marker Status = 0) 1 = Speed is < 1 RPM and good quality (Event Marker Status = 1) Invalid IP Address This value indicates if the IP address or subnet mask is invalid. 0 = IP Address and Subnet mask is valid 1 = IP Address or Subnet mask is invalid Profibus Active This value indicates a Profibus Master is communicating 0 = Profibus not communicating 1 = Profibus is communicating Software Version These values indicate the software Version major.minor / revision.prerelease. Speed This value indicates the current speed in RPM. Overall Output This value indicates the overall movement or position in Engineering Units according to channel type. (Valid for all channels) DC Voltage This value indicates the current DC component of the output value in Volts. (Valid for channels 1-4) DC Relative Gap This value indicates the current DC component of the output value in Engineering Units according to channel type. (Valid for channels 1-4, Ethernet Only) Order 0.5x Amplitude This value indicates the Half Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only) Order 0.5x Phase This value indicates the Half Order phase angle in degrees. (Valid for channels 1-6, Vibration only) Order 1x Amplitude This value indicates the First Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only) 25

27 Order 1x Phase This value indicates the First Order phase angle in degrees. (Valid for channels 1-6, Vibration only) Order 2x Amplitude This value indicates the Second Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only) Order 2x Phase This value indicates the Second Order phase angle in degrees. (Valid for channels 1-6, Vibration only) Order Nx Amplitude This value indicates the N th Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only) Order Nx Phase This value indicates the N th Order phase angle in degrees. (Valid for channels 1-6, Vibration only) Order Not1x Amplitude This value indicates the Not First Order Vibration components in Engineering Units. (Valid for channels 1-6, Vibration only) N for N th Order This value indicates the N th Order phase angle in degrees. (Valid for channels 1-6, Vibration only) Critical Error This value indicates any module error detected by the system. 0 = Normal 1 = Error Configuration Error This value indicates a channel is configured improperly. 0 = Normal 1 = Error Probe Voltage Error This value indicates the channels DC voltage is out of limits. 0 = Normal 1 = Error Bad Data This value indicates the overall value is out of the specified limits. 0 = Normal 1 = Bad Quality Suspect Data This value indicates the Overall value is within 5% of the specified limit. 0 = Normal 1 = Suspect Quality Alert, Alert Low, Alert High Active These values indicate the Overall value has exceeded the specified range. 0 = Normal 1 = Alert Danger, Danger Low, Danger High Active These values indicate the Overall value has exceeded the specified range. 0 = Normal 1 = Danger Time Waveform Buffer Full This value indicates Capture buffer is full. 0 = Normal 1 = Buffer Full Time Waveform Capture Complete This value indicates a single capture has completed. 0 = Normal 1 = Complete Time Waveform Runup, Rundown, & Event Active These values indicate the MCM800 is actively capturing respective waveform data. 0 = Normal 1 = Active 26

28 4 Operation 4.1 General Description The MCM800 system is part of ABB s 800 xa technology platform. The modules that comprise this system operate independently from the main DCS controller, providing dedicated monitoring and protective features, including: Vibration Monitoring Eccentricity Thrust (Rotor) Position Differential Expansion Case Expansion The TBU850 conditions these field signals and passes the digitized results to the MPM810 controller. The MPM810 uses the field data in the execution of its functions. In the next sections of this manual, the MCM800 system is broken down into three main functional areas for analysis purposes: I/O Functions Protective Functions Testing Functions. These functions include both hardware and software components. 4.2 I/O Conditioning Functions Signal Inputs I/O Conditioning functions convert the field electrical signals into digital data, which is then transferred to the micro-controller in the MPM810. The MCM800 can accept up to four signal inputs. These can range from approximately +20 volts to 20volts. They pass through over-voltage protection devices then into a differential input to reduce common mode noise. The signal passes through a four-pole low-pass anti-aliasing filter with a corner frequency of about 20 khz. This filter reduces high frequencies that may be falsely interpreted. Finally, the signal is digitized by an Analog-to-Digital converter sampling at 50 khz. The digitized signal is passed to the MPM810 where it is processed. Internally the signal is separated into an AC and a DC component. The AC component is used for vibration and eccentricity measurements. The DC component is used for Thrust, Differential Expansion, Case Expansion, and for signal quality. The AC signal is filtered using the frequency parameters set by the user to reduce unwanted frequencies. The filters used are digital 2-pole Butterworth high-pass and low-pass filters. The output of the filter may be integrated from velocity to displacement or acceleration to velocity. The signal is finally analyzed and output as a peak, peak-to-peak, RMS or average value. The DC signal is filtered to remove the AC component providing a steady output value. For all type of configurations the DC voltage provides ranging from about +24 volts to 24 volts. This signal is used to determine signal quality as specified by the user. It is 27

29 4.2.2 Event Marker Inputs Relay Outputs also used for all position measurements. The position is determined from a null position previously set. The MCM800 accepts a once-per-revolution pulse with a minimum pulse height of 1.7 v and a minimum pulse width of 100 µsec (larger signals are preferred). The Event Marker has two functions: Shaft speed (in RPM s) Orders calculations Speed is measured between 1 RPM and over 20,000 RPM s. When the speed goes below 1 RPM, the module interprets this as zero speed. If the speed is suddenly lost above 20 RPM s the speed output is set bad quality. For orders calculations, the event marker is used to determine the running speed of the shaft. These calculations produce an amplitude of 1 times running speed (1X), 2 times running speed (2X), one-half times running speed (half-x), and N times running speed (NX). N is a number between 3 and 10 specified by the user. In addition, a Not 1X value is calculated. A phase angle is produced for half-x, 1X, 2X, and NX. For each signal channel there are up to four alarm levels available. High Danger High Alert Low Alert Low Danger If enabled, the MCM800 will activate on-board relays indicating a problem exists. There is one relay for Alert and one relay for Danger. Time delays of 0.1 to 300 seconds are available to avoid false alarms. The relays are Form-C providing a normally open and normally closed contact. In addition, parameters enable the user to specify normally energized and normally deenergized relays. The user must be careful when using these features to ensure expected results. 28

30 4.3 Functions Vibration The MCM800 System provides all the Turbine Supervisor Instrumentation functions. These functions can be individually configured for maximum flexibility. The sections below list typical parameter settings for the various functions. Some parameters are application specific and may deviate from those listed. Not all parameters are used for every function and are ignored. For those parameters, the default setting is recommended. This function measures shaft vibration. Typical Vibration Configuration (valid for channels 1-4) Channel Type Output Select Probe Type Probe Sensitivity Integration 1 = Vibration 0 = Peak-to-peak 1 = Peak 2 = RMS 3 = Average 4 = Calculated peak-to-peak 5 = Calculated peak 1 = Proximity Probe 3 = Accelerometer 4 = Moving Element velocity probe 5 = Piezoelectric velocity probe Millivolts / EU 0 = None 1 = Velocity to displacement (velocity probes only) 2 = Acceleration to velocity (accelerometers only) Angular Position of Probe High Failure Threshold Low Failure Threshold N for Nth Order Typical settings Proximity Probe = -0.5 Accelerometer = 20.0 Moving Element velocity probe = 20.0 Piezoelectric velocity probe = 20.0 Typical settings Proximity Probe = Accelerometer = 0.5 Moving Element velocity probe = Piezoelectric velocity probe = (User specified) 29

31 Filter Low Cutoff Frequency Filter High Cutoff Frequency Shaft Rotation Direction User defined (recommendations listed below) Proximity Probe = 1 Accelerometer = 10 Moving Element velocity probe = 10 Piezoelectric velocity probe = 10 Integrated signals with low frequency noise = 40 User defined (recommendations listed below) Low Speed (< 1000 RPM) = 200 Medium Speed ( RPM) = 600 to 2000 High Speed (> 5000 RPM) = up to 2000 Highest speed of interest in Hertz times 10 Shaft rotation is determined looking axially from the driver to driven direction. 0 = Clockwise 1 = Counter-clockwise Eccentricity This function measures shaft eccentricity. Typical Eccentricity Configuration (valid for channels 1-4) Channel Type Output Select Probe Type Probe Sensitivity 2 = Eccentricity 0 = Peak-to-peak 1 = Proximity Probe Millivolts / EU Angular Position of Probe High Failure Threshold Low Failure Threshold Proximity Probe = -0.5 Proximity Probe =

32 4.3.3 Thrust (Rotor) Position This function measures Thrust or Rotor Position. Typical Thrust Configuration (valid for channels 1-4) Channel Type Probe Type Probe Sensitivity High Failure Threshold Low Failure Threshold Null Position in Engineering Units Null Position voltage 3 = Thrust 1 = Proximity Probe 6 = Complementary proximity probe Millivolts / EU Proximity Probe = -0.5 Proximity Probe = User defined. Set by user Differential Expansion This function measures Differential Expansion. See Complementary Position for complementary applications Typical Differential Expansion Configuration (valid for channels 1-4) Channel Type Probe Type Probe Sensitivity Ramp Angle (for probe type 7 only) 4 = Differential Expansion 1 = Proximity Probe 2 = DC LVDT 6 = Complementary proximity probe 7 = Ramped Complementary proximity probe Millivolts / EU High Failure Threshold Low Failure Threshold Null Position in Engineering Units Null Position voltage Non-linear Correction Proximity Probe = -0.5 DC LVDT = probe dependent Proximity Probe = DC LVDT = probe dependent User defined. Set by user. User defined. This is intended to extend the usable range of a probe. (For Future Use Only) 31

33 Case Expansion This function measures Case Expansion. Typical Case Expansion Configuration (valid for channels 1-4) Channel Type Probe Type Probe Sensitivity High Failure Threshold Low Failure Threshold Null Position in Engineering Units Null Position voltage 5 = Case Expansion 1 = Proximity Probe 2 = DC LVDT Millivolts / EU Proximity Probe = -0.5 DC LVDT = probe dependent Proximity Probe = DC LVDT = probe dependent User defined. Set by user Dual Probe This function measures shaft vibration using a Dual Probe. The Dual Probe application combines a Relative Probe (channel 1) with a Seismic Probe (channel 2) producing an Absolute signal (channel 5). Likewise, channel 3 (Relative) and channel 4 (Seismic) produces channel 6 (Absolute). Typical Dual Probe Configuration Parameter Relative (1/3) Seismic (2/4) Absolute (5/6) Channel Type 6 = Relative 7 = Seismic 8 = Absolute Output Select 0 = Peak-to-peak 0 = Peak-to-peak 0 = Peak-to-peak Probe Type 1 = Proximity Probe 4 = Moving Element N/A velocity probe 5 = Piezoelectric velocity probe Probe Millivolts / EU Millivolts / EU N/A Sensitivity Integration 0 = None 1 = Velocity to displacement N/A 32

34 Parameter Relative (1/3) Seismic (2/4) Absolute (5/6) Angular N/A Position of Probe High Failure Proximity Probe = -0.5 velocity probe = 20.0 N/A Threshold Low Failure Threshold Proximity Probe = Moving Element velocity probe = Piezoelectric velocity probe =0.5 N for Nth Order Filter Low Cutoff Frequency Filter High Cutoff Frequency SMAX 3 10 (User specified) Same as relative Same as relative User defined (recommendations listed below) 1 to 10 Hz User defined (recommendations listed below) Low Speed (< 1000 RPM) = 200 Medium Speed ( RPM) = 600 to 2000 High Speed (> 5000 RPM) = up to 2000 Highest speed of interest in Hertz times 10 User defined (recommendations listed below) 5 to 10 Hz Same as relative This function measures shaft vibration using two probes in an X/Y configuration. It determines the maximum displacement of the shaft by trigonometrically combining the two signals. The SMAX application combines an X (channel 1) with a Y (channel 2) producing an SMAX signal (channel 5). Likewise, channel 3 (X) and channel 4 (Y) produces channel 6 (SMAX). In addition, if two Dual Probes are placed in an X/Y configuration SMAX is calculated using channel 7. The X and Y designators are arbitrary. What is more important is the probe angles and direction of rotation. Typical SMAX Configuration (valid channels 5-7) Configure the X and Y channels as vibration channels or dual probes. N/A N/A Channel Type Output Select 9 = SMAX 0 = Peak-to-peak 1 = Peak 33

35 4.3.8 Complementary Position This function measures Thrust or Differential Expansion in a complementary position. The Complementary Position application compares the signals from channels 1 and 2 to output channel 5, or channels 3 and 4 for channel 6. Typical Complementary Position Configuration (valid channels 5&6) Channel Type 10 = Complementary Position Set Sensitivity for channel 1 or 3 to mv / EU and 2 or 4 to (-) mv /EU Set Sensitivity for channel 1 or 3 to (-)mv / EU and 2 or 4 to mv /EU Set Sensitivity for channel 1 or 3 to mv / EU and 2 or 4 to (-) mv /EU Set Sensitivity for channel 1 or 3 to (-)mv / EU and 2 or 4 to mv /EU The value of the Complementary output depends on the quality of each of the two hardware inputs. The quality is based on the High and Low failure voltages. Refer to the section that explains the Probe Failure Voltage setting. The two probes can be mounted in such a way that the probes are either overlapping or non-overlapping as shown below. 34

36 4.3.9 Waveform Capture Settings The MCM800 has 4 logic signals that control when time waveform data is captured. Controller logic can be written to capture a single time waveform or capture a series of time waveforms during a runup, a rundown or during an event such as a plant trip. Capture Waveform On a transition from false to true the current waveform will be captured and transmitted to the Data Server. Once captured, the Capture Time Waveform flag becomes true. At least 5 waveforms can be retained in a buffer to await transfer. If the buffer fills, the Buffer Full flag becomes true and the MCM800 will not capture additional waveforms until buffer space is available. If Capture Waveform remains true, no additional waveforms will be captured. While it is not normally necessary, DCS logic can check the Capture Time Waveform and Buffer Full flags. Runup Capture When Runup Capture is true, the current waveform will be stored every time speed increases by Delta RPM or more. Runup Capture continues while the flag is true and there is enough storage on the MCM800. There is enough memory to store up to 40 files, but files can be off-loaded to the Data Server while the data is being captured. Delta RPM is specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the Runup Data flag. Rundown Capture Same as Runup Capture except speed must decrease by Delta RPM or more. Event Active The Event Waveform file contains up to 40 waveforms. The MCM800 will retain a configurable amount of waveforms from the Current Data Buffer at a configurable Skipover Factor prior to Event Active. The purpose is to store data from before and after an event such as a Danger alarm or a machinery trip. Construction of the Event Waveform file starts when Event Active becomes true. Construction continues until 40 waveforms, including pre-event captures, are stored or Event Active becomes false, constituting a file. When a file is complete, the Event Data flag becomes true until the waveforms are uploaded to the Data Server. If Event Active remains true, no additional Event Waveform files will be constructed. The Skip-over Factor and Number of Pre-trigger Waveforms are specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the Event Data flag. 35

37 5 Maintenance 5.1 Preventive Maintenance Periodically (every six months) or during a plant shutdown, inspect modules and clean any dust accumulation with a static safe vacuum cleaner. 5.2 Hardware Indicators MPM810 I/O Module LEDs LED R/F Description Health LED. If module is OK the LED is GREEN. On failure, the LED is either RED or OFF. During startup this LED may flash GREEN and RED while going through diagnostics. RxTxA Profibus Bus A communication. The LED is AMBER if the module is communicating over Bus A RxTxB Profibus Bus B communication. The LED is AMBER if the module is communicating over Bus B STATUS The LED is GREEN when running normally, completed diagnostics, or completed calibration. It is AMBER during startup, running diagnostics or calibration. It is RED if the module failed startup, diagnostics or calibration CH1 CH2 CH3 CH4 CH5 CH6 CH7 Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 2 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 3 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 4 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 5 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 6 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Channel 7 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured. Table 5-1 MPM810 LEDs 36

38 5.3 Troubleshooting Symptom Possible Causes Corrective Action Module is not plugged in correctly. Re-adjust the module to fit properly. Check Profibus Address Module does not initialize. Operating mode not set up DIPswitch. correctly. Check Ethernet IP address. Check option DIPswitch. Hardware failure. Replace the module. No power to module Check +24 & -24 volt power supplies and connector. R/F LED is OFF. Module is not plugged in Re-adjust the module to fit correctly. properly. Hardware failure. Replace the module. R/F LED is RED. Module is not plugged in correctly. Re-adjust the module to fit properly. Hardware failure. Replace the module. Profibus not communicating Check Profibus master and configuration RxTxA & RxTxB LED s are OFF Loose or disconnected Check the cable for proper fitting. Profibus not properly terminated Check Profibus termination DIPswitch S3. STATUS LED is AMBER. If LED does not turn green after The module is on startup, several minutes the module may calibration or diagnostic mode. be faulty. Replace module. Module failed startup Replace MPM810 STATUS LED is RED. Module failed diagnostic Replace MPM810 Module failed calibration Replace TBU850. CHn LED is OFF. Channel not configured Check configuration This is usually a normal condition. However, it could be caused by a Channel is in Alert condition. CHn LED is AMBER noisy signal or an improper configuration. This is usually a normal condition. However, it could be caused by a Channel is in Danger condition. CHn LED is RED noisy signal or an improper configuration. CHn LED is blinking AMBER There is a configuration error. Check configuration. No configuration defined for Configure channel using Channel status indicates a channel. configuration tool. Critical error, but no Configuration error. Re-configuration channel and set Configuration not saved. dipswitch to save parameters. 37