Rev.7 CSI 6500 Install

Reference Manual
CSI 6500
Machinery Health
TM
Monitor

Online System Installation and Configuration
Part #MHM-97125 Rev 7
2
Copyright
2012 by Emerson Process Management.
All rights reserved.
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permission of Emerson Process Management.
Disclaimer
This manual is provided for informational purposes.
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RANTY OF ANY KIND WITH REGARD TO THIS MATE-
RIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
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The information in this manual is not all-inclusive and
cannot cover all unique situations.
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License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMS
AND CONDITIONS OF THIS AGREEMENT BEFORE
OPENING THE PACKAGE OR PROCEEDING WITH
INSTALLATION. OPENING THE PACKAGE OR COM-
PLETING THE INSTALLATION INDICATES YOUR
ACCEPTANCE OF THE TERMS AND CONDITIONS
CONTAINED IN THIS AGREEMENT.
IF YOU DO NOT AGREE TO THE TERMS AND CON-
DITIONS CONTAINED IN THIS AGREEMENT,
CANCEL ANY INSTALLATION AND PROMPTLY
RETURN THIS PRODUCT AND THE ASSOCIATED
DOCUMENTATION TO CSI, AND YOUR MONEY
WILL BE REFUNDED. NO REFUNDS WILL BE GIVEN
FOR PRODUCTS WITH DAMAGED OR MISSING
COMPONENTS.
Definition of Software
As used herein, software refers to any computer program
contained on any medium. Software includes downloadable
firmware for use in devices such as analyzers or MotorSta-
tus units and it includes computer programs executable on
computers or computer networks.
Software License
You have the non-exclusive right to use this software on
only one device at a time. You may back-up the software for
archival purposes. For network systems, you have the non-
exclusive right to install this software on only one server.
Read/write access is limited to the number of concurrent use
licenses purchased. The number of guest-only accesses is up
to a maximum of 250.
CSI grants you a non-exclusive right to use the Software
solely for your own internal data processing operations on
the CSI designated supported operating platform for up to
any applicable maximum number of licensed users. You
may not relicense the Software or use the Software for third
party training, commercial time sharing, rental, or service
bureau use. Client may not use the Software in, as, or with
an ASP (Application Service Provider).
Software Updates
CSI agrees to provide you, at no charge except for media,
preparation and shipping charges, for one (1) year from the
date of purchase, all updates to the software made at the sole
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agreement for the next succeeding year following the first
year from the date of purchase, and thereafter on an annual
basis, and if CSI is still providing support, you may pur-
chase the same, annually, at the then existing rate.
Updates/Upgrades
Upon receipt of new CSI software replacing older CSI soft-
ware, you have 30 days to install and test the new CSI soft-
ware on the same or a different device. At the end of the 30-
day test period, you must both remove and return the new
CSI software or remove the older CSI software.
3
Ownership
The licensed software and all derivatives are the sole prop-
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gram or documentation, in whole or in part, to another party.
You may not in any way distort, or otherwise modify the
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Transfer
You may transfer the software and license to another party
only with the written consent of CSI and only if the other
party agrees to accept the terms and conditions of this
Agreement. If you transfer the program, you must transfer
the documentation and any backup copies or transfer only
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The software and documentation are copyrighted. All rights
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If you commit a material breach of this Agreement, CSI
may terminate the Agreement by written notice.
Virus Disclaimer
CSI uses the latest virus checking technologies to test all its
software. However, since no antivirus system is 100% reli-
able, we strongly advise that you use an anti-virus system in
which you have confidence to verify the software is virus-
free. CSI makes no representations or warranties to the
effect that the licensed software is virus-free.
NO WARRANTY
THE PROGRAM IS PROVIDED "AS-IS" WITHOUT
ANY WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO ANY WARRAN-
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PARTICULAR PURPOSE.
LIMITATION OF LIABILITY AND REMEDIES
IN NO EVENT WILL CSI BE LIABLE TO YOU OR ANY
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INCLUDING ANY LOST PROFITS, LOST SAVINGS,
OR OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES ARISING OUT OF THE USE OR THE
INABILITY TO USE THIS PROGRAM.
THE LICENSEE'S SOLE AND EXCLUSIVE REMEDY
IN THE EVENT OF A DEFECT IN WORKMANSHIP OR
MATERIAL IS EXPRESSLY LIMITED TO THE
REPLACEMENT OF THE DISKETTES OR OTHER
MEDIA. IN NO EVENT WILL CSIS LIABILITY
EXCEED THE PURCHASE PRICE OF THE PRODUCT.
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subject to the same license rights as those enumerated
above.
Hardware Repair
Emerson Process Management repairs and updates its hard-
ware products free for one year from the date of purchase.
This service warranty includes hardware improvement,
modification, correction, recalibration, update, and mainte-
nance for normal wear. This service warranty excludes
repair of damage from misuse, abuse, neglect, carelessness,
or modification performed by anyone other than Emerson
Process Management.
After the one year service warranty expires, each return of
an Emerson Process Management hardware product is sub-
ject to a minimum service fee. If the cost of repair exceeds
this minimum fee, we will call you with an estimate before
performing any work. Contact Emerson Process Manage-
ments Product Support Department for information con-
cerning the current rates.
Obsolete Hardware
Although Emerson Process Management will honor all
contractual agreements and will make every effort to ensure
that its software packages are backward compatible, to
take advantage of advances in newer hardware platforms
and to keep our programs reasonably small, Emerson Pro-
cess Management reserves the right to discontinue support
for old or out-of-date hardware items.
4
Software Technical Help
1. Please have the number of the current version of your
software ready when you call. The version number for
software operating under Windows
is displayed by
selecting About under the Help menu bar item.
2. If you have a problem, explain the exact nature of your
problem. For example, what are the error messages?
(If possible, make a printout of the error message.)
When do they occur? Know what you were doing
when the problem occurred. For example, what mode
were you in? What steps did you go through? Try to
determine before you call whether the problem is
repeatable.
3. Please be at your computer when you call. We can
serve you better when we can work through the
problem together.
5
CSI 6500 Contents
Chapter 1 Introduction
Special Emphasis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Plant Appointed Project Manager. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Where to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Chapter 2 Pre-Installation Review
Contractor Kickoff Meeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Final Walk-Through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
System Component Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Chapter 3 System Documentation
System Overview Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
System Layout Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Cable Administration Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
J unction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
CSI 6500 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Documentation Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Chapter 4 Install Instrumentation
Description and Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . .4-1
Required Tools & Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
A911 Mounting Stud Installation (Stud Mounting Only). . . . . . . . .4-10
Sensor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
A0322LC, A0322DS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . .4-14
Required Tools & Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
AO322LC Sensor Mounting (without Quick-Connect) . . . . . . . . . .4-23
6
A0322LC with Quick-Connect Mounting Instructions . . . . . . . . . . 4-25
A0322RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
A0322RM Mounting Stud Installation (Stud Mounting Only) . . . . 4-35
Sensor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
V425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Description & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Choosing Proper Actuator (Target) . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Mounting Sensor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Mounting Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Eddy Current Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
Chapter 5 Enclosure Mounting
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Mounting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Mount the CSI 6500 Rack Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Mounting Instructions (19 cabinet enclosure) . . . . . . . . . . . . . . . . . . 5-7
Mounting Instructions (stainless steel enclosure). . . . . . . . . . . . . . . . . 5-8
Prepare Cable Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Determine Hole Size & Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Installing CSI 6500 modules into the chassis. . . . . . . . . . . . . . . . . . . 5-11
Chapter 6 Cabling Requirements
Pull Instrumentation Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Pull V680 Bundled Cable from J unction Box to CSI 6500 . . . . . . . . . 6-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
CSI 6500 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Guidelines for Dedicated CSI 6500 Network Segment . . . . . . . . . . . 6-10
7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
Power Circuit Guidelines for the CSI 6500 enclosure . . . . . . . . . . . .6-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
Recommended Sensor Wiring and Grounding Practices. . . . . . . . . . .6-12
Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
CSI 6500 System Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Chapter 7 Wire Terminations
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Terminate Instrumentation Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Terminate V680 Bundled Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Terminate CSI 6500 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
A6500-M-RTRM Rear Termination Panel: . . . . . . . . . . . . . . . . . . . .7-7
Terminate Discrete Input/Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
A6500-M-RSH Rear Shield / Adapter Panel . . . . . . . . . . . . . . . . . .7-18
A6500-M-FTRM Front Termination Panel . . . . . . . . . . . . . . . . . . .7-19
Terminate +24V Power for the CSI 6560 and CSI 6510 modules . .7-21
Terminate -24V power supply for Eddy Current sensors. . . . . . . . .7-22
Dual Prediction only system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
CSI 6500 Default Network Addressing Schema. . . . . . . . . . . . . . . .7-28
Chapter 8 Hardware Configuration of CSI 6560 and CSI 6510
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Monitoring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
CSI 6560 / CSI 6510 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
Signal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4
CSI 6500 System Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-7
CSI 6560 Processor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
CSI 6510 Signal Input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-14
CSI 6510 Tachometer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
CSI 6510 I/O Relay Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17
CSI 6500 Transient Daughterboard . . . . . . . . . . . . . . . . . . . . . . . . .8-22
Replacing the CSI 6500 Transient Daughterboard Hard Drive . . . .8-25
8
CSI 6500 Transient Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
General Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Configuring a CSI 6500 with Hyperterminal . . . . . . . . . . . . . . . . . . 8-31
CSI 6560 Processor Module LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
CSI 6510 Signal Input module LEDs. . . . . . . . . . . . . . . . . . . . . . . . 8-41
Backplane/Termination Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Overall Level Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Spectral Scan Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44
Calibrating the CSI 6500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-49
Test Signal Generator (TSG) Calibration. . . . . . . . . . . . . . . . . . . . . 8-51
Gross Scan (GS) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
DSP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Transient Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52
Index
Chapter
1-1
1
Introduction
Preface
Congratulations on your purchase of the CSI 6500 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 CSI 6500 Machinery Health Monitor -
Installation and Configuration manual. The purpose of this manual is to provide
system installers specific requirements and instructions for the correct installa-
tion and configuration of the CSI 6500 and accessories.
This manual does not attempt to explain the operation or application of the CSI
6500.
1-2 Introduction
Note
Normal installation for the Model CSI 6500 Machinery Health
Monitor unit is in an orientation such that the front panels are ver-
tical.
CSI 6500
1-3
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.
1-4 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 6500 Machinery Health Monitor rack 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.
1-5 How to Use
Plant Appointed Project Manager
The project manager will be involved in budgeting money for the installation
work, setting schedules, procuring bids from contractors, and supervising the
system install. Therefore, it is important that the project manager understand the
scope of work which is involved with an on-line system installation which can
be properly estimated by reviewing each section of this manual. Furthermore,
this manual is divided into sections:
Pre-Installation Review
System Documentation
Install Instrumentation
Enclosure Mounting
Cabling Requirements
Wire Terminations
System Hardware Configuration.
These sections follow the natural progression of a system installation which
should make it easier for the project manager to estimate schedules and budgets
for the installation. Another important function of the project manager is to pro-
cure bids from contractors. Each contractor should receive a copy of this manual
and use that as a basis for their scope of work. Apart from the installation
manual, all the contractor should need is a copy of the system proposal and any
supplemental information for special purchases. When reviewing bids from
contractors it is very important that each contractors scope of work is based on
this installation manual and all exceptions are noted.
Before the contractor begins work, the project manager will have the important
duty of performing an installation review and creating proper system documen-
tation. The installation review, which may include a Contractor Kickoff
Meeting attended by a CSI 6500 online project manager, is intended to educate
everyone involved with the installation on requirements, deadlines, procedures,
etc. The installation review also requires the project manager to perform a final
walk-through of the installation site and determine if the purchased hardware is
adequate and if any additional hardware will be required.
1-6 Introduction
System documentation is often neglected until an installation is completed. The
project manager must be in charge of creating proper system documentation for
the contractor before the installation begins. This includes assigning labels, cre-
ating system diagrams, and filling out cable administration charts. Having the
proper system documentation will make the contractors job easier and reduce
the number of mistakes made.
Finally the project manager should use this installation manual to validate the
work being performed by the contractor. Particular attention should be paid to
any Notes or Cautions within the document. Doing so will help eliminate
the most common causes of a poor installation.
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.
1-7 Supplemental Information
Supplemental Information
This installation and configuration manual covers the standard online system
components. For specific customer installations, there will be non-standard
components purchased with the online system. For each of these components,
an installation guide supplement will be prepared by Emerson and included with
the installation guide. If a purchased component cannot be found in the installa-
tion guide, please contact your CSI 6500 Monitor project manager and request
an installation guide supplement.
1-8 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.
Chapter 2 Pre-Installation Review
The pre-installation review could also be called installation preparation. This
involves a contractor kickoff meeting, a final walkthrough of the installation
site, and examination of the delivered system components.
Chapter 3 System Documentation
System documentation is prepared before the system installation begins. This
involves assigning sensor names, wire tag designations, enclosure names, pre-
paring system layout diagrams, and filling out the cable administration charts.
Chapter 4 Install Instrumentation
The online system instrumentation includes the 322 family of accelerometers
and the 425 tachometer. This chapter covers the handling requirements, required
tools, and the installation procedures for each piece of instrumentation.
Chapter 5 Enclosure Mounting
This chapter covers choosing proper mounting locations, and procedures for
mounting the CSI 6500 and junction boxes, as well as preparing the CSI 6500
stainless steel enclosure for conduit access.
Chapter 6 Cabling Requirements
This chapter covers conduit installation guidelines, network cabling guidelines,
power line specifications, and pulling the online instrumentation cabling as well
as the bundled (multi-pair) cable from junction boxes to the CSI 6500.
1-9 Where to Start
Chapter 7 Wire Terminations
Improper wiring is often the cause of system failures. Proper wire terminations
within the online system components is critical for a successful system startup.
This chapter covers routing, tagging, preparing, and terminating cables within
the V707, 727, 745 junction boxes and the CSI 6500.
Chapter 8 System Hardware Configuration
The CSI 6500 may be configured into a variety of configurations. This chapter
covers the hardware configuration for the CSI 6500, as well as how to review/
change the firmware settings.
1-10 Introduction
Chapter
2-1
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 6500 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 customers 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 6500 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.
2-2 Pre-Installation Review
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.
2-3 Final Walk-Through
Final Walk-Through
The final walk-through is attended by the plant assigned project manager, con-
tractor representative(s), and the CSI 6500 online project manager or online sys-
tems engineer. Using the system documentation (see chapter 3) as reference, this
is the opportunity to physically walk-through each part of the installation with
the contractors representative(s) and the vendors representative (online project
manager or online systems engineer) to review:
Sensor Mounting Locations
Cable Pulls
Conduit/Cable Tray Use
Enclosure Mounting Locations
Environmental Concerns
Hazardous Locations.
2-4 Pre-Installation Review
System Component Review
The system component review confirms that the proper system components
have been shipped and that nothing has been lost or damaged during shipment.
The review should be attended by the plant assigned project manager, contractor
representative(s), and the CSI 6500 online project manager or online systems
engineer. It is the responsibility of the plant assigned project manager to gather
shipped components into an accessible area for the review process. The review
process simply consists of unpacking and inspecting system components to con-
firm all components are present. This is also the opportunity to familiarize the
plant assigned project manager and the contractor with the different system
components. In particular, the following items should be confirmed during the
review.
Any non-standard system components
Sensor mounting accessories (studs, mounting pads, quick-connects,
etc.)
Manuals
J unction box mounting tabs
CSI 6500 module and backplane configurations
CSI 6500 discrete input/output relays for correct configuration.
Chapter
3-1
3
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 6500
data collection unit and junction/switch box enclosures include see-through
pouches for storing the on-line system documentation.
3-2 System Documentation
System Overview Drawings
The system overview drawings illustrate how system components interconnect.
These drawings are normally prepared by a CSI 6500 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.
Example of System Overview Drawing (overall)
3-3 System Overview Drawings
Example of System Overview Drawing (Machine Level)
As illustrated, the system overview drawings should consist of an overall system
diagram and then machine level diagrams showing sensor locations. In general
the following information should exist on each diagram.
Overall System Diagram:
CSI 6500
J unction/Switch Boxes
Cables
CSI 6500 Network Segment Cables
Tags for each CSI 6500, J unction/Switch box, and Cables
Machine Level Diagram:
Machine with Tag
Sensor Location with Tag
J unction/Switch Boxes with Tag
Location on Plant Floor
Additional Information to Keep:
IP address of online server
IP addresses of CSI 6500s
Note
Each IP address should be linked to the corresponding CSI 6500.
3-5 System Layout Drawings
System Layout Drawings
The system layout drawings illustrate exact locations for enclosure mounting,
conduit installation, cable pulls, and sensor mounting. These are prepared by the
plant assigned project manager utilizing facility blueprints. The most common
method for preparing these drawings is to copy blueprints of the plant floor/pro-
duction line and mark the system installation locations. Use color-coded high-
lights and symbols to mark the different types of cable runs and enclosure
mountings. The following is a recommended method of marking system layout
drawings.
System Layout Marking Guidelines
Cable Administration Charts
Cable administration charts are a convenient way to document wire terminations
within system enclosures. Before the system installation begins and preferably
before bids are procured from contractors, the project manager should work
with the end user in the plant to determine sensor tags, enclosure tags, and cable
tags. There is no recommended method for assigning tags but the names should
be consistent and represent physical locations or machines. For instance, instead
of naming a sensor, 23001, which represents nothing, a more meaningful name
such as FAN1OV (fan number 1 outboard vertical) will make system mainte-
nance and troubleshooting much easier. After tags are assigned, it is important
to document these in cable administration charts. All enclosures for the CSI
online system will need to have cable administration charts created. For this
reason, each enclosure will include a special clear plastic pouch on the inside
cover of the enclosure to hold these cable administration charts for reference.
There are two types of cable administration charts for the online system: junc-
tion box and CSI 6500.
3-7 Cable Administration Charts
Junction Box
The online system junction boxes each serve the same purpose: to provide a
junction between the instrumentation cable and the multi-pair bundled cable
which is pulled back to the CSI 6500. The cable administration chart for a junc-
tion box simply documents the channel number, wire tag, sensor type, and
sensor location if the wire tag does not contain location information. The fol-
lowing is an example of the junction box cable administration chart for a typical
installation. These charts are shipped with the system and can be found inside
the online system junction boxes.
J unction Box Cable Administration Chart
CSI 6500 Enclosure
The CSI 6500 has cable terminations for sensors, tachometers, discrete I/O, net-
work, and power; as well as configurable DIP switches and jumpers.
The cable terminations and DIP switch settings must be documented in the cable
administration charts. The following template is an example cable administra-
tion chart for the Prediction side of the CSI 6500.
3-9 Documentation Storage
Documentation Storage
After the system installation is complete, it is the project managers job to
review the system documentation and make any revisions such as rerouted
cables, misspelled wire tags, etc. and make the necessary revisions in the system
documentation. The last step is to create copies of the completed system docu-
mentation and distribute to the appropriate plant personnel. One copy should be
sent to the CSI 6500 online project manager. This is also the appropriate time to
place the cable administration charts in the online enclosures to allow easy ref-
erence by contractors and service personnel. In each CSI 6500 enclosure, it is
recommended that a copy of the system overview and layout drawings be placed
in a pouch for quick reference.
Chapter
4-1
4
Install Instrumentation
A0322RI, A0322RA, A0322DR
Description and Handling Instructions
A0322RI, A0322DR Image & Outline Drawing
4-2 Install Instrumentation
A0322RA Image & Outline Drawing
4-3
Description
The A0322RI and A0322RA are general purpose accelerometers with 90-
degree integral cable connections. The A0322DR sensor is a general purpose
accelerometer and temperature sensor with a 90-degree cable connection.These
sensors are stud mounted or epoxy mounted to machinery surfaces and transmit
vibration data to the on-line monitoring system. The integral cable connection
joins the sensor housing at a 90-degree angle to provide a low-profile installa-
tion. The A0322RI has a distinguishing bright yellow polyurethane jacket for
easy identification. The A0322DR has a red polyurethane jacket, three wires
(signal/power, temperature, return) instead of two (signal/power and return),
and requires two channel connections to the CSI 6500. The A0322RA is con-
tained in a steel housing with an armored covered jacket.
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 gs will damage sensor and void
manufacturers warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or
after installation.
When tightening down stud mounted accelerometers it is very important not to
exceed specified torque. Over-tightening of accelerometer will damage sensing
element and void manufacturers warranty.
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.
If sensor mounting occurs before cable is pulled in conduit or raceway to junc-
tion box it is important to leave cable bundled and secured to machine. Sensor
cable cannot be stepped on or severely kinked or permanent signal degradation
will occur. Also, cable bundle should not be placed in such a manner that it will
cause undue strain at the sensor/cable connection.
Required Tools & Parts
Below is a listing of the required tools and parts in order to install the A0322RI
and A0322RA accelerometers.
Spot Face and End Mill Tool, part number 88001.
Description: the spot face tool attaches to a standard electric drill and provides
a machined surface at least 1.1 times greater than the diameter of the sensor. At
the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
Spot Face and End Mill Tool
4-5
A901-1
A901-1 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)
Note
Contractor should confirm Material Data Sheet conforms to plant
safety regulations and substitute epoxy if necessary.
40-200 inch-lbs. Torque Wrench with 1/8" hex bit
Suggested Vendor:
Grainger Part #4J W57
Description:
3/8" drive inch-lbs. torque wrench. Any torque wrench with a range of 40
to 70 inch-lbs. and less than 5 inch-lbs. increments can be substituted.
1/4"-28 taps & tap handle
9/16" open end wrench
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.
Note
Mounting location must provide a case thickness exceeding .4". If
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.
4-7
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".
Spot Facing Tool
Proper (left) & Improper Spot Facing
4-9
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1/2" in diameter. If
1. . . If necessary, use spot facing tool to prepare flat surface.
2. . . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
3. . . Keeping spot face and end milling tool perpendicular to machine surface,
4. . . Screw AO322 mounting stud into A901-1 mounting pad applying 7-8 ft.-
lbs. of torque.
5. . . Using A92016 2-part epoxy, spray activator onto mounting surface.
Place a light coat of epoxy on surface of A0901-1 mounting pad and hold
firmly against surface for 1 minute.
6. . . If adhesive does not setup within 1 minute, this is an indication that too
much epoxy was applied or that the mounting surface was not prepared
properly. Repeat installation steps 1-5.
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.
A911 Quick Connect
4-11
Sensor Mounting
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.
1. . . If necessary, clean A0322 mounting stud 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 A0322 and hold in desired position to create the least
amount of cable strain and cable exposure. Holding sensor, hand-tighten
9/16" captive nut and use a torque wrench with 9/16" open end to finish
tightening to 50-60 in-lbs.
4. . . Secure sensor cable to machine approximately 4" to 5" from mounting
location using an appropriate size cable clamp. Do not exceed bending
radius of 2.8".
5. . . If not ready to perform cable pulls, it will be necessary to secure bundled
sensor cable to machine in such a manner that no strain is placed on
integral sensor/cable connector. Bundled cable must not be left hanging
from sensor nor should bundled cable be exposed to damage such as on
the plant floor, maintenance access footholds, etc.
Mounting Procedure
4-13
Proper Sensor Mounting with cable secured
A0322LC, A0322DS
Description & Handling Instructions

A0322LC, A0322DS Image & Outline Drawing
4-15 A0322LC, A0322DS
Description
The A0322LC is a general purpose accelerometer with a top exit integral con-
nection. The A0322DS is a general purpose accelerometer and temperature
sensor with a top exit integral connection. The sensors are stud mounted or
epoxy mounted to machinery surfaces and transmit vibration data to the on-line
monitoring system. The integral cable connection enters the top of the sensor
housing. An optional quick release connection, A0322LC-NT can be purchased
to allow the A0322LC or A0322DS to be easily removed from machine for
maintenance.
Caution!
after installation.
exceed specified torque. Over tightening of accelerometer will damage sensing
Caution!
accelerometers.
not be strained with excessive pulling force during cable pulls. No more than 5
lation if possible.
Caution!
cause undue strain at the sensor/cable connection.
Below is a listing of the required tools and parts in order to install the A0322LC
and A0322DS accelerometers.
Spot Face and End Mill Tool, part number 88001.
The spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the sensor.
At the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
4-17 A0322LC, A0322DS
A212 Mounting Pad
A212 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)
Note
A0322LC-NT Quick Release SS Nut & Threaded Base (Optional)
A0322LC-NT Quick Release
40-200 inch-lbs. Torque Wrench with 1/4" hex bit
Suggested Vendor:
Description:
Surface Preparation
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
4-19 A0322LC, A0322DS
Note
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,
Note
4. . Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
4-21 A0322LC, A0322DS
Epoxy Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter. If
1. . If necessary, use spot facing tool to prepare flat surface.
2. . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
4. . Screw mounting stud into A212 mounting pad until stud is flush with
bottom of mounting pad. If using A0322LC-NT Quick-Connect then
screw threaded base into mounting pad and torque to 5 ft-lbs.
5. . Using A92016 2-part epoxy, spray activator onto mounting surface. Place
a light coat of epoxy on surface of A212 mounting pad and hold firmly
against machine spot face surface for 1 minute.
6. . If adhesive does not setup within 1 minute, this is an indication that too
4-23 A0322LC, A0322DS
AO322LC Sensor Mounting (without Quick-Connect)
1. . .If necessary, clean mounting location threads using plant approved
degreaser/cleaner.
2. . .Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on mounting stud.
3. . .Screw mounting stud into sensor housing and hand tighten. Screw sensor
and mounting stud into mounting location and tighten with 9/16" torque
wrench to 5 ft-lbs.
4. . .Secure sensor cable to machine approximately 4 to 5" from mounting
radius of 2.8".
5. . .If not ready to perform cable pulls, it will be necessary to secure bundled
the plant floor, maintenance accesses, footholds, etc.
Caution!
If not ready to pull cables, it is recommended that sensors not be
mounted to machine. If necessary to mount sensor, then bundled
cable must be secured to machine and protected from damage.
Caution!
Do not terminate or secure cable to machine before mounting
sensor.
4-25 A0322LC, A0322DS
A0322LC with Quick-Connect Mounting Instructions
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 AO322LC-NT into mounting
location.
4. . .Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A0322LC-NT Quick-Connect base is not seated against spot
face this is an indication that the tap was not deep enough. It will be
necessary remove quick-connect base and tap hole deeper.
5. . .If sensor is not to be mounted immediately, it is necessary to cover
is recommended.
6. . .If necessary, clean A0322LC-NT Quick-Connect threads using plant
approved degreaser/cleaner.
7. . .Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
8. . .Place sensor onto A0322LC-NT 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.
9. . .Secure sensor cable to machine approximately 4 to 5" from mounting
radius of 2.8".
10. .If not ready to perform cable pulls, it will be necessary to secure bundled
the plant floor, maintenance accesses, footholds, etc.

Mounting Procedure
4-27 A0322RM
A0322RM
Description & Handling Instructions

A0322RM Image & Outline Drawing
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.
Caution!
after installation.
exceed specified torque. Over tightening of accelerometer will damage sensing
Caution!
accelerometers.
not be strained with excessive pulling force during cable pulls. No more than 5-
lation if possible.
Caution!
4-29 A0322RM
cause undo strain at the sensor/cable connection.
Spot Face & End Mill Tool, part number 88001.
The spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the sensor.
At the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
A212 Mounting Pad (Epoxy Mounting Only)
A212 Mounting Pad
A92106 Loctite Depend Mounting Pad Epoxy (Epoxy Mounting Only)
Note
40-200 inch-lbs Torque Wrench with 1/4" hex bit
Suggested Vendor:
Description:
Surface Preparation
those ways and what you need to do to successfully mount your accelerometers.
4-31 A0322RM
Stud Mounting
Note
Mounting location must provide a flat surface 1" in diameter. If
Note
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,
Note
4. . Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
4-33 A0322RM
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1" in diameter. If
1. . If necessary, use spot facing tool to prepare flat surface.
2. . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
4. . Screw mounting stud into A212 mounting pad applying 7-8 ft-lbs. of
torque.
5. . Using A92016 2-part epoxy, spray activator onto mounting surface. Place
a light coat of epoxy on surface of the A212 mounting pad and hold firmly
against surface for 1 minute.
6. . If adhesive does not setup within 1 minute, this is an indication that too
4-35 A0322RM
A0322RM 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 mounting stud into mounting
location.
4. . .Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A0322 Quick-Connect base is not seated against spot face
this is an indication that the tap was not deep enough. It will be necessary
remove mounting stud and tap hole deeper.
5. . .If sensor is not to be mounted immediately, it is necessary to cover
is recommended.

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.
4-37 V425
V425
Description & Handling
V425 Outline Drawing & Image
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.
Mounting Bracket & Locking Nut (included)
A universal mounting bracket is included with sensor which will fit a variety of
applications. If the included bracket will not work, then the contractor will have
to fabricate a custom bracket.
V425 Mounting Bracket
4-39 V425
Choosing Proper Actuator (Target)
Actuator Dimensions
The V425 is designed to be used with a key meeting the following minimum
specifications:
Key (Target) Dimensions
A >.15 inches
B >.5 inches
F >.3 inches
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.
Modifying Large Actuators
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.
4-41 V425
Mounting Sensor Bracket
1. . .Turn machinery shaft so that actuator is at mounting location.
2. . .Place sensor in mounting bracket and screw sensor into bracket exposing
equal amount of threads on back and front of mounting bracket.
3. . .Place sensor/bracket assembly into mounting location and center sensor
pole piece over actuator with pole piece touching actuator. Mark hole
locations on bracket.
4. . .Drill and tap hole locations for appropriately sized bolt to fit .250 inch
opening on mounting bracket.
5. . .Secure bracket to mounting location and torque to bolt specifications
V425 Mounting
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.
4-43 Eddy Current Sensors
Eddy Current Sensors
Installation instructions for PR 6422 through PR6426 eddy current probes and
Con 011 through Con 041 probe drivers are available in separate manuals.
Chapter
5-1
5
Enclosure Mounting
Mount V707, V727, and V745 Junction Boxes
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 6500 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.
5-2 Enclosure Mounting

J unction box outline drawing
5-3
V745 outline drawing
Mounting Feet (supplied with enclosure)
Mounting Feet
5-5
Mounting Instructions
1. . .Ensure chosen mounting location allows proper clearance for
maintenance access. Location should be well lit and should be at
appropriate height off floor to allow service technician comfortable
access.
2. . .After choosing location, prepare mounting bracket using outline drawing
as a template for the mounting hole locations.
3. . .Attach mounting feet to back of enclosure using the 10-32x.375 machine
screws included with mounting feet. Torque screws to 31 in-lbs.
Mounting feet should be aligned vertically to box to insure proper access
for mounting.
4. . .Attach enclosure to mounting bracket, using bolts which will be provided
by the contractor.
J unction Box Access Requirements
Mount the CSI 6500 Rack Chassis
Description
The CSI 6500 rack chassis is either mounted on 19" rack mounting rails in a cab-
inet enclosure (with rear termination panels) or in a stainless steel housing (with
a front termination panel) to protect it from harsh industrial environments.
Note
All CSI 6500 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.
Mounting hardware not included.
5-7 Mounting Instructions (19 cabinet enclosure)
Mounting Instructions (19 cabinet enclosure)
The CSI 6500 is generally installed in a cabinet enclosure with 19" rack
mounting rails. Example mounting hardware would include four sets of M5 cap-
tive nuts, M5 cone washers, and M5x12 screws. The installation is carried out
by attaching the captive nuts in the mounting rails and fastening the system
frame to the mounting rails with the screws and cone washers.
Mounting the CSI 6500 to 19 rack mounting rails.
The CSI 6500 chassis has two oblong holes for attaching to the mounting rails
at the left and right sides respectively.
When mounting CSI 6500 units above each other in one cabinet, a cooling fan
rack should be placed between each CSI 6500 unit. This will help maintain the
specified environmental operating conditions for all components. The necessary
requirements for cooling fans depends on the environmental conditions of the
cabinet.
Mounting Instructions (stainless steel enclosure)
1. . Ensure mounting location has proper access for installation and
maintenance. In particular, the door should be free to completely open to
the side and there should be enough room to run conduit into the bottom
of the box. Location should be well lit and should be at appropriate height
off floor to allow service technician comfortable access.
2. . If not using conduit into box, confirm that mounting location provides a
path to earth ground.
3. . The preferred method of mounting the CSI 6500 is to mount the enclosure
on two unistrut rails. Attach all 4 mounting feet to rails and use hardened
steel bolts with lock washer torqued to 50 ft.-lbs.
5-9 Prepare Cable Access
Prepare Cable Access
Stainless steel hole punch or drill.
Conduit fittings.
Determine Hole Size & Location
As a general best practice, conduit should enter from the bottom of the enclo-
sure. Power, sensor, and communication cables should enter through separate
conduit and be routed separately inside the enclosure.
Multi-pair Bundled Cable Pulls
1. . .Multi-pair sensor cable pulls should be made on the bottom left so that
cables can be easily routed along left side of enclosure.
2. . .If used, optional conduit fittings must be sized according to the number of
multi-pair cable pulls coming from a junction box. For example, a
standard 12-channel box will require two pulls. An optional 6-channel
junction box will use one cable pull. The multi-pair cable is normally 0.5"
(1.27 centimeters) in diameter and will require a 1.5" (3.81 centimeters)
conduit run. Two multi-pair cable pulls will require a 2" (7.11
centimeters) conduit run.
CSI 6500 Power
1. . .Power line pull should be made to the bottom right rear so that power
cable is routed along right rear of enclosure.
2. . .The conduit should be sized according to plant code and NEC for running
power in the plant.
CSI 6500 Ethernet Connection
1. . .The CSI 6500 Ethernet connection is a 100BaseT. Category 5
cableprovided by the plant. The CAT5 cable should be to the bottom right
front so that the CAT5 cable can be routed as far from the CSI 6500 power
supply as possible along the right side of the enclosure.
2. . .The Cat5 cable requires a minimum 0.5" (1.27 centimeters) conduit run.
CSI 6500 Discrete Input/Outputs
1. . The CSI 6500 Discrete input/output cable pulls are low voltage DC only,
so they can be routed with sensor cables or routed separately.
2. . The CSI 6500 Discrete input/output cable pulls will consist of either:
a) Multi-pair bundled cable pulls which will require 1.5" (3.81 centi-
meter) conduit for 1 cable and 0.5" (1.27 centimeters) extra for each
additional cable in pull.
b) A672 single twisted pair cable, which will be 0.225 inches (0.57 cen-
timeters) in diameter and either run in conduit, or pulled through the
enclosure using 1/4" (0.64 centimeters) cord grips.
5-11 Installing CSI 6500 modules into the chassis
Installing CSI 6500 modules into the chassis
Close-up photo showing how clips/ejectors work.
To install a module, line up the guide rails and push the module into the slot until
fully seated, then tighten the mounting screws.
To remove a 3U high module, loosen the mounting screws, then simply pull
from the slot by the handle.
To remove a 6U high module, loosen the mounting screws, push outward on the
handles as shown to eject the module from the backplane connectors, then pull
from the slot by the handle.
Chapter
6-1
6
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 6500.
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.
6-2 Cabling Requirements
Junction box/CSI 6500 Cable Recommendations
Note
For cables with overall braided shield, the shield should be
grounded to the CSI 6500 enclosure.
Table 1: Cable pulled in Steel Conduit
Belden # Application Description
9732 V707/V727 9-pair, 24 AWG, Individual foil shield, PVC jacket
9734 V727/ V745 12 pair, 24 AWG, Individual foil shield, PVC jacket
Table 2: Cable pulled in Tray or Aluminum Conduit
Belden # Application Description
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
6-3
Conduit Installation Guidelines
Note
All conduit must be bonded to earth ground and adhere to IEEE
1100 specifications for grounding.
1. . .The following cables must be pulled in Conduit:
a) Between junction boxes and the CSI 6500
b) Any CSI 6500 dedicated network segment cables not pulled in
existing plant network infrastructure
c) Power cables for the CSI 6500 power supplies
d) Any instrumentation cabling exceeding 50 feet.
2. . .The conduit must be sized to not exceed a 40 percent fill.
3. . .Steel Conduit must be used. If plant codes will not allow the use of steel
conduit then please contact project manager.
4. . .Effort should be made to route conduit away from power trays using the
following guidelines:
6" ... 110VAC
12" ... 220VAC
2 ... 440VAC
5. . Conduit must enter the CSI 6500 enclosure and junction boxes from
bottom of enclosures.

Conduit Access from Bottom
6-5 Pull Instrumentation Wiring
Pull Instrumentation Wiring
Description
The on-line instrumentation wiring is a polyurethane jacketed, twisted pair,
shielded, instrumentation cable used to transmit millivolt level instrumentation
signals to the online system. The cable is designed to provide noise shielding
and protection within harsh industrial environments. The instrumentation wire
is pulled to the junction/switch boxes where it is joined to bundled, multi-pair
cabling routed back to the CSI 6500. Because the instrumentation to junction
box pull is relatively short (<50 feet / <15.24 meters) and close to the machinery,
it is not normally enclosed in conduit although conduit will be required for spe-
cific applications. Care must be taken to ensure that exposed cabling is secured
to machinery and plant infrastructure so as to not interfere with maintenance or
cause safety hazards.
Cable Variations
There are four variations of instrumentation cable which are used in the on-line
system:
A. . 2 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
Sensor
B. . 2 Conductor, Single Twisted-Pair Armored Cable Integrated into Sensor
C. . 4 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
A0322 Series Sensor
D. . 2 Conductor, Single Twisted-Pair Polyurethane Cable With 2-Pin Mil
Splash Proof Connector.

Instrumentation Cables
6-7 Pull Instrumentation Wiring
cable tie downs
wire labels
dielectric grease
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.
b) Do not pull cable across machinery maintenance access areas:
guards, shields, access panels.
c) Do not pull cable in machinery control/starting cable trays.
d) Do not run any cable on floor.
e) Do not run cable near pathways where it will be exposed to damage
from moving machinery.
4. . Starting at sensor housing, secure cable in 2-foot (0.61-meter) intervals to
machinery and plant infrastructure using cable tie downs.
5. . At junction/switch box cable should be pulled through an existing
PGME07 cord grip. Tighten cord grip with 9/16 wrench until cable is
secure. (Do not overtighten.) Blunt cut cable leaving approximately 2 feet
(0.61 meter) in box and relabel wire if necessary. If using armored cable,
remove armor before pulling through box by snipping the end of the
armor with a pair of wire cutters and unraveling the length to be removed.
Cut armor off with wire cutters and use heat shrink to seal end of armor.
6-9 Pull V680 Bundled Cable from J unction Box to CSI 6500
Pull V680 Bundled Cable from Junction Box to CSI 6500
Description
The V680 bundled cable is a nine-pair twisted-pair instrumentation grade cable
with individual foil shielding on each pair. The twisted-pair is 24 gauge and
individually color-coded. The V680 is used to extend the on-line instrumenta-
tion wiring from the V707 and V745 junction boxes to the CSI 6500 enclosure.
V680
wire labels
CSI 6500 Enclosure
Installation
1. . .Starting at junction box, pull cable through conduit run. At the CSI 6500
enclosure, blunt cut cable, leaving enough cable inside the enclosure for
routing to terminal connectors.
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.
Guidelines for Dedicated CSI 6500 Network Segment
Description
The CSI 6500 Processor module communicates with a database server via a
100BaseT connection adhering to the IEEE 802.3 Ethernet protocol. It is recom-
mended that customers run a dedicated physical network segment between the
database server and the CSI 6500. Although it is ultimately the responsibility of
the plant to install and maintain the network, the following guidelines are rec-
ommended:
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.
2. . Pathways & Cable Trays per EIA/TIA 569.
Note
Network Cabling to the CSI 6500 should be in steel conduit.
6-11 Power Circuit Guidelines for the CSI 6500 enclosure
Power Circuit Guidelines for the CSI 6500 enclosure
Description
The CSI 6500 Data Collection Unit is a laboratory grade instrument measuring
millivolt level instrument signals. Therefore, the quality of the power provided
to the CSI 6500 is very important. Although the CSI 6500 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 6500 enclosure.
Note
Contractors should adhere to the IEEE 1100 specification for pow-
ering and grounding electronic equipment.
Prediction Side -- 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.
Prediction Side -- AC Power Specifications:
Nominal voltage:110VAC to power 24 volt power supply
Circuit Breaker:10 Amps (with duplex receptacle)
Power ground:Isolated (from production equipment)
Recommended Sensor Wiring and Grounding Practices
Scope
This section will present some recommended practices to follow when speci-
fying and installing 6500 systems and their related sensor and ground wiring.
Installation Considerations
Signal Quality
The data collected by the CSI 6500 system can only be as good as the signals
presented at the CSI 6500 inputs. The 6500 system is capable of resolving
microvolt level dynamic signal components. Typically, signals from sensors
such as accelerometers mounted on operating machinery are millivolt level sig-
nals. Signals of this low magnitude can easily be overwhelmed by interference
from any number of sources in an industrial environment.
Sensor Cable Type
Low capacitance shielded-twisted-pair cable is recommended for all CSI 6500
System sensor inputs. This type of cable provides protection from both low fre-
quency interference such as 50Hz-60Hz sources due to the conductor twisting
(which minimizes antenna loop area and maximizes common mode rejection),
and protection due to RF and static discharge sources due to the overall
shielding. Conductor size may vary from 22 to 16 AWG.
Excessive cable capacitance will affect the high frequency response of acceler-
ometer signals. Low capacitance cable (<15pf/ft) is recommended for longer
cable runs, especially for channels used for PeakVue measurements.
There is evidence that braided shield cables are more effective than foil shield
cables due to reduced impedance of the shield conductor. Braided shield cable
should be considered for long cable runs, electrically noisy installations, or for
critical sensor channels.
6-13 Recommended Sensor Wiring and Grounding Practices
Coaxial cable or other non-twisted cable types are not recommended. This type
of cable has lower immunity to 50Hz-60Hz interference than twisted pair
cable.If multiple conductor cable is used, it must be of the type constructed with
individual isolated shields for each twisted signal pair and an overall shield iso-
lated from all cable pair shields.
Sensor Cable Routing
Sensor cables should be routed in grounded conduit or in cable trays reserved
for low voltage control type signals. Sensor cables must not be routed in conduit
or cable trays containing AC power lines, including the 6500 enclosure cable
entries. If low voltage sensor cables are routed in cable trays containing AC
power cables, it is likely that line frequency components will be induced into the
sensor signals. Also, when electrical equipment is switched on or off, the
changes in current can induce large spikes or jumps in nearby sensor sig-
nals. A minimum of 3ft should be maintained between sensor lines and ac power
lines. Larger distances should be allowed for higher voltage AC power lines.
Accelerometer, velometer, and passive magnetic tachometer cable distance is
limited to 500ft, 150m. Displacement sensor cable distance from amplifier is
limited to 1000ft, 300m. Note: If high g level, high frequency signals are to
be measured (such as those present on gearboxes), particularly for PeakVue
measurements, the maximum cable length may be much shorter unless low
capacitance cable is used.
Shielding
The shield termination of each shielded twisted pair cable must be connected as
required by the particular installation. The normal installation is to tie the shield
drain wire only at the 6500 input. However, if the sensor cable shield is
grounded at the sensor side, the cable shield should not be connected at the CSI
6500 input side. The shield connection at the CSI 6500 inputs is connected
directly to the CSI 6500 chassis ground. Therefore, if a grounded shield connec-
tion has also been made at the sensor side, a noise current, typically at line fre-
quency, can flow in the shield conductor. This noise current flow will induce a
noise voltage into the sensor signal lines. This condition is referred to as a
ground loop.
If the primary noise pickup problem in a sensor line is due to static or RF fre-
quency sources, it has been shown experimentally that tying the sensor side
shield to the sensor side - conductor is effective at reducing the effects of RF
and static interference. To prevent ground loops, the sensor side - conductor
and shield must be isolated from ground if this connection is made.
It is important to realize that there is no best way to terminate cable shields.
Shield termination sometimes must be determined on a sensor-by-sensor basis
to correct the noise problems of a particular installation.
Cable Terminations
Cables should be terminated neatly at the CSI 6500 system inputs. The outer
cable coverings should not be stripped back farther than necessary, and the
exposed cable shields should not be allowed to touch from cable to cable. The
shields should be cut back as little as possible so that the minimum of unshielded
signal conductors are exposed.
Cables should be clearly marked at the CSI 6500 inputs with labels indicating
the sensor location.
Note
Unused shield drain wires should not be cut. Unused shield drain
wires should be folded back and taped to allow their use if it should
prove necessary to make a double shield tie to reduce RF or static
interference.
Overall shields in multiple conductor cables must be tied to earth ground at one
end. Unused overall shield drain wires should be folded back and taped to allow
their use if it should prove necessary to make a double shield tie to reduce RF
or static interference.
Junction Boxes
In most installations, sensor cables are routed through 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 earth ground.
J unction box enclosures should be grounded to earth ground. If possible, accel-
erometer signals should be routed through dedicated junction boxes not used for
any other signals. No AC power signals should be routed through a sensor junc-
tion box.
System Grounding
For personnel safety and correct system operation, the CSI 6500 system must be
grounded properly. If possible, the CSI 6500 enclosure should be bolted to a
grounded beam or wall. A ground bonding wire must also be connected from the
CSI 6500 enclosure to a nearby earth ground. Use a minimum 14 AWG stranded
cable for grounding.
Inside the CSI 6500 enclosure, verify grounding wires from the CSI 6500
chassis, the CSI power supply, the enclosure frame, the enclosure door, and the
AC power cable ground and have been installed. These should be connected to
the main enclosure earth ground.
CSI 6500 System Environment
The CSI 6500 system has been designed to withstand moderate industrial con-
ditions. The maximum allowable ambient temperature for the CSI 6500 system
enclosure is 120F, 48C. The CSI 6500 system enclosure should never be
mounted in direct sunlight. The CSI 6500 system enclosure should be kept
sealed so that water leakage and condensation does not occur.
CSI 6500 system enclosures installed in 100F to 120F ambient environments
should have the CSI 6500 Fan Tray installed to eliminate hot spots in the CSI
6500 enclosure. CSI 6500 system enclosures installed in locations exceeding
120F must be actively cooled. CSI 6500 system enclosures mounted in locations
that are colder than 32F should be actively heated. Thermostats should be used
inside the CSI 6500 enclosure to keep the temperatures between 50F and 100F
for maximum system reliability.
Note
Temperatures inside the CSI 6500 enclosures can exceed 140F
when ambient temperatures reach 120F. While the CSI 6500
system has been tested to operate reliably in temperatures this
high, it should be realized that the CSI 6500 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 6500 system electronics below 100F at all times for max-
imum system reliability and longevity.
Note
The use of a hard drive on the CSI 6500 Transient Daughterboard
places strict temperature limits on the CSI 6500 system. The CSI
6500 Fan Tray (PN B6500FT) must be used in CSI 6500 systems
equipped with Transient Ambient temperature must be limited to
30C. or 86F.
Chapter
7-1
7
Wire Terminations
Terminate V707, 727, and 745 Wiring
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.

J unction Box routing
7-2 Wire Terminations
wire labels
24 AWG wire strippers
cable tie down
7-3
Terminate Instrumentation Wire
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.
Twisted Pair Prepared
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.
Terminal Connections
6. . Relabel wire at phoenix connector
7. . After all cables are terminated, bundle cables and secure against side of
junction box using only one cable tie down.
7-5
Terminate V680 Bundled Cable
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:
Terminal Block Positive Conductor
Negative
Conductor
Foil Shield
1 Yellow Black Black
2 Blue Black Blue
3 Brown Black Blue
4 Orange Black Blue
5 White Black Red
6 Red Black Red
7 Green Black Green
8 Red White Blue
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.

V680 Cable Preparation
7-7 Terminate CSI 6500 Wiring
Terminate CSI 6500 Wiring
Description
The CSI 6500 is designed to have sensor cables terminate in three different
ways.
1...Sensors can be terminated directly into the CSI 6510 (12-2-2) modules at a
rear A6500-M-RTRM termination panel.
2...Sensors can be terminated at the inputs on the A6500-P-RTRM termination
panel and then buffered outputs can be routed to the CSI 6510 (12-2-2)
modules with DIP switches.
3. . .Sensors can be terminated directly into the CSI 6510 (12-2-2) modules at
a front A6500-M-FTRM termination panel.
A6500-M-RTRM Rear Termination Panel:
The A6500-M-RTRM rear termination panel, shown in the following photo,
plugs onto the A6500-M-BP backplane.
This termination panel has connectors for sensor inputs, tachometer inputs, and
discrete input/output relays into the 12-2-2 modules. It provides DIP switches
for routing signals from the A6500-P-RTRM side of the rack. Additionally,
there are DIP switches for turning accelerometer power on or off, and an output
connector for the internal test signal generator.
Below the termination panel are connectors for +24V DC power supply, SysFail
relay output, and network connections.
A6500-M-RTRM Rear Termination Panel
A6500-M-RTRM Rear Termination Panel and backplane connectors
Termination Panel:
1. . .Sensor inputs MSIG1 (Ch1 - 12) and MSIG2 (Ch13 - 24)
2. . .Tach inputs MSIG1 Ch1 - 2 and MSIG2 Ch 3 - 4
3. . .Relay I/O MSIG1 I/O 1 - 2 and MSIG2 I/O 3 - 4
4. . .DIP switches for routing buffered sensor/tach inputs from A6500-P-
RTRM side of the rack of the backplane
5. . .DIP switches for configuring accelerometer input powering On or Off
6. . .Calibration test signal output port (SMB connector)
7. . .-24V sensor power input for eddy current sensors.
Backplane:
8. . .SysFail relay connector
9. . .DC Power input connector for Prediction Side
10. .HUB network connector
11. .NIC network connector
12. .Chassis Ground lug.
13. .Power On LED
14. .+24V Input LED
15. .Status LED
Note
For the Tach and Relay channels the DIP switches must be left in
the OFF position.
Small flat screwdriver
Wire strippers
RJ 45 CAT5 connector and tools
Velcro cable tie downs
Terminate A680 Bundled Cable Instrumentation Wiring
Caution!
Use 24 AWG gauge strippers on individual conductors. Do not
strip more than a 1/4" (0.64 centimeters) off conductor. Do not
overtighten connector. Turn terminal screw clockwise until contact
with wire is made then1/4 turn additional.
Each signal input channel has an associated DIP switch for connecting acceler-
ometer power. (See callout number 5 in photo on page 8.) For accelerometer
channels that require power, set the associated DIP switch to the right (ON posi-
tion). For sensor channels that do not require power from the CSI 6500, set the
associated DIP switch to the left (OFF position).
Sensor Input Termination
1. . Pull cable to sensor input connectors on termination panel.
2. . Secure cable to side of enclosure with cable tie down.
3. . Blunt cut excess wire. Strip cable jacket beginning where it first reaches
the termination panel.
4. . Pull individual pairs down to proper channel inputs on termination panel.
5. . Remove 1" of foil shield and place wire label around end of foil shield.
Wire label must match sensor wire label in junction box.
6. . Strip 1/4" from each conductor and terminate to screw terminals
following the pinouts in the tables below.
7. . Document sensor name, wire label name, and CSI 6500 channel number
on CSI 6500 cable administration chart.
A6500-M-RTRM Terminal Descriptors
The following table describes the function of the terminals on the A6500-M-
RTRM termination panels.
Note
These functions are duplicated on the front termination panel.
Each channel has 5 terminals. The first two are for the +and - signal inputs. If
the associated DIP switch is set to ON, these terminals will also supply +24V
constant current accelerometer power.
The second two are for the -24V power supply for eddy current probes. These
terminals only supply power if an external -24V power supply is connected to
the J 19 power input terminal at the edge of the termination panel.
The last terminal for each channel is a chassis ground for connecting the sensor
cable shield.
MSIG 1
J 1 J 2 J 3 J 4
SIG+1 / +24V SIG+5 / +24V SIG+9 / +24V Tach+1
SIG- 1 / +24V return SIG- 5 / +24V return SIG- 9 / +24V return Tach- 1
-24V -24V -24V -24V
Gnd (-24V return) Gnd (-24V return) Gnd (-24V return) Gnd (-24V return)
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
SIG- 2 / +24V return SIG- 6 / +24V return SIG- 10 / +24V
return
Tach- 2
-24V -24V -24V -24V
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
SIG+3 / +24V SIG+7 / +24V SIG+11 / +24V I/O+1
return
I/O- 1
-24V -24V -24V -24V
Gnd (-24V return*) Gnd (-24V return*) Gnd (-24V return*) Gnd (-24V return*)
Shield Shield Shield Shield
SIG+4 / +24V SIG+8 / +24V SIG+12 / +24V I/O+2
return
I/O- 2
-24V -24V -24V -24V
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
Chassis GND
(Shield)
*NOTE: -24V terminals on I/O channels are not used for I/O connections.
MSIG 2
J 5 J 6 J 7 J 8
SIG+13 / +24V SIG+17 / +24V SIG+21/ +24V Tach+3
SIG- 13 / +24V
return
SIG- 17 / +24V
return
SIG- 21 / +24V
return
Tach- 3
-24V -24V -24V -24V
SIG- 14 / +24V
return
SIG- 18 / +24V
return
SIG- 22 / +24V
return
Tach- 4
-24V -24V -24V -24V
SIG+15 / +24V SIG+19 / +24V SIG+23 / +24V I/O+3
SIG- 15 / +24V
return
SIG- 19 / +24V
return
SIG- 23 / +24V
return
I/O- 3
-24V -24V -24V -24V
SIG+16 / +24V SIG+20 / +24V SIG+24 / +24V I/O+4
SIG- 16 / +24V
return
SIG- 20 / +24V
return
SIG- 24 / +24V
return
I/O- 4
-24V -24V -24V -24V
Routing signals from A6500-P-RTRM side of rack
Alternatively, the DIP switches on the right side of the A6500-M-RTRM termi-
nation panel can be set to route the sensor and tachometer signals from the
A6500-P-RTRM side of the rack.
DIP switches
Set these switches to the right (ON position) to connect to the respective A6500-
P-RTRM buffered outputs.
Sensor inputs 1-12 on the A6500-M-RTRM panel are connected to buffered out-
puts from monitor positions 1-6 on the A6500-P-RTRM panel (connectors
XR11-XR64).
Sensor inputs 13-24 on the A6500-M-RTRM panel are connected to buffered
outputs from monitor positions 7-12 on the A6500-P-RTRM panel (connectors
XR71-XR125).
Tach inputs 1 and 3 on the A6500-M-RTRM panel are connected to the channel
1 Pulse output of the CSI 6312 (connector XR131).
Tach inputs 2 and 4 on the A6500-M-RTRM panel are connected to the channel
2 Pulse output of the CSI 6312 slot (connector XR132).
Relay I/O Channels 1, 2, 3, and 4 on the A6500-M-RTRM panel are not con-
nected to the A6500-P-RTRM outputs. These DIP switches are not used.
Channel Input Cross Reference
Note
The external input connectors on the A6500-M-RTRM termination
panel remain connected to the 12-2-2 module signal inputs, regard-
less of which way these DIP switches are set. Therefore, if a DIP
switch is set to route an input from the A6500-P-RTRM side of the
rack, an external sensor should not be connected to the associated
external input of the A6500-M-RTRM termination panel. The DIP
switches for accelerometer power should also be set to the OFF
position, when routing inputs from the A6500-P-RTRM side of the
rack.
Terminate Discrete Input/Outputs
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.
1. . Pull cable to the I/O Relay channel inputs on the termination panel.
2. . Blunt cut excess wire. Strip 1" from cable jacket and 1/4 from each
conductor.
3. . Terminate as follows, referring to the previous Terminal Panel Pin-Out
table:
a. Relay Excitation Voltage... (SIG +)
b. Voltage Return... (SIG -)
c. Shield Drain... (Shield)
4. . Relabel wire at connector.
5. . After all wires are pulled, bundle wires with Velcro cable wrap. Secure
bundle to side of enclosure.
6.. Document discrete input/output name, wire label name, and CSI 6500
channel number on cable administration chart.
Discrete I/O cable termination
Note
Load may be placed on either -L2 or +L1.
A6500-M-RSH Rear Shield / Adapter Panel
If all sensor and tachometer inputs are to be routed from the A6500-P-RTRM
side of the rack, the A6500-M-RTRM termination panel is not required.
In this case, a simpler adapter panel is available which provides the appropriate
jumper connections to the A6500-P-RTRM sensor and tach signals. This panel
also has connectors for the four external relay I/O termination, since the I/O
channels are not connected to the A6500-P-RTRM side of the rack.
A modified version (A6500-M-RSHF) of this adapter panel is also used to route
inputs from a A6500-M-FTRM front termination panel to the backplane.
A6500-M-RSH Rear Shield / Adapter Panel
A6500-M-FTRM Front Termination Panel
The A6500-M-FTRM front termination panel provides the same sensor input
connectors as the A6500-M-RTRM rear termination panel. It also has connec-
tors for +24V system power, -24V proximity probe power, SysFail relay, and
test signal, as well as LED indicators. This panel is used when no protection
monitors are required and when front mounted wire terminations are preferred.
CSI 6500 with A6500-M-FTRM front termination panel
Ribbon cables connect the signal inputs from the front termination panel to an
adapter board at the rear of the backplane. Additional cables connect the Power
and SysFail relay inputs from the front panel to the backplane. DIP switches are
also located on the rear of the panel for turning accelerometer power On or Off
for each channel.
Rear view of A6500-M-FTRM Front Termination Panel
Terminate +24V Power for the CSI 6560 and CSI 6510 modules
Caution!
The CSI 6500 +24V power terminals are not wired the same as the
CSI 4500 power terminals. Do not use a connector that was previ-
ously wired for a CSI 4500 without reconfiguring the wiring.
Caution!
The +24V power input for the CSI 6560/6510 requires a +24V
power supply. Do not connect the -24V power supply intended for
Eddy Current Probe power to this input. Verify all power supply
connections are wired and connected properly before powering the
unit.
The +24V power input for the CSI 6560/6510 Prediction modules is located on
the A6500-M-BP backplane (as well as on the A6500-M-FTRM front termina-
tion panel). This connector is isolated from the CSI 6000 Protection modules,
which are powered separately. The use of a separate power supply is recom-
mended for the CSI 6000 Protection modules.
Note
Use of an Uninterruptable Power Supply (UPS) is recommended
for both Prediction and Protection modules.
1. . .Route Cable to the power connector.
2. . .Leave a service loop.
3. . .Strip conductors 1/4 and terminate to Phoenix connection as follows:
a) +DC to +
b) DC to
c) Shield to SHLD
4. . .Secure power cable to side of enclosure using only one cable tie down.
Note
When connecting a 24 Volt power supply to the CSI 6500, connect
the DC side of the power supply to the CSI 6500 before connecting
the AC side of the power supply to AC line power.
Terminate -24V power supply for Eddy Current sensors
Caution!
The -24V Eddy Current Probe power input requires a -24V power
supply. Do not connect the +24V power supply intended for the
CSI 6560/6510 power to this input. Verify all power supply connec-
tions are wired and connected properly before powering the unit.
The -24V Eddy Current Probe power input connector is located on the A6500-
M-RTRM rear termination panel, and also on the A6500-M-FTRM front termi-
nation panel.
Power
DC Input Voltage 18 VDC - 31 VDC (24 VDC Nominal)
DC Input Current (with Transient) 1.0 ADC @ 24 VDC (no termination panel)
1.25 ADC @ 24 VDC (with termination panel, all
channels powered)
DC Input Current(w/o Transient) 0.65 ADC @ 24 VDC (no termination panel)
0.9 ADC @ 24 VDC (with termination panel, all
channels powered)
Maximum Input Surge Current
(All versions)
7A DC @ 24 VDC for 1mS
3A DC @ 24 VDC for 20mS
Maximum Power Dissipation 22W, (30W with Transient)
Ratings CE EN50081-2 Emissions (Pending)
CE EN50082-2 Immunity (Pending)
CSA (Pending)
When using Eddy Current sensors, feed in a -24V sensor supply at this con-
nector. This connector then supplies all the -24V sensor supply terminals on the
termination panel.
The supply terminals at each channel have built-in auto-resetting breakers to
protect against a short circuit on one channel from bringing down the power
supply for all channels.
Note
The CSI 6500 performs an internal test to verify that -24V power
is connected. If a -24V supply is not connected, the CPU Status
LEDs on the CPU, and the Status LED on the left side of the ter-
mination panel will turn from green to red. If eddy current sensor
power is not required, this internal test can be disabled by installing
a jumper on the termination panel at the pins labeled -24V Dis-
able.
Caution!
The SysFail Relay connection is an output for relays only. Do not
connect the +24V power supply intended for the CSI 6560/6510
power or the -24V power supply intended for the Eddy Current
Probe power to this output. Verify all power supply connections are
wired and connected properly before powering the unit.
Terminate SysFail Relay
The SysFail Relay output connector is located on the bottom left corner of the
A6500-M-BP backplane, and on the A6500-M-FTRM front termination panel,
labeled as SYSFAIL RELAY.
The SysFail Relay output can be terminated as either normally-open (terminate
to C and NO) or normally-closed (terminate to C and NC).
Dual Prediction only system
When the CSI 6500 is ordered as a dual Prediction only system, it includes two
CSI 6560 processor modules, up to four CSI 6510 modules, and two A6500-M-
RTRM rear termination panels.
CSI 6500 4-20ma Current Loop Interconnection
When connecting 4-20mA signal inputs, install a 250 ohm resistor between the
+and - signal inputs, to convert the milliamp signal to a voltage signal.
1
Note
CSI 6500 MUX (SIG) channels do not provide loop power to 4-
20mA devices. A separate source / module is required to provide
loop power.
Terminate Network Connection
1. . .Route network cable to RJ 45 connectors, at either the front of the CSI
6560 module, or at the rear of the A6500-M-BP backplane.
2. . .Blunt cut excess wire and attach RJ 45 CAT5 connector.
Note
Eight-position jack pinout should conform to plant standards for
10/100Base-T connections.
4. . Secure network connection to right side of enclosure using cable tie
down.
NIC Network Connector
Note
The NIC connector is used when connecting to an ethernet hub or
switch. The HUB connector is used when connecting directly to a
PC (i.e. the HUB connector provides the same function as a cross-
over cable).
Note
Daisy Chaining of multiple CSI 6500s using the NIC/HUB is not
recommended. This introduces a single point of failure, where if
one network connection fails it will disrupt network communica-
tion for multiple units.
CSI 6500 Default Network Addressing Schema
2
Note
The network arrangement shown above assumes one of the CSI
6500s is a transient model (CSI 6500T).
Network Planning Considerations:
Separate Plant LAN / 6500 LAN
The 6500M requires one (1) IP address
The 6500T requires two (2) IP addresses.
Chapter
8-1
8
Hardware Configuration of CSI 6560 and CSI 6510
Introduction
Description
The CSI 6560 processor module (in combination with the CSI 6510 signal input
module) 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 accel-
erometers, velocity probes, or proximity probes. These signals include two com-
ponents: the dynamic AC component, which represents machine vibration, and
a DC component, which represents the sensor bias level. In the case of a prox-
imity probe, the DC component represents the gap, or average distance between
the probe tip and the machine shaft. Other signal inputs include process signals;
these are DC parameters 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 6560 uses three basic data monitoring methods.
8-2 Hardware Configuration of CSI 6560 and CSI 6510
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
6500 Processor module. 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 Monitoring.
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. Prep rog rammed 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.
Transient Data Capture
Transient data capture is the acquisition of continuous time waveforms of
dynamic AC signals. Transient data is captured in parallel for all channels.
Other data stored as Transient data include 1/sec Overall Level data, tach pulse
records, and acquisition timestamps. The Transient data is stored on hard disk,
and is available for real time analysis via Ethernet.
8-3 CSI 6560 / CSI 6510 Configuration
CSI 6560 / CSI 6510 Configuration
The CSI 6500M has a Processor module, and one or two CSI 6510 Signal Input
modules.
The CSI 6500T has a Processor module with a Transient Daughterboard, and
one or two CSI 6510 Signal Input modules with Transient Filter Boards.
CSI 6500Syst
Installation Considerations
Signal Quality
The data collected by the CSI 6560 system can only be as good as the signals
presented at the CSI 6510 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.
Sensor Cable Type
Shielded-twisted-pair cable is recommended for all CSI 6500 System sensor
inputs. Conductor size can vary from 22 to 16 AWG. This type of cable provides
protection from both low frequency interference such as 50Hz-60Hz sources
due to the twisting, and protection from RF and static discharge sources due to
the overall shielding.
Coaxial cable is not recommended. This type of cable has lower immunity to
50Hz-60Hz interference.
If multiple twisted-pair is used, it must be of the type that maintains an isolated
100% shield for each cable pair.
Sensor Cable Routing
Sensor cables should be routed in grounded conduit or in cable trays reserved
for low voltage control type signals. Sensor cables must not be routed through
conduit or cable trays containing AC power lines. If low voltage sensor cables
are routed in cable trays containing AC power cables, it is likely that line fre-
quency components will be induced into the sensor signals. These induced com-
ponents can be larger than the actual signal from the sensors.
Accelerometer, velocity sensor, and passive magnetic tachometer cable distance
is limited to 500ft, 150m. Displacement sensor cable distance from amplifier is
limited to 1000ft, 300m.
Note
Distances are reduced if non-standard cable is used.
8-5 Installation Considerations
Note
Displacement probe power signals should be individually fused, so
that a single probe failure (short), does not disable other probes.
Ethernet Cable Routing
Ethernet cables should be routed in grounded conduit or in cable trays reserved
for low voltage control type signals. Ethernet cables must not be routed through
conduit or cable trays containing AC power lines. If ethernet cables are routed
in cable trays containing AC power cables, it is likely that line frequency com-
ponents will be induced into the ethernet cable.
Ethernet cable distance is limited to 300ft,100m.
Grounding and Shielding
The shield termination of each shielded twisted pair cable must be terminated as
required by the particular installation. If the cable shield is connected to the
sensor case or to the sensor cable - conductor at the sensor end, the cable
shield should not be connected at the CSI 6500 input side. The shield connection
at the CSI 6500 inputs is connected directly to the CSI 6500 chassis ground.
Therefore, if a shield connection has also been made at the sensor side, a noise
current, typically at line frequency, can flow in the shield conductor. Voltage
produced by this noise current will then be coupled into the sensor signal lines.
This condition is referred to as a ground loop.
In general, the shield should be connected at either the sensor end or the CSI
6500 end of the cable, but not both. However, this is just a guideline. If the pri-
mary noise pickup problem in a sensor line is due to static or RF frequency
sources, the shield connection can be tied at both ends to provide a better shield
for this condition. If this causes a ground loop condition, the shield connection
can be made at the CSI 6500 end via a resistor or capacitor, which will break the
ground loop current flow while still providing some measure of overall
shielding.
It is important to realize that there is no best way to terminate cable shields.
Shield termination sometimes must be determined on a sensor by sensor basis
to correct noise problems of the particular installation.
Cable Terminations
Cables should be terminated neatly at the CSI 6500 system inputs. The outer
cable coverings should not be stripped back farther than necessary, and the
exposed cable shields should not be allowed to touch from cable to cable. The
shields should be cut back as little as possible so that the minimum amount of
unshielded signal conductors is exposed.
Cables should be clearly marked at the CSI 6500 inputs with labels indicating
the sensor location.
Sufficient cable slack should be left in the CSI 6500 enclosure to prevent having
to pull new cables if wiring mistakes are made when terminating the sensor
lines.
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 of different cables must not be allowed to touch,
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 6500 system must be
grounded properly.
Inside the CSI 6500 cabinet enclosure, verify grounding wires have been con-
nected from the CSI 6500 chassis to the enclosure ground. Also verify the enclo-
sure doors and side panels are grounded to the enclosure frame. Use a minimum
14 AWG stranded cable for grounding.
Outside, the CSI 6500 cabinet enclosure should be connected to a nearby earth
ground.
CSI 6500 System Environment
The CSI 6500 system has been designed to withstand moderate industrial con-
ditions. The CSI 6500 system enclosure should never be mounted in direct sun-
light. The CSI 6500 system enclosure should be kept sealed so that water
leakage and condensation does not occur.
CSI 6500 system enclosures installed in 100F to 120F ambient environments
should have circulation fans installed to eliminate hot spots in the enclosure.
CSI 6500 system enclosures installed in locations exceeding 120F must be
actively cooled.
CSI 6500 system enclosures mounted in locations that are colder than 32F
should be actively heated. Thermostats should be used inside the CSI 6500
enclosure to keep the temperatures between 50F and 100F for maximum system
reliability.
Note
Temperatures inside the CSI 6500 enclosures can exceed 140F
when ambient temperatures reach 120F. While the CSI 6500
system has been tested to operate reliably in temperatures this
high, it should be realized that the CSI 6500 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 6500 system electronics below 100F at all times for max-
imum system reliability and longevity.
Environmental
Environmental
CSI 6500 0 to 150F (-17 to 65C)* 0 - 95% R.H. non-condensing
CSI 6500 with Transient 0 to 150F (-17 to 65C)* 0 - 50% R.H. non-condensing
0 to 130F (-17 to 55C)* 0 - 95% R.H non-condensing
*Temperature ratings are for internal enclosure temperature, not external ambient
temperature. Cooling is required if enclosure temperature (ambient +enclosure's internal
heat rise) exceed these limits.
The 6500 conforms to the following standards to meet the requirements for
application of the CE mark.
EN 61000-6-2: 2005
EN 61000-6-4: 2007
CSI 6560 Processor module
The CSI 6560 Processor module provides all data acquisition, data storage, and
data communications functions for the CSI 6500 system. The Processor module
is capable of simultaneous, continuous measurement of detailed Spectral anal-
ysis on two channels, RMS and DC values for Gross Scan measurements on all
signal channels, machine speed measurement on all tachometer channels, and
the states of all digital inputs.
The CSI 6560 Processor module provides all data acquisition, data storage, and
data communications functions for the CSI 6500 system. The CSI 6560 Pro-
cessor module is capable of simultaneous, continuous measurement for detailed
Spectral analysis, thirty-two RMS and DC values for Gross Scan measurements,
up to sixteen tachometers for machine speed measurement, and up to sixteen
digital state inputs.
The CSI 6560 Processor module is capable of up to 24 simultaneous and con-
tinuous waveform measurements (for detailed Spectral analysis), up to 24 RMS
and DC values for Gross Scan measurements, up to 4 tachometers for machine
speed measurement, and up to 4 digital state inputs.
Gross Scan values, tachometer values, and digital input states may be combined
logically to determine machine operating state, which may be used to define
specific data acquisition states. The system can be configured to transmit and
store data on either time interval or based on the amount of change of the data
values.
Four 100Base-T Ethernet ports and one RS-232 serial port are provided for
system communications and diagnostics. Additional connections are available
for the calibration signal and a dry contact SPDT SysFail relay. (See diagram
of backplane.) This relay is energized when the CSI 6500 Processor CPU suc-
cessfully boots. On a CPU failure or power loss, the relay will de-energize.
Note
The SysFail relay may not be used for other, e.g., vibration moni-
toring, purposes.
The CSI 6560 Processor module may be configured to download its operational
firmware via Ethernet upon every boot, or operate on firmware which has been
stored in FLASH memory.
The CSI 6560 Processor module has an on-board signal generator capable of
producing sinusoidal and DC signals which are routed to the input modules
during system calibration and on Power On Self Test (POST). The function gen-
erator should be recalibrated at least once a year with a NIST traceable volt
meter. Consult the Appendix for specific procedures to calibrate the CSI 6500
system.
The CSI 6560 Processor module automatically detects input module type and
configuration, and only permits database configurations based on the existing
channel set.
The CSI 6560 Processor module supports the CSI 6500 Transient Daughter-
board, which add parallel time waveform acquisition capabilities for all chan-
nels.
CSI 6560 Processor module Specifications
CSI 6560 Processor Module Specifications (@25C)
Memory Capacity 32 Mb SDRAM, 32 Mb Flash
Network Communications 10/100 BaseT Ethernet dual RJ 45 jacks wired for
NIC and HUB, with two additional jacks on
backplane
Local Communications RS232 (up to 38.4Kbs)
Onboard Test Generator All sensor channels, tachometer channels, AC, DC
amplitude, phase (0v - 3v pk, 0.25Hz - 50kHz sine +/
-7.2V DC, GND +/- 1mv)
CSI 6500 Rack Health Relay SPDT 24 VDC @ 0.5A DC dry contact
Sensor Channel Scan RMS +DC, rate equivalent to 16 ch per 500 msec
Overall Vibration Units RMS, RMS or Peak-to-Peak with Transient Option
DC Scan Simultaneously scanned with overall vibration scan
(includes DC Gap, temperature, and accelerometer
bias)
Overall Level and DC Accuracy 1% at input channel range full scale amplitude @
1KHz
Gross Scan ADC Resolution 16 bit
Data Acquisition Event Basis Relay input, RPM, DC, AC or software controlled
Data Collection Event based adaptive
Data Collection Interval Event based and/or time based
Data Storage Interval Exception based and/or time based
Spectral ADC Resolution 24 bit, 2 channel simultaneous
Dynamic Range 100 dB, all frequency ranges
Spectral Resolution 100 to 6400 lines
Analysis Bandwidth Fmax 10 Hz to 40 kHz, discrete steps
Spectral Scan Rate Depends on analysis configuration (1 second per two
channels @ 400 lines, 400 Hz, 1 avg.)
Spectral Amplitude Accuracy 5% 0.2Hz - 0.5Hz
2% 0.5Hz - 25KHz
4% 25KHz - 40KHz
Frequency Accuracy 0.01%, crystal based
Total Harmonic Distortion <-90 dB, all ranges
1X Synchronous Peak Accuracy 3% 0.5Hz - 3Hz
2% 3Hz - 1KHz
5% 1KHz - 5KHz
1X Synchronous Phase Accuracy 4
0
1Hz - 1KHz (not calibrated below 1Hz)
5
0
>1KHz
Analysis and Trend Types Configurable, with user defined parameter names
Multiple analysis types per machine and per sensor
(Total Energy, Energy in a range, Non-sync energy
in a range, Sync energy in a range, Sync peak, Sync
phase, True peak, HFD, Waveform peak to peak,
RPM, Gap, Orbit)
Averaging Types Normal, PeakVue, Order Tracking, Synchronous
Time Averaging
Units Types English, Metric, Hz, CPM, Order
Scaling Types Linear, Log, dB
Window Types Hanning, Uniform
CSI 6560 Processor Module Specifications (@25C)
CSI 6560 Processor Front Panel
Caution!
The NIC / HUB connections should not be used to create a daisy
chain connection, as this creates a single point of communication
failure for multiple CSI 6500 units.
CSI 6560 Processor PCB
CSI 6510 Signal Input module
The CSI 6510 module combines the features of Signal Input, Tachometer Input,
and I/O Relays to allow a combination of sensor and relay types in one module.
The CSI 6510 module provides twelve channels of vibration or process sensor
inputs, two channels of tachometer sensor inputs, and two optically isolated I/O
relay channels.
CSI 6510 Vibration Signal Inputs
The vibration sensor types include accelerometer, passive velocity, active
velocity, and displacement. The CSI 6510 module will also accept non-specific
AC or DC inputs from any source that conforms to the CSI 6500 input range
limits.
The vibration inputs provide the following programmable functions for each
channel: Input Attenuator /1, /2, Gain x1, x10, integrator on/off. The combina-
tion of input attenuator and gain setting provide four input range combinations
as shown in Table 1.
Table 1: CSI 6500 Signal Input module Input Ranges
The integrator allows acceleration signals to be converted to velocity.
The CSI 6510 module selects two of the twelve vibration channels at a time and
routes them to the Processor module for Spectral analysis. RMS-to-DC conver-
sion is performed on all twelve channels. The RMS and DC signals are routed
to the Processor module for Overall Level collection.
The CSI 6500 Transient Filter Board is required for Transient data acquisition.
4-20mA signals may be measured provided a resistor is added across the
channel input. A typical value is 250 ohms, which converts 4-20mA to 1-5 volts.
Maximum series resistor value is 1000 ohms.
Attenuator Gain Input Range +/-
/2 x1 10.0v, 100g, 100ips, 50mil
/1 x1 5.0v, 50g, 50ips, 25mil
/2 x10 1.0v, 10g, 10ips, 5mil
/1 x10 0.5v, 5g, 5ips, 2.5mil
CSI 6510 Tachometer Inputs
The Tachometer inputs allow measurement of two pulse tachometer sources per
CSI 6510 module. Tachometer sensor types may include, but are not limited to:
Active displacement sensor, passive magnetic, or TTL pulse type from various
sources.
The CSI 6510 Tachometer Input module features either fixed voltage trigger or
adaptive automatic triggering. Triggering parameters may be set indepen-
dently for each tachometer sensor input.
An input gain selection of x1 or x5 may be selected for each channel. A gain of
x5 is recommended for tachometer inputs smaller than 1V pk-pk. If the x5 input
gain is used, care should be taken to make sure that the input signal remains
within +/-24V, including any sensor bias or gap voltage.
CSI 6510 I/O Relay Channels
Each CSI 6510 module has two I/O Relay channels that provide optically iso-
lated digital inputs or dry contact outputs. Inputs can be between 5V and 24V
DC. Outputs are limited to 24VDC @ 0.5A.
Note
AC-relays are not provided.
CSI 6510 Signal module PCB
CSI 6510 12-2-2 Signal Input Module Specifications (@25C)
Sensor Input Types Dynamic displacement probe, Accelerometer,
Velocity probe, AC input - custom definable (e.g.
Flux, Dynamic pressure sensor, Dynamic
basisweight input, etc.), DC input - custom
definable (e.g. Temperature or other process
input), 4-20 mA Signal (with external shunt
resistor).
Number of Sensor Inputs 16 inputs per module (12 sensor, 2 tach, 2 I/O), 2
modules per rack
Analysis Bandwidth 0.2 Hz to 40 kHz (0.2 Hz to 2Khz for Transient
Analysis)
AC Coupling Corner Frequency 0.5 Hz
RMS Conversion Accuracy 1% at full scale amplitude 30Hz - 40KHz
2.5% at full scale amplitude 20 Hz
5% at full scale amplitude 10Hz (uncalibrated
below 10Hz)
DC Accuracy 1% at full scale amplitude
Analog Integration 1 per channel (acceleration to velocity or velocity
to displacement)
Analog Integrator Accuracy 2% (frequency and amplitude)
AC Input Ranges Software configurable: +0.5 Vpk, +1.0 Vpk,
+5 Vpk, +10 Vpk
DC Input Range +22 VDC
Maximum AC +DC Input Range +22 V
Powered Sensor Types ICP Accelerometer and velocity probes by each
sensor channel, and displacement probes by fused
-24 VDC power supply on each channel
Sensor Power 4 mA (nominal) constant current, with 22V
compliance per channel
Powered ch Input Impedance 500 kOhm (single ended)
Non Powered ch Input Impedance 1 MOhm (differential)
Non Powered Sensor Types Displacement, AC or DC process
RMS to DC Converter 1 per channel, 1 Hz to 40 kHz
Number of Tachometer Channels 2 inputs per module, 4 total per rack
Tachometer Frequency Range 0.1 Hz to 2 kHz (6 RPM to 120,000 RPM)
Tachometer Frequency Accuracy 0.1%
Tachometer Resolution 0.002 Hz @ 60 Hz (0.1RPM)
Tachometer Types Eddy current displacement probe, TTL, passive
magnetic
Tachometer Amp. Range Input and trigger pulse range +0.5 Vpk to +22 Vpk
Pulse Characteristics 1 pulse per revolution, 500 uS min. pulse width,
tach divider on module
Modes Volt compare, automatic adaptive, divide by N
(N=1-1024)
Input Impedance 1 MOhm (differential)
Number of Dig. I/O Channels 2 per module (configurable as input or output), 4
total per rack
Relay Type SPST 24 VDC @ 0.5 ADC dry contact
Digital Input Current Max. 10mA @ 24 VDC
Digital Input High Voltage 5 VDC - 24 VDC
Digital Input Low Voltage <3 VDC
CSI 6510 12-2-2 Signal Input Module Specifications (@25C)
CSI 6510 Signal module
Typical wiring connection
Each I/O Relay channel on the CSI 6510 module contains both input and output
hardware. The relays are configurable as either input or output relays, with a
DIP switch (SW1) on the circuit board. A relay channel that is configured in
software can not be utilized unless the corresponding DIP switch is set to the
correct position. The firmware will detect the DIP switch state at startup and
generates a flag in the hyperterminal session if the software configuration does
not match the DIP switch setting.
The DIP switches are used to protect a user input device from inadvertently
being shorted by a relay output configuration. Set the corresponding DIP switch
to the ON position for output relays, and to the OFF position for input
relays. The factory default state of the DIP switches is OFF (Input). DIP switch
1 is for the first relay channel and DIP switch 2 is for the second relay channel.
Switches 3 and 4 are not used and have no function.
The shelf-state of the output relays is normally open, meaning that they are
open when the power is disconnected. During operation of the unit, the relays
are closed until activated by an alarm, then they open.
CSI 6500 Transient Daughterboard
The CSI 6500 Transient Daughterboard adds the capability for parallel, contin-
uous time waveform acquisition on all channels. All collected time waveform
data, along with Overall Level data and up to four tachometer pulse records is
stored on an internal hard drive, which provides approximately 60 minutes per
Gbyte of storage.
The Transient Daughterboard can also stream data via Ethernet to analysis
applications in near real time, without affecting data collection or on-board data
storage.
While collecting time waveforms and tachometer pulses, the Transient daugh-
terboard continuously calculates the peak-to-peak value of each channel's wave-
form. When configured, this value may be sent to the Processor module for use
as the overall level instead of the RMS value produced by the CSI 6510 module.
The hard drive used on the Transient Daughterboard is specially rated for 24-7
operation. It is recommended that this drive be replaced on a yearly basis. In
emergencies, any 2-1/2 in. parallel IDE drive may be used temporarily, but these
drives are not generally rated for continuous operation.
When installing the CSI 6500 Transient Daughterboard on the CSI 6560 Pro-
cessor module, make sure all five mating connectors are fully engaged, and then
install all six mounting screws.
CSI 6500 Transient Specifications
CSI 6500 Transient Specifications (@ 25C)
Number of Channels Up to 24 channels
Memory Capacity 64 Mb SDRAM, 16 Mb Flash
AC Channel Spectral Accuracy 5% 0.2Hz - 0.5Hz
2% 0.5Hz - 2KHz
Frequency Accuracy 0.01%, crystal based
1X Synchronous Peak Accuracy 3% 0.5Hz - 3Hz
2% 3Hz - 1KHz
5% 1KHz - 5KHz
1X Phase Accuracy 4
0
1Hz - 1KHz (not calibrated below 1Hz)
5
0
>1KHz
THD 70 dB, all ranges
Overall Levels Accuracy 2% 0.5 to 2KHz, True Peak-to-Peak
ADC Resolution 16 bits
Spectral Resolution 200 lines - 6400 lines
Dynamic Range >80 dB
Number of Tach Channels 4
On-Board Data Storage 60 Gbytes, upgradeable
Communication 10 \100base-T Ethernet HUB and NIC
100 BaseT recommended for Transient
CSI 6500 Transient Daughterboard PCB
(mounted on CSI 6560 processor)
(Hard drive inset)
Replacing the CSI 6500 Transient Daughterboard Hard Drive
To change the CSI 6500 Transient Daughterboard hard drive, remove the four
hard drive mounting screws as shown in the above photo. Gently remove the
hard drive ribbon cable from the hard drive and remove the old hard drive.
Install the new hard drive in the bracket. Do not over tighten the screws. Replace
the ribbon cable, taking care that it is correctly lined up.
Before the new hard drive can be used, it must first be formatted by the Transient
Daughterboard. Apply power to the CSI 6500 system. Ignore any hard drive
error messages produced by the Transient Daughterboard on the HyperTerminal
monitor. When the 6500 System has booted, use the DHM program to format
the hard drive.
When the drive has been formatted, reboot the CSI 6500. Again, ignore any hard
drive error messages produced by the Transient Daughterboard on the Hyper-
Terminal monitor. When the POST process is complete, the firmware will auto-
matically prepare the hard drive with the Transient File System. This process
may take up to an hour. When this process is complete, reboot the CSI 6500. The
boot process should now complete normally, with no hard drive error messages,
and, if configured, Transient data collection should begin (indicated by a
flashing hard drive indicator on the CSI 6560 Processor front panel).
Note
Emerson provides an industrial rated HDD, capable of 100% duty
cycle. Emerson recommends that an equivalent HDD be utilized.
CSI 6500 Transient Filter Board
The CSI 6500 Transient Filter Board provides parallel anti-aliasing filters for
the signal channels on the CSI 6510 Signal Input module. Either one or two
Transient Filter Boards may be used to configure either a 12 or 24 channel Tran-
sient System.
When installing the CSI 6500 Transient Filter Board on the CSI 6510 Signal
Input module, make sure both mating connectors are fully engaged, then install
all three mounting screws.
CSI 6500 Transient Filter Board Specifications
Number of channels 12
Filter type 8th order elliptic low pass
Filter passband frequency DC to 2kHz
Attenuation 80dB
Passband ripple <1dB
Stop band frequency 3.12kHz
CSI 6500 Transient Filter Board PCB
(mounted on CSI 6510 Signal Input module)
General Wiring Notes
CSI 6510 Signal, Tach, and I/O module wiring notes
J unction box wiring notes
Configuring a CSI 6500 with Hyperterminal
Connecting
Using a standard serial cable make a connection from the serial port on your PC
to the serial port on the CSI 6560 Processor front panel.
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 the CSI 6500. From here, you can 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 allotted for pressing a key has passed. Interrupting
the boot process will allow the configuration of boot specific parameters.
VxWorks System Boot
Copyright 1984-2002 Wind River Systems, Inc.
CPU: CSI 6500
Version: 5.5
BSP version: 1.2/4.00f
Creation date: May 5, 2008, 10:38:03
Image: bootrom
Press any key to stop auto-boot...
If allowed to complete without interruption, the boot process should finish with
a screen similar to this:
Cfg Table Last 'Put' (GUID: 0x774059b0-e72b-4e09-a690fc0c10ab007d)
(GUID time: 2008-08-13 19:09:29)
Component Last Calibrated
---------------- -------------------------------------
DIO 2008-08-13 19:09:25
GS 2008-08-13 19:09:25
TACH 2008-08-13 19:09:25
SCHED 2008-08-13 19:09:26
PRED 2008-08-13 19:09:25
LIMIT 2008-08-13 19:09:26
TRANS 2008-08-13 19:09:29
EGU_FAC Default Table
EGU_ASN Default Table
BRS_initRamdisk_i32f: No browser disk image found in FLASH
Initializing empty browser RAM disk /browser...Succeeded.
/browser/ - Volume is OK
Base Modbus register table size (excluding DCS info): 0xcf8a (53130)
This unit will begin announcing it's availability in 84 seconds
0x7942148 (t_startup): HLTMON_sysCheck_i32f: All expected modules were success-
fully registered.
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
z adrs - modify memory
f adrs, nbytes, value - fill memory
t adrs, adrs, nbytes - copy memory
e - print fatal exception
n netif - network interface device address and other
important information
Using the above commands, you should be able to navigate through the boot
configuration console. Typically the only commands that will be used here are
the ?, the @, the p, and the c. Note: When modifying an entry simply
type new setting in, do not attempt to backspace over existing entry.
Transient console redirect
If the Transient system has the 0x0400 boot flag set, its I/O text output is redi-
rected to COM1 on the front of the Processor module and
No output will be seen when connected to the internal COM2 port on the
Transient circuit board
Pressing CTRL-B will switch between the Main Processor and Transient
output on the COM1 terminal session
Pressing CTRL-T will display which current console output is currently
being shown in the COM1 terminal session.
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.
CSI 6560 Main Processor Configurations
CSI 6560 Processor Configuration
boot device : shend0
processor number : 0
host name :
file name : bin/6500
inet on ethernet (e) : 192.168.0.10:ffffff00
inet on backplane (b) :
host inet (h) : 192.168.0.1
gateway inet (g)* :
user (u) : anonymous
ftp password (pw) (blank =use rsh) : anonymous
flags (f) : 0x1409
target name (tn) :
startup script (s) :
other (o) :
* If a gateway is used, the address must be specified as a boot parameter.
Transient Configuration
boot device : shend0
processor number : 0
host name :
file name : bin/6500t
inet on ethernet (e) : 192.168.0.11ffffff00
inet on backplane (b) :
host inet (h) : 192.168.0.1
gateway inet (g) :
user (u) : anonymous
ftp password (pw) (blank =use rsh) : anonymous
flags (f) : 0x1409
target name (tn) :
startup script (s) :
other (o) : (IP Address of WINS server, if configured)
Explanation of CSI 6560 Main Processor and Transient boot flags
0x0001 - skip SDRAM testing on cold boot (for testing)
0x0002 - load local system symbols (for debug)
0x0004 - don't autoboot (for testing)
0x0008 - quick autoboot (no countdown)
0x0010 - disable input from shell
0x0020 - disable login security
0x0040 - use bootp to get boot parameters (network boot only)
0x0080 - use tftp to get boot image (network boot only)
0x0100 - use proxy arp (network boot only)
0x0200 - ignore BOOTROM update image in FLASH (for testing)
0X0400 - change Ethernet speed from 100 Mbps to 10 Mbps (Main Processor only)
0x0400 - redirect the console I/O to COM1 (Transient only)
0x0800 - disable boot file update in FLASH (for development)
0x0800 - boot over a WAN, requiring extended FTP timeouts
The 0x0800 flag applies only if one of the three flags below is set:
0x1000 - attempt network, fallback on FLASH boot (legacy 4500 mode)
0x2000 - boot ALWAYS from network, never fallback on FLASH
0x4000 - boot ONCE from network. This flag clears itself after one boot
The system will normally try to get boot params, boot image, and startup script first from
FLASH. If the FLASH boot fails, the system will revert to a network boot as a backup. The
0x1000, 0x2000, and 0x8000 flags modify this default behavior (listed with highest prece-
dence first).
Typical CSI 6560 Processor Boot Flags in the field:
CPU With Bootp Without Bootp
Main 0x1449 0x1409
Transient 0x1449 0x1409
General Boot Flag Notes
For CSI 6560 Main Processor, and Transient systems, boot flags can be listed
by typing a question mark (?) into the HyperTerminal at the vxWorks boot
prompt.
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
A subnet mask is normally represented in Windows as a series of four decimal
numbers, each of which can have a value from 0 to 255, separated by periods
(e.g. 255.255.248.0)
In the CSI 6560, the subnet mask is represented as a series of four hexadecimal
pairs with no separators (i.e. 255.255.248.0 is represented as fffff800). A hexa-
decimal conversion table can be used to convert the subnet mask numbers from
decimal to hexadecimal. The calculator in the Windows' Accessories folder will
also perform this conversion when it is set to the scientific mode.
The subnet mask on a CSI 6560 defaults to 255.255.255.0 (ffffff00). When con-
figuring the CSI 6560, the subnet mask should be set to match the subnet mask
used on the server PC. If they do not match, network communication failure is
possible. To specify a subnet mask, enter it on the configuration labeled inet on
ethernet. The IP address of the unit should be entered first, followed by a colon
and then the subnet mask in the hexadecimal format.
CSI 6560 Processor Module LEDs
The CSI 6560 Processor module has seven (7) two-color LEDs. From top to
bottom these are: Input Power, CPU Status, Transient Status, System Status,
Server Connect, Modbus Connect, and HD Active.
CSI 6560 Processor module LEDs
Input Power
The Input Power LED indicates the status of the power converters that distribute
various voltages within the Processor module. A steady green color indicates
that all power converters are within the proper voltage ranges, while a steady or
blinking red condition indicates a power fault somewhere inside the Processor
module.
CPU Status
The CPU Status LED indicates the status of the Main Processor board. The four
(4) status conditions are listed below along with their assigned priorities.
Note
It is possible for more than one status condition to be active at one
time. When this happens, the LED will indicate the active status
condition with the highest priority. For example if the module is
both Uncalibrated (3) and is also currently Performing POST
(1), the LED would indicate Performing POST. Additionally, if
the module is both Uncalibrated (3) and in Failure (2) then the
LED will indicate the Failure.
Transient Status
The Transient Status LED indicates the status of the Transient Daughter Board.
The LED is always off when a Transient board is not installed in the system.
LED color Status Priority Comments
Blinking
Green
In POST 1 Typically only seen during system startup.
Indicates that POST (Power On Self Test)
is being performed, which involves
Processor board resources
Solid Red Failure 2 Failures include: Power supply POST
failure, or other hardware failure on
processor board
Alternating
Red/Green
Uncalibrated 3 The onboard Test Function generator is
uncalibrated
Solid Green OK 4 Normal Operation
The four (4) Transient board status conditions are listed below along with their
assigned priorities. Note that it is possible for more than one status condition to
be active at one time. When this happens, the LED will indicate the active status
condition with the highest priority.
System Status
The System Status LED indicates the status of the overall system. It reflects the
worst case state of all boards in the system. For example, if the Test Function
generator on the Main Processor board is uncalibrated, and the first MSIG
module has a power fault, then the LED will show a solid red color to indicate
the worst case of these two which is a Failure state.
When all the firmware components are operating as expected, this LED overlays
a heartbeat pulse pattern on top of the system status. The heartbeat pattern
occurs in a 4 count cycle. The LED is pulsed off briefly during each of the first
and second counts, and then left on during the 3rd and 4th counts. In practice it
gives the appearance of a human heartbeat. If the heartbeat stops, it indicates a
firmware fault has occurred. Many times the system is capable of recovering
from a missed heartbeat. However, if the system cannot recover quickly it will
automatically reboot itself to clear up the fault and then it will resume moni-
toring.
Blinking
Green
is being performed, which involves
Transient board resources
Solid Red Failure 2 Failures include: Power supply POST
failure, or other hardware failure on
Transient board
Alternating
Red/Green
Uncalibrated 3 One or more Transient channels are
uncalibrated
Server Connect
The Server Connect LED indicates when Machinery Health Manager software
or the DHM diagnostic software are connected. A green color indicates that at
least one Machinery Health Manager software client is connected or that the
DHM software is connected in the client mode. A red color indicates the DHM
software is connected in the Single User mode. In this state, no other clients can
connect. If the LED is OFF it indicates that none of these types of software cli-
ents are connected. There is no indication of client data transfer, only the pres-
ence of at least one established connection.
Modbus Connect
The Modbus Connect LED indicates when a Modbus client, Web Browser, or
Transient Live client are connected. A green color indicates that at least one of
these types of clients has established a connection. If the LED is OFF it indicates
that none of these types of clients are connected. There is no indication of client
data transfer, only the presence of at least one established connection. The red
color is not used with this LED.
HD Active
The HD Active LED indicates when the onboard Transient Hard Drive is being
accessed with read/write activity. The green LED blinks on each time a read or
write activity accesses the Transient hard drive. The more time the LED is
green, the more hard drive activity. This LED is always off if there is no Tran-
sient board installed in the system.
CSI 6510 Signal Input module LEDs
Every CSI 6510 Signal Input module has two (2) two-color LEDs. The top LED
indicates the CSI 6510 power converter status and the bottom LED indicates
overall CSI 6510 module status.
CSI 6510 Signal Input module LEDs
Power LED
The Power LED indicates the status of the MSIG module power converters. A
steady green color indicates that all voltage levels are OK, while a steady or
blinking red condition indicates a power fault somewhere within the CSI 6510
module.
Status LED
The Status LED indicates the overall status of the CSI 6510 module. The four
(4) CSI 6510 module status conditions are listed below along with their assigned
priorities.
Note
It is possible for more than one status condition to be active at one
time. When this happens, the LED will indicate the active status
condition with the highest priority.
If the Status LED is off entirely, it indicates that the CSI 6510 module is being
ignored by the Processor module. This is a special case which should not be
encountered in practice. Modules are only ignored if the addition of the module
would exceed the maximum channel count limits that the Processor module can
support (32 analog, 16 Tach, 16 I/O) as channels are counted starting in the left
most slot and working toward the right.
Blinking
Green
is being performed on channels supplied
by this board
Solid Red Failure 2 Failure include: Power supply POST
failure, or other hardware failure on MSIG
board
Alternating
Red/Green
Uncalibrated 3 One or more channels are uncalibrated
8-43 Backplane/Termination Panel LEDs
Backplane/Termination Panel LEDs
+24v Input: This LED is lit Green when +24V is connected.
Power ON: This LED is green when the power switch on the front of the CSI
6560 is turned ON.
Status: This LED turns from green to red with the status of the SysFail relay
(Green =OK, Red =Failed).
NOTE: On the backplane, the LED indicates the status of the internal circuitry.
On the term panel(s), this LED indicates the status of the internal circuitry plus
the -24V sensor supply. If the jumper on the term panel (s) is closed, the check
of the -24V sensor supply is disabled.
Data Types
Overall Level Parameters
All Overall Level inputs must be DC in nature. Any Overall Level input of a
dynamic nature must be fed through the RMS / DC converter path. It is not tech-
nically valid to convert RMS values from an RMS/DC converter to Pk or Pk-Pk
Measurement Units unless the input is sinusoidal in nature. However, the CSI
6500 allows this. RMS values are multiplied by 1.414 or 2.828 to convert from
RMS to Pk and Pk-Pk respectively.
Spectral Scan Parameters
All Spectral Scan Parameters must be AC in nature. It is possible to convert
some analysis type results between Measurement Unit types and Display Unit
types.
Analysis Type: Overall Level
Includes Overall RMS Level, Sensor DC Bias, Gap, DC or AC Process signals
Note
Some DC Process inputs could provide Pk, Pk-Pk, or other Mea-
surement Units
8-45 Data Types
Analysis Type: Spectral
Includes: Total Energy, Energy within a Frequency Range, Synchronous Energy
within a Frequency Range, Non-Synchronous Energy within a Frequency
Range, HFD, Relative Synchronous Harmonics, Average, Synchronous Peak
Note
RMS, PK, PK-PK Measurement Units are valid and can be freely
converted.
Input Type Input Unit HW Int. RMS/DC Meas. Unit Disp. Unit
DC V / E.U. no no DC E.U.
AC V / E.U. no yes RMS E.U.
ACCEL V / 32.2 ft/sec
V / 32.2 ft/sec
V / 9.81 m/s
V / 9.81 m/s
no
yes
no
yes
yes
yes
yes
yes
RMS
RMS
RMS
RMS
gs
in/s
gs
mm/s
VEL V / i/s
V / i/s
V / mm/s
V / mm/s
no
yes
no
yes
yes
yes
yes
yes
RMS
RMS
RMS
RMS
i/s
mils
mm/s
microns
DISP V / mil
V / micron
no
no
yes
yes
RMS
RMS
mils
microns
Input Type Input Unit HW Int. SW Int. SW Diff. Disp. Unit
AC V / E.U. no no no E.U.
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
no
no
no
yes
yes
yes
no
no
no
yes
yes
yes
no
single
double
no
single
no
no
single
double
no
single
no
no
no
no
no
no
single
no
no
no
no
no
single
gs
in/s
mils
i/s
mils
gs
gs
mm/s
micons
mms
micons
gs
VEL V / i/s
V / i/s
V / i/s
V / i/s
V / i/s
V / mm/s
V / mm/s
V / mm/s
V / mm/s
V / mm/s
no
no
yes
no
yes
no
no
yes
no
yes
yes
yes
yes
yes
no
single
no
no
no
no
no
no
single
single
no
no
no
single
single
i/s
mils
mils
gs
i/s
mm/s
microns
microns
gs
mm/s
DISP V / mil
V / mil
V / mil
V / micron
V / micron
V / micron
no
no
no
no
no
no
no
no
no
no
no
no
no
single
double
no
single
double
mils
i/s
gs
microns
mm/s
gs
8-47 Data Types
Analysis Type: Time Waveform
Includes Variance, True Peak, Waveform Pk-Pk
Note
Measurement Unit Type is specific to Analysis Type. No Software
Integration or Differentiation can be performed.
Input Type Input Unit HW Int. Disp. Unit
AC V / E.U. no E.U.
V / 32.2 ft/sec
V / 9.81 m/s
V / 9.81 m/s
no
yes
no
yes
gs
in/s
gs
mm/s
VEL V / i/s
V / i/s
V / mm/s
V / mm/s
no
yes
no
yes
i/s
mils
mm/s
microns
DISP V / mil
V / micron
no
no
mils
microns
Non Vibration Unit Analysis Types
Includes Peak to Average Ratio, Average to Minimum Ratio, Kurtosis, Skew-
ness, Synchronous Phase
These analysis types produce non unit ratios or specific unit types such as
degrees of phase. Measurement Unit Type will not apply to these parameters.
Offset Adjustment
For thrust probes, the CSI 6510 input channel is defined as a DC Process input.
To set the DC offset so that the thrust reading may be zeroed, use a DC voltmeter
(or the DHM program) to measure the DC voltage as seen directly on the CSI
6510 inputs. Enter this value into the offset field in the sensor set up page in
OCONFIG.
8-49 Data Types
CSI 6500 System Calibration
The CSI 6500 system calibration consists of two steps:
1) . .Calibrate the on board signal generator
2) . .Calibrate the system.
The CSI 6560 Processor signal generator should be recalibrated at least once a
year.
The CSI 6500 should be recalibrated at least once a year, or if the processor or
a signal input module has been replaced.
The CSI 6560 Processor on board generator and system should be calibrated
when the CSI 6500 system is commissioned, at the normal temperature for the
mounting location.
Calibrating the CSI 6500
The CSI 6500 uses internal calibration tables to compensate for slight measure-
ment variations that can occur across the temperature, voltage ranges, and vari-
ations in individual electronic components used by processing circuitry. These
calibration tables are stored in each CSI 6500 when it is assembled and verified
at the factory. The units apply calibration connections automatically during
signal measurement and processing.
The CSI 6560 Main Processor
Four circuits are calibrated. These are:
Test Signal Generator (TSG)
Gross Scan (GS)
Digital Signal Processor (DSP)
Transient
A key element is the Test Signal Generator (TSG) circuit.This circuit provides
an extremely precise output signal, which is used as an input during GS, DSP,
Tachometer and Transient Calibrations. During calibrations, the TSG output is
routed internally in each CSI 6560, to processing electronics (GS, DSP, Tach,
Transient), and individual calibration tables for each processing circuit are cre-
ated and stored in CSI 6560 memory. These tables are stored in non-volatile
memory, which means that the tables are not erased if the CSI 6560 is powered-
down. Calibration circuit inputs and outputs are shown in the following table
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 6560, since
their (original) calibration tables used the TSG signal from the original CPU
board.
Calibration tables may be copied from each CSI 6560 onto an online server, and
those can be downloaded into the same CSI 6560. Emerson Online Product Sup-
port personnel, and Online Systems Engineers, can assist customers with this
type of operation.
Should it be desirable or necessary to recalibrate an installed system, it is rec-
ommended that this be accomplished with the support of the local Emerson
Online Product Support office, and that it be scheduled during an equipment
outage. Calibrations can be accomplished in less than an hour (per CSI 6500),
but during that time, the units cannot be monitoring rotating equipment.
Table 3: Calibration Circuit Inputs and Outputs
Calibration Circuit Input Output
TSG (Test Signal
Generator)
(external) signal TSG table (internal) TSG
signal
GS (Gross Scan) TSG signal GS table
DSP (Digital Signal
Processor)
TSG signal DSP table
Transient TSG signal Transient table
8-51 Data Types
Test Signal Generator (TSG) Calibration
All CPU boards provided by Emerson are shipped with a calibrated Test Signal
Generator circuit. If the CPU board is purchased as part of a system (i.e. the ini-
tial shipment), the entire system is calibrated, using the CPU board TSG circuit.
The TSG circuit is the only element which requires an external piece of test
equipment, and special connection cables. TSG calibration requires:
Digital Multi Meter (such as the HP 34401A)
Laptop\computer configured as online server
Special calibration utility program (DHM)
Cable which connects the laptop\computer to the CSI 6560 Ethernet port
Cable which connects the laptop\computer to the Digital Multi Meter
Cable which connects the Digital Multi Meter to the test port on the CSI
6500.
TSG calibration is unique in that it requires a separate test instrument, unique
cables, and a laptop which is configured as an online server. It is recommended
that TSG calibration or recalibration be performed by qualified Emerson Online
Systems Engineers.
Gross Scan (GS) Calibration
Gross Scan (GS) calibration:
uses a Processor modules TSG output signal
does not require that any wire harnesses be disconnected
is completed in about 10 minutes (per CSI 6500)
does not require any special cables or test equipment
uses a special calibration utility program (DHM).
GS recalibration should be performed:
annually
whenever a CSI 6510 module is replaced
whenever a Processor module is replaced
if calibration table has a status of Unknown.
Product Support personnel, can guide a plant engineer or technician through GS
calibration over the phone.
DSP Calibration
Digital Signal Processing (DSP) calibration
uses a CPU boards TSG output signal
is completed in about 30-40 minutes (per CSI 6500)
DSP recalibration should be performed:
annually
whenever a Processor module is replaced
Product Support personnel can guide a plant engineer or technician through
DSP calibration over the phone.
Transient Calibration
The CSI 6500T includes two processing boards; a Main Processor 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 Main Processor DSP circuit does. However it is calibrated sepa-
rately, it is not calibrated as part of a DSP calibration for a Main Processor.
Transient calibration
uses a Processor Modules TSG output signal
is completed in about 30-40 minutes (per CSI 6500T)
8-53 Data Types
Transient recalibration should be performed:
annually
whenever a Transient board is replaced
whenever a Main Processor board is replaced
Product Support personnel can guide a plant engineer or technician through
Transient calibration over the phone.
I-1
Symbols
+24V power input 7-21
Numerics
1/4"-28 taps & tap handle 4-5, 4-18, 4-30
110AC 6-3
220AC 6-3, 6-7
24 AWG gauge strippers 7-5
24 AWG wire strippers 7-2
440AC 6-3, 6-7
9/16" open end wrench 4-5, 4-18, 4-30
A
A0322 Quick-Connect 4-11, 4-35
A0322DR 4-1
A0322DS 4-14
A0322LC 4-14
A0322LC with Quick-Connect 4-25
A0322LC-NT 4-15
A0322LC-NT Quick Release SS Nut &
Threaded Base 4-17
A0322LC-NT Quick-Connect 4-22, 4-25
A0322RA 4-1
A0322RI 4-1
A0322RM 4-27, 4-35
A0322RM Quick-Connect 4-36
A212 Mounting Pad 4-17, 4-30
A212 mounting pad 4-22
A612-I-30 cable 6-7
A680 Bundled Cable 7-10
A901-1 mounting pad 4-9
A911 4-10
A911 Quick-Connect 4-10
A92016 2-part epoxy 4-9, 4-22, 4-34
A92106 4-5, 4-17
A92106 Loctite Depend Mounting Pad Epoxy
(Epoxy Mounting Only) 4-30
Actuator Dimensions 4-39
Actuator Material 4-40
AO322 Quick-Connect 4-9
AO322LC Sensor Mounting 4-23
C
cable tie down 7-2
cable tie downs 6-7
Cable Variations 6-6
Chapter 2 Pre-Installation Review 1-8
Chapter 3 System Documentation 1-8
Chapter 4 Instrumentation Installation 1-8
Chapter 5 Enclosure Mounting 1-8
Chapter 6 Cabling Requirements 1-8
Chapter 7 Wire Terminations 1-9
Chapter 8 System Hardware Configuration
1-9
conduit
steel 6-2
tray or aluminum 6-2
Configuring a 4500 with Hyperterminal
General Boot Flag Notes 8-35
Navigation 8-32
Configuring a 6500 with Hyperterminal 8-31
Connecting 8-31
Configuring a CSI 6500 with Hyperterminal
Subnet Masks 8-36
Contractor Kickoff Meeting 2-2
CSI 6500 6-11
Enclosure 3-7
CSI 6500 4-20ma Current Loop
Interconnection 7-24
CSI 6500 dedicated network segment cables
6-3
Index
I-2
CSI 6500 Discrete Input/Outputs 5-10
CSI 6500 Enclosure 6-9
CSI 6500 enclosure and junction boxes 6-4
CSI 6500 Ethernet Connection 5-9
CSI 6500 Power 5-9
CSI 6500 Transient Daughterboard 8-22
Replacing the Hard Drive 8-25
Specifications 8-23
CSI 6500 Transient Filter Board 8-27
CSI 6500 Wiring 7-7
CSI 6510 Signal Input module 8-14
CSI 6510 Tachometer Input Module
Specifications 8-20
CSI 6560 Processor module 8-9
CSI 6560 Processor Module Specifications
8-11
D
Data Types
Analysis Type
Overall Level 8-44
Spectral 8-45
Time Waveform 8-47
CSI 4500 System Calibration 8-49
Non Vibration Unit Analysis Types 8-48
Offset Adjustment 8-48
Overall Level Parameters 8-44
Spectral Scan Parameters 8-44
Dedicated CSI 6500 Network Segment 6-10
Description 4-3, 4-15, 4-28
dielectric grease 6-7
Documentation Storage 3-9
E
EIA/TIA 568/569 6-10
Epoxy Mounting 4-9, 4-22, 4-34
F
Final Walk-Through 2-3
Foil Shield 7-5
G
General Wiring Notes 8-29
H
Handling Instructions 4-3, 4-15, 4-28
I
Installation 6-7
J
J box 6-2
M
Monitoring Methods
Overall Level Monitoring 8-2
Spectral Scan 8-2
Transient Data Capture 8-2
Mount the IMR 6500xx Rack 5-6
Mounting Bracket & Locking Nut 4-38
Mounting Sensor 4-42
Mounting Sensor Bracket 4-41
Multi-pair Bundled Cable Pulls 5-9
N
Negative Conductor 7-5
P
PGME07 cord grip 6-8
Positive Conductor 7-5
Power Circuit Guidelines 6-11
Prediction Side -- AC Power Specifications
6-11
I-3
Prediction Side -- DC Power Specifications
6-11
Prepare the CSI 4500 Cable Access Plate 5-9
Project Manager 1-5
Pull Instrumentation Wiring 6-5
R
Required Tools & Parts 4-4
S
SENSOR LOCATION CARD 6-7
Sensor Mounting 4-11, 4-36
Signal Quality 8-4
Cable Terminations 8-6
Ethernet Cable Routing 8-5
Grounding and Shielding 8-5
J unction Boxes 8-6
Sensor Cable Routing 8-4
Sensor Cable Type 8-4
System Grounding 8-6
Special 1-3
Spot Face & End Mill Tool 4-29
Spot Face and End Mill Tool 4-4, 4-16
Stud Mounting 4-6, 4-18, 4-31
Surface Preparation 4-5, 4-18, 4-30
System Component Review 2-4
System Overview Drawings
Additonal Information to Keep 3-4
Machine Level Diagram
3-3
Overall System Diagram
3-3
T
terminal block 7-3
7-5
Terminate Network Connection 7-25
Torque Wrench 4-5, 4-18, 4-30
V
V425 4-37
V425 Passive Magnetic Pickup 4-37
V680 Bundled Cable 7-5
V701 and V745 series junction 7-1
V745 junction/switch box 5-1
W
wire labels 6-7, 6-9, 7-2
I-4

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