SIGNAL CONDITIONER

5500 SERIES

OPERATION AND INSTALLATION

MANUAL

Corporate Headquarters
3860 Calle Fortunada
San Diego, CA 92123-1825
Phone: (858) 278-2900
FAX: (858) 278-6700
Web-Site: http://www.hardyinstruments.com
Hardy Instruments Document Number: 0296-0026-01 Rev E
Copyright November 2000 Hardy Instruments, Inc. All Rights Reserved. Printed in the U.S.A. (941028)

Table of Contents

Table of Contents
TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - I
TABLE OF ILLUSTRATIONS- - - - - - - - - - - - - - - - - - - - I
OVERVIEW - - - - - - - - - A Brief Description of Chapter 1 About Hardy Manuals - - - - - Description - - - - - - - - - - Industries- - - - - - - - - - - Applications - - - - - - - - - Options- - - - - - - - - - - - HI 5500PS Power Supply - Transducers - - - - - - - NEMA Enclosures - - - - Back Plate/Not Wired - Back Plate/Wired - - - -

CHAPTER 2 - SPECIFICATIONS - - - - - - - - A Brief Description of Chapter 2 - - - - - - - - - Specifications for a Standard HI 5000 Series Signal
Conditioning Module - - - - - - - - - - - - - Electrical Characteristics - - - - - - - - - - Input Sensor Sensitivity - - - - - - - - - Sensor Excitation Current- - - - - - - - Current Output - - - - - - - - - - - - - Voltage Output - - - - - - - - - - - - - Maximum Load Resistance - - - - - - - Frequency Range (3 dB) - - - - - - - Vibration Range - - - - - - - - - - - - Sensor Fault - - - - - - - - - - - - - - Power Requirements - - - - - - - - - - - - Physical Characteristics - - - - - - - - - - Mounting - - - - - - - - - - - - - - - - Physical Dimensions - - - - - - - - - - Length - - - - - - - - - - - - - - - Width - - - - - - - - - - - - - - - Height - - - - - - - - - - - - - - - Weight - - - - - - - - - - - - - - - - - Environmental Characteristics - - - - - - - Temperature Range - - - - - - - - - - Operating - - - - - - - - - - - - - -

- 1-1
- 1-1
- 1-2
- 1-3
- 1-3
- 1-4
- 1-4
- 1-4
- 1-5
- 1-5
- 1-5
- 1-5

- - - - - - - - - 2-1
- - - - - - - - - 2-1
-

- 2-1
- 2-1
- 2-1
- 2-1
- 2-1
- 2-1
- 2-1
- 2-1
- 2-1
- 2-2
- 2-2
- 2-2
- 2-2
- 2-2
- 2-2
- 2-2
- 2-2
- 2-2
- 2-3
- 2-3
- 2-3
i

HI 5500 SERIES SIGNAL CONDITIONERS

Storage - - - - - - - Humidity - - - - - - - - - Ordering Information for the HI 5501
Ordering Information for the HI 5502
HI 5501E (Only) - - - - - - - - - Temperature Range - - - - - Operating - - - - - - - - Humidity - - - - - - - - - - - Enclosure Requirements - - - Approvals - - - - - - - - - - Optional Equipment- - - - - - - - HI 5500PS Power Supply - - - Regulation - - - - - - - - Environmental - - - - - - Operating - - - - - - Storage - - - - - - - Temperature Coefficient
Dimensions- - - - - - - - Physical - - - - - - - Weight - - - - - - - - Output Power- - - - - - - Options- - - - - - - - - - HI 5532 - - - - - - - - - HI 5533 - - - - - - - - - -

-2-3
-2-3
-2-3
-2-4
-2-4
-2-4
-2-4
-2-4
-2-4
-2-4
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5
-2-5

CHAPTER 3 - INSTALLATION - - - - - - - - - - - A Brief Description of Chapter 3 - - - - - - - - - - - Unpacking - - - - - - - - - - - - - - - - - - - - - Pre-Installation Engineering Procedures- - - - - - - Electrical Wiring Precautions - - - - - - - - - - - - Installing the HI 5500 Standard Module Onto a DIN Rail
Electrical Installation Procedures - - - - - - - - - - LED OK Indicator - - - - - - - - - - - - - - - - BNC Connector- - - - - - - - - - - - - - - - - Terminal Assignments - - - - - - - - - - - - - TB2-1,2 - - - - - - - - - - - - - - - - - - TB2-3,4 - - - - - - - - - - - - - - - - - - TB2-5,6 - - - - - - - - - - - - - - - - - - TB1-1 - - - - - - - - - - - - - - - - - - - TB1-2 - - - - - - - - - - - - - - - - - - - TB1-3 - - - - - - - - - - - - - - - - - - - TB1-4 - - - - - - - - - - - - - - - - - - - TB1-5 - - - - - - - - - - - - - - - - - - - -

-3-1
-3-1
-3-1
-3-2
-3-3
-3-4
-3-5
-3-6
-3-7
-3-7
-3-7
-3-7
-3-7
-3-7
-3-8
-3-8
-3-8
-3-8

ii

Table of Contents
Installing modules in an Enclosure (See Fig. 3-5) - - - - - - Pump Monitoring with Transducers and HI 5500 Series Module
Threaded Stud - - - - - - - - - - - - - - - - - - - Cementing Pad - - - - - - - - - - - - - - - - - - - Wiring Diagram Example for 5501/55032/5533 with no
Power Supply - - - - - - - - - - - - - - - - - - - - - - Wiring Diagram for Acceleration and Velocity Monitoring
System with Alarm and Danger Relays - - - - - - - - - - -

- 3-8
- 3-9
- 3-10
- 3-10

- - - 3-12
- - - 3-13

CHAPTER 4 - SETUP - - - - - - - - - - - - - - - - - A Brief Description of Chapter 4 - - - - - - - - - - - - - Test Equipment and Tools Required - - - - - - - - - - Quick Calibration Check Using An HI 813 Portable Shaker
Calibration System - - - - - - - - - - - - - - - - - - Calibration Setup Procedures Using a Frequency
Generator and Power Supply - - - - - - - - - - - - - Full Scale and Zero Scale Adjustment - - - - - - - - - - Input Sensitivity Selection - - - - - - - - - - - - - - - - Monitoring System Configuration - - - - - - - - - - - - Reference Voltage Jumper Setting Procedures - - - -

- - - - - 4-1
- - - - - 4-1
- - - - - 4-1

CHAPTER 5 - CALIBRATION - - - - - - - - - - - - - A Brief Description of Chapter 5 - - - - - - - - - - - - - Full Scale Output/Span Adjustment - - - - - - - - - - - Bench Calibration Using the Hardy HI 813 Portable
Shaker System - - - - - - - - - - - - - - - - - - Bench Calibration Using a Frequency Generator and
Power Supply - - - - - - - - - - - - - - - - - - Current Limit Test - - - - - - - - - - - - - - - - - Final Check - - - - - - - - - - - - - - - - - - - - Calculation of HI 5501/5502 Full Scale Calibration voltage Acceleration or Velocity - - - - - - - - - - - - - - - Accelerometer or Velocity Input with Signal Integration
Log Mid-Frequency - - - - - - - - - - - - - - - Convert Output EUs F.S. to Input EUs for Three
Different HI 5501/HI 5502 Configurations - - - Three Examples Based on Part Numbers - - - - -

- - - - - 5-1
- - - - - 5-1
- - - - - 5-1

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

- - - - - 4-2
-

- 4-4
- 4-6
- 4-9
- 4-10
- 4-10

- - - - - 5-1
-

- 5-5
- 5-6
- 5-6
- 5-7
- 5-7
- 5-7
- 5-8

- - - - - 5-8
- - - - - 5-8
-

- 6-1
- 6-1
- 6-1
- 6-1

iii

HI 5500 SERIES SIGNAL CONDITIONERS

iv

Table of Illustrations

Table of Illustrations
OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
FIG. 1-1
FIG. 1-2

STANDARD HI 5500 SIGNAL CONDITIONER MODULE - 1-1

HI 5500PS +24VDC POWER SUPPLY - - - - - - - - - - 1-4

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

FIG. 2-1
FIG. 2-2

SPECIAL PRODUCT CONFIGURATION MENU - HI 5501 2-3

SPECIAL PRODUCT CONFIGURATION MENU - HI 5502 2-4

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

FIG. 3-1
FIG. 3-2
FIG. 3-3
FIG. 3-4
FIG. 3-5
FIG. 3-6
FIG. 3-7
FIG. 3-8
FIG. 3-9

INSTALLING THE MODULE ONTO A DIN RAIL - - - MOUNTING LATCH HIGHLIGHTED - - - - - - - - - MODULES INSTALLED ON DIN RAIL - - - - - - - - FUNCTIONAL BLOCK DIAGRAM FOR HI 5501/HI 5502
CONNECTIONS/5501 - - - - - - - - - - - - - - - - INSTALLING THE MODULES IN AN ENCLOSURE - PUMP MONITORING - - - - - - - - - - - - - - - - CEMENTING PAD INSTALLATION - - - - - - - - - WIRING DIAGRAM FOR 5501/5532/5533 WITH
NO POWER SUPPLY - - - - - - - - - - - - - - - FIG. 3-10 WIRING DIAGRAM FOR MONITORING SYSTEM
WITH ALARM AND DANGER RELAYS - - - - - - - -

- 3-4
- 3-5
- 3-5
- 3-6
- 3-6
- 3-9
- 3-9
- 3-11
- 3-12
- 3-13

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

FIG. 4-1
FIG. 4-2
FIG. 4-3
FIG. 4-4
FIG. 4-5
FIG. 4-6
FIG. 4-7

FIELD CHECKOUT USING HI 813 CALIBRATION

SHAKER - - - - - - - - - - - - - - - - - - - - CONNECTING TRANSDUCER LEADS TO
HI 5501 MODULE - - - - - - - - - - - - - - - CALIBRATION EQUIPMENT SETUP- - - - - - - HI 5500 SERIES SIGNAL CONDITIONER
CIRCUIT BOARDS - - - - - - - - - - - - - - - REMOVING THE MODULE COVER - - - - - - - J4 SENSITIVITY JUMPER SETTINGS - - - - - - JUMPER SETTINGS FOR REFERENCE VOLTAGE

- - - 4-3
- - - 4-3
- - - 4-5
-

- 4-6
- 4-7
- 4-10
- 4-11

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

FIG. 5-1

REMOVE PHILLIPS PAN HEAD SCREWS - - - - - - - - 5-4

I

HI 5532/5533 MODULES

II

Chapter 1 - Overview

CHAPTER 1 - OVERVIEW
A BRIEF
DESCRIPTION OF
CHAPTER 1

This manual provides the user and service personnel

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

FIG. 1-1 STANDARD HI 5500 SIGNAL

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

HI 5500 SERIES SIGNAL CONDITIONERS

the vibration transducer (HI 111, HI 113) to a calibrated 4-20mA current output. The 4-20mA output is
proportional to the measured vibration amplitude for
trending by a PLC or DCS. The HI 5500 Series can be
used with either a set point module (HI 5532) and a
relay module (HI 5533) to provide a monitoring system (HI 5500 MS) with alarm and/or shut down capabilities. The HI 5500 Series conditioning monitoring
system detects machine problems early so that catastrophic failure can be minimized and any problems
can be repaired during scheduled downtime. The HI
5500 Series Signal Conditioner Modules are essential
for successful predictive maintenance.
To get the maximum service life from this product,
users should operate this module in accordance with
recommended practices either implied or expressed in
this manual. Before using the HI 5500 Signal Conditioning modules, all users and maintenance personnel
should read and understand all cautions, warnings,
and safety procedures, either referenced or explicitly
stated in this manual, to ensure the safe operation of
the module. Hardy Instruments appreciates your business. Should you not understand any information in
this manual or experience any problems with the
product, please contact our Customer Support Department at:
Phone: (858) 278-2900
FAX: (858) 278-6700
e-mail: support@hardyinst.com
Web Address: http://www.hardyinstruments.com
ABOUT HARDY
MANUALS

Every Hardy Installation and Operation manual is

organized into easily referenced chapters, that are
almost always the same:

1-2

Chapter 1 - Provides an introduction to the

instrument and an Overview of the equipment
and its capabilities.
Chapter 2 - Provides a complete list of Specifications.

Chapter 1 - Overview

Chapter 3 - Contains complete instructions

needed to install the HI 5500 Series Vibration
Signal Conditioners.
Chapter 4 - Provides complete hardware Configuration instructions for setting dip switches
and jumpers.
Chapter 5 - Pertains to the firmware/software
Setup and preparation procedures to calibrate
and operate the instrument.
Chapter 6 - Provides all Calibration instructions.
Chapter 7 - Pertains to the Operating Procedures of the HI 5500 Series Vibration Signal
Conditioners.
Chapter 8 - Pertains to the Troubleshooting
procedures for repair of the instrument.

Hardy Instruments hopes that this manual meets your

needs for installation and operation. All corrections or
suggestions for improvements of this manual are welcome and can be sent to the Technical Publications
Department or Customer Support Department at
Hardy Instruments Inc.
DESCRIPTION

The Hardy Instruments DI 5500 Series Signal Conditioning Modules are specifically designed to:

INDUSTRIES

Continuously monitor the condition rotating

machinery vibration.
Monitor machine vibration in a plant computer
using 4-20 milliamp and 0-5 VDC outputs.
Set off an alarm to alert maintenance personnel of
excessive vibration.
Provide vibration analysts the raw vibration signal for diagnosing machine vibration essential for
predictive maintenance.
Petroleum
Chemical
Power
Pulp and Paper
Food/Beverage
Metal Fabrication
Transportation
1-3

HI 5500 SERIES SIGNAL CONDITIONERS

APPLICATIONS

Pumps
Fans/Blowers
Motors
Chillers
Compressors
Machine Tools

OPTIONS
HI 5500PS Power
Supply

The Hardy HI 5500PS is a compact power source that

converts 110VAC to 24VDC to provide power for
Hardys HI 5500 Series Signal Conditioners. It is ruggedly constructed and designed to withstand substantial overloads or short circuits for reasonable lengths
of time. The power supply can be connected to a type
C or D style mounting rail for easy installation. Recognized by Underwriters Laboratories (UL)
(See Fig. 1-2)

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

1-4

Chapter 1 - Overview
Transducers

NEMA Enclosures

HI 111 (General Purpose) Accelerometer - 100

mV/g, 250 F Service, 2-Pin MS connector, Case
Isolated.
HI 113 (Premium) Accelerometer - 100 mV/g,
250 F Service, 2-Pin MS connector Case Isolated.
HI 113SM Accelerometer, 100 mV/g, 250 F Service, 2-Pin MS Connector, Case Isolated, Side
Mount.

Enclosures constructed of Fiberglass, Mild Steel or

Stainless Steel without back plate.

Back Plate/Not
Wired

Aluminum back plate with Type C Din Rail(s) and

two rail stops to mount HI 5500 Series modules. Wiring of modules is not included.

Back Plate/
Wired

Aluminum back plate with Type C Din Rail(s) and

two rail stops to mount HI 5500 Series modules.
Wired per customer configuration. Also includes AC
input terminal and fuse block.

1-5

HI 5500 SERIES SIGNAL CONDITIONERS

1-6

Chapter 2 - Specifications

CHAPTER 2 - SPECIFICATIONS
A Brief Description of
Chapter 2

Chapter 2 lists the specifications for the HI 5000

Series Signal Conditioning Module. Specifications
are listed for the standard instrument and for optional
equipment. The specifications listed are designed to
assist in the installation, operation and troubleshooting of the instrument. All service personnel should be
familiar with this section before attempting an installation or repair of this instrument.

Specifications for a
Standard HI 5000
Series Signal
Conditioning Module
Electrical
Characteristics
Input Sensor
Sensitivity

10, 100, 500 mV/g User Selectable

Sensor
Excitation
Current

+24 VDC @ 4 mA

Current Output

4-20mA 10%

Voltage Output

0-5 VDC 10%

Maximum
Load
Resistance

1.2 KOhms

Frequency
Range (3 dB)

See Table 2-1

Vibration
Range

See Table 2-1

2-1

HI 5500 SERIES SIGNAL CONDITIONERS

Table 2-1: Frequency Range

Standard
Models

Frequency Range
( 3dB)

HI 5501 - ASTD

2 - 10 KHz

0 - 10 g

HI 5501 - VSTD

2 - 10 KHz

0 - 1 ips

HI 5501 - VLF

2 - 1 KHz

0 - 1 ips

HI 5502 - STD

2 - 10 KHz

0 - 1 ips

Hazardous
Models

Frequency Range
( 3dB)

Vibration
Range

HI 5501E - ASTD

2 - 10 KHz

0 - 10 g

HI 5501E - SPEC

ACCEL, VEL, DISPLACE

Special Order*

HI 5501E - VLF

2 - 1 KHz

0 - 1 ips

HI 5501E - VSTD

2 - 10 KHz

0 - 1 ips

NOTE:

*Special Orders are available at various Frequency

and Vibration Ranges.
Sensor Fault

Power
Requirements

0mA output in Fault Condition

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

Physical
Characteristics
Mounting

DIN Rail (35mm x 15mm)

Physical
Dimensions
Length
Width
Height
Weight
2-2

Vibration
Range

Approx. 4.00 (102mm)

Approx. 1.9 (48mm)
Approx. 3.25 (80mm)
Approx. 4.6 oz. (131 grams)

Chapter 2 - Specifications
Environmental
Characteristics
Temperature
Range
Operating
Storage
Humidity

0-70 C (32-158 F)
0-85 C (32-185 F)
0-95% Non-Condensing

Ordering Information
for the HI 5501

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

NOTE:

AR pertains to Active Reference, and IR to Inactive Reference. Active Reference designates an HI

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

HI 5500 SERIES SIGNAL CONDITIONERS

Ordering Information
for the HI 5502

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

NOTE:

These menus are for standard product configurations

only. Special product configurations can be provided.
Contact your local Hardy Representative for more
information.

HI 5501E (Only)
Temperature
Range
Operating

-40 to +85 C (-40 - 185 F)

Humidity

0-95% Non-Condensing

Enclosure
Requirements

These devices are intended to be installed within an

enclosure rated to at least IP54/NEMA 3 or 3S

Approvals

2-4

UL
CUL
This equipment is suitable for use in Class I,
Division 2, Groups A,B,C and D Hazardous locations.
This equipment is suitable fore use in Class I,
Zone 2, Ex nL IIC T4 X, AEx nC IIC T4

Chapter 2 - Specifications
Optional Equipment
HI 5500PS Power
Supply

The HI 5500PS Power Supply is a compact power

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

Regulation

0.1% load
0.5% line
Impedance: 0.07 ohms at 1kHz
0.20 ohms at 10 kHz

Environmental
Operating

-20

to +71

C (-4

Storage

-55

to +85

C (-67

Temperature
Coefficient

-.015%/ C

to +160
to +185

F)
F)

Dimensions
Physical

4.0L x 2.875W x 3.375H (101.6mmL x 73.0mmW

x 85.72mmH)

Weight

2 lbs, 1 oz. (.48Kgs)

Output Power

.6 Amps
Provides power for up to 12 Signal Conditioner Modules

Options

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

HI 5532

Dual Alarm Setpoint Module

HI 5533

Relay Module, DPDT

2-5

HI 5500 SERIES SIGNAL CONDITIONERS

2-6

Chapter 3 - Installation

CHAPTER 3 - INSTALLATION
A Brief Description of
Chapter 3

All information contained in Chapter 3 pertains to

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

Unpacking

Step 1.
Step 2.
Step 3.
Step 4.

WARNING

Before signing the packing slip, inspect

the packing for damage of any kind.
Report any damage to the carrier company
immediately.
Check to see that everything in the package matches the bill of lading.
Write down the Model(s) and Serial number(s) of the module(s). Store this information in a convenient location for reference
when contacting The Customer Support
Department for parts or service.

ELECTROSTATIC DISCHARGE MAY DAMAGE SEMICONDUCTOR COMPONENTS IN

THE MODULE. DO NOT TOUCH THE CONNECTOR PINS. PLEASE OBSERVE THE FOLLOWING HANDLING PRECAUTIONS:

Wear an approved wrist-strap

grounding device when handling
the module.
Touch a grounded object or surface to rid yourself of any electrostatic discharge prior to
handling the module.
Only Handle the module by
grasping the DIN Rail Mount.

3-1

HI 5500 SERIES SIGNAL CONDITIONERS

Pre-Installation
Engineering
Procedures

Step 1.

WARNING

DO NOT INSTALL THE MODULES IN HAZARDOUS AREAS WHERE THE MODULE

DOES NOT MEET THE HAZARDOUS AREA
CLASSIFICATION.
Step 2.

Step 3.

Step 4.

Step 5.

WARNING

Choose a location in where the temperature and humidity meets the limits specified for the HI 5500 Series signal
conditioners (See Chapter 2). Always keep
the modules dry and try to maintain a constant temperature. Temperature recycling
can lead to moisture build-up inside the
module.
The HI 5500 Series terminal blocks permit
solderless and lugless connections of 16 to
22 GA stranded wiring. Strip back the
insulation.25 to.30 before making connections to make sure there is a good connection.
Always use rigid metal conduit whenever
possible for field wiring transducers to the
HI 5500 Conditioners.
Make sure to separate the low level vibration signal cabling from other instrument
and control signals.

NEVER RUN THE TWISTED, SHIELDED OR

COAXIAL CABLES CONTAINING LOW LEVEL
VIBRATION SIGNALS IN THE SAME CONDUIT WITH AC WIRING.
Step 6.

3-2

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

Shielding must be pulled back from the

transducer wire in order to terminate them.
Unshielded wire is susceptible to Radio

Chapter 3 - Installation

Step 7.

Step 8.

Step 9.

Electrical Wiring
Precautions

1.

2.

Frequency Interference (Walkie Talkie, 2Way Radios etc.) Always locate the DI5500 Series units in a metal enclosure to
shield unshielded wires.
It is important to know the machine or
mounting position resonant frequency (at
running speed) in order to achieve accurate measurements. Your machinery supplier can provide you with this
information. Mounting resonance can give
a false indication of high frequency
machinery faults such as gear mesh and
bearing problems. In some cases the
mounting resonance can cause sensor
overload if it is excited by a machinery
fault. An accelerometers region and linear
frequency response generally extends well
above and below running speed of most
rotating machinery.
Make sure that all covers, fittings and
accessories are tightly fastened to the
machine. Readings are corrupted by
vibrating loose parts and degrade the quality of the measurement.
After completing the field installation and
system commissioning, set up a schedule
for regular calibration and maintenance.
This will make sure the results from the
instrument are reliable so that others in
your facility can rely on the information.
For calibration we recommend the Hardy
HI 803, HI 813, HI 823 Transducer Calibration Systems. Contact your local Hardy
Instruments Dealer for more information.

Never route the cable along side high voltage

power lines and only cross high voltage power
lines at right angles. For example, if a power line
is 440 volts and 60 Hz and the signals from the
sensor are at the milli and microvolt levels any
cross talk can severely corrupt the data.
Cable and Shielding should be grounded at one
end only preferably at the controller.
3-3

HI 5500 SERIES SIGNAL CONDITIONERS

3.
Installing the
HI 5500 Standard
Module Onto a DIN
Rail

Shield and Common wires must be wired to earth

ground.

Step 1.

Step 2.
Step 3.

Step 4.
Step 5.

Hold the module with the DIN Rail

Mounting facing down and what appears
to be a spring type mounting latch. (See
Figs. 3-1 & 3-2)
Tilt the front of the module and mount
slightly down about 30 degrees.
Slide the mounting latch over the edge of
the DIN Rail until the rail edge touches the
bottom of the DIN Mount frame.
Slide the mount back until it stops.
Gently push the back of the mount down
until the mount snaps onto the DIN Rail.
(See Fig. 3-3)

FIG. 3-1 INSTALLING THE MODULE ONTO A DIN RAIL

3-4

Chapter 3 - Installation

FIG. 3-2 MOUNTING LATCH HIGHLIGHTED

FIG. 3-3 MODULES INSTALLED ON DIN RAIL

Step 6.
Electrical Installation
Procedures

Now wire the module to the transducer

and the power supply.

The following describes the electrical components of

a module and terminal assignments. A block diagram
3-5

HI 5500 SERIES SIGNAL CONDITIONERS

is provided to assist in installation. (See Figs. 3-4 & 35)

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

FIG. 3-5 CONNECTIONS/5501

LED OK Indicator

3-6

A green LED illuminates when the sensor connection

and power is OK. The LED goes off when a circuit
fault exists.

Chapter 3 - Installation
BNC Connector

WARNING

The vibration signal can be accesses at the BNC connector or at the Terminal Connector. The Vibration
signal can be accessed in either the filtered or unfiltered form.
DO NOT REMOVE OR REPLACE WHILE CIRCUIT IS LIVE UNLESS THE AREA IS KNOWN
TO BE FREE OF IGNITABLE CONCENTRATIONS OF FLAMMABLE GASES OR VAPORS.

Terminal
Assignments
TB2-1,2

Power supply input terminals - The voltage measured

between TB2-1 and TB2-2 should be within the range
of +22 to +28VDC. Nominal voltage should be
+24VDC.

TB2-3,4

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

TB2-5,6

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

TB1-1

Connect the shield from the transducer cable to this

terminal if the shield is isolated from ground at the
truncates end. If the shield is common to the transducer case, the shield must be tied back to the cable
and NOT connected to the HI 5501/5502 shield terminal.

3-7

HI 5500 SERIES SIGNAL CONDITIONERS

TB1-2

The output signal from the field mounted sensor is

connected to this terminal. Power to accelerometers is
provide via this terminal.

TB1-3

Connect the common terminal from the transducer to

this terminal. This terminal could be called signal
return.

TB1-4

The voltage at this terminal is the internal circuit reference. This terminal is used when connecting the HI
5532 Setpoint and HI 5533 Relay modules to the HI
5501/5502 Signal Conditioners and are to provide
relay outputs for annunciation or shutdown. Self-generating velocity pickups (no external voltage applied)
will require the low side or return wire to be connected to this terminal. No connection will terminate
at TB1-3 in this case. For example:
When one transducer is connected to several 5501
modules, you make one module the Active Reference
Voltage (AR) by setting the jumper at JP1. The
remaining modules you set for Inactive Reference
voltage (IR) by setting the jumpers for IR.
Another example is when you have several individual
modules connected to individual sensors and you
want to use the Auctioneering mode to check each.

TB1-5
Installing modules in
an Enclosure (See Fig.
3-5)

This is an optional buffered signal out connection in

case you dont have a cable with a BNC connector.
Step 1.

Step 2.

Step 3.

Step 4.
3-8

Mount the DIN Rail(s) (Standard 35mm

DIN RAIL) onto the back plate of the
enclosure. The center distance between the
installed DIN Rails should be no less than
5.5 (139.7mm) to allow for proper wiring
of the modules.
Mount the modules onto the DIN Rail. See
Installing the HI 5500 Standard Module
onto a DIN Rail above.
It is recommended that you install a DIN
Rail Stop or Stops to prevent the modules
from accidentally sliding off the DIN Rail.
Its that easy.

Chapter 3 - Installation

FIG. 3-6 INSTALLING THE MODULES IN AN ENCLOSURE

Pump Monitoring with
Transducers and HI
5500 Series Module

FIG. 3-7 PUMP MONITORING

Step 1.

Select a sensor mounting location that

minimizes the vibration transmission route
through the machine. Avoid mounting the
sensor on thin sections or vibration-free
areas.
3-9

HI 5500 SERIES SIGNAL CONDITIONERS

Step 2.

Step 3.

Select the mounting configuration based

on whether the mount is permanent or
temporary. In most cases the mounting
configuration is permanent and you should
use a stud mount or cementing pad.
Install the sensor according to the chosen
mounting configuration and sensor supplier instructions. See instructions below:

Threaded Stud

Stud mounting requires a tapped hole drilled directly

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

Cementing
Pad

Cementing pads eliminate drilling/tapping into the

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

3-10

Bore a spot face 1.1 times larger

than the diameter of the cementing pad to be installed on the
bearing housing. Allow the
machine tool to groove and
abrade the surface to prepare for
the adhesive bonding. Do not use
cutting fluids as they may contaminate the bonding area.

Chapter 3 - Installation

Apply the primer with a brush

and let dry for 5 minutes.
Mix the Bi-pack thoroughly by
removing the clip and working
the epoxy and catalyst into each
other.
Apply a generous amount to the
spot face and set the Cementing
pad with a turning motion.
Filet the adhesive around the
sides of the pad to increase shear
strength and assist electrical isolation. The working time is usually 5 minutes but may vary
depending the on the ambient
temperature. (See Fig. 3-8) Do
not get epoxy in the sensor
mounting surface.

FIG. 3-8 CEMENTING PAD INSTALLATION

Step 4.

Test the electrical isolation from

the pad to the machine with an
ohmmeter.
Apply a service removable
threadlock such as Loctite 242
blue to the tapped hole in the sensor.
Torque the sensor to the manufacturers specifications.

Connect the Sensor Waveform lead to the

In Connection (TB1-2) on the HI 5500
Series Signal Conditioning Module.
3-11

HI 5500 SERIES SIGNAL CONDITIONERS

Step 5.

Connect the ground lead to the Common

Connection (TB1-3) on the HI 5500 Series
Signal Conditioning Module. (See Fig. 39)

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

TB2

+ 24 VDC
COMMON
4-20 mA Output

+ 24
VDC

OUTPUT

SIGNAL
CONDITIONER

OK

TB1

COM

SHD

4-20

IN

MA

DC
OUT
REF

REF
SIG

HI550 1-00005-99 999

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

TB1

TB2
ALARM #1
+ 24CVDC
COM
RESET

DUAL

READ#1
AUX1

ADJ.

SETPOINT
MODULE
HI 5532

OUT1A
OUT1B

ACK

READ#2

INPUT #1

AUX 2

REF

OUT 2A

ADJ.

INPUT #2

OUT 2B

ALARM #2

COM

N.C.
Common
N.O.
N.C.
Common
N.O.

N.C.
SET #1

CONTACT

+ 24CVDC

COM
N.O.

DISABLE
INPUT
REF

RELAY CONTACTS ARE

DPDT 3 AMPS SUPPRESSED
(MAYBE PROGRAMMED FOR
FAIL SAFE. SEE MANUAL)

CONTACT

+ 24 VDC
DC Common
Relay Inhibit

RELAY CONTACTS

RELAY MODULE
HI 5533

TB1

N.C.
SET #2

+ 24 VDC
DC Common
Alarm Reset

CABLE SHIELD
TRANSDUCER SIGNAL (+)
TRANSDUCER SIGNAL (-)

COM

COM

COM
N.O.

TB2

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

SUPPLY

3-12

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

AC

AC

Model 5500PS
54EB60

+24 VDC

AC TO DC
POWER SUPPLY

DC COMMON

TB2

Input
Power
Recorder
Output

Input
Power
Recorder
Output

+ 24 VDC
COMMON
4-20 mA Output
COMMON

+ 24
VD C

O U TPU T

SIG N A L

OK

CO N D ITIO N ER

TB1

CO M

SH D

4 -2 0
MA
CO M

RE F

DC

TB2

OUT

H I55 01- 0 000 5- 99 999

RE F

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

+ 24

O U TPU T

SIG N A L
CO N D ITIO N ER

VD C

+ 24 VDC
COMMON
4-20 mA Output
COMMON

SIG

OK

TB1

CO M

SH D

4 -2 0
MA

IN
CO M

CO M

RE F

DC
OUT

H I55 01- 0 000 5- 99 999

RE F

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

SIG

TB1

Input
Power

TB2
AL A RM #1

+ 24 VDC
DC Common
Alarm Reset

TRANSDUCER SIGNAL (+) WHITE

TRANSDUCER SIGNAL (-) BLACK

IN
CO M

+ 2 4C VD C
CO M
RE SET

DU A L
SETPO IN T

RE AD #1
AD J.

AU X 1

M O DU L E

O U T1 A

H I 5 53 2

O U T1 B

AC K

RE AD #2

IN PU T # 1

AU X 2

RE F

AD J.

O U T 2A

IN PU T # 2

O U T 2B

AL A RM #2

ALARM RELAY
CONTACTS

RE LAY M O DU L E
H I 5 53 3

+ 2 4C VD C
CO M

N.C.
Common
N.O.

N .C.
SET #1

+ 24 VDC
DC Common

CO M
N .O.

DI SAB LE

RE F

RE LAY C O N TAC TS AR E
DP DT 3 A M PS SU PPR ESSED

N .C.
SET #2

IN PU T

C O N TAC T

Input
Power

C O N TAC T

TB1

CO M
N .O.

(M AYB E PRO G RA M M ED F O R
FAI L SAF E. SEE M A N UA L)

TB2

DANGER RELAY
CONTACTS
N.C.
Common
N.O.
N.C.
Common
N.O.

RE LAY M O DU L E

CO M

SET #1

+ 2 4C VD C

N .C.
CO M
N .O.

DI SAB LE
IN PU T
RE F

RE LAY C O N TAC TS AR E
DP DT 3 A M PS SU PPR ESSED
(M AYB E PRO G RA M M ED F O R
FAI L SAF E. SEE M A N UA L)

N .C.
SET #2

+ 24 VDC
DC Common

C O N TA CT

Input
Power

C O N TA CT

H I 5 53 3

TB1

CO M
N .O.

TB2

FIG. 3-10 WIRING DIAGRAM FOR MONITORING SYSTEM WITH

ALARM AND DANGER RELAYS
3-13

HI 5500 SERIES SIGNAL CONDITIONERS

3-14

Chapter 4 - Setup

CHAPTER 4 - SETUP
A Brief Description of
Chapter 4

All information contained in Chapter 4 pertains to setting up for a Bench Check and Calibration of the HI
5501/HI 5502 Signal Conditioner Modules. All Service Personnel should read this chapter before
attempting to calibrate or perform a bench check of
any 5500 Series Module. Alternatives to any procedures explicit or implied in this chapter are not recommended. Be sure to have on hand, all the equipment
necessary to perform these tests. All safety precautions should be taken when performing a calibration
or bench check.

NOTE:

The HI 5500 Series Signal Conditioners are shipped

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

Test Equipment and

Tools Required

Phillips screw driver - #0 or #1 tip.

Small Flat Head screw driver for HI 5501 or HI
5502 terminals and potentiometers.
Digital Multi-Meter

NOTE:

Must read DC milliamps

Must be Broadband
Must be capable of accurate measurements over the expected frequency
ranges.

Not all Digital Volt Meters are accurate below 5060Hz. Check your multi-meter specification sheet to
verify that the instrument accuracy is adequate below
50-60Hz. If the accuracy of the meter is not adequate
below 50-60Hz the calibration or calibration check of
the HI 5500 Module is not very accurate. A rule of
thumb for calibration is that the instrument you are
using to calibrate or check calibration should be 4
4-1

HI 5500 SERIES SIGNAL CONDITIONERS

times more accurate than the instrument being calibrated.

NOTE:

If a signal generator with 0-20VDC offset capability

is not available, a second DC power supply is
required to produce the DC offset voltage required to
simulate accelerometer bias voltage (a 9VDC battery
is sufficient).

Quick Calibration
Check Using An HI 813
Portable Shaker
Calibration System

Variable voltage DC Power supply - 0 to

+30VDC at 250mA.
HI 813 Portable Shaker System (Desirable but
not Mandatory)
Assorted test leads and connectors.
Signal generator with variable DC positive offset
capability (0 to +20VDC), required to calibrate
the HI 5501 or HI 5502

Frequency Counter - Resolution to 0.1 Hz minimum

Oscilloscope

Step 1.
Step 2.
Step 3.
Step 4.

Step 5.

Step 6.

4-2

Make sure the transducer you are going to

use is calibrated.
Make sure the HI 813 Portable Shaker is
calibrated.
Do not connect any equipment to the HI
813 Portable Shaker unless it is OFF.
Place the HI 813 Portable Shaker on a surface that is free from any measurable
vibration. If the shaker is placed on a surface that is vibrating, the zero adjustment
of the 4-20mA output might be set artificially high.
Install transducer and cable assembly that
is the same type that will be used with the
field installed HI 5500 Series Signal Conditioners, onto the adapter head of the HI
813 Portable Shaker System for Calibration. (See Fig. 4-1)
Connect the accelerometer cable, power/
signal and common leads or velocity transducer signal and common leads to the ter-

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

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

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

Step 7.
Step 8.

Make sure the power supply is off.

Connect the +24VDC Power Supply to the
TB2-1 and TB2-2 terminals on the HI
4-3

HI 5500 SERIES SIGNAL CONDITIONERS

Step 9.
Step 10.

Step 11.
Step 12.
Step 13.

Step 14.

Step 15.

Step 16.

Step 17.

Calibration Setup
Procedures Using a
Frequency Generator
and Power Supply

It is important to note that the Frequency Generator

creates a known input frequency and the power supply generates a know input voltage thereby simulating
the output from a transducer.
Step 1.

NOTE:

4-4

5501/HI 5502. Do not apply power to the

module yet. (See Fig. 4-1)
Connect the Ammeter to the4-20mA
and Com terminals. (See Fig. 4-1)
Using the +24VDC Power Supply apply
power to the TB2-1 and TB2-2 terminals
on HI 5501/HI 5502.
Apply the +24VDC power to the module.
Turn ON the HI 813 Portable Shaker.
On the shaker set the Amplitude to the full
scale Gs that the 5501 or 5502 you are
checking is rated for. For example: If you
bought an HI 5501 with a full scale rating
of 10 Gs, set the amplitude for 10Gs.
Check the ammeter. If the ammeter is
reading 20mA (within a tolerance range of
19.5 to 20.5mA), the HI 5500 Series Module is in calibration.
Set the Amplitude to 0Gs. If the ammeter
is reading 4mA ( 5%), the HI 5500 Series
module is in calibration.
If the reading is outside the tolerance
range, check to be sure the cables are
securely fastened and the transducer is
securely fastened to the shaker.
If the reading continues to be outside the
tolerance range, calibrate the HI 5500
Series Module.

Connect the Frequency Generator output

to the HI 5501/HI 5502s transducer input
terminals marked IN+ and COM-. The
IN terminal is positive and the COM terminal is negative. (See Fig. 4-3)

If you do not have a 10VDC Power Supply you can

use a 9VDC battery in its place.

Chapter 4 - Setup

FIG. 4-3 CALIBRATION EQUIPMENT SETUP

Step 2.

NOTE:

Set the Frequency Generators DC offset

to +10VDC.

The AC (sinewave) output from the frequency generator remains OFF until an input signal is required.
Step 3.

Step 4.

Step 5.

Step 6.

Using the +24VDC Power Supply apply

power to the TB2-1 and TB2-2 terminals
on HI 5501/HI 5502. (See Fig. 4-3)
The Green LED on the cover should illuminate indicating that the circuitry senses
an acceptable bias voltage at the transducer input terminals.
If the LED does not light up turn off the
power to the system and check all the connections to be sure they are securely fastened.
Apply power to the system again. If the
LED lights up the system is ready for testing.

4-5

HI 5500 SERIES SIGNAL CONDITIONERS

Step 7.

Step 8.
Full Scale and Zero
Scale Adjustment

If the LEd still does not light up, contact

the Hardy Customer Support Department
for assistance.
Go to Chapter 5 - Calibration.

This adjustment is required if you find the milliamp

output at full scale or zero scale is not stable. This
adjustment is performed by adjusting potentiometer
R14 located on the Top Circuit board (Prt. # 02350106-01) and potentiometers R24, R25 located on the
Bottom circuit board (Prt. # 0235-0105-01). (See Fig.
4-4)

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

Step 1.

Step 2.

4-6

Make sure that you have completed the

Calibration setup and have all the equipment installed correctly. (See Chapter 4 Setup/Calibration Setup Procedures)
Check to be sure the +24VDC Input Power
Supply is OFF.

Chapter 4 - Setup
Step 3.

Use a phillips head screw driver and

remove the two phillips pan head screws
that fasten the cover to the two standoffs.
(See Fig. 4-5)

FIG. 4-5 REMOVING THE MODULE COVER

Step 4.

Step 5.

NOTE:

The HI 5500 Series Signal Conditioners are calibrated using a +24VDC Power input.
Step 6.

NOTE:

Lift off the cover and move it to the side.

Be careful not to damage the attached
wires.
Turn ON the +24VDC Input Power Supply.

Set the frequency to full scale of the HI

5501/HI 5502 you are going to calibrate
and the frequency generator power supply
to 10VDC.

It is a good idea if you have two multimeters to install

them both. One to read output amperage (4-20mA)
connected to terminals TB2-3 and TB2-4 as in the
diagram. One to read voltage connected to terminals
TB2-5 and TB2-6. (See Fig. 4-4)
Step 7.

Set the multimeter to read volts and connect the multimeter to terminals TB2-5+

4-7

HI 5500 SERIES SIGNAL CONDITIONERS

Step 8.

Step 9.

Step 10.
Step 11.

Step 12.
Step 13.

Step 14.

Step 15.
Step 16.

Step 17.
Step 18.

Step 19.

4-8

and TB2-6- on the input side of the HI

5501/HI 5502 module. (See Fig. 4-4)
Use the small flat head screw driver and
adjust the R14 potentiometer until the
voltmeter reads 5.0VDC.
Set the multimeter to read milliamps. Connect the multimeter leads back to terminals
TB1-3+ and TB1-4-.If the milliamp reading is 20.0mA you are done.
If the milliamp reading is more than 5%
of 20.0mA go to Step 11.
Use the small flat head screw driver to
adjust the R24 potentiometer until the
meter reads 20mA.
Set the frequency to 0 output.
Set the multimeter to voltage. Connect the
leads to terminals TB2-5 and TB2-6. See if
the output voltage reading is 0 volts.
Set the multimeter to read milliamps. Connect the leads to terminals TB1-3 and
TB1-4. The reading should be within 5%
of 4.0mA. If it is you are done and ready to
calibrate.
If the milliamp reading is above 5% of
4.0mA go to Step 16
Use the small flat head screw driver to
adjust the R25 potentiometer until the
multimeter reads 4.0mA.
Set the frequency to full scale again.
Again check the voltage and milliamp
readings and set them as close to 5VDC
and 20mA as possible by adjusting the
R24 potentiometer. (See Fig. 4-4)
Continue going through this adjustment
process by going from full scale frequency
to zero scale frequency until you have a
5VDC reading @ 20mA and a 0VDC
reading @ 4mA 5%. Do the adjustment
process a few times. If you cannot get the
voltage or amperage readings within tolerance, contact Hardy Instruments Customer
Support for further assistance.

Chapter 4 - Setup
CAUTION:

NEVER ALLOW THE POWER SUPPLY VOLTAGE TO EXCEED +30VDC.

Step 20. Turn off the +24VDC power supply.
Step 21. Place the cover on the standoffs.
Step 22. Use the phillips head screw driver and
replace the two phillips pan head screws
that fasten the cover to the standoffs.

Input Sensitivity
Selection

The Input Sensitivity of the HI 5501 & HI 5502 can

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

Pins Jumpered

Full Scale
Multiplier

Voltage
Input

Current
Output

1 to 2

X2.0

35.35mVrms

20mA

2 to 3

X1.0

70.70mVrms

20mA

None

X.5

141.4mVrms

20mA

Examples:

X 1.0 - with J4 pins 2 to 3 jumpered. An HI 5501

or HI 5502 calibrated for 1.0 IPS full scale, will
produce 20mA at the 4-20mA output terminal
when the vibration input is 1.0 IPS.
X 2.0 - with J4 pins 1 to 2 jumpered. An HI 5501
or HI 5502 will produce 20mA output with a
vibration input of 0.5 IPS 0-pk or 35.35mVrms.
X 0.5 - with jumpers at J4 removed entirely, the
HI 5501 or HI 5502 will produce 20mA output
with a vibration input of 2.0 IPS 0-pk. This in
effect halves the sensitivity.

4-9

HI 5500 SERIES SIGNAL CONDITIONERS

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

FIG. 4-6 J4 SENSITIVITY JUMPER SETTINGS

Monitoring System
Configuration

Reference Voltage
Jumper Setting
Procedures

4-10

If no HI 5532 Dual Set Point Module is being used, or

if one (1) Set Point Module is being used per HI 5500
Series Signal Conditioner, no jumper changes are
required to the Signal Conditioners. The factory set
Default Modes are AM (Auctioneering Mode) and
AR (Active Reference Voltage) for individually
shipped modules.
You need to set jumper (JP1) to Inactive Reference
Mode when more than one Signal Conditioner is connected to one HI 5532 Set Point Module and if the
modules are being powered with a +24VDC Power
Supply. (See Fig. 4-6) One module must be set for AR
(the master module) in group mode.

Chapter 4 - Setup
Step 1.
Step 2.

Step 3.

Step 4.

Turn the +24VDC Input Power Supply

OFF.
Use a phillips head screw driver and
remove the two phillips pan head screws
that fasten the cover to the two standoffs.
(See Fig. 4-5)
Lift off the cover and move it to the side.
Be careful not to damage the attached
wires.
Jumper JP1 is located on the Bottom board
and can be removed without taking off the
Top board. (See Fig. 4-6)

FIG. 4-7 JUMPER SETTINGS FOR REFERENCE VOLTAGE

Step 5.

To set the module Reference Voltage to

Inactive.

Step 6.

Use a small needle nose pliers and

gently lift the jumper off the pins.

To set the module Reference Voltage to

Active.

Use a small needle nose pliers and

gently press the jumper on the pins.

4-11

HI 5500 SERIES SIGNAL CONDITIONERS

4-12

Chapter 5 - Calibration

CHAPTER 5 - CALIBRATION
A Brief Description of
Chapter 5

Chapter 5 pertains to the calibration procedures for

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

Full Scale Output/

Span Adjustment

The HI 5501/HI 5502 full scale output may be set

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

Bench Calibration
Using the Hardy HI
813 Portable
Shaker System
NOTE:

See Chapter 4 for the Setup using the HI 813 Portable

Shaker System.
Step 1.

NOTE:

Calculate the Log Mid-Frequency by

using the following formula:

See the calibration example below. This is one example only, do not use these values for all transducers.

The HP Frequency = 00002 Hz

The LP Frequency = 02000 Hz

5-1

HI 5500 SERIES SIGNAL CONDITIONERS

Log Mid Frequency = AntiLog ((Log HP Freq + Log LP Freq) 2)
CALCULATION EXAMPLE FOR HI 5501 (MODEL #5501-00002-02000-1.0V100):
Log Mid Frequency = 10x ((Log2 + Log 2,000) 2)
Log Mid Frequency = 10x ((.3 + 3.3) 2)
Log Mid Frequency = 10x ((3.6) 2)
Log Mid Frequency = 10x (1.80)
The Log Mid Frequency for calibrating this HI 5501 = 63.09 Hz
HP Frequency is the corner frequency in Hz of the HP
(Highpass) filter.
LP Frequency is the corner frequency in Hz of the LP
(Lowpass) filter.

Low Pass
Frequency

High Pass
Frequency

Log Mid
Frequency

2 Hz

1 KHz

44.7 Hz

2 KHz

63.1 Hz

3 KHz

79.4 Hz

5 KHz

100 Hz

10 KHz

141.3 Hz

30 KHz

251.2 Hz

1 KHz

70.8 Hz

2 KHz

100 Hz

3 KHz

125.9 Hz

5 KHz

158.5 Hz

5 Hz

Table 5-1: Log Mid Frequency Table

5-2

Chapter 5 - Calibration

Low Pass
Frequency

High Pass
Frequency

Log Mid
Frequency

10 KHz

223.9 Hz

30 KHz

398.1 Hz

1 KHz

100 Hz

2 KHz

141.3 Hz

3 KHz

177.8 Hz

5 KHz

223.9 Hz

10 KHz

316.2 Hz

30 KHz

562.3 Hz

10 Hz

Table 5-1: Log Mid Frequency Table

Step 2.

Step 3.

Step 4.
Step 5.

Step 6.

Turn the HI 813 Shaker amplitude knob to

counter-clockwise until it stops. This is the
minimum frequency.
Set the HI 813 Shaker Function Display
Switch to Acc, Vel, or Disp to match the
HI 5501/HI 5502 output mode. In our
example the HI 813 switch is set to Vel to
match the V (velocity) output mode of the
HI 5501 model 5501-00002-02000-1.0V100
Set the HI 813 power switch to ON.
Adjust the HI 813 vibration amplitude to
the desired full scale amplitude which is
shown in the display. In our example the
HI 5501 is calibrated for a full scale of 1.0
IPS, indicated by the 1.0V in the model
number. Set the shaker amplitude to 1.0
for our example by turning the amplitude
knob clockwise until 1.0 appears in the
display.
Adjust the HI 813 vibration frequency to
the Log Mid Frequency from the Log Mid
Frequency Table 5-1or as calculated using

5-3

HI 5500 SERIES SIGNAL CONDITIONERS

Step 7.
Step 8.
Step 9.

the formula provided. The Log Mid Frequency in our example is 63.09Hz.
Verify the Analog output reading to be 20
mA 5%.
Check to be sure the +24VDC Input Power
Supply is OFF.
Use a phillips head screw driver and
remove the two phillips pan head screws
that fasten the cover to the two standoffs.
(See Fig. 5-1)

FIG. 5-1 REMOVE PHILLIPS PAN HEAD

SCREWS
Step 10. Lift off the cover and move it to the side.
Be careful not to damage the attached
wires.
Step 11. Turn ON the +24VDC Input Power Supply.
Step 12. If necessary use a small flat head screw
driver to adjust the R14 potentiometer
until the multimeter is reading 20.0mA
5%.
Step 13. This completes the calibration of an HI
5501 Signal Conditioner that contains a
2Hz HP filter, a 2,000Hz LP filter and one
stage of integration with 20.0mA output
when the vibration input is 1.0 inches per
second.

5-4

Chapter 5 - Calibration
Step 14. This completes the span or full scale calibration using the HI 813 Portable Shaker
System to the full scale amplitude.
Step 15. Shut OFF the +24VDC power supply.
Step 16. Place the cover on the standoffs.
Step 17. Use the phillips head screw driver and
replace the two phillips pan head screws
that fasten the cover to the standoffs.
Step 18. Using the formula above and the frequency range to be monitored by the HI
5500 Series Signal Condition Monitor,
calculate the Log Mid-Frequency for each
HI 5500 Series Monitor in your system.
Bench Calibration
Using a Frequency
Generator and
Power Supply
NOTE:

See Chapter 4 for the Setup using the Frequency Generator and Power Supply.
Step 1.
Step 2.
Step 3.

Set the Frequency Generators DC Offset

to +10VDC.
Make sure the Green OK light is on.
Adjust the frequency generators AC sinewave output to the voltage the vibration
transducer would produce when set to the
full scale output for the HI 5501/HI 5502
module you are calibrating. For example:

Step 4.
Step 5.
Step 6.

To calibrate an HI 5501 for 20mA at 2

Gs of acceleration when connected to
a 100mV per G accelerometer, the
frequency generators sinewave output would be set to 200mV 0-pk or
141.1mV RMS.

Check the milliamp reading.

Check to be sure the +24VDC Input Power
Supply is OFF.
Use a phillips head screw driver and
remove the two phillips pan head screws
5-5

HI 5500 SERIES SIGNAL CONDITIONERS

that fasten the cover to the two standoffs.
(See Fig. 4-5)
Step 7. Lift off the cover and move it to the side.
Be careful not to damage the attached
wires.
Step 8. Turn ON the +24VDC Input Power Supply.
Step 9. Use a small flat head screw driver to adjust
the R14 potentiometer until the multimeter
is reading 20.0mA 5%.
Step 10. This completes the calibration of an HI
5501 Signal Conditioner that contains a
2Hz HP filter, a 2,000Hz LP filter and one
stage of integration with 20.0mA output
when the vibration input is 1.0 inch per
second.
Step 11. This completes the span or full scale calibration using the Frequency Generator to
duplicate the full scale amplitude.
Current Limit Test

The Current Limit Test insures the 4-20mA circuitry

is properly limiting the output current to approximately 34mA.
Step 1.

Step 2.

Step 3.
Step 4.
Step 5.

Final Check

5-6

Step 1.

With the Frequency Generator apply

100Hz sinewave of 100mV RMS amplitude to the HI 5501 transducer input terminals with the DC Offset set to +10VDC.
Increase the AC input voltage to approximately 2V RMS while observing the 420mA current output. Current limiting
should begin to occur when the input voltage gets to about 1.875V RMS, and limit
the output current to approximately 30 to
40mA.
Shut off the +24VDC Input Power Supply.
Place the cover on the standoffs.
Use the phillips head screw driver and
replace the two phillips pan head screws
that fasten the cover to the standoffs.
Turn ON the +24VDC Input Power Supply.

Chapter 5 - Calibration
Step 2.

Check the OK light and the full scale

output again to make sure no wiring was
shorted on reassembly.

This completes the bench calibration of the HI

5501 or HI 5502 Signal Conditioner. The module(s) is fully calibrated and ready for field installation.
Calculation of HI 5501/
5502 Full Scale
Calibration voltage
Acceleration or
Velocity

When the connected transducers output matches the

HI 5501/HI 5502/s output mode, no signal integration
is required. For this condition, full scale calibration
voltage is derived by multiplying the number of EUs
full scale by the transducers milli-volt per EU Sensitivity.
For example:
HI 5501 w/Accel IN - Accel OUT:
HI 5501-00010-02000-5.0G-100 - Pk

= Calibration Voltage = EUs Full Scale * millivolts per EU

= 5.0 * 100mV
= Calibration Voltage = 500mV

HI 5502 w/ Vel IN - Vel OUT:

HI 5502-00002-01500-2.0V-400

Accelerometer or
Velocity Input with
Signal Integration

= Calibration Voltage = EUs Full Scale * millivolts per EU

= 2.0 * 400mV
= Calibration Voltage = 800mV

When the transducer input signal must be single or

double integrated to provide the desired vibration
parameter, the Hardy HI 5500 Signal Condition can
5-7

HI 5500 SERIES SIGNAL CONDITIONERS

contain one or two stages of integration. With integration installed, the transducer input voltage required to
produce the HI 5501/HI 5502s integrated full scale
output must be calculated and used as the input voltage when calibrating the 4-20mA output.
There are three Procedures to follow when deriving
the full scale calibration voltage for HI 5500 Series
Signal Conditioners containing one or two stages of
signal integration.
1.
2.
3.

Calculate the Log Mid-Frequency (See procedures above)

Convert Output Eus F.S. to Input EUs F.S at f
(Log Mid-Freq).
Convert derived Input Eus F.S. to Volts for the
specific transducer.

Log MidFrequency

Get from Table 5-1.

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

1.

Three
Examples
Based on Part
Numbers

Prt. # HI-5501-00005-01500-2.0V-100 Covers the

Accel to Velocity Configuration:

HI 5501 with Accel to Vel Single Integration

requires Vel to Accel conversion:

Accel = 0.0162 * Vel EUs F.S. * f

(Log Mid-Freq)

Accel = 0.0162 * V (Vel EUs F.S.) * f (Log-MidFreq)

Accel = 0.0162 * 2.0 * 86.6
Accel = 2.806
4-20mA F.S. Calibration Voltage = 281mV pk.
This example covers an HI 5501, acceleration input
signal, which requires double integration to displacement.
Prt. # HI 5501-00003-01000-5.0D-100 Covers the
Accel to Displacement Configurations:

5-8

Chapter 5 - Calibration

Log Mid-Freq = 54.77 Hz

Accel =.0511 * f2 (Log Mid-Freq2 * Disp EUs F.S.
(inches)
Accel =.0511 * (54.77)2 *.005
Accel =.766
4-20mA F.S. Calibration Voltage = 76.6 mV pk.

5-9

HI 5500 SERIES SIGNAL CONDITIONERS

5-10

Chapter 6 - Troubleshooting

CHAPTER 6 - TROUBLESHOOTING
A Brief Description of
Chapter 6

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

Problem: Green Light

Not Illuminated

Step 1.

Step 2.

Step 3.
Step 4.

Step 5.

Step 6.

Check Output
Amperage

Step 1.

Step 2.

Use a Volt meter and check the Loop

Power (Terminals TB2-1 & 2) to see if
you have +24VDC to the board. If the
voltage is not +24VDC there is a problem
with the circuit board or the power source.
Use a Volt meter and check terminals
TB2-5&6 to see if you have 5VDC. If the
voltage is not 5VDC there is a problem
with the circuit board. Go to Step 7.
Turn the Power from your +24VDC
Source OFF.
Remove the Cover and check the BNC and
LED connectors to see if they are connected to the proper pins or completed
seated on the pins. Note: There is a white
dot on the connector which should match
the position of the dot on the circuit board.
If they do not match up, re-connect the
connector(s) so they do.
After each Step, check to see if the green
OK light comes on. If it does not got to
another step until you have found the
problem.
If the green OK light still does not come
on after going through all the steps. Contact Hardy Instruments, Customer Support
Department for assistance.
Use an ammeter and check terminals TB23&4 to see if you have 20mA. If the
amperage is not 20mA there is a problem
with the circuit board.
Check to be sure that the 4-20mA output is
suppressed to 0mA whenever the DC bias
6-1

HI 5500 SERIES SIGNAL CONDITIONERS

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

6-2