6479A1 3500-72 Rodrop

Part number 146479-01
Revision A, April 2004
3500/72M Recip
Rod Position Monitor
Operation and Maintenance Manual
3500/72M Recip Rod Position Monitor Operation and Maintenance Manual
Copyright 2001 - 2004 Bently Nevada, LLC

All Rights Reserved.
The information contained in this document is subject to change without notice.
The following are trademarks of Bently Nevada, LLC in the United States and other
countries:
ACM, Actionable Information, Actionable Information to the
Right People at the Right Time, ADRE, Asset Condition
Management, Asset Condition Monitoring, Bently ALIGN,
Bently BALANCE, Bently DOCUVIEW, Bently LUBE,
Bently PERFORMANCE, Bently Nevada, CableLoc,
SM
ClickLoc, Data Manager, Decision Support , DemoNet,
Dynamic Data Manager, Engineer Assist, FieldMonitor,
flexiTIM, FluidLoc, Helping You Protect and Manage All Your
Machinery, HydroScan, HydroView, Key ,
Keyphasor, Machine Condition Manager 2000,
MachineLibrary, Machine Manager, MicroPROX, Move
Data, Not People, Move Information, Not Data, NSv, Prime
Spike, PROXPAC, Proximitor, REBAM, RuleDesk, SE,
Seismoprobe, Smart Monitor, Snapshot, System 1,
System Extender, TDXnet, TDIXconnX, TipLoc,
TorXimitor, Transient Data Manager, Trendmaster,
TrimLoc, Velomitor.
Bently Nevadas orbit logo and other logos associated with the
trademarks in bold above, are also all trademarks or registered
trademarks of Bently Nevada in the United States and other
countries
The following ways of contacting Bently Nevada are provided for those times when you
cannot contact your local Bently Nevada representative:
Mailing Address
Telephone
Fax
Internet
ii
1631 Bently Parkway South

Minden, NV 89423
USA
1 775 782 3611
1 800 227 5514
1 775 215 2876
www.bently.com
Additional Information
Notice:
This manual does not contain all the information required to operate and maintain the
3500/72M Recip Rod Position Monitor module. Refer to the Following manuals for
other require information.
3500 Monitoring System Rack Installation and Maintenance Manual (129766-01)
general description of a standard system
general description of a Triple Modular redundant (TMR) system
instructions for installing the removing the module from a 3500 rack
drawings for all cables used in the 3500 Monitoring System
3500 Monitoring System Rack Configuration and Utilities Guide ( 129777-01)
guidelines for using the 3500 Rack Configuration software for setting the operating
parameters of the module
Guidelines for using the 3500 test utilities to verify that the input and output terminals on
the module are operating properly
3500 Monitoring system Computer Hardware and Software Manual (128158-01)
instructions for connecting the rack to 3500 host computer
procedures for verifying communication
procedures for installing software
guidelines for using Data Acquisition / DDE Server and Operator Display Software
procedures and diagrams for setting up network and remote communications
3500 Field Wiring Diagram Package (130432-01)
diagrams that show how to hook up a particular transducer
lists of recommended wiring
iii
Contents
1.
Receiving and Handling .............................................................. 1

1.1 Receiving Inspection........................................................................................... 1
1.2 Handling and Storing Considerations ................................................................. 1
1.3 Disposal Statement............................................................................................. 1
2.
General Information ..................................................................... 3

2.1 Triple Modular Redundant Description ............................................................... 5
2.2 Available Data..................................................................................................... 5
2.2.1 Statuses .............................................................................................. 5
2.2.2 Proportional Values ............................................................................. 8
2.3 LED Descriptions ................................................................................................ 9
3.
Configuration Information......................................................... 11
3.1 Software Configuration Options........................................................................ 11
3.1.1 Recip Rod Position Monitor Configuration Options ........................... 12
3.1.2 Rod Position Single Channel Configuration ...................................... 15
3.1.3 Rod Position Pair Channel Configuration.......................................... 23
3.1.4 Rod Drop Channel Configuration ...................................................... 31
3.1.5 Hyper Channel Configuration ............................................................ 38
3.1.6 Rod Position Transducer Calibration................................................. 44
3.2 Setpoints........................................................................................................... 48
3.3 Software Switches ............................................................................................ 52
4.
I/O Module Descriptions ............................................................ 55

4.1 Setting the I/O Jumper...................................................................................... 55
4.2 Prox/Velom I/O Module (Internal Termination) ................................................. 57
4.2.1 Wiring Euro Style Connectors ........................................................... 58
4.3 Barrier Proximitor Internal I/O Module (Internal Termination) ........................... 59
4.4 Prox/Velom I/O Module (External Termination) ................................................ 60
4.4.1 External Termination Blocks.............................................................. 61
4.4.2 Cable Pin Outs .................................................................................. 65
5.
Maintenance ............................................................................... 67
5.1 Verifying a 3500 Rack Recip Rod Position Monitor Module .......................... 67
5.1.1 Choosing a Maintenance Interval...................................................... 68
5.1.2 Required Test Equipment and Setup ................................................ 68
5.1.3 Typical Verification test setup............................................................ 70
5.1.4 Using the Rack Configuration Software ............................................ 71
5.1.5 Rod Position Single Channels........................................................... 74
5.1.6 Rod Position Pair Channels .............................................................. 93
5.1.7 Rod Drop Channels......................................................................... 115
5.1.8 Hyper Channels............................................................................... 125
5.1.9 Verify Recorder Outputs.................................................................. 139
5.1.10 If a Channel Fails a Verification Test............................................... 140
6.
Troubleshooting....................................................................... 141
6.1 Self-test........................................................................................................... 141
iv
6.2 LED Fault Conditions ......................................................................................142

6.3 System Event List Messages ..........................................................................143
6.4 Alarm Event List Messages ............................................................................154
7.
Ordering Information ............................................................... 155

7.1 Ordering Considerations .................................................................................155
7.2 List of Options and Part Numbers ...................................................................155
7.2.1 Recip Rod Position Monitor .............................................................155
7.2.2 External Termination Blocks............................................................155
7.2.3 3500 Transducer Signal to External Termination Block Cable ........155
7.2.4 3500 Recorder Output to External Termination (ET) Block Cable...156
7.2.5 Spares .............................................................................................156
8.
Specifications .......................................................................... 157

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
Inputs ..............................................................................................................157
Outputs ...........................................................................................................157
Data Values ....................................................................................................157
Signal Conditioning .........................................................................................158
Rod Drop:........................................................................................................159
Hyper-Channel:...............................................................................................159
Alarms .............................................................................................................160
Environmental Limits.......................................................................................160
CE Mark Directives .........................................................................................161
Hazardous Approvals......................................................................................161
Physical...........................................................................................................162
vi
Section 1 Receiving and Handling
1.
1.1
Receiving and Handling

Receiving Inspection
Visually inspect the module for obvious shipping damage. If shipping damage is
apparent, file a claim with the carrier and submit a copy to Bently Nevada
Corporation.
1.2
Handling and Storing Considerations

Circuit boards contain devices that are susceptible to damage when exposed to
electrostatic charges. Damage caused by obvious mishandling of the board will
void the warranty. To avoid damage, observe the following precautions in the
order given:
Application Alert: Machinery protection will be lost when this module is
removed from the rack.
1.3
Do not discharge static electricity onto the circuit board. Avoid tools or
procedures that would subject the circuit board to static damage. Some
possible causes include ungrounded soldering irons, nonconductive plastics,
and similar materials.
Personnel must be grounded with a suitable grounding strap (such as 3M

Velostat No. 2060) before handling or maintaining a printed circuit board.
Transport and store circuit boards in electrically conductive bags or foil.
Use extra caution during dry weather. Relative humidity less than 30 %
tends to multiply the accumulation of static charges on any surface.
Disposal Statement
Customers and third parties that are in control of product at the end of its life or
at the end of its use are solely responsible for proper disposal of product. No
person, firm, corporation, association, or agency that is in control of the product
shall dispose of it in a manner that is in violation of United States state laws,
United States federal laws, or any applicable international laws. Bently Nevada
Corporation is not responsible for disposal of product at the end of its life or at
the end of its use.
Section 2 General Information
2.
General Information
The 3500/72M Recip Rod Position Monitor is a four-channel monitor that accepts
input from Proximitor Transducers which measure the position of the
reciprocating rod on a rev-to-rev basis. The monitor uses this input to drive
alarms for protection and provide waveform data to System 1 for management
via 3500 TDI. The monitor can be programmed using the 3500 Rack
Configuration Software to perform any of the following functions: Rod PositionPair, Rod Position-Single, Rod Drop, and Hyper compressor Rod Movement.
The monitor can receive input from many types of transducers including the
following Bently Nevada transducers:
Proximitor Transducers
3300XL 8mm and 11mm

3300 8mm
7200 8mm, 11mm, and 14mm
(1) Main module front view.

(2) Status LEDs, refer to Section 2.3.
(3) Buffered transducer outputs, provide an unfiltered output for each of the four transducers. All are
short circuit protected.
(4) I/O module rear views.
(5) Barrier I/O module, Internal Termination. Refer to Section 4.3.
(6) I/O module, Internal Termination. Refer to Section 4.2
(7) I/O module, External Termination. Refer to Section 4.4.
The primary purpose of the 3500/72M monitor is to provide 1) machinery

protection by continuously comparing current machine wear against configured
alarm setpoints to drive alarms and, 2) essential machine wear information to
both operator and maintenance personnel. Alarm setpoints are configured using
the 3500 Rack Configuration Software. Alarm setpoints can be configured for
each active proportional value, and danger setpoints can be configured for two of
the active proportional values.
When shipped from the factory, the 3500/72M is delivered unconfigured. When
needed, the 3500/72M can be installed into a 3500 rack and configured to
perform the required monitoring function. This lets you stock a single monitor for
use as a spare for many different reciprocating compressor applications.
2.1
Triple Modular Redundant Description

Not available with this monitor.
2.2
Available Data
The Recip Rod Position Monitor returns specific proportional values dependent
upon the type of channel configured. This monitor also returns both monitor and
channel statuses which are common to all types of channels.
2.2.1
Statuses
The following statuses are provided by the Recip Rod Position Monitor. This
section describes the available statuses and where they can be found.
2.2.1.1
Monitor Status
Statuses
Monitor
Front
Panel
Monitor OK
Communication
Gateway Module
Rack Configuration
Software
Monitor Alert/Alarm 1
Monitor Danger/Alarm 2
Monitor Bypass
Monitor Configuration Fault
Monitor Special Alarm Inhibit
Operator
Display
Software
OK
This indicates if the monitor is functioning correctly. A NOT OK status is returned
under any of the following conditions:
Module Hardware Failure
Node Voltage Failure
Configuration Failure
Transducer Failure
5
Slot ID Failure
Channel not OK
If the Monitor OK status goes not OK, then the system OK Relay on the Rack
Interface I/O Module will be driven not OK.
Alert/Alarm 1
This indicates whether the monitor has entered Alert/Alarm 1. A monitor will enter
the Alert/Alarm 1 state when any proportional value provided by the monitor exceeds
its configured Alert/Alarm 1 setpoint.
Danger/Alarm 2
This indicates whether the monitor has entered Danger/Alarm 2. A monitor will enter
the Danger/Alarm 2 state when any proportional value provided by the monitor
exceeds its configured Danger/Alarm 2 setpoint.
Bypass
This indicates when the monitor has bypassed alarming for one or more proportional
values of a channel. When a channel bypass status is set, this monitor bypass
status will also be set.
Configuration Fault
This indicates if the monitor configuration is valid.
Special Alarm Inhibit

This indicates whether all the non-primary Alert/Alarm 1 alarms in the associated
monitor are inhibited.
The Channel Special Alarm Inhibit function is active when:
2.2.1.2
The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

(active).
A Channel Special Alarm Inhibit software switch is enabled.
Channel Status
Statuses
Communication
Gateway Module
Rack Configuration
Software
Operator
Display
Software
Management
Software
Channel OK
Channel Alert/Alarm 1
Channel Danger/Alarm 2
Channel Bypass
Channel Special Alarm

Inhibit
Channel Off
OK
This indicates that no fault has been detected by the associated Recip Rod Position
Monitor channel.
There are two types of channel OK checking: Transducer Input Voltage and
Transducer Supply Voltage A channel OK status will be deactivated if either of the
OK types goes not OK.
Alert/Alarm 1
This indicates whether the associated monitor channel has entered Alert/Alarm 1. A
channel will enter the Alert/Alarm 1 state when any proportional value provided by
the channel exceeds its configured Alert/Alarm 1 setpoint.
Danger/Alarm 2
This indicates whether the associated monitor channel has entered Danger/Alarm 2.
A channel will enter the Danger/Alarm 2 state when any proportional value provided
by the channel exceeds its configured Danger/Alarm 2 setpoint.
Bypass
This indicates that the channel has bypassed alarming for one or more of its
proportional values. A channel bypass status may result from the following
conditions:
The Keyphasor transducer associated with the channel has gone invalid
causing all proportional values associated with the Keyphasor to be
bypassed.
The monitor has detected a serious internal fault.
A software switch is bypassing any channel alarming function.
The Special Alarm Inhibit is active and causing enabled alarms not to be
processed.

This indicates whether all the nonprimary Alert/Alarm 1 alarms in the associated
Recip Rod Position Monitor channel are inhibited. This status is active when:
The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

(active).
Software Special Channel Alarm Inhibit is active.
Off
This indicates whether the channel has been turned off. The monitor channels may
be turned off (inactivated) using the Rack Configuration Software.
2.2.2
Proportional Values
Proportional Values are measurements used to monitor the machine. The Recip
Rod Position Monitor returns Proportional values for the following channel types:
Rod Position Single
Position Magnitude, Position Angle, Crank Angle, Pk-Pk
Displacement, Gap, 1X Amplitude, 2X Amplitude, and Not
1X Amplitude
Rod Position Pair
Displacement, Gap, 1X Amplitude, 2X Amplitude, and Not
1X Amplitude
Rod Drop
Average Piston Position, Average Probe Gap, Instantaneous
Piston Position, and Instantaneous Probe Gap
Hyper Channel
Pk-Pk Displacement, Gap, 1X Amplitude, 2X Amplitude, and
Not 1X Amplitude
2.3
LED Descriptions
The LEDs on the front panel of the Recip Rod Position Monitor indicate the
operating status of the module as shown in the following figure. Refer to Section
6.2 for all of the available LED conditions.
(1) OK: Indicates that the Recip Rod Position Monitor and the Prox/Velom I/O module are operating
correctly.
(2) TX/RX: Flashes at the rate that messages are received and transmitted.
(3) BYPASS: Indicates that some of the monitor functions are temporarily suppressed.
10
Section 3 Configuration Information
3.
Configuration Information
This section describes how the 3500/72M Recip Rod Position Monitor is
configured using the Rack Configuration Software. It also describes any
configuration restrictions associated with this module. Refer to the 3500
Monitoring System Rack Configuration and Utilities Guide and the Rack
Configuration Software for the details on how to operate the software.
Configuration Overview
A series of steps is required to configure the Recip Rod Position Monitor. The
basic steps in this process are: 1) Enter channel type and machine parameters
into the software configuration screens. 2) Download the incomplete
configuration to the 3500 Rack. 3) While the configuration computer is
connected to the Rack, use the software Calibrate Channel screen and calibrate
the transducer(s) and configure the options for the channel in the Options
screen. 4) While in the Options screen, gap the probe at the required position.
5) Adjust the Zero Position or Setup Voltage in the Options screen accordingly.
6) Adjust alarm setpoints to the desired levels in the Setpoint configuration
screen. 7) Download the completed channel configuration to the 3500 Rack.
3.1
Software Configuration Options

This section shows the configuration screens of the Rack Configuration Software
that are associated with the monitor and discusses the configuration
considerations. It will show a copy of the software screens and will explain the
options that are available.
11
3.1.1
Recip Rod Position Monitor Configuration Options

This section describes the options available on the Recip Rod Position Monitor
configuration screen.
Reference Information
These fields contain information that indicates which module you are configuring.
Slot
The location of the monitor in the 3500 rack (2 through 15).
Rack Type
The type of Rack Interface Module installed in the rack (Standard or TMR). This field
is always set to standard since the Recip Rod Position Monitor can only be installed
in a standard rack.
Configuration ID
A unique six character identifier which is entered when a configuration is downloaded
to the 3500 rack.
Slot Input/Output Module Type

The I/O field lets you identify the type of I/O Module that is attached to the
monitor (The option selected must agree with the I/O module installed). These
choices are:
12
Prox/Velom Internal I/O

The transducer field wiring is connected directly to the I/O module.
Prox/Velom External I/O

The transducer field wiring is connected to an External Termination Block and then
routed from the External Termination Block to the I/O module through a 25-pin cable.
The recorder field wiring is connected to an External Termination Block and then
routed from the External Termination Block to the I/O module through a 9-pin cable.
Prox/Accel Internal Barrier I/O

The transducer field wiring is connected directly to the Internal Barrier I/O Module.
Note that selecting the Prox/Accel Internal Barrier I/O option will disable certain
transducer type options.
Throw Configuration
The fields within these tabs pertain to the monitoring of each individual throw.
Channel Type
The type of monitoring which is to be performed by the channel pair. The following
Channel types are available in the monitor:
Rod Position Single
Rod Position Pair
Rod Drop
Hyper
Keyphasor Association
No Keyphasor
Can be used when a Keyphasor is not available. If this is marked, then it will restrict
data available for each channel type. Rod Position Single and Rod Position Pair
channel types will only have Position Magnitude, Position Angle, Pk-Pk, and Gap
measurements. Rod Drop will only allow Average measurements. Hyper channels
will only have Pk-Pk and Gap available.
Design Speed
When the No Keyphasor box is selected for Rod Position Single and Rod Position
Pair channel types, the configuration software creates a new box called Design
Speed. You are required to enter the designed operating RPM of the system.
Primary
The Keyphasor channel selected that is normally used for measurement. When this
Keyphasor transducer is marked invalid, the backup Keyphasor will provide the shaft
reference information.
Backup
The Keyphasor channel selected that will be used if the primary fails. If you do not
have a backup Keyphasor, select the same Keyphasor channel as the primary.
13
Piston Angle
When the piston hits top dead center, this is the angular measurement between the
centerline of the Keyphasor probe to the keyphasor leading edge. This is measured
to the left edge (for CCW rotating crankshaft) or to the right edge (for CW rotating
crankshaft) of the index notch on the crankshaft position wheel in the direction of
crank rotation when the piston is at Top Dead Center.
Channel
Active
Select whether the functions of the channel will be turned on ( ) or off ( ).
Channel Selection
Use the pull down menu to determine which channel(s) are to be used with the
throw. Only one channel is used with Rod Position Single and Rod Drop channel
types. For Rod Position Pair and Hyper channel types, you must use dual channels,
either 1-2 or 3-4.
Configuration
A button used to display the configuration options for the selected channel type.
Barriers
Select the MTL 796(-) Zener External option, or Galvanic Isolators if external safety
barriers are connected between the monitor and the transducer. If the Prox/Accel
Internal Barrier I/O Module is selected for Slot Input/Output Module Type, the Internal
option is selected for you. These devices are used to restrict the amount of energy
that can flow into a hazardous area.
14
3.1.2
Rod Position Single Channel Configuration

This section discusses the Configuration Considerations and the Rack
Configuration Software screens associated with the Rod Position Single channel
type.
3.1.2.1
Rod Position Single Channel Configuration Considerations

Consider the following items before configuring a Rod Position Single Channel:
Internal Barrier I/O Modules and External barriers are not currently supported
with 7200 11 mm or 14 mm.
When NO Keyphasor is selected, the Design Speed is used to calculate

Position Magnitude, Position Angle, 1X Amplitude, 2X Amplitude, and Not 1X
Amplitude. Differences between the input Design Speed and the actual
machine running speed will produce inconsistent data. Crank Angle
measurements are not valid.
If a Keyphasor Channel is selected, a Keyphasor Module must be installed in

the rack.
The full scale options allowed for each proportional value are dependent
upon the transducer type and rod material.
Setpoints may only be set on proportional values which are enabled.
Monitors must be configured in channel pairs. Channels 1 and 2 must be

configured to be the same Channel type. Channels 3 and 4 must be
configured to be the same channel type. (Ex: Channels 1 and 2 may be
configured as Rod Position Single and Channels 3 and 4 may be configured
as Hyper)
When a full-scale range is modified, the setpoints associated with this

proportional value should be readjusted.
You should run the transducer calibration and download it to the monitor
before you do the center position setup.
The configuration program will not allow you to make a change without
checking for proper settings in the options screen.
15
3.1.2.2
Rod Position Single Channel Configuration Screen

This section describes the required inputs and options available on the Rod
Position Single Channel Configuration screen.
Average Reference Temperature

The average temperature of the environment when the piston clearance and cylinder
bore measurements were taken.
Average Suction Temperature

The average temperature of the suction gas under normal operating conditions.
Average Discharge Temperature

The average temperature of the discharge gas under normal operating conditions.
Piston Material
The material from which the piston was made. The materials to choose from are
iron, steel, or aluminum.
Piston Top Clearance

The measurement from the top of the piston to the cylinder internal diameter, taken
while the piston is at rest in the cylinder supported by its rider band(s).
16
Piston Bottom Clearance

The measurement from the bottom of the piston to the cylinder internal diameter,
taken while the piston is at rest in the cylinder supported on its rider band(s).
Direction of Rotation:
The direction of the rotation of the crank shaft as viewed from the driver end of the
machine. This value will be Clockwise (CW) or Counter Clockwise (CCW).
Stroke
The length that the piston travels in one direction.
Cylinder Bore Diameter

The measurement of the cylinder internal diameter.
Probe Position
The distance from the crosshead pin pivot to the probe when the piston is at Top
Dead Center (TDC) at the head end of the cylinder.
Connecting Rod Length

The length between the hole center to hole center on the connecting rod, or length
between the center of the connecting rod journal to the center of the crosshead pin.
Piston Rod Length

The length from the crosshead pin pivot center to rider band (if only one) or to the
center of the rider bands (if two or more).
Channel Transducer Tab

For Rod Position Single there will be only one channel transducer tab.
Transducer Type
The following transducer types are available for the Rod Position Single NONBARRIER I/O modules:
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
7200 11mm
7200 14mm
The following transducer types are available for the Rod Position Single BARRIER
I/O modules:
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
17
Transducer Orientation
The physical position of the transducer with respect to the rod. The orientation is
specified as 0 to 180 degrees left or right. Zero degrees is defined as follows:
For horizontal machines:
Stand at the driver end (crankshaft) and look towards the driven end (cylinder). Zero
degrees is located at the top (up) of the case; the 180 degree mark is located at the
bottom (down).
For vertical machines:
Stand at the top of the machine and look down. Zero degrees can be associated with
any recognizable physical reference point. Typically this might be set to the direction
North.
Calibrate Channel Button

A button to display the transducer calibration screen. See Section 3.1.6 for
transducer calibrations. It is always recommended to calibrate all transducers for
any rod material.
Note: Calibrate the selected transducer before continuing with the transducer
options.
Options Button
A button to display the configuration options for the selected transducer type.
Point Names Button

This button allows the user to define and input custom names to each channel.
CP Mod
Selecting the CP Mod button Channel Options Dialog Box, allows a Custom channel
configuration to be downloaded to the monitor. Custom configuration data is stored
in a Custom Products Modification File. Custom Products Modification files follow
the naming convention <modification #.mod>. These files must be located in the
\3500\Rackcfg\Mods\ directory. When a CP Mod file is selected, a window is
displayed which describes the function of the modification. CP Mod files are
available through Bently Nevada's Custom Products Division. Contact your local
Bently Nevada Sales Representative for details.
18
3.1.2.3
Rod Position Single Channel Options Screen

This section describes the options available on the Rod Position Single Channel
Transducer Options screen.
Channel
The channel of the monitor being configured.
Slot
Rack Type
in a standard rack.
19
Enabled
An enabled proportional value specifies that the value will be provided by the
channel ( enabled, disabled).
Position Magnitude
The maximum value of the position vector magnitudes calculated every one degree
of crank rotation over one cycle. The position vector magnitudes are the rod center
position relative to a zero position representing the piston being concentric to the
cylinder bore.
Position Angle
The angle made by the vector representation of the maximum position magnitude.
Represents where the center of the rod is with respect to the zero position when the
position vector is at its maximum magnitude. 0 degrees is defined as vertical with
CW being positive rotation viewed from crank end. For Rod Position Single channel
types, Position Angle measurements can only be 0 or 180 degrees.
Crank Angle
The rotational angle of the crank corresponding to the axial position of the rod
(referenced from piston Top Dead Center) when the position vector is at its maximum
magnitude. Represents where the rod is located in its stroke when the position
vector is at its maximum magnitude. The crank angle is referenced from the piston
angle (TDC being 0 degrees) with positive rotation in the direction of crank rotation.
Pk Pk Displacement
Data which represents the overall peak to peak vibration. For the Recip Rod Position
Monitor the frequency response for Pk Pk displacement is always 1 to 600 Hz or 60
to 36,000 CPM.
Gap
A voltage representing the physical distance between the face of a proximity probe
tip and the observed surface. Standard polarity convention dictates that a
decreasing gap results in an increasing (less negative) output signal.
1X Amplitude
In a complex vibration signal, notation for the amplitude component that occurs at the
rotative speed frequency.
2X Amplitude
In a complex vibration signal, notation for the amplitude component having a
frequency equal to two times the shaft rotative speed.
Not 1X Amplitude
In a complex vibration signal, notation for the peak to peak amplitude of the wave
shape after the rotative speed component is removed.
Full Scale Range

Each selectable proportional value provides the ability to set a full scale value. The
Full Scale Range selections are dependant upon the transducer calibration. The Full
Scale cannot be set larger than the linear range of the transducer. All scales for the
Rod Position channel types have a minimum value of 0.
Clamp Value
The value that a proportional value goes to when that channel or proportional value
is bypassed or defeated (For example when a problem occurs with the transducer).
20
The selected value can be between the minimum and maximum full-scale range
values. Only the values available from the Recorder Outputs, Communication
Gateway and Display Interface Module are clamped to the specified value when the
proportional value is invalid.
Recorder Output
The proportional value of a channel that is sent to the 4 to 20 mA recorder. The
recorder output is proportional to the measured value over the channel full scale
range. An increase in the proportional value that would be indicated as upscale on a
bar graph display results in an increase in the current at the recorder output.
If the channel is Bypassed, the output will be clamped to the selected clamp value or
to 2 mA (if the 2 mA clamp is selected).
Alarm Mode
Alert should be the first level alarm that occurs when the transducer signal level
exceeds the selected value. Danger should be the second level alarm that occurs
when the transducer signal level exceeds the selected value. The Alert and Danger
values are set on the Setpoint screen.
Latching
Once an alarm is active it will remain active even after the proportional value enters
back into the configured non-alarm setpoint level. The channel will remain in alarm
until it is reset using one of the following methods:
the reset switch on the front of the Rack Interface Module
the contact on the Rack Interface I/O Module
the Reset button in the Operator Display Software
the reset command through the Communication Gateway Module
the reset command through the Display Interface Module
the reset command in the Rack Configuration Software
Nonlatching
When an alarm is active it will go inactive as soon as the proportional value enters
back into the configured non-alarm setpoint level.
Delay
The time which a proportional value must remain at or above an over alarm level or
below an under alarm level before an alarm is declared as active.
Alert
First level alarm that occurs when the transducer signal level exceeds the selected
Alert/Alarm 1 setpoint. This setpoint can be set on the Setpoint screen. The Alert
time delay is adjustable in one second intervals (from 1 to 60) for all available
proportional values.
Danger
Second level alarm that occurs when the transducer signal level exceeds the
selected Danger/Alarm 2 setpoint. This setpoint can be set on the Setpoint screen.
100 ms option
The 100 ms (typical) option applies to the Danger time delay only and has the
following results:
21
If the 100 ms option is off ( ):
The Danger time delay can be set at one second intervals (from 1 to 60).
The Danger time delay can be set for up to two available proportional
values.
If the 100 ms option is on ( ):
The Danger time delay is set to 100 ms.
The Danger time delay can only be set for the primary proportional value.
Channel Centered Position Setup

Setup Crank Angle
The angular rotation measurement of the crank from when the piston is at top dead
center to the point when the Setup Voltage is read.
Current Gap Voltage

The current voltage reading from the transducer. A connection with the rack is
required and Gap must be currently enabled in the configuration for the monitor for
this value to be returned.
Setup Voltage
The voltage the channels transducer reads when the piston is at the setup crank
angle and is at rest in the cylinder on its initial rider band thickness (bottom
clearance).
Channel Offset
The distance aligned with the channels transducer that shows how far from ideal
center the rod is during setup when the piston is resting on its bottom rider band
thickness. A channel offset AWAY means that the rod is further away from the probe
face than when at ideal center. A channel offset TOWARD means that the rod is
closer to the probe face than when at ideal center.
Calculated Center Voltage

The voltage the channels transducer would read if the piston were being held in the
center of the cylinder clearance. This centered voltage is calculated using the
transducer scale factor, the cylinder I.D., the piston-to-cylinder bottom and top
clearances, the calculated thermal growth of the piston, and the CF when the rod is
at the setup crank angle specified.
Setup = Gap Button

Adjust the Setup voltage to the current transducer gap voltage. When this button is
clicked, the current gap voltage is automatically read into the Setup Voltage box.
Since this utility provides active feedback from the 3500 rack, a connection with the
rack is required.
Timed OK Channel Defeat

When enabled, this feature normally suppresses channel alarms and data values
when the channel transitions to a Not OK condition. This feature is always
disabled in the Recip Rod Position Monitor, so the action taken by the monitor if
a channel goes Not OK is:
1) the Not OK will be reported in the channel status, 2) the proportional values
will continue to be calculated and reported, and 3) the channel will annunciate
22
and maintain an alarm if the data value in the Not OK condition exceeds the
alarm setpoint.
3.1.3
Rod Position Pair Channel Configuration

This section discussees the Configuration Considerations and the Rack
Configuration Software screens associated with the Rod Position Pair channel
type.
3.1.3.1
Rod Position Pair Channel Configuration Considerations

Consider the following items before configuring a Rod Position Pair Channel:
When NO Keyphasor is selected, the Design Speed is used to calculate

Position Magnitude, Position Angle, 1X Amplitude, 2X Amplitude, and Not 1X
Amplitude. Differences between the input Design Speed and the actual
machine running speed will produce inconsistent data. Crank Angle
measurements are not valid.

the rack.

as Hyper)

You should run the transducer calibration and download it to the monitor
before you do the center position setup.
23
3.1.3.2
Rod Position Pair Channel Configuration Screen

This section describes the required inputs and options available on the Rod
Position Pair Channel Configuration screen.
Average Reference Temperature

The average temperature of the environment when the piston clearance and cylinder
bore measurements were taken.
Average Suction Temperature

The average temperature of the suction gas under normal operating conditions.
Average Discharge Temperature

The average temperature of the discharge gas under normal operating conditions.
Piston Material
The material from which the piston was made. The materials to choose from are
iron, steel, or aluminum.
Piston Top Clearance

The measurement from the top of the piston to the cylinder internal diameter, taken
while the piston is at rest in the cylinder supported by its rider band(s).
24
Piston Bottom Clearance

The measurement from the bottom of the piston to the cylinder internal diameter,
taken while the piston is at rest in the cylinder supported on its rider band(s).
Direction of Rotation:
The direction of the rotation of the crank shaft as viewed from the driver end of the
machine. This value will be Clockwise (CW) or Counter Clockwise (CCW).
Stroke
Cylinder Bore Diameter

The measurement of the cylinder internal diameter.
Probe Position

Piston Rod Length


For Rod Position Pair there will be two channel transducer tabs, one for each
transducer.
Transducer Type
The following transducer types are available for the Rod Position Pair NONBARRIER I/O modules:
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
7200 11mm
7200 14mm
The following transducer types are available for the Rod Position Pair BARRIER I/O
modules:
-
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
25
bottom (down).
North.
For Rod Position Pair channel type, transducer probes must be set at an angle apart
no less than 75 Degrees and no greater than 105 Degrees. For the best acuracy,
probes should be set as close to 90 Degrees apart as possible.

any rod material.
options.
Options Button
Point Names Button

CP Mod
26
3.1.3.3
Rod Position Pair Channel Options Screen

This section describes the options available on the Rod Position Pair Channel
Channel
The channels of the monitor being configured.
Slot
Rack Type
in a standard rack.
27
Enabled
Position Magnitude
The maximum value of the position vector magnitudes calculated every one degree
of crank rotation over one cycle. The position vector magnitudes are the rod center
position relative to a zero position representing the piston being concentric to the
cylinder bore.
Position Angle
The angle made by the vector representation of the maximum position magnitude.
Represents where the center of the rod is with respect to the zero position when the
position vector is at its maximum magnitude. 0 degrees is defined as vertical with
CW being positive rotation viewed from crank end.
Crank Angle
The rotational angle of the crank corresponding to the axial position of the rod
(referenced from piston Top Dead Center) when the position vector is at its maximum
magnitude. Represents where the rod is located in its stroke when the position
vector is at its maximum magnitude. The crank angle is referenced from the piston
angle (TDC being 0 degrees) with positive rotation in the direction of crank rotation.
Pk Pk Displacement
to 36,000 CPM.
Gap
1X Amplitude
2X Amplitude
Not 1X Amplitude
Full Scale Range

Full Scale Range selections are dependant upon the transducer calibration. The Full
Scale cannot be set larger than the linear range of the transducer. All scales for the
Rod Position channel types have a minimum value of 0.
Clamp Value
28
Recorder Output
bar graph display results in an increase in the current at the recorder output
Alarm Mode
Latching
Nonlatching
Delay
Alert
Danger
100 ms option
following results:
29
values.
Channel Centered Position Setup

Setup Crank Angle
The angular rotation measurement of the crank from when the piston is at top dead
center to the point when the Setup Voltage is read.
Current Gap Voltage

required and Gap must currently be enabled in the configuration of the monitor for
this value to be returned.
Setup Voltage
The voltage the channels transducer reads when the piston is at the setup crank
angle and is at rest in the cylinder on its initial rider band thickness (bottom
clearance).
Channel Offset
The distance aligned with the channels transducer that shows how far from ideal
center the rod is during setup when the piston is resting on its bottom rider band
thickness. A channel offset AWAY means that the rod is further away from the probe
face than when at ideal center. A channel offset TOWARD means that the rod is
closer to the probe face than when at ideal center.
Calculated Center Voltage

The voltage the channels transducer would read if the piston were being held in the
center of the cylinder clearance. This centered voltage is calculated using the
transducer scale factor, the cylinder I.D., the piston-to-cylinder bottom and top
clearances, the calculated thermal growth of the piston, and the CF when the rod is
at the setup crank angle specified.
Setup = Gap Button

Adjust the Setup voltage to the current transducer gap voltage. When this button is
clicked, the current gap voltage is automatically read into the Setup Voltage box.
Since this utility provides active feedback from the 3500 rack, a connection with the
rack is required.

disabled in the Recip Rod Position Monitor and so the action taken by the
monitor if a channel goes Not OK is:
Rod Position Pair Channel TypesFor the independent data values being
reported (those that only use the values from a single channel such as Pk-Pk
30
Displacement, Gap, 1X Amplitude, 2X Amplitude, Not 1X Amplitude): 1) the Not

OK will be reported in the channel status, 2) the proportional values will continue
to be calculated and reported, and 3) the channel will annunciate and maintain
an alarm if the data value in the Not OK condition exceeds the alarm setpoint.
For the composite data values (those that use the values from two channels such
as Position Magnitude, Position Angle, Crank Angle): if either channel goes Not
OK; 1) the appropriate channel status will be reported as Not OK, 2) the
composite data values will be reported as invalid, and.3) the channel pair will
defeat an alarm for the composite data values.
3.1.4
Rod Drop Channel Configuration

This section discussees the Configuration Considerations and the Rack
Configuration Software screens associated with the Rod Drop channel type.
3.1.4.1
Rod Drop Channel Configuration Considerations

Consider the following items before configuring a Rod Drop Channel:

the rack.
When NO Keyphasor is selected Instantaneous Gap and Position

measurements will not be available. Also, Instantaneous Correction Factor
will not be used.

as Hyper)

31
3.1.4.2
Rod Drop Channel Configuration Screen

This section describes the required inputs and options available on the Rod Drop
Channel Configuration screen.

Stroke
Trigger Angle
The angular measurement of the crankshaft rotation in the direction of rotation from
the piston Top Dead Center (TDC) to the position at which the instantaneous
measurement will be taken. This is only applicable to Rod Drop channel type
configurations that have a Keyphasor.
32
Piston Rod Length

Probe Position

For Rod Drop channel types, there will be only one channel transducer tab.
Transducer Type
The following transducer types are available for the Rod Drop NON-BARRIER I/O
modules:
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
7200 11mm
7200 14mm
The following transducer types are available for the Rod Drop BARRIER I/O
modules:
-
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
33
bottom (down).
North.

any rod material.
options.
Options Button
Point Names Button

CP Mod
34
3.1.4.3
Rod Drop Channel Options Screen

This section describes the options available on the Rod Drop Channel
Channel
Slot
Rack Type
in a standard rack.
Enabled
Average Correction Factor
The Piston Rod Length divided by the calculated average Probe Position throughout
the stroke --displayed for information only.
Instantaneous Correction Factor

The Piston Rod Length divided by the calculated instantaneous Probe Position set by
the Trigger Angledisplayed for information only.
35
Average Piston Position

The time average (over the complete stroke) of the physical distance between the
face of the proximity probe tip and the observed rod with respect to the zero position
times the average correction factor.
Average Probe Gap

The time average of a voltage representing the physical distance between the face of
the proximity probe tip and the observed rod.
Instantaneous Piston Position

The physical distance between the face of the proximity probe tip and the observed
rod with respect to the zero position times the instantaneous correction factor when
the rod is in its stroke position described by the configured trigger angle position.
Instantaneous Probe Gap

A voltage representing the physical distance between the face of the proximity probe
tip and the observed rod when it is in its stroke position described by the configured
trigger angle position.
Full Scale Range

Full Scale Range selections are dependant upon the transducer calibration cannot
be set larger than the linear range of the transducer.
Clamp Value
Recorder Output
Zero Position
The volts corresponding to the nominal DC shaft position. This voltage will be shown
on the user display.
Adjust Button
Adjust the Zero Position voltage. When this button is clicked, the current gap voltage
is automatically read into the Zero Position box. Since this utility provides active
feedback from the 3500 rack, a connection with the rack is required.
Current Gap Voltage

required for this value to be returned.
36
Alarm Mode
Latching
Nonlatching
Delay
Alert
Danger
100 ms option
following results:
values.
37

Rod Drop Channel Types - 1) the Not OK will be reported in the channel status,
2) the data values will continue to be calculated and reported, and 3) the channel
will annunciate and maintain an alarm if the data value in the Not OK condition
exceeds the alarm setpoint.
3.1.5
Hyper Channel Configuration

This section discusses the Configuration Considerations and the Rack
Configuration Software screens associated with the Hyper channel type.
3.1.5.1
Hyper Channel Configuration Considerations

Consider the following items before configuring a Hyper Channel:
38
When NO Keyphasor is selected, 1X Amplitude, 2X Amplitude, and Not 1X

Amplitude are not available.

the rack.

as Hyper)

3.1.5.2
Hyper Channel Configuration Screen

This section describes the options available on the Hyper Channel Configuration
screen.

For Rod Position Single and Rod Drop channel types, there will be only one
channel transducer tab. For Rod Position Pair and Hyper channel types, there
will be two channel transducer tabs, one for each transducer.
Transducer Type
The following transducer types are available for the Hyper NON-BARRIER I/O
modules:
3300 8mm
3300XL 8mm
3300XL 11mm
7200 8mm
7200 11mm
7200 14mm
The following transducer types are available for the Hyper BARRIER I/O modules:
-
3300 8mm
3300XL 8mm
39
3300XL 11mm
7200 8mm
bottom (down).
North.

any rod material.
options.
Options Button
Point Names Button

CP Mod
40
3.1.5.3
Hyper Channel Options Screen

This section describes the options available on the Hyper Channel Transducer
Options screen.
Channel
Slot
Rack Type
in a standard rack.
Enabled
Pk Pk Displacement
to 36,000 CPM.
41
Gap
1X Amplitude
2X Amplitude
Not 1X Amplitude
Full Scale Range

Full Scale Range selections are dependant upon the transducer calibration cannot
be set larger than the linear range of the transducer. All scales for the Hyper channel
types are zero based.
Clamp Value
Recorder Output
Alarm Mode
Note: If both channels of a Hyper channel pair go Not OK, all enabled alarms
configured for Danger/Alarm 2 will become active.
Latching
42
Nonlatching
Delay
Alert
Danger
100 ms option
following results:
values.
Note: When both channels in a Hyper pair become Not OK, all configured
Danger/Alarm 2 alarms become active.

Hyper Channel Types 1) the Not OK will be reported in the channel status, 2)
the data values will continue to be calculated and reported, and 3) the channel
will annunciate and maintain an alarm if the data value in the Not OK condition
exceeds the alarm setpoint.
43
3.1.6
Rod Position Transducer Calibration

This section describes the options available on the Recip Rod Position Monitor
Transducer Calibration Screens. A rod transducer calibration is necessary to
determine the useable linear range of the transducer when viewing the piston rod
material.
The shaft calibrator kit, p/n 330186, is one tool used to temporarily mount a
spindle micrometer to the piston rod so that the transducer curve can be
generated. The kit includes a spindle micrometer, strap, 4140 target button for
system verification with a collet for alignment, eight probe adapters to
accommodate most Bently Nevada proximity probes, and an instruction card.
A proximity probe is mounted so that the probe face is flush with the piston rod
(mechanical zero). It is then backed out in small increments where the voltages
are recorded for each gap. The usable linear range can then be calculated using
the recorded voltages.
The default linear range and gap mil increments are determined by the
transducer selected in the previous screen.
44
The gap voltage values may be recorded with conventional methods and directly
entered into the calibration screen. Blue values are determined by the software
to be outside the useable linear range of the selected transducer.
Note: If internal or external barriers are being used, it is critical that the gap
voltage be measured on the safe side of the barrier or errors will result in the
monitor setup.
Adjust Button
The Adjust button next to each voltage may be used to read values directly from the
transducer into the calibration screen. This feature requires that the computer used
for configuring be connected to the 3500 rack and all wiring be correct within the
system. You must also have the configuration on the previous screen downloaded to
the rack and the Gap must have been enabled in the Options screen and
downloaded using the 3500 Config software. When connected to the 3500 rack a
current Gap measurement is shown in the lower right hand corner.
Note: The Adjust Button reads the current voltage value of the system. Proper
care must be taken to match up the correct physical gap of the probe with the
corresponding voltage.
After the probe has been backed out to a new gap, wait a period of 10 to 15
seconds before taking the Adjust Button reading from the Current Gap Voltage.
This accounts for the gap voltage filter setting time.
It is important to run the calibration with the probe viewing an area of the piston
rod actually viewed during normal operation of the compressor.
Calculated Values
As voltage values are entered for increasing gap values, the Incremental Scale
Factors are determined automatically.
Channel Setup
Total Linear Range
The Total Linear Range is calculated by the software using the values recorded in
the transducer curve. It is defined as the range over which the variation between
each Incremental Scale Factor and the Average Scale Factor are less than or equal
to 10%. This range can also be identified by the change in colors seen in the
transducer curve data.
Lower Gap
The Lower Gap is determined by picking the least negative voltage within the linear
range. It is the lower value in the range to be used, defines one end of the bar
graph, and defines one setpoint limit.
Upper Gap
The Upper Gap is determined by picking the most negative voltage within the linear
range. It is the upper value in the range to be used, defines one end of the bar
graph, and defines one setpoint limit.
Note: The user must set the Upper and Lower Gaps after entering all the
transducer curve data. The upper and lower gaps must be within the linear
range of the transducer.
45
Scale Factor
The calculated average scale factor within the chosen Upper and Lower Gaps. This
is the change in output per change in input (sensitivity) of a transducer.
OK Limits
The upper and lower OK limit voltages are displayed for reference.
Current Gap Voltage

Displays the current voltage of the transducer channel. This value can be read into
the curve data fields by using the adjust buttons.
Calibration Data
Save Button
Calibration data will be saved for the channel as a text file that can be used for later
retrieval.
Load Button
Calibration data will be loaded for the channel from a saved calibration file.
To use data from a calibration file the transducer, barrier, and unit data must be
consistent with the current configured parameters.
46
3.1.6.1
Sample Transducer Calibration

The following calibration was made using a Tungsten Carbide target material.
The system included a 3300XL 8mm Proximitor and 5m probe combination. The
3500 rack was also connected to the software.
1. After the shaft calibrator kit was installed, the probe was backed out to 5 mils
of Gap. This value, -0.92 V, was input into the 5 mil voltage block using the
Adjust Button and reading from the Current Gap Voltage in the lower right
hand corner. Remember, the BLUE values are not used in linear range
calculations, but are only for reference.
2. The probe was then backed out to a 10 mil gap. Again, the Adjust Button
read the Current Gap Voltage and input the reading into the Voltage box.
3. The gap voltage was recorded in 5 mil increments until the voltage values
failed to change. This occurred at 85 mils of gap.
Note: Be sure to fill in all voltage spaces down to the bottom of the screen.
4. The ISF for every Gap Increment was calculated by the software along with
the percentage of deviation. The software automatically calculates the
useable linear range to be 55 mils. The useable linear range is defined as
47
values with less than 10% deviation to its ISF and is within the OK limits of
the transducer. This is shown by the Black colored voltage values (10 to 65
mils).
5. The Lower Gap can be set to 10 mils (Least negative voltage inside the linear
range).
6. The Upper Gap can be set to 65 mils (Most negative voltage inside the linear
range).
3.2
Setpoints
This section specifies the available setpoints for each type of channel. A setpoint
is the level within the full-scale range that determines when an alarm occurs.
The 3500 Monitoring System allows Alert/Alarm 1 setpoints to be set for every
proportional value on each channel. The channel will drive an Alert/Alarm 1
indication if one or more of the channel proportional values exceeds its setpoints.
The 3500 Monitoring System also allows up to four Danger/Alarm 2 setpoints
(two over setpoints and two under setpoints) to be set for up to two of the
proportional values. You may select any two of the available proportional values
for the channel.
Note: The setpoint over and under limits can only be placed within the upper
and lower gap values of the specified transducer.
Use the following screen in the Rack Configuration Software to adjust

Alert/Alarm 1 and Danger/Alarm 2 setpoints. This screen will vary depending
upon the type of channel.
48
The following table lists the Alert/Alarm 1 and Danger/Alarm 2 setpoints available
for each channel pair type. The setpoint number is used in the Communication
Gateway and Display Interface Modules.
49
Setpoint
Number
Rod Position Single and

Pair
Rod Drop
Hyper
Over Position Magnitude
Under Average Piston Position
Over Pk-Pk Displacement
Over Pk Pk Displacement
Under Instantaneous Piston

Position
Over Gap
Over Gap
Danger (Configurable)
Under Gap
Under Gap
Over 1X Amplitude
Over 1X Amplitude
Under 1X Amplitude
Over 2X Amplitude
Over 2X Amplitude
Over Not 1X Amplitude
Under 2X Amplitude
Over Not 1X Amplitude
All the Alert/Alarm 1 setpoints are provided first, followed by the configured
danger setpoints.
Example 1:
Rod Position Single with the Danger/Alarm 2 Over Gap setpoint and the
Danger/Alarm 2 Under Gap setpoint selected.
Alert/Alarm 1 setpoints:
Danger/Alarm 2 setpoints:
50
setpoints 1 through 7
setpoint 8 is Over Gap (Danger)
Setpoint 9 is Under Gap (Danger)
Example 2:
Rod Drop with the Danger/Alarm 2 Over Instantaneous Piston Position setpoint
selected.
Alert/Alarm 1 setpoints:
Danger/Alarm 2 setpoint:
Position (Danger)
setpoints 1 through 2
setpoint 3 is Over Instantaneous Piston
Notes:
The alarming hysteresis for all channel configurations for a 72M Monitor is 1/64 of
Full Scale. When a channel exceeds an alarm setpoint, it must fall back below the
setpoint less the hysteresis before it can go out of alarm. For example, consider a
channel configuration with a 010 mils full scale and an alarm setpoint at 6 mils as
illustrated below:
The hysteresis = 10 mils/64 = 0.16 mils. The channel input must fall below 6 mils 0.16 mils (5.84 mils) before the channel is out of alarm.
51
3.3
Software Switches
The Recip Rod Position Monitor supports two module software switches and four
channel software switches. These switches let you temporarily bypass or inhibit
monitor and channel functions. Set these switches on the Software Switches
screen under the Utilities Option on the main screen of the Rack Configuration
Software.
No changes will take effect until the Set button is pressed.

Module Switches (Screen Not Shown)
Configuration Mode
A switch that allows the monitor to be configured. To configure the monitor, enable
()this switch and set the key switch on the front of the Rack Interface Module in the
PROGRAM position. When downloading a configuration from the Rack
Configuration Software, this switch will automatically be enabled and disabled by the
Rack Configuration Software. If the connection to the rack is lost during the
configuration process, use this switch to remove the module from Configuration
Mode.
52
Monitor Alarm Bypass

When enabled, the monitor does not perform alarming functions. All proportional
values are still provided. The monitor switch number is used in the Communication
Gateway and Display Interface Modules.
Monitor Switch Number
Switch Name
Configuration Mode
Monitor Alarm Bypass
Channel Switches
Alert Bypass
When enabled, the channel does not perform Alert alarming functions.
Danger Bypass
When enabled, the channel does not perform Danger alarming functions.

When enabled, all nonprimary Alert alarms are inhibited.
Bypass
When enabled, the channel provides no alarming functions and supplies no
The channel switch number is used in the Communication Gateway and Display
Interface Modules.
Channel Switch Number
Switch Name
Alert Bypass
Danger Bypass
Bypass
53
54
Section 4 I/O Module Descriptions
4.
I/O Module Descriptions

The Recip Rod Position Monitor will use Prox/Velom I/O Modules and the Barrier
Proximitor I/O Module, which receive signals from the transducers and routes the
signals to the monitor. The I/O module also supplies power to the transducers.
The I/O module provides a 4 to 20mA recorder output for each transducer input
channels. Only one I/O module can be installed at any one time and must be
installed behind the Recip Rod Position Monitor (in a Rack Mount or Panel Mount
rack) or above the Recip Rod Position Monitor (in a Bulkhead rack).
In addition, Internal Barrier I/O Modules provide four channels of intrinsically safe
signal conditioning for Proximitor transducers. There are two internally mounted
zener barrier modules, one for each pair of transducer channels.
This section describes how to use the connectors on the I/O modules, lists what
cables to use, and shows the pin outs of the cables. The 3500 Field Wiring
Diagram Package (part number 130432-01) shows how to connect transducers
to the I/O module or the External Termination Block.
4.1
Setting the I/O Jumper

The I/O jumper on the Prox/Velom I/O Module is used to identify the type of
transducer connected to the I/O module. However, the Recip Rod Position
Monitor only uses Proximitor type transducer inputs. The jumper must always be
set to the Prox/Accl position.
Note:
The connector shunt must be installed vertically on the top or bottom 8 terminal
posts to select the corresponding transducer type.
WARNING- The connector shunt must be placed over the terminal posts for
which the channel pair is configured, even when the channel pair is inactivated.
55
PROX/ACCL (Proximitor/Accelerometer):
The eight-pin connector shunt must be installed on the top eight terminal posts.
56
4.2
Prox/Velom I/O Module (Internal Termination)

Internal Termination I/O modules require you to wire each transducer and
recorder to the I/O module individually. This section shows what this Internal
Termination I/O module looks like and how to connect the wires to the Euro Style
connector.
(1)
(2)
(3)
(4)
(5)
Connect the wire from the transducers associated with Channel 1 and 2.
The jumper must be set to Prox/Accl transducer type for Channel 1 and 2.
Connect the wire from the transducers associated with Channel 3 and 4.
The jumper must be set to Prox/Accl transducer type for Channel 3 and 4.
INHB/RET: Connect to an external switch. Used to inhibit all non-primary Alert/Alarm 1 functions
for all four channels.
(6) COM/REC: Connect each channel of the I/O module to a recorder.
57
4.2.1
Wiring Euro Style Connectors

To remove a terminal block from its base, loosen the screws attaching the
terminal block to the base, grip the block firmly and pull. Do not pull the block out
by its wires because this could loosen or damage the wires or connector.
Figure 4-1 Typical I/O module

Refer to the 3500 Field Wiring Diagram Package for the recommended wiring.
Do not remove more than 6mm (0.25 in) of insulation from the wires.
58
4.3
Barrier Proximitor Internal I/O Module

(Internal Termination)
Internal Barrier I/O modules require you to wire each transducer to the I/O
module individually. This section shows what this Internal Termination Barrier
I/O module looks like and where to connect the wires to the Euro Style
connectors.
(1) Connect the wire from the transducers associated with Channel 1 and 2.
(2) Connect the wire from the transducers associated with Channel 3 and 4.
(3) INHB/RET: Connect to an external switch. Used to inhibit all nonprimary Alert/Alarm 1 functions
for all four channels.
(4) COM/REC: Connect each channel of the I/O module to a recorder.
59
4.4
Prox/Velom I/O Module (External Termination)

External Termination I/O modules let you simplify the wiring to the I/O modules in
a 3500 rack by using a 25-pin cable to route the signals from the four
transducers and a nine pin cable to route the signals from the recorders to the
I/O module. This section describes and shows the External Termination I/O
module, the External Termination Blocks, and the pin outs for the cables that go
between the External Termination I/O module and the External Termination
Blocks.
(1) Connect the Prox/Velom I/O Module to the Proximitor External Termination Block using cable
129525-XXXX-XX.
(2) The jumper must be set to Prox/Accl transducer type for Channel 1 and 2.
(3) The jumper must be set to Prox/Accl transducer type for Channel 3 and 4.
(4) Connect the I/O module to the Recorder External Termination Block using Cable 129529-XXXXXX.
60
4.4.1
External Termination Blocks

The two types of External Termination Blocks used with a Prox/Velom I/O
Module are the Prox/Velom External Termination Blocks and the Recorder
External Termination Blocks. Each type comes with either Terminal Strip or Euro
Style connectors.
4.4.1.1
Prox/Velom External Termination Block (Terminal Strip connectors)
(1) Connect the wire from the transducers associated with Channel 1, 2, 3, and 4 to the External
Termination Block. INHB/RET: Connect to an external switch.
(2) Connect the I/O module to the External Termination Block using cable 129525-XXXX-XX
(3) Channel 1 and Channel 2
61
4.4.1.2
Prox/Velom External Termination Block (Euro Style connectors)
(1) Connect the wire from the transducers associated with Channel 1, 2, 3, and 4 to the External
Termination Block. INHB/RET: Connect to an external switch.
(2) Connect the I/O module to the External Termination Block using cable 129525-XXXX-XX
62
4.4.1.3
Recorder External Termination Block (Terminal Strip connectors)
(1) Connect the recorders associated with Channel 1, 2, 3, and 4 to the Recorder External Termination
Block.
(2) Connect the I/O module to the Recorder External Termination Block using cable 129529-XXXXXX.
63
4.4.1.4
Recorder External Termination Block (Euro Style connectors)
(1) Connect the recorders associated with Channel 1, 2, 3, and 4 to the Recorder External Termination
Block.
(2) Connect the I/O module to the Recorder External Termination Block using cable 129529-XXXXXX.
64
4.4.2
Cable Pin Outs

Cable Number 129525-XXXX-XX
3500 Transducer Signal to External Termination Block Cable
65
Cable Number 129529-XXXX-XX

3500 Recorder Output to External Termination Block Cable
66
Section 5 Maintenance
5.
Maintenance
The boards and components inside of 3500 modules cannot be repaired in the
field. Maintaining a 3500 rack consists of testing module channels to verify that
they are operating correctly. Modules that are not operating correctly should be
replaced with a spare.
This section shows how to verify the operation of channels in a Recip Rod
Position Monitor.
5.1
Verifying a 3500 Rack Recip Rod Position

Monitor Module
The 3500 Monitoring System is a high precision instrument that requires no
calibration. The functions of monitor channels, however, must be verified at
regular intervals. At each maintenance interval, we recommend that you use the
procedures in this section to verify the operation of all active channels in the
monitor. It is only necessary to verify the alarms and accuracy of channel
proportional values that are active.
Section
Topic
Number
5.1.1
Choosing a Maintenance Interval
5.1.2
Required Test Equipment
5.1.3
Typical Verification test setup
5.1.4
Using the Rack Configuration Software
5.1.5
Rod Position Single Channels
5.1.6
Rod Position Pair Channels
5.1.7
Rod Drop Channels
5.1.8
Hyper Channels
5.1.9
Verify Recorder Outputs
5.1.10
If a Channel Fails a Verification Test
67
5.1.1
Choosing a Maintenance Interval

Use the following approach to choose a maintenance interval:
5.1.2
Start with an interval of one year and then shorten the interval if any of the
following conditions apply:
-
The monitored machine is classified as critical
The 3500 rack is operating in a harsh environment such as in extreme

temperature, high humidity, or in a corrosive atmosphere.
At each interval, use the results of the previous verifications and ISO
Procedure 10012-1 to adjust the interval.
Required Test Equipment and Setup

The verification procedures in this section require the following test equipment
and setup.
All Recip Rod Position Monitor Channels

Power Supply (single channel)
Multimeter 4 digits
Function Generator
100 F capacitor
40 k resistor
Bently Nevada Corporation TK 16 Keyphasor Multiplier/Divider or equivalent

(Instructions in this manual refer to the TK 16)
Additional 18 Vdc Supply for use with the TK 16
2 channel Oscilloscope
WARNING
High Voltage Present. Contact
could cause shock, burns, or
death.
Do not touch exposed wires or
terminals.
Application Alert: Tests will exceed alarm setpoint levels causing alarms to
activate. This could result in a relay contact state change.
Disconnecting the field wiring will cause a Not OK condition.
68
Figure 5-1 Recip Rod Position Monitor Test Setup

The Test Equipment outputs should be floating relative to earth ground. For
external termination I/O modules, the test setup is identical except that the test
equipment outputs connect to the external termination block.
69
The equipment shown in the dashed box is required for Crank Angle, 1X
Amplitude, 2X Amplitude, Not 1X Amplitude, Instantaneous Piston Position, and
Instantaneous Gap.
1. Keyphasor Signal
2. Keyphasor I/O Module
3. 40 K Resistor
4. 100 F Capacitor
5. Keyphasor Multiplier/Divider
6. Input Signal
7. Multimeter
8. Proximitor I/O Module
9. Function Generator
10. Power Supply
5.1.3
Typical Verification test setup

The following figure shows the typical test setup for verifying a Recip Rod
Position Monitor. The test equipment is used to simulate the transducer signal
and the laptop computer is used to observe the output from the rack.
Figure 5-2 General layout for Maintenance

Transducers can be connected to a 3500 rack in a variety of ways. Depending
on the wiring option for the I/O module of the monitor, connect the test equipment
to the monitor using one of the following methods.
70
(1)
(2)
(3)
(4)
5.1.4
Connect test equipment here.

Proximitor I/O Module (Internal Termination)
External Termination Block (Euro Style Connectors)
External Termination Block (Terminal Strip Connectors)
Using the Rack Configuration Software

The laptop computer that is part of the test setup uses the Rack Configuration
Software to display output from the rack and to reset certain operating
parameters in the rack. To perform the test procedures in this section you must
be familiar with the following features of the Rack Configuration Software:
upload, download, and save configuration files
enable and disable channels and alarms
bypass channels and alarms
display the Verification screen
The Rack Configuration and Test Utilities Guide explains how to perform these
operations.
Note: It is important to save the original rack configuration before doing any
Maintenance or Troubleshooting Procedures. It may be necessary during these
procedures to change setpoints, etc. which must be restored to their original
values at the conclusion of the procedures. At that time the original configuration
should be downloaded to the rack.
The Keyphasor module must not be configured for the Recip Multi-Event Wheel
to do the verification.
71
The following figures show how the Verification screen displays output from a
3500 rack:
Alarm Verification Fields:
(1) These fields display output for verifying channel alarms. Alert/Alarm 1 alarms are
displayed in yellow in the bar graph and with the word Alarm under the current value
box. Danger/Alarm 2 alarms are displayed in red in the bar graph and with the word
Alarm under the current value box.
(2) Current Value: The current proportional value is displayed in this box.
Setpoints are indicated by lines on the bargraph display
Danger/Alarm 2 Over = Solid Red Line
Alert/Alarm 1 Over = Solid Yellow Line
Alert/Alarm 1 Under = Dashed Yellow Line
Danger/Alarm 2 Under = Dashed Red Line
The Zero Position Voltage is the voltage input that will cause the reading on the
bar graph display and current value box to be zero. The Zero Position Volts
value is displayed in the Zero Position Volts box above each channel value bar
graph.
72
OK Limit Verification Fields

These fields display output for verifying OK limits.
Current Value Verification Fields:

These fields display output for verifying channel output.
73
5.1.5
Rod Position Single Channels

The following sections describe how to test alarms, verify channels, and test OK
limits for channels configured as Rod Position Single. The output values and
alarm setpoints are verified by varying the input signal levels and observing that
the correct results are reported in the Verification screen on the test computer.
Rod Position Single channels can be configured for the following channel values
and alarms:
Channel Values
Alarms
Over
Position Magnitude
Under
Position Angle
Crank Angle
5.1.5.1
Pk Pk Displacement
Gap
1X Amplitude
2X Amplitude
Not 1X Amplitude
Test Equipment and Software Setup Rod Position Single

The following test equipment and software set up can be used as the initial setup
needed for all the Rod Position Single channel verification procedures (Test
Alarms, Verify Channels, and Test OK Limits).
WARNING
death.
terminals.
74
Test Equipment Setup Rod Position Single

Simulate the transducer signal by connecting the power supply, function
generator, and multimeter to COM and SIG of channel 1 with polarity as shown
in Section 5.1.2, Recip Rod Position Monitor Test Setup Figure. Set the test
equipment as specified below:
Power Supply
Function Generator
Keyphasor Multiplier/Divider
-7.00 Vdc
Wave Form: sinewave
Multiply Switch: 001
DC Volts: 0 Vdc
Divide Switch: 001
Frequency: 15 Hz
Amplitude Level: Minimum
(above zero)
Verification Screen Setup Rod Position Single

Run the Rack Configuration Software on the test computer. Choose Verification
from the Utilities menu and choose the proper Slot number and Channel number
then click on the Verify button.
The following table directs you to the starting page of each maintenance section
associated with the Rod Position Single Channels:
Section
Number
Topic
5.1.5.2
Test Alarms Position Magnitude
5.1.5.2
Test Alarms Pk Pk Displacement
5.1.5.2
Test Alarms Gap
5.1.5.2
Test Alarms 1X Amplitude
5.1.5.2
5.1.5.2
Test Alarms Not 1X Amplitude
5.1.5.3
Verify Channel Values Position Magnitude
5.1.5.3
Verify Channel Values Position Angle
5.1.5.3
Verify Channel Values Crank Angle
5.1.5.3
Verify Channel Values Pk Pk Displacement
5.1.5.3
Verify Channel Values Gap
5.1.5.3
Verify Channel Values 1 X Amplitude
5.1.5.3
Verify Channel Values 2X Amplitude
5.1.5.3
Verify Channel Values Not 1X Amplitude
5.1.5.4
Test OK Limits
75
5.1.5.2
Test Alarms Rod Position Single

The general approach for testing alarm setpoints is to simulate the position and
Keyphasor signals with a function generator. The alarm levels are tested by
varying this input signal and observing that the correct results are reported in the
Verification screen on the test computer. It is only necessary to test those alarm
parameters that are configured and being used. The general test procedure to
verify current alarm operation will include simulating a transducer input signal
and varying this signal:
1. to exceed Over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and
2. to drop below any Under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and
3. to produce a non-alarm condition.
When varying the signal from an alarm condition to a non-alarm condition, alarm
hysteresis must be considered. Adjust the signal well below the alarm setpoint
for the alarm to clear.
Position Magnitude
Note: The Calculated Center Voltage value can be seen in the verification
screen.
1. Disconnect PWR, COM, and SIG field wiring from the channel terminals on
the I/O module.
2. Connect test equipment and run software as described in Section 5.1.2,
Required Test Equipment and Setup. Set the function generator to have
Sine wave output.
3. Set the Keyphasor multiplier/divider so that the multiply setting is one and the
divide setting is one. Turn down the Amplitude on the function generator to
have the minimum possible value and adjust the power supply DC voltage
level to produce a gap reading that results in a Position Magnitude that is
above (more negative than) the Calculated Center Voltage level and below
(less negative than) the Position Magnitude setpoint levels on the bar graph
display of the Verification screen.
4. Press the RESET switch on the Rack Interface Module (RIM). Verify that the
OK LED is on, the bar graph indicator for Position Magnitude is green, and
the Current Value field contains no alarm indication.
5. Increase (more negative) the power supply voltage such that the signal just
exceeds the Position Magnitude Over Alert/Alarm 1 setpoint level. Wait until
2 or 3 seconds after the alarm time delay expires and verify that the bar
graph indicator for Position Magnitude changes color from green to yellow
and that the Current Value Field indicates an Alarm.
6. Press the RESET switch on the RIM. Verify that the bar graph indicator for
Position Magnitude remains yellow and that the Current Field still indicates
an Alarm.
7. Increase (more negative) the power supply such that the signal just exceeds
the Position Magnitude Over Danger/Alarm 2 setpoint level. Wait until 2 or 3
seconds after the alarm time delay expires and verify that the bar graph
76
indicator for Position Magnitude changes color from yellow to red and that the
Current Value Field indicates an Alarm.
Position Magnitude remains red and that the Current Value Field still
indicates an Alarm.
9. Decrease (less negative) the power supply voltage such that the gap signal
reads above the Calculated Center Voltage level and below the Over Alarm
setpoint levels. If the non-latching option is configured, observe that the bar
graph indicator for Position Magnitude changes color to green and that the
Current Value Box contains no indication of alarms. Press the RESET switch
on the RIM to reset latching alarms.
10. Press the RESET switch on the RIM. Verify that the OK LED is on, the bar
graph indicator for Position Magnitude is green, and the Current Value field
contains no alarm indication.
11. Adjust the power supply level to produce a gap reading that is below (less
negative than) the Calculated Center Voltage level and results in a Position
Magnitude that is below (more negative than) the Position Magnitude setpoint
levels on the bar graph display of the Verification screen.
Note: The Position Magnitude value will always be positive. Notice when the
power supply voltage level crosses the Calculated Center Voltage level, the
Position Angle value changes by 180 degrees. This is the angle of the Position
Magnitude vector. This is always 0 or 180 only for Rod Position Single channel
types.
13. Decrease (less negative) the power supply voltage such that the signal just
an Alarm.
15. Decrease (less negative) the power supply such that the signal just exceeds
indicates an Alarm.
17. Increase (more negative) the power supply voltage such that the signal reads
below the Over Alarm setpoint levels. If the non-latching option is configured,
observe that the bar graph indicator for Position Magnitude changes color to
green and that the Current Value Box contains no indication of alarms. Press
the RESET switch on the RIM to reset latching alarms.
77
18. If you cannot verify any configured alarm, recheck the configured setpoints.
If the monitor still does not alarm properly or fails any other part of this test,
go to Section 5.1.10 (If a Channel Fails a Verification Test).
19. Disconnect the test equipment and reconnect the PWR, COM, and SIG field
wiring to the channel terminals on the I/O module. Verify that the OK LED
comes on and the OK relay energizes. Press the RESET button on the RIM
to reset the OK LED.
20. Repeat steps 1 through 19 for all configured channels.
Pk Pk Displacement
the I/O module.
Sine wave output.
divide setting is one. Adjust the function generator amplitude to produce a
reading that is below the Pk-Pk Displacement setpoint level on the bar graph
OK LED is on, the bargraph indicator for Pk-Pk Displacement is green, and
5. Adjust the function generator amplitude such that the signal just exceeds the
Pk-Pk Displacement Over Alert/Alarm 1 setpoint level. Wait for 2 or 3
indicator for Pk-Pk Displacement changes color from green to yellow and that
the Current Value Field indicates an Alarm.
Pk-Pk Displacement remains yellow and that the Current Value Field still
indicates an Alarm.
Pk-Pk Displacement Over Danger/Alarm 2 setpoint level. Wait for 2 or 3
indicator for Pk-Pk Displacement changes color from yellow to red and that
the Current value Field indicates an Alarm.
Pk-Pk Displacement remains red and that the Current Value Field still
indicates an Alarm.
9. Adjust the function generator amplitude such that the signal reads below the
Over Alarm setpoint levels. If the nonlatching option is configured, observe
that the bar graph indicator for Pk-Pk Displacement changes color to green
and that the Current Value Box contains no indication of Alarms. Press the
RESET switch on the RIM to reset latching alarms.
10. If you can not verify any configured alarm, recheck the configured setpoints.
78
comes on and the OK relay energizes. Press the RESET button on the RIM
Gap
the I/O module.
Sine wave output.
divide setting is one. With minimal Amplitude level on the function generator,
adjust the power supply to produce a voltage that is within the Gap setpoint
levels on the Gap bar graph display of the Verification Screen.
OK LED is on, the bargraph indicator for Gap is green and the Current Value
Field contains no alarm indication.
5. Adjust the power supply voltage such that the signal just exceeds the Gap
Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the alarm
time delay expires and verify that the bar graph indicator for Gap changes
color from green to yellow and that the Current Value Field indicates an
Alarm.
6. Press the RESET switch on the RIM. Verify that the OK LED is on, the
bargraph indicator for Gap is yellow and the Current Value Field indicates an
alarm.
Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm
color from yellow to red and that the Current Value Field indicates an Alarm.
Gap remains red and that the Current Value Field still indicates an Alarm.
9. Adjust the power supply voltage such that the signal reads below the Over
Alarm setpoint levels. If the nonlatching option is configured, observe that
the bar graph indicator for Gap changes color to green and that the Current
Value Box contains no idication of Alarms. Press the RESET switch on the
RIM to reset latching alarms.
10. Repeat steps 5 through 9 to test the Under Alert/Alarm 1 and Under
Danger/Alarm 2 setpoints by adjusting the power supply to exceed the Under
Alarm setpoint levels.
11. If you cant verify any configured alarm, recheck the configured setpoints. If
the monitor still does not alarm properly or fails any other part of this test, go
to Section 5.1.10 (If a Channel Fails a Verification Test).
79
comes on and the OK relay energizes. Press the RESET switch on the RIM
1X Amplitude
Note: The Keyphasor must be triggering and have a valid rpm value to check
this parameter.
the I/O module.
Sine wave output.
reading that is within the 1X Ampl setpoint levels on the 1X Ampl bar graph
OK LED is on, the bargraph indicator for 1X Ampl is green and the Current
Value Field contains no alarm indication.
1X Ampl Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for 1X Ampl
changes color from green to yellow and that the Current Value Field indicates
an Alarm.
1X Ampl remains yellow and that the Current Value Field still indicates an
alarm.
1X Ampl Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after
the alarm time delay expires and verify that the bar graph indicator for 1X
Ampl changes color from yellow to red and that the Current Value Field
indicates an Alarm.
1X Ampl remains red and that the Current Value Field still indicates an Alarm.
that the bar graph indicator for 1X Ampl changes color to green and that the
Current Value Box contains no indication of Alarms. Press the RESET switch
80

2X Amplitude
this parameter.
the I/O module.
Sine wave output.
divide setting is two. Adjust the function generator amplitude to produce a
an Alarm.
alarm.
Ampl changes color from yellow to red and that the Current Value Field
indicates an Alarm.
81
Not 1X Amplitude
this parameter.
the I/O module.
Sine wave output.
reading that is within the Not 1X setpoint levels on the Not 1X bar graph
OK LED is on, the bargraph indicator for Not 1X is green and the Current
Not 1X Over Alert/Alarm 1 setpoint level. Wait for 2 or 3 seconds after the
alarm time delay expires and verify that the bar graph indicator for Not 1X
an Alarm.
Not 1X remains yellow and that the Current Value Field still indicates an
alarm.
Not 1X Over Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the
changes color from yellow to red and that the Current Value Field indicates
an Alarm.
Not 1X remains red and that the Current Value Field still indicates an Alarm.
that the bar graph indicator for Not 1X changes color to green and that the
Repeat steps 1 through 11 for all configured channels.
82
5.1.5.3
Verify Channel Values Rod Position Single

The general approach for testing channel values is to simulate the position and
Keyphasor input signals with a function generator and power supply. The output
values are verified by varying the input signal level and observing that the correct
results are reported in the Verification screen on the test computer.
Note: These parameters have an accuracy specification of 1% of full scale for
amplitude.
Position Magnitude Position Angle

1. Disconnect the PWR, COM, and SIG field wiring from the channel terminals
on the I/O module.
Sine wave output.
divide setting is one.
4. Calculate the Full scale voltage according to the equation and examples
shown below.
Full Scale Voltage = Calculated Center Voltage - (Position Magnitude Top Scale
x Transducer Scale Factor)
Note: Use the Calculated Center Voltage and the Transducer Scale Factor
displayed on the Verification Screen.
Example 1:
Calculated Center Voltage = -10.250 Vdc
Position Magnitude Meter Top Scale = 40 mil
Transducer Scale Factor = 200mV/mil
Full Scale = -10.250 - (40 X 0.200) = -18.250 Vdc
Example 2:
Position Magnitude Meter Top Scale = 800m
Transducer Scale Factor = 7,874 mV/mm
= 7.874 mV/m
Full Scale = -10.25 - (800 X 0.007874) = -16.5492 Vdc
5. Turn down the Amplitude on the function generator to have the minimum
possible value and adjust the power supply DC voltage level to the calculated
Full Scale voltage.
6. Verify that the Position Magnitude bar graph display and Current Value Box is
reading 1% of full scale. If the recorder output is configured, refer to section
5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.
7. Verify the Position Angle bar graph display and Current Value Box is reading
correctly. If the Transducer Orientation is configured as 0, the Position
Angle should read 180. If the Transducer Orientation is configured as 180,
the Position Angle should read 0. If the recorder output is configured, refer
83
to section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder
output.
8. Set the power supply input voltage equal to the Calculated Center Voltage.
Verify that the Position Magnitude bar graph display and Current Value Box is
reading aproximately Zero. If the recorder output is configured, refer to
section 5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.
9. Calculate the Opposite Full scale voltage according to the equation and
examples shown below.
Note: The Opposite Full scale voltage will result in a full scale reading on the
bar graph display and Current Value Box reading.
Opposite Full Scale Voltage = Calculated Center Voltage + (Position Magnitude

Top Scale x Transducer Scale Factor)
Note: Use the Calculated Center Voltage and the Transducer Scale Factor
Example 1:
Position Magnitude Meter Top Scale = 40 mil
Opposite Full Scale = -10.250 + (40 X 0.200) = -2.250 Vdc
Example 2:
Position Magnitude Meter Top Scale = 800m
= 7.874 mV/m
Opposite Full Scale = -10.25 + (800 X 0.007874) = -3.9508 Vdc
10. Turn down the Amplitude on the function generator to have the minimum
possible value and adjust the power supply DC voltage level to the calculated
Full Scale voltage.
reading 1% of full scale. If the recorder output is configured, refer to section
5.1.9 (Verify Recorder Outputs) for steps to verify the recorder output.
12. Verify the Position Angle bar graph display and Current Value Box is reading
correctly. If the Transducer Orientation is at 0, the Position Angle should
read 0. If the Transducer Orientation is at 180, the Position Angle should
read 180. If the recorder output is configured, refer to section 5.1.9 (Verify
Recorder Outputs) for steps to verify the recorder output.
13. If the reading does not meet specifications, check that the input signal is
correct. If the monitor still does not meet specifications of fails any other part
of this test, go to section 5.1.10 (If a Channel Fails a Verification Test).
comes on and the OK relay energizes. Press RESET switch on the Rack
Interface Module to reset the OK LED.
84
Crank Angle
this parameter.
on the I/O module.
Required Test Equipment and Setup. Set the function generator to Triangle
wave output.
3. Using a 2-Channel oscilloscope, look at the triangle wave at the input to the
monitor on one channel and look at the input to the keyphasor module on the
other channel. Be sure to look at the keyphasor signal on the I/O side of the
capacitor.
4. Set both channels of the oscilloscope to be DC coupled.
Note: Due to the low frequencies, making this measurement with the scope AC
coupled will introduce error in the Sync_Offset.
5. Measure and calculate the Crank Angle using the following instructions and
referencing the drawing below:
Turn down the DC offset to minimum level with out clipping the signal on the
triangle wave input channel so that it can be seen on the scope. Adjust the
vertical scale on the scope on the Keyphasor channel so that the Keyphasor
pulse can be seen.
Note: This may cause the channel to go Not OK and the proportional value to
go Invalid, but it will be reset after calculating the crank angle.
Measure the time of the full Keyphasor_Cycle_Time (6) as shown.
Calculate the Piston_Angle_Time using the following equation (The time from
the Keyphasor leading edge to the Piston Top Dead Center). Refer to the
monitor Configuration Options screen to get the Piston Angle value.
Piston_Angle_Time = (Piston Angle / 360) X Keyphasor_Cycle_Time
Mark the Piston_Angle_Time (7) on the scope.
Measure the time from the Piston_Angle_Time to the next

Positive_Peak_Value_Time (8) on the oscilloscope as shown.
Calculate the Crank Angle using the following equation:
Crank Angle = (Positive_Peak_Value_Time / Keyphasor_Cycle_Time) X 360
Adjust the DC offset of the triangle wave input such that the signal is in the
OK voltage range.
85
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Syncd Triangle wave input

Keyphasor Notch Signal
Keyphasor Projection Signal
Time Scale
Leading edge of the Keyphasor
One Crank Shaft Revolution = Keyphasor_Cycle_Time
Piston_Angle_Time (time from Keyphasor to Top Dead Center)
Positive_Peak_Value_Time (Crank Angle)
6. Verify that the Crank Angle bar graph display and Current Value Box is
reading approximately what was calculated above. If the recorder output is
configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to verify
recorder output.
correct. If the monitor still does not meet specifications or fails any other part
comes on and the OK relay energizes. Press the RESET button on the Rack
Interface Module (RIM) to reset the OK LED.
Pk Pk Displacement
on the I/O module.
86

Required Test Equipment and Setup. Set the function generator to Sine
wave output.
3. Calculate the full scale voltage according to the equation and examples
shown below. Adjust the amplitude of the function generator to the
calculated Full Scale voltage.
Full Scale Voltage = Pk-Pk Displacement Meter Top Scale x Transducer Scale
Factor
Note: Use the Transducer Scale Factor displayed in the Scale Factor Box on
the Verification Screen.
Example 1:
Direct Meter Top Scale = 40 mil
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (Vpp), for sinewave input
Vrms = (.0707/2) X (8)
Vrms = 2.828 Vrms
Example 2:
Direct Meter Top Scale = 800m
Transducer Scale Factor = 7,874 mV/mm = 7.874 mV/m
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
divide setting is one. Verify that the Pk-Pk Displacement bar graph display
and Current Value Box is reading 1% of full scale. If the recorder output is
the recorder output.
Gap
on the I/O module.
87

wave output.
3. Adjust the power supply to produce a voltage equal to 18.00 Vdc on the Volt
Meter. Verify that the Gap bar graph display and Current Value Box is
reading 18.00 Vdc 1% of Full Scale. If the recorder output is configured,
refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify recorder
output.
4. Adjust the power supply to produce a voltage equal to mid-scale on the Volt
reading the mid-scale value 1% of Full Scale. If the recorder output is
configured, refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify
1X Amplitude
this parameter.
on the I/O module.
wave output.
3. Calculate the full-scale voltage according to the equation and examples
shown below. Adjust the function generator amplitude to the calculated Full
Scale voltage.
Full Scale Voltage = 1X Ampl Meter Top Scale X Transducer Scale Factor
Example 1:
1X Ampl Meter Top Scale = 40 mil
Transducer Scale Factor = 200 mV/mil
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (Vpp), for a sinewave input
Vrms = (0.707/2) X (8)
Vrms = 2.828 Vrms
88
Example 2:
1X Ampl Meter Top Scale = 800 m
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268
divide setting is one. Verify that the 1X Ampl bar graph display and Current
Value Box is reading 1% of full scale. If the recorder output is configured,
refer to Section 5.1.9 (Verify Recorder Outputs) for steps to verify the
recorder output.
2X Amplitude
this parameter.
on the I/O module.
wave output.
Scale voltage.
Example 1:
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (8)
Vrms = 2.828 Vrms
89
Example 2:
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
divide setting is two. Verify that the 2X Ampl bar graph display and Current
recorder output.
Not 1X Amplitude
this parameter.
on the I/O module.
wave output.
Scale voltage.
Full Scale Voltage = Not 1X Ampl Meter Top Scale X Transducer Scale Factor
Example 1:
Not 1X Ampl Meter Top Scale = 40 mil
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (8)
90
Vrms = 2.828 Vrms

Example 2:
Not 1X Ampl Meter Top Scale = 800 m
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
divide setting is two. Verify that the Not 1X Ampl bar graph display and
Current Value Box is reading 1% of full scale. If the recorder output is
5.1.5.4
Test OK Limits Rod Position Single

The general approach for testing OK limits is to input a DC voltage and adjust it
above the Upper OK limit and below the Lower OK limit. This will cause a
channel not OK condition and the OK Relay to change state (de-energize). The
Upper and Lower OK limits are displayed in the Verification screen on the test
computer.
the Rod Position I/O Module.
wave output. Set the input to only DC signal into the monitor by adjusting the
amplitude of the function generator to approximately zero.
3. Bypass all other configured channels.
4. Adjust the power supply voltage to -7.00 Vdc.
monitor OK LED is on and that the Channel OK State line in the Channel
Status box of the Verification screen reads OK.
91

Note: If the Danger Bypass has been activated, then the BYPASS LED will be
on. All other channels in the rack must be OK or bypassed for the relay to be
energized.
6. Verify that the OK relay on the Rack Interface I/O Module indicates OK
(energized). See 3500/20 Rack Interface Module Operation and
Maintenance Manual.
7. Increase the power supply voltage (more negative) until the OK LED just
goes off (upper limit). Verify that the Channel OK State line in the Channel
Status box reads not OK and that the OK Relay indicates not OK. Verify that
the Upper OK limit voltage displayed on the Verification screen is equal to or
more positive than the input voltage.
8. Decrease the power supply voltage (less negative) to -7.00 Vdc.
9. Press the RESET switch on the Rack Interface Module. Verify that the OK
LED comes back on and the OK relay energizes. Verify that the Channel OK
State line in the Channel Status box reads OK.
10. Gradually decrease the power supply voltage (less negative) until the OK
LED just goes off (lower limit). Verify that the Channel OK State line in the
Channel Status box reads not OK and that the OK Relay indicates not OK.
Verify that the Lower OK limit voltage displayed on the Verification screen is
equal to or more negative than the input voltage.
11. Increase the power supply voltage (more negative) to -7.00 Vdc.
LED comes back on, the OK relay energizes, and that the Channel OK State
line in the Channel Status box reads OK.
13. If you cannot verify any configured OK limit, go to Section 5.1.10 (If a
Channel Fails a Verification Test).
wiring to the channel terminals on the Monitor I/O Module. Press the RESET
switch on the Rack Interface Module and verify that the OK LED comes on
and the OK relay energizes.
16. Return the bypass switch for all configured channels to their original setting.
Table 5-1 Rod Position Single Default OK Limits Table
Transducer
3300 8 mm w/ Galvanic
Isolation
3300 8 mm w/ External
barriers
3300 8 mm w/ Internal barriers
3300 8 mm w/o barriers
3300XL 8 mm w/ Galvanic
Isolation
3300XL 8 mm w/ External
barriers
3300XL 8 mm w/ Internal
barriers
3300XL 8 mm w/o barriers
92
Lower OK Limit (Volts)

-1.1
Upper OK Limit (Volts)

-18.2
-1.1
-18.2
-1.28
-1.28
-1.1
-18.2
-19.04
-18.2
-1.1
-18.2
-1.28
-18.2
-1.28
-19.04
Transducer
3300XL 11 mm w/ Galvanic
-1.1
Isolation
3300XL 11 mm w/ External
-1.1
barriers
3300XL 11 mm w/ Internal
-1.28
barriers
-1.28
7200 8 mm w/ Galvanic
-1.1
Isolation
7200 8 mm w/ External
-1.1
barriers
7200 8 mm w/ Internal barriers -1.28
-1.28
-3.55
-1.65
Note: Assume & 50 mV accuracy for check tolerance.
5.1.6

-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-20.39
-18.05
Rod Position Pair Channels

limits for channels configured as Rod Position Pair. The output values and alarm
setpoints are verified by varying the input signal levels and observing that the
correct results are reported in the Verification screen on the test computer.
Rod Position Pair channels can be configured for the following channel values
and alarms:
Channel Values
Alarms
Over
Position Magnitude
Under
Piston Angle
Crank Angle
Pk Pk Displacement
Gap
1X Amplitude
2X Amplitude
Not 1X Amplitude
93
5.1.6.1
Test Equipment and Software Setup Rod Position Pair

The following test equipment and software set up can be used as the initial set
up needed for all the Rod Position Pair channel verification procedures (Test
Alarms, Verify Channels, and Test OK Limits).
WARNING
death.
terminals.
94
Test Equipment Setup Rod Position Pair

Power Supply
Function Generator
-7.00 Vdc
Wave Form: sinewave

DC Volts: 0 Vdc
Frequency: 15 Hz
(above zero)

Divide Switch: 001
Connect the input from Channel 1 to the Channel 2 inputs at the I/O Module as
shown.
Note: Rod Position Pair Channel Types require input to two channels. This is
accomplished with one function generator by giving the same input to both
channels.
Note: When using the Software Verification screens for Rod Position Pair, the
screen for the first channel of the pair displays the Position Magnitude, Position
Angle, and Crank Angle proportional values. These are common/composite
proportional values, with all others being independent.
Verification Screen Setup Rod Position Pair

associated with the Rod Position Pair Channels:
95
5.1.6.2
Section
Number
Topic
5.1.6.2
Test Alarms Position Magnitude
5.1.6.2
Test Alarms Pk Pk Displacement
5.1.6.2
Test Alarms Gap
5.1.6.2
5.1.6.2
5.1.6.2
5.1.6.3
Verify Channel Values Position Magnitude
5.1.6.3
Verify Channel Values Position Angle
5.1.6.3
Verify Channel Values Crank Angle
5.1.6.3
Verify Channel Values Pk Pk Displacement
5.1.6.3
5.1.6.3
Verify Channel Values 1 X Amplitude
5.1.6.3
5.1.6.3
5.1.6.4
Test OK Limits
Test Alarms Rod Position Pair

Keyphasor signals with a function generator. The alarm levels are tested by
varying the this input signal and observing that the correct results are reported in
the Verification screen on the test computer. It is only necessary to test those
alarm parameters that are configured and being used. The general test
procedure to verify current alarm operation will include simulating a transducer
input signal and varying this signal:
1. to exceed over Alert/Alarm 1 and Danger/Alarm 2 Setpoints, and
2. to drop below any under Alert/Alarm 1 and Danger/Alarm 2 Setpoints and
Position Magnitude
Note: The Calculated Center Voltage value can be seen in the verification
screen.
the I/O module.
Required Test Equipment and Setup and Section 5.1.6.1, Test Equipment
96
and Software Setup Rod Position Pair. Set the function generator to Sine
wave output.
Note: When using the Software Verification screens for Rod Position Pair, the
screen for the first channel of the pair displays the Position Magnitude, Position
Angle, and Crank Angle values. These are common/composite values between
the two channels, with all others being independent.
divide setting is one. Turn down the Amplitude on the function generator to
have the minimum possible value and adjust the power supply DC voltage
level to produce a gap reading that results in a Position Magnitude that is
above (more negative than) the Calculated Center Voltage level and below
(less negative than) the Position Magnitude setpoint levels on the bar graph
OK LED is on, the bar graph indicator for Position Magnitude is green, and
5. Increase (more negative) the power supply voltage such that the signal just
an Alarm.
7. Increase (more negative) the power supply such that the signal just exceeds
indicates an Alarm.
9. Decrease (less negative) the power supply voltage such that the gap signal
reads above (more negative) the Calculated Center Voltage level and below
(less negative) the Over Alarm setpoint levels. If the non-latching option is
configured, observe that the bar graph indicator for Position Magnitude
changes color to green and that the Current Value Box contains no indication
of alarms. Press the RESET switch on the RIM to reset latching alarms.
11. Adjust the power supply level to produce a gap reading that is below (less
negative) the Calculated Center Voltage level and results in a Position
Magnitude that is below (more negative than) the Position Magnitude setpoint
levels on the bar graph display of the Verification screen.
Note: The Position Magnitude value will always be positive.
97
13. Decrease (less negative) the power supply voltage such that the signal just
an Alarm.
15. Decrease (less negative) the power supply such that the signal just exceeds
indicates an Alarm.
17. Increase (more negative) the power supply voltage such that the signal reads
below (more negative) the Over Alarm setpoint levels. If the non-latching
option is configured, observe that the bar graph indicator for Position
Magnitude changes color to green and that the Current Value Box contains
no indication of alarms. Press the RESET switch on the RIM to reset latching
alarms.
18. If you cannot verify any configured alarm, recheck the configured setpoints.
19. Disconnect the test equipment and channel jumpers and reconnect the PWR,
COM, and SIG field wiring to the channel terminals on the I/O module. Verify
that the OK LED comes on and the OK relay energizes. Press the RESET
button on the RIM to reset the OK LED.
Pk Pk Displacement
the I/O module.
wave output.
98
indicates an Alarm.
indicates an Alarm.
Gap
the I/O module.
wave output.
adjust the power supply to produce a voltage that is within the Gap setpoint
99
Alarm.
alarm.
1X Amplitude
this parameter.
the I/O module.
wave output.
100
an Alarm.
alarm.
Ampl changes color from yellow to red and that the Current value Field
indicates an Alarm.
2X Amplitude
this parameter.
the I/O module.
wave output.
101
an Alarm.
alarm.
indicates an Alarm.
Not 1X Amplitude
this parameter.
the I/O module.
wave output.
102
an Alarm.
alarm.
changes color from yellow to red and that the Current value Field indicates an
Alarm.
5.1.6.3
Verify Channel Values Rod Position Pair

Position Magnitude Position Angle
on the I/O module.
wave output.
103
divide setting is one. Set the Amplitude level on the function generator for a
1 Vpp Sine wave and adjust the power supply DC voltage level to produce a
gap reading that is at least two volts less negative than the Calculated Center
Voltage level.
Note: The Pk_Pk voltage cannot cross the Calculated Center Voltage level.
4. Record the transducer orientation angles from the monitor Options screen.
These angles are to be between 0 and 359 with 0 being vertical or
opposing gravity and going in the CW direction as viewed from the driver
end. These angles will be 1 and 2 for Channels 1 and 2 respectively.
Example:
1 = 10 Left (options screen) = 350
2 = 85 Right (options screen) = 85
5. Calculate (the angle between the probes) with the following equation:
= 1 2
Example:
1 = 350
2 = 85
= 1 2 = 350 - 85 = 265
6. Calculate x and y (translated orthogonal probe gaps) with the following

equations:
x (mils) = (P1 ZP1) / SF1
y (mils) = [(P2 ZP2) / SF2 xCos] / Sin
Example:
DC Offset = -5.00 Vdc
Sine wave Amplitude = 1 Vpp
= 265
ZP1 = ZP2 = -10.50 Vdc
SF1 = SF2 = 200 mV/mil = .200 V/mil
P1 = P2 = -5.00 + .50 = -4.5 Volts
x = [-4.50 (-10.50)] / .200
x = 6.00 / .200 = 30.0 mil
y = [ [-4.50 (-10.5)] / .200 (30*Cos265) ] / Sin265
y = [ 6 / .200 (-2.61) ] / (-.996)
y = -32.7 mils
P1 and P2 are the DC offset Voltage value plus of the Vpp Voltage value.
Note: Since the same input signal is going into Channel 1 and 2, the values of
P1 and P2 will be the same.
ZP1 and ZP2 are the Calculated Center Voltage levels given on the Software
Verification Screens. These values will most likely be different for each channel.
104
SF1 and SF2 are the probe Scale Factors for each channel given on the
Software Verification Screens.
7. Calculate the Position Magnitude vector value with the following equation:
Position Magnitude (mils) = Sqrt(x^2 + y^2)
Example:
x = 30.0 mils
y = -32.7 mils
Position Magnitude = Sqrt [(30)^2 + (-32.7)^2]
Position Magnitude = Sqrt [900 + 1069]
Position Magnitude = 44.4 mils
reading of the calculated value 1% of Full Scale. If the recorder output is
9. Transform the coordinates to the actual X and Y values of the position vector
with the following equations:
= 90 - 1
x = xCos ySin
y = xSin + yCos
Example:
= 90 - 350
= -260
x = 30.0*Cos(-260) (-32.7)*Sin(-260)
x = -5.21 + 32.20
x = 26.99 mils
y = 30.0*Sin(-260) + (-32.7)*Cos(-260)
y = 29.54 + 5.68
y = 35.22 mils
10. Determine the Position Angle with the following rules and equations:
For y = 0
If x > 0 If x < 0 If x = 0 -
Position Angle = 90
Position Angle = 270
Position Angle = 0
For y > 0
If x >= 0 If x < 0 -
Position Angle = arctan (x/y)

Position Angle = arctan (x/y) + 360
For y < 0 -
Position Angle = arctan (x/y) + 180
Example:
x = 26.99 mils
y = 35.22 mils
y>0
105
x >= 0
Position Angle = arctan(26.99/35.22)
Position Angle = 37.5
11. Verify that the Position Angle bar graph display and Current Value Box is
reading of the calculated value 1% of Full Scale. If the recorder output is
Crank Angle
this parameter.
on the I/O module.
and Software Setup Rod Position Pair. Set the function generator to
Triangle wave output.
3. Using a 2-Channel oscilloscope, look at the triangle wave at the input to the
capacitor.
5. Measure and calculate the Crank Angle using the following instructions and
referencing the drawing below:
-
Turn down the DC offset to minimum level with out clipping the signal on
the triangle wave input channel so that it can be seen on the scope.
Adjust the vertical scale on the scope on the keyphasor channel so that
the keyphasor pulse can be seen.
106
Calculate the Piston_Angle_Time using the following equation (The time

from the Keyphasor leading edge to the Piston Top Dead Center). Refer
to the monitor Configuration Options screen to get the Piston Angle value.
Piston_Angle_Time = (Piston Angle / 360) X Keyphasor_Cycle_Time

-
Mark the Piston_Angle_Time (7) on the scope.
Measure the time from the Piston_Angle_Time to the next

Positive_Peak_Value_Time (8) on the oscilloscope as shown.
Calculate the Crank Angle with the following equation:
Crank Angle = (Positive_Peak_Value_Time / Keyphasor_Cycle_Time) X 360

-
Adjust the DC offset of the triangle wave input such that the signal is in
the OK voltage range.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Syncd Triangle wave input

Time Scale
Piston_Angle_Time (time from Keyphasor to Top Dead Center)
Positive_Peak_Value_Time (Crank Angle)
6. Verify that the Crank Angle bar graph display and Current Value Box is
reading approximately what was calculated above. If the recorder output is
107
recorder output.
Pk Pk Displacement
on the I/O module.
wave output.
3. Calculate the Full Scale voltage according to the equation and examples
calculated voltage.
Factor
Example 1:
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (.0707/2) X (8)
Vrms = 2.828 Vrms
Example 2:
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
108
Gap
on the I/O module.
wave output.
output.
1X Amplitude
this parameter.
on the I/O module.
wave output.
109

shown below. Adjust the function generator amplitude to the calculated
voltage with sinewave output.
Example 1:
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (8)
Vrms = 2.828 Vrms
Example 2:
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268
recorder output.
2X Amplitude
this parameter.
on the I/O module.
110
wave output.
Example 1:
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (8)
Vrms = 2.828 Vrms
Example 2:
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
recorder output.
7. Repeat steps 1 through 6 for all configured channels
Not 1X Amplitude
this parameter.
on the I/O module.
111

wave output.
Example 1:
Full Scale = (40 X 0.200) = 8.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (8)
Vrms = 2.828 Vrms
Example 2:
Full Scale = (800 X 0.007874) = 6.2992 Vpp
For Vrms input:
Vrms = (0.707/2) X (6.2992)
Vrms = 2.2268 Vrms
5.1.6.4
Test OK Limits Rod Position Pair

112
computer.
wave output. Set the input to only DC signal into the monitor by adjusting the
amplitude of the function generator to approximately zero.
energized.
Maintenance Manual.
113

Table 5-2 Rod Position Pair Default OK Limits Table
Transducer
3300 8 mm w/ Galvanic Isolation
-1.1
3300 8 mm w/ External barriers
-1.1
-1.28
-1.28
3300XL 8 mm w/ Galvanic Isolation
-1.1
3300XL 8 mm w/ External barriers
-1.1
3300XL 8 mm w/ Internal barriers
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-3.55
-1.65
Assume & 50 mV accuracy for check tolerance.
114

-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-20.39
-18.05
5.1.7
Rod Drop Channels

limits for channels configured as Rod Drop. The output values and alarm
setpoints are verified by varying the input signal levels and observing that the
correct results are reported in the Verification screen on the test computer.
Rod Drop channels can be configured for the following channel values and
alarms:
Channel Values
Alarms
Over
Under
Average Gap
Instantaneous Gap
5.1.7.1
Test Equipment and Software Setup Rod Drop

The following test equipment and software setup can be used as the initial setup
needed for all the Rod Drop channel verification procedures (Test Alarms, Verify
Channels, and Test OK Limits).
WARNING
death.
terminals.
115
Test Equipment Setup Rod Drop

Power Supply
Function Generator
-7.00 Vdc
Wave Form: sinewave

DC Volts: 0 Vdc
Frequency: 15 Hz
(above zero)

Divide Switch: 001
Verification Screen Setup Rod Drop

associated with the Rod Drop Channels:
116
Section
Number
Topic
5.1.7.2
Test Alarms Average Gap
5.1.7.2
Test Alarms Average Piston Position
5.1.7.2
Test Alarms Instantaneous Gap
5.1.7.2
Test Alarms Instantaneous Piston Position
5.1.7.3
Verify Channel Values Average Gap and Piston Position
5.1.7.3
Verify Channel Values Instantaneous Gap and Piston Position
5.1.7.4
Test OK Limits
5.1.7.2
Test Alarms Rod Drop

Keyphasor input signals with a function generator and power supply. The
alarm levels are tested by varying the input signals and observing that the correct
results are reported in the Verification screen on the test computer. It is only
necessary to test those alarm parameters that are configured and being used.
The general test procedure to verify current alarm operation will include
simulating a transducer input signal and varying this signal:
the I/O module.
wave output.
adjust the DC power supply level to produce a reading that is above the
Average Piston Position setpoint level on the bar graph display of the
Verification screen.
OK LED is on, the bar graph indicator for Average Piston Position is green,
and the Current Value field contains no alarm indication.
5. Adjust the power supply voltage such that the signal just exceeds the
Average Piston Position Under Alert/Alarm 1 setpoint level. Wait until 2 or 3
indicator for Average Piston Position changes color from green to yellow and
that the Current Value Field indicates an Alarm.
bar graph indicator for Average Gap remains yellow and that the Current
Field still indicates an Alarm.
7. Adjust the power supply such that the signal just exceeds the Average Piston
Position Under Danger/Alarm 2 setpoint level. Wait until 2 or 3 seconds after
the alarm time delay expires and verify that the bar graph indicator for
Average Piston Position changes color from yellow to red and that the
117
bar graph indicator for Average Piston Position remains red and that the
Current Value Field still indicates an Alarm.
9. Adjust the power supply voltage such that the signal reads above the Under
Alarm setpoint levels. If the non-latching option is configured, observe that
the bar graph indicator for Average Piston Position changes color to green
and that the Current Value Box contains no indication of alarms. Press the
RESET switch on the Rack Interface Module (RIM) to reset latching alarms.
the I/O module.
wave output.
adjust the DC power supply to produce a reading that is above the
Instantaneous Piston Position setpoint levels on the Instantaneous Piston
Position bar graph display of the Verification screen. Be sure to set the DC
Voltage levels such that all Sine wave values are still above the setpoint
level.
OK LED is on, the bar graph indicator for Instantaneous Gap is green, and
5. Adjust the DC power supply output such that the signal just exceeds the
Instantaneous Piston Position Under Alert/Alarm 1 setpoint level. Be sure to
set the DC Voltage level such that all Sine wave values are still below the
setpoint level (and above the Danger/Alarm 2 setpoint level). Wait until 2 or 3
indicator for Instantaneous Gap changes color from green to yellow and that
bar graph indicator for Instantaneous Gap remains yellow and that the
Current Field still indicates an Alarm.
7. Adjust the power supply output such that the signal just exceeds the
Instantaneous Piston Position Under Danger/Alarm 2 setpoint level. Be sure
to set the DC Voltage level such that all Sine wave values are still below the
setpoint level. Wait until 2 or 3 seconds after the alarm time delay expires
118
and verify that the bar graph indicator for Instantaneous Piston Position
changes color from yellow to red and that the Current Value Field indicates
an Alarm.
bar graph indicator for Instantaneous Gap remains red and that the Current
Value Field still indicates an Alarm.
9. Adjust the power supply output such that the signal reads below the Over
Alarm setpoint levels. If the non-latching option is configured, observe that
the bar graph indicator for Instantaneous Piston Position changes color to
green and that the Current Value Box contains no indication of alarms. Press
the RESET switch on the Rack Interface Module (RIM) to reset latching
alarms.
go to Section 5.1.10 (If a Channel Fails a Self Test).
5.1.7.3
Verify Channel Values Rod Drop

Average Gap Average Piston Position
the I/O module.
wave output.
3. Adjust the DC power supply to produce a voltage equal to -18.00 Vdc on the
voltmeter display. Verify that the Average Gap bar graph display, and
Current Value Box, is reading -18.00 Vdc 1% of Full Scale. If the recorder
output is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps
to verify recorder output.
4. Using the equation shown below, calculate the Average Piston Position.
Verify that the Average Piston Position bar graph display, and Current Value
Box, is reading the calculated value 1% of Full Scale. If the recorder output
is configured, refer to section 5.1.9 (Verify Recorder Outputs) for steps to
verify recorder output.
Average Piston Position = (Average Gap ZP) / SF * ACF
Example:
119
Average Gap = -18.0 Vdc

ZP = -8.59 Vdc
SF = 200mV/mil = .200 V/mil
ACF = 2.05
Average Piston Position = [ (-18.0) (-8.59) ] / .200 * 2.05
Average Piston Position = -9.41 / .200 * 2.05
Average Piston Position = 96.5 mils
Note: Use the Scale Factor (SF), Zero Position (ZP), and Average Correction
Factor (ACF) displayed on the Verification Screen.
Instantaneous Gap Instantaneous Piston Position
this parameter.
the I/O module.
wave output.
3. Using a 2-Channel oscilloscope, look at the Sine wave at the input to the
capacitor.
5. Measure and calculate the Sync_Offset_Angle using the following

instructions and referencing the drawing below:
-
Turn down the DC offset to minimum level with out clipping the signal on
the Sine wave input channel so that it can be seen on the scope. Adjust
the vertical scale on the scope on the keyphasor channel so that the
keyphasor pulse can be seen.
120
Center the signal vertically about an axis on the scope. This makes it
easier to see the zero crossing.
Measure the time of the Sync_Offset_Time as shown (7). Calculate the

Sync_Offset_Angle:
Sync_Offset_Angle = (Sync_Offset_Time / Keyphasor_Cycle_Time) X 360

Example:
Keyphasor_Cycle_Time = 66.4 ms
Sync_Offset_Time = 32.4 ms
Sync_Offset_Angle = (32.4 / 66.4) X 360
Sync_Offset_Angle = 175
Using the following equation and configured machine parameters,

calculate the Instantaneous Gap:
Instantaneous Gap = Vp * Sin(PA + TA Sync_Offset_Angle) + DC Offset

Example:
Sync_Offset_Angle = 175
Vpp = 2 Volt, Vp = 1 Volt
P.A. = 60
T.A. = 55
DC_Offset = -7.00 Volt
I.G. = 1.0V * Sin(60 + 55 - 175) 7.00V
I.G. = 1.0V * Sin(-60) 7.00V
I.G. = 1.0V * (-.866) 7.00V
I.G. = -7.87 Vdc
Vp is input peak amplitude (NOT peak to peak).
DC Offset is the DC offset of the input sine wave in negative volts.
PA is the machine parameter Piston Angle. TA is the maching parameter

Trigger Angle. These values are available in the monitor options screen.
Sync_Offset_Angle is the value in degrees from the falling edge

keyphasor signal to the next zero value of the Sine wave heading in the
positive direction.
121
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Syncd Sine wave input

Time Scale.
Sync_Offset
6. Verify that the Instantaneous Gap bar graph display, and Current Value Box,
is reading approximately what was calculated above. If the recorder output is
recorder output.
7. Using the equations shown below, calculate the Instantaneous Piston
Position. Verify that the Instantaneous Piston Position bar graph display, and
Current Value Box, is reading the calculated value 1% of Full Scale. If the
recorder output is configured, refer to section 5.1.9 (Verify Recorder Outputs)
for steps to verify recorder output.
If Transducer Orientation (from monitor Options screen) is 0:
Instantaneous Piston Position = ICF * (Instantaneous Gap ZP) / SF
If Transducer Orientation (from monitor Options screen) is 180:
Instantaneous Piston Position = -1 * ICF * (Instantaneous Gap ZP) / SF
Example:
Transducer Orientation = 180
122
I.G. = -7.87 Volts

ZP = -10.00 Volts
SF = 200 mV/mil = .200 V/mil
ICF = 1.84
I.P.P. = -1*[(-7.87 + 10.00) / .200 * 1.84]
I.P.P. = -1*[10.65 * 1.84]
I.P.P. = -19.6
Note: Use the Scale Factor, Zero Position, and Instantaneous Correction Factor
5.1.7.4
Test OK Limits Rod Drop

computer.
Required Test Equipment and Setup.
energized.
Maintenance Manual.
123
Status box reads Not OK and that the OK Relay indicates not OK. Verify that
Channel Status box reads Not OK and that the OK Relay indicates not OK.
Table 5-3 Rod Drop Default OK Limits Table
Transducer
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-3.55
-1.65
Note: Assume & 50 mV accuracy for check tolerance.
124

-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-20.39
-18.05
5.1.8
Hyper Channels
limits for channels configured as Hyper. The output values and alarm setpoints
are verified by varying the input signal levels and observing that the correct
Hyper channels can be configured for the following channel values and alarms:
Channel Values
Alarms
Over
5.1.8.1
Under
Pk Pk Displacement
Gap
1X Amplitude
2X Amplitude
Not 1X Amplitude
Test Equipment and Software Setup Hyper

The following test equipment and software setup can be used as the initial setup
needed for all the Hyper channel verification procedures (Test Alarms, Verify
Channels, and Test OK Limits).
WARNING
death.
terminals.
125
Test Equipment Setup Hyper

Power Supply
Function Generator
-7.00 Vdc
Wave Form: sinewave

DC Volts: 0 Vdc
Frequency: 15 Hz
(above zero)

Divide Switch: 001
Verification Screen Setup Hyper

associated with the Hyper Channels:
126
Section
Number
Topic
5.1.8.2
Test Alarms Pk-Pk Displacment
5.1.8.2
Test Alarms Gap
5.1.8.2
5.1.8.2
5.1.8.2
5.1.8.3
Verify Channel Values Pk-Pk Displacment
5.1.8.3
5.1.8.3
5.1.8.3
5.1.8.3
5.1.8.4
Test OK Limits
5.1.8.2
Test Alarms Hyper

Keyphasor input signals with a function generator and power supply. The
alarm levels are tested by varying the input signals and observing that the correct
results are reported in the Verification screen on the test computer. It is only
necessary to test those alarm parameters that are configured and being used.
The general test procedure to verify current alarm operation will include
simulating a transducer input signal and varying this signal:
Pk Pk Displacement
the I/O module.
wave output.
indicates an Alarm.
indicates an Alarm.
127
Gap
the I/O module.
wave output.
3. Adjust the power supply to produce a voltage that is within the Gap setpoint
Alarm.
alarm.
128
1X Amplitude
this parameter.
the I/O module.
wave output.
an Alarm.
alarm.
indicates an Alarm.
129
Danger/Alarm 2 setpoints by adjusting the function generator amplitude to
exceed the Under Alarm setpoint levels.
2X Amplitude
this parameter.
the I/O module.
wave output.
an Alarm.
alarm.
indicates an Alarm.
130
Danger/Alarm 2 setpoints by adjusting the function generator amplitude to
exceed the Under Alarm setpoint levels.
Not 1X Amplitude
this parameter.
the I/O module.
wave output.
an Alarm.
alarm.
changes color from yellow to red and that the Current value Field indicates an
Alarm.
131
5.1.8.3
Verify Channel Values Hyper

Note: These parameters have an accuracy specification of 1% of full scale for
amplitude.
Pk Pk Displacement
on the I/O module.
wave output.
3. Calculate the full scale voltage according to the equation and examples
calculated voltage.
Factor
Example 1:
Transducer Scale Factor = 200mV/mil = .200 V/mil
Full Scale = (10 X 0.200) = 2.000 Vpp
For Vrms input:
= (.0707/2) X (2)
= 0.707 Vrms
Example 2:
132

= 7.874 mV/m
Full Scale = (200 X 0.007874) = 1.5748 Vpp
For Vrms input:
= (.0707/2) X (1.574)
= 0.5566 Vrms
Gap
on the I/O module.
wave output.
output.
133
1X Amplitude
this parameter.
on the I/O module.
wave output.
voltage.
Example 1:
Full Scale = (10 X 0.200) = 2.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (2)
Vrms = 0.707
Example 2:
Full Scale = (200 X 0.007874) = 1.5748 Vpp
For Vrms input:
Vrms = (0.707/2) X (1.5748)
Vrms = 0.5566
recorder output.
134
2X Amplitude
this parameter.
on the I/O module.
wave output.
voltage.
Example 1:
Full Scale = (10 X 0.200) = 2.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (2)
Vrms = 0.707
Example 2:
Full Scale = (200 X 0.007874) = 1.5748 Vpp
For Vrms input:
Vrms = (0.707/2) X (1.5748)
Vrms = 0.5566
recorder output.
135
Not 1X Amplitude
this parameter.
on the I/O module.
wave output.
voltage.
Example 1:
Full Scale = (10 X 0.200) = 2.000 Vpp
For Vrms input:
Vrms = (0.707/2) X (2)
Vrms = 0.707
Example 2:
Full Scale = (200 X 0.007874) = 1.5748 Vpp
For Vrms input:
Vrms = (0.707/2) X (1.5748)
Vrms = 0.5566
136
5.1.8.4
Test OK Limits - Hyper

computer.
Note: If both channels of a Hyper channel pair go Not OK, all enabled alarms
configured for Danger/Alarm 2 will become active.
Required Test Equipment and Setup.
energized.
(energized). See 3500 Rack Interface Module Operation and Maintenance
Manual.
9. Press the RESET switch on the RIM. Verify that the OK LED comes back on
and the OK relay energizes. Verify that the Channel OK State line in the
Channel Status box reads OK.
12. Press the RESET switch on the RIM. Verify that the OK LED comes back on,
the OK relay energizes, and that the Channel OK State line in the Channel
Status box reads OK.
137
Table 5-4 Hyper Default OK Limits Table
Transducer
138
Lower OK Limit
(Volts)
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-1.1
-1.1
-1.28
-1.28
-3.55
-1.65
Upper OK Limit
(Volts)
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-18.2
-18.2
-18.2
-19.04
-20.39
-18.05
5.1.9
Verify Recorder Outputs

The following test equipment and procedure should be used in the verification of
the recorder outputs. Recorder outputs for the 3500/72M Recip Rod Position
Monitor Module are 4 to 20 mA.
(1)
(2)
(3)
(4)
Connect test equipment here.

Prox/Velom I/O Module (Internal Termination)
Recorder External Termination Block (Euro Style Connectors)
Recorder External Termination Block (Terminal Strip Connectors)
1. Disconnect the COM and REC field wiring from the channel terminals on the
I/O module.
2. Connect a multimeter to the COM and REC outputs of the I/O module. The
multimeter should have the capability to measure 4 to 20 mA.
3. If the proportional value is not Gap: Set the proportional value that the
recorder is configured for to full-scale (refer to the proportional value of the
channel pair type you are testing in the Verify Channel Values portion of this
manual). Verify that the recorder output is reading 20 mA 1%. Go to step
5.
4. If the proportional value is Gap: Set the Gap proportional value to 18.00
Vdc (Refer to the proportional value of the channel pair type you are testing
in the Verify Channel Values portion of this manual). Verify that the recorder
output is reading 16 mA 1%.
5. Set the proportional value that the recorder is configured for to mid-scale.
Verify that the recorder output is reading 12 mA 1%.
6. Set the proportional value that the recorder is configured for to bottom-scale.
Verify that the recorder output is reading 4 mA 1%.
139
7. Disconnect transducer input and verify that the recorder output matches the
set monitor clamp value 1%.
8. If you can not verify the recorder output, the recorder configuration and
connections should be checked. If the monitor recorder output still does not
verify properly, go to Section 5.1.10 (If a Channel Fails a Verification Test).
9. Disconnect the multimeter and reconnect the COM and REC field wiring to
the channel terminals on the I/O module.
10. Repeat steps 1 through 9 for all configured recorder channels.
5.1.10
If a Channel Fails a Verification Test

When handling or replacing circuit boards, always be sure to adequately protect
against damage from Electrostatic Discharge (ESD). Always wear a proper wrist
strap and work on a grounded conductive work surface.
1. Save the configuration for the module using the Rack Configuration Software.
2. Replace the module with a spare. Refer to the installation section in the 3500
Monitoring System Rack Installation and Maintenance Manual.
3. Return the faulty board to Bently Nevada Corporation for repair.
4. Download the configuration for the spare module using the Rack
Configuration Software.
5. Verify the operation of the spare.
140
Section 6 Troubleshooting
6.
Troubleshooting
This section describes how to troubleshoot a problem with the Recip Rod
Position Monitor or the I/O module by using the information provided by the selftest, the LEDs, the System Event List, and the Alarm Event List.
6.1
Self-test
To perform the Recip Rod Position Monitor self-test:
1. Connect a computer running the Rack Configuration Software to the 3500
rack (if needed).
2. Select Utilities from the main screen of the Rack Configuration Software.
3. Select System Events/Module Self-test from the Utilities menu.
4. Press the Module Self-test button on the System Events screen.
Application Alert: Machinery protection will be lost while the self-test is being
performed
5. Select the slot that contains the Recip Rod Position Monitor and press the
OK button. The Recip Rod Position Monitor will perform a full self-test and
the System Events screen will be displayed. The list will not contain the
results of the self-test.
6. Wait 30 seconds for the module to run a full self-test.
7. Press the Latest Events button. The System Events screen will be updated
to include the results of the Recip Rod Position Monitor self-test.
8. Verify if the Recip Rod Position Monitor passed the self-test. If the monitor
failed the self-test, refer to Section 7.3.
141
6.2
LED Fault Conditions

The following table shows how to use the LEDs to diagnose and correct
problems.
OK Led
TX/RX
1 Hz
1 Hz
Condition
Solution
<<>>
Monitor is not configured, is in

Configuration Mode, or in
Calibration Mode.
Reconfigure the Monitor, or

exit Configuration, or
Calibration Mode.
<<>>
<<>>
Monitor error
Check the System Event

List for severity.
Flashing
<<>>
Module is operating correctly
No action required.
OFF
<<>>
<<>>
Monitor is not operating

correctly or the transducer has
faulted and has stopped
providing a valid signal.

List and the Alarm Event
List.
2 Hz
<<>>
<<>>
Monitor is configured for

and has been not OK since
the last time the RESET
button was pressed.
Press the Reset button on

the Rack Interface Module.
List.
<<>>
Monitor is not operating

correctly.
Monitor is not executing

alarming functions.
Replace immediately.
5 Hz
ON
<<>>
BYPASS
Not
flashing
<<>>
<<>>
OFF
Alarm Enabled
No action required.
<<>>
<<>>
ON
Some or all Alarming Disabled
No action required.
<<>> = Behavior of the LED is not related to the condition.
142
6.3
System Event List Messages

This section describes the System Event List Messages that are entered by the
Recip Rod Position Monitor and gives an example of one.
Example of a System Event List Message:
Sequence
Event
Event
Number
Information
Number
Class
Event
Event
Event
Date
Time
Specific
Slot
DDMMYY
0000000123
Device Not
Communicating
32
02/01/90
12:24:31:99
5L
Sequence Number:
The number of the event in the System Event List (for example 123).
Event Information:
The name of the event (for example Device Not Communicating).
Event Number:
Identifies a specific event.
Class:
Used to display the severity of the event. The following classes are available:
Class Value
Classification
Severe/Fatal Event
Potential Problem Event
Typical logged Event
Reserved
Event Date:
The date the event occurred.
Event Time:
The time the event occurred.
Event Specific:
It provides additional information for the events that use this field.
Slot:
Identifies the module that the event is associated with. If a half-height module is
installed in the upper slot or a full-height module is installed, the field will be 0 to 15.
If a half-height module is installed in the lower slot, then the field will be 0L to 15L.
For example, a module installed in the lower position in slot 5 would be 5L.
143
The following System Event List Messages may be placed in the list by the Recip
Rod Position Monitor and are listed in numerical order. If an event marked with a
star (*) occurs the Recip Rod Position Monitor will stop alarming. If you are
unable to solve any problems contact your nearest Bently Nevada Corporation
office.
Flash Memory Failure
Event Number: 11
Event Classification: Severe / Fatal Event
Action: Replace the Monitor Module as soon as possible.
EEPROM Memory Failure
Event Number: 13
Event Classification: Potential Problem or Severe / Fatal Event
Action: Replace the Monitor Module as soon as possible.
Device Not Communicating
Event Number: 32
Event Classification: Potential Problem
Action: Check to see if one of the following components is faulty:
the Monitor Module
the rack backplane
Device Is Communicating
Event Number: 33
Action: Check to see if one of the following components is faulty:
the Monitor Module
the rack backplane
* Neuron Failure
Event Number: 34
Action: Replace the Monitor Module immediately.
Monitor Module will stop alarming.
* I/O Module Mismatch
Event Number: 62
Action: Verify that the type of I/O module installed matches what was selected in the
software. If the correct I/O module is installed, there may be a fault with the Monitor
Module or the Monitor I/O module.
144
I/O Module Compatible

Event Number: 63
* Fail I/O Jumper Check
Event Number: 64
Pass I/O Jumper Check
Event Number: 65
Fail Main Board +5V-A
(Fail Main Board +5V - upper Power Supply)
Event Number: 100
Action: Verify that noise from the power source is not causing the problem. If the
problem is not caused by noise, check to see if one of the following components is
faulty:
the Monitor Module
the Power Supply installed in the upper slot
Pass Main Board +5V-A

(Pass Main Board +5V - upper Power Supply)
Event Number: 101
faulty:
the Monitor Module
Fail Main Board +5V-B

(Fail Main Board +5V - lower Power Supply)
Event Number: 102
faulty:
the Monitor Module
the Power Supply installed in the lower slot
145
Pass Main Board +5V-B

(Pass Main Board +5V - lower Power Supply)
Event Number: 103
faulty:
the Monitor Module
Fail Main Board +5V-AB

(Fail Main Board +5V - upper and lower Power Supplies)
Event Number: 104
Event Classification: Severe/Fatal Event
faulty:
the Monitor Module

Pass Main Board +5V-AB
(Pass Main Board +5V - upper and lower Power Supplies)
Event Number: 105
faulty:
the Monitor Module
Fail Main Board +15V-A

(Fail Main Board +15V - upper Power Supply)
Event Number: 106
faulty:
the Monitor Module
Pass Main Board +15V-A

(Pass Main Board +15V - upper Power Supply)
Event Number: 107
faulty:
146
the Monitor Module
Fail Main Board +15V-B

(Fail Main Board +15V - lower Power Supply)
Event Number: 108
faulty:
the Monitor Module
Pass Main Board +15V-B

(Pass Main Board +15V - lower Power Supply)
Event Number: 109
faulty:
the Monitor Module
Fail Main Board +15V-AB

(Fail Main Board +15V - upper and lower Power Supplies)
Event Number: 110
faulty:
the Monitor Module

Pass Main Board +15V-AB
(Pass Main Board +15V - upper and lower Power Supplies)
Event Number: 111
faulty:
the Monitor Module
Fail Main Board -24V-A

(Fail Main Board -24V - upper Power Supply)
Event Number: 112
faulty:
the Monitor Module

147
Pass Main Board -24V-A

(Pass Main Board -24V - upper Power Supply)
Event Number: 113
faulty:
the Monitor Module
Fail Main Board -24V-B

(Fail Main Board -24V - lower Power Supply)
Event Number: 114
faulty:
the Monitor Module
Pass Main Board -24V-B

(Pass Main Board -24V - lower Power Supply)
Event Number: 115
faulty:
the Monitor Module
Fail Main Board -24V-AB

(Fail Main Board -24V - upper and lower Power Supplies)
Event Number: 116
faulty:
the Monitor Module

Pass Main Board -24V-AB
(Pass Main Board -24V - upper and lower Power Supplies)
Event Number: 117
faulty:
148
the Monitor Module
* Configuration Failure
Event Number: 301
Action: Download a new configuration to the Monitor Module. If the problem still
exists replace the Monitor Module immediately.
Configuration Failure
Event Number: 301
Action: Download a new configuration to the Monitor Module. If the problem still
exists replace the Monitor Module as soon as possible.
Module Entered Cfg Mode
(Module Entered Configuration Mode)
Event Number: 302
Event Classification: Typical Logged Event
Action: No action required.
Software Switches Reset
Event Number: 305
Action: Download the software switches to the Monitor Module. If the software
switches are not correct, replace the Monitor Module as soon as possible.
Internal Cal Reset
(Internal Calibration Reset)
Event Number: 307
Event Specific: Ch pair x
Action: Replace Monitor Module immediately.
Monitor TMR PPL Failed
(Monitor TMR Proportional value Failed)
Event Number: 310
Action: Replace the Monitor Module.
Monitor TMR PPL Passed
(Monitor TMR Proportional value Passed)
Event Number: 311
Action: Replace the Monitor Module.
Module Reboot
Event Number: 320
149
* Module Removed from Rack

Event Number: 325
Module Inserted in Rack
Event Number: 326
Device Events Lost
Event Number: 355
This may be due to the removal of the Rack Interface Module for an extended period
of time.
Module Alarms Lost
Event Number: 356
This may be due to the removal of the Rack Interface Module for an extended period
of time.
Module Entered Calibr.
(Module Entered Calibration Mode)
Event Number: 365
Module Exited Calibr.
(Module Exited Calibration Mode)
Event Number: 366
Pass Module Self-test
Event Number: 410
Enabled Ch Bypass
(Enabled Channel Bypass)
Event Number: 416
Event Classification: Typical logged event
Event Specific: Ch x
Alarming has been inhibited by this action.
150
Disabled Ch Bypass
(Disabled Channel Bypass)
Event Number: 417
* Enabled Alert Bypass
Event Number: 420
Disabled Alert Bypass
Event Number: 421
* Enabled Danger Bypass
Event Number: 422
Disabled Danger Bypass
Event Number: 423
Enabled Special Inh
(Enabled Special Inhibit)
Event Number: 424
Disabled Special Inh
(Disabled Special Inhibit)
Event Number: 425
151
Enabled Mon Alarm Byp

(Enabled Monitor Alarm Bypass)
Event Number: 426
Disabled Mon Alarm Byp
(Disabled Monitor Alarm Bypass)
Event Number: 427
* Fail Slot Id Test
Event Number: 461
Action: Verify that the Monitor Module is fully inserted in the rack. If the Monitor
Module is installed correctly, check to see if one of the following components is
faulty:
the Monitor Module
the rack backplane

Pass Slot Id Test
Event Number: 462
Action: Verify that the Monitor Module is fully inserted in the rack. If the Monitor
Module is installed correctly, check to see if one of the following components is
faulty:
the Monitor Module
the rack backplane
* Enabled Test Signal

Event Number: 481
Disabled Test Signal
Event Number: 482
Switch To Primary Kph
Event Number: 491
Action: Check to see if one of the following is faulty:
152
the secondary Keyphasor transducer on the machine
the Monitor Module
Switch To Backup Kph

Event Number: 492
the primary Keyphasor transducer on the machine
the Monitor Module
* Kph Lost
Event Number: 493
both Keyphasor transducers on the machine
the Monitor Module
the Keyphasor Module
For vector and Keyphasor based, alarms the Monitor Module will stop alarming.
DSP Reset Attempted
Event Number: 501
Action: If the message is seen repeatedly in the System Event List, then replace the
Monitor Module immediately.
* DSP Self-test Failure
Event Number: 502
Action: Replace the Monitor Module immediately.
153
6.4
Alarm Event List Messages

The following Alarm Event List Messages are returned by the Recip Rod Position
Monitor.
154
Alarm Event List Message

Entered Alert / Alarm 1
When the message will occur

A proportional value in the channel has
entered Alert / Alarm 1 and changed the
channel Alert / Alarm 1 status
Left Alert / Alarm 1
A proportional value in the channel has left

Alert / Alarm 1 and changed the channel Alert /
Alarm 1 status
Entered Danger / Alarm 2
A proportional value in the channel has

entered Danger / Alarm 2 and changed the
channel Danger / Alarm 2 status
Left Danger / Alarm 2
A proportional value in the channel has left

Danger / Alarm 2 and changed the channel
Danger / Alarm 2 status
Entered not OK
module went not OK
Left not OK
module returned to the OK state
Section 7 Ordering Information
7.
7.1
Ordering Information
Ordering Considerations
When ordering I/O Modules with External Terminations the External Termination
Blocks and Cable must be ordered separately for each I/O Module.
The 3500 Internal Barrier Specification sheet should be consulted if the Internal
Barrier Option is selected.
Version 3.20 or higher of the 3500 Rack Configuration Software is required.
7.2
List of Options and Part Numbers
7.2.1
Recip Rod Position Monitor

3500/72M-AXX-BXX
A: I/O Module Type
01
02
03
I/O Module with Internal Terminations

I/O Module with External Terminations
I/O Module with Internal Barriers and Internal
Terminations
00
01
None
CSA/NRTL/C
B: Agency Approval Option
7.2.2
External Termination Blocks

125808-08
128015-08
Proximitor / Velomitor External Termination Block (Euro

Style connectors).
Proximitor / Velomitor External Termination Block
(Terminal Strip connectors).
128702-01
Recorder External Termination Block (Euro Style
connectors)
128710-01
Recorder External Termination Block (Terminal Strip
connectors)
7.2.3
3500 Transducer Signal to External Termination Block

Cable
129525 -AXXXX-BXX
A: Cable Length
0005
0007
0010
0025
0050
5 feet (1.5 metres)

7 feet (2.1 metres)
10 feet (3 metres)
25 feet (7.5 metres)
50 feet (15 metres)
155
0 1 0 0 100 feet (30.5 metres)

B: Assembly Instructions
01
02
7.2.4
Not Assembled
Assembled
3500 Recorder Output to External Termination (ET) Block

Cable
129529 -AXXXX-BXX
A: Cable Length
0005
0007
0010
0025
0050
0100
5 feet (1.5 metres)

7 feet (2.1 metres)
10 feet (3 metres)
50 feet (15 metres)
B: Assembly Instructions
01
02
7.2.5
Not Assembled
Assembled
Spares
140734-08
3500/72M Recip Rod Position Monitor
140471-01
I/O Module with Internal Terminations
140482-01
I/O Module with External Terminations
135489-01
I/O Module with Internal Barriers and Internal Terminations
146479-01
3500/72M Rod Position Manual
00580434
Internal I/O Module connector header, Euro Style, 8-pin,
green. Used on I/O modules 140471-01
00580441
green. Used on I/O modules 135489-01 and 140471-01
00502133
blue. Used on I/O modules 135489-01
156
Section 8 Specifications
8.
8.1
Specifications
Inputs
Signal:
Accepts from 1 to 4 proximity probe signals.
Input Impedance:
10 k
Nominal Scale Factor:

Rod Position:
3.94 mV/m (100 mV/mil) or
7.87 mV/m (200 mV/mil)
Rod Drop:
7.87 mV/m (200 mV/mil)
Hyper-Compressor:
7.87 mV/m (200 mV/mil)
Note: Configuration allows a wide range of adjustment to accommodate
transducer sensitivity for different rod materials.
Power Consumption:
Nominal Consumption of 7.7 watts
8.2
Outputs
Front Panel LEDs:
OK LED:
Indicates when the 3500/72M is operating properly.
TX/RX LED:
Indicates when the 3500/72M is communicating with other
modules in the 3500 rack.
Bypass LED:
Indicates when the 3500/72M is in Bypass Mode.
Buffered Transducer Outputs

The front of each monitor has one coaxial connector for
each channel. Each connector is short-circuit protected.
Output Impedance:
550
Transducer Power Supply:

-24 Vdc
8.3
Data Values
The Recip Rod Position Monitor returns the following data values from
measurements used to monitor the machine:
157
Rod Position Single

Amplitude, Gap, 1X Amplitude, Not 1X Amplitude, and 2X
Amplitude
Rod Position Pair

Amplitude, Gap, 1X Amplitude, Not 1X Amplitude, and 2X
Amplitude
Rod Drop
Average Piston Position, Average Probe Gap, Instantaneous
Piston Position, and Instantaneous Probe Gap
Hyper Channel
Pk-Pk Displacement, Gap, 1X Amplitude, Not 1X Amplitude,
and 2X Amplitude
8.4
Signal Conditioning
Specified at +25 C (77 F)
Rod Position Single & Pair:
Frequency Response:
Note: 1X and 2X vector and Not 1X parameters are valid for machine operation
of 60 cpm to 2000 cpm.
Peak-Peak Filter:
Fixed 1 Hz to 600 Hz
Gap Filter:
-3 dB at 0.09 Hz
Not 1X Filter:
Constant Q notch filter with minimum rejection in stop-band
of 34.9 dB over frequency range of 60 cpm to 15.8 times
running speed.
1X Vector Filter:
Constant Q filter with minimum rejection in stop-band of 57.7
dB
2X Vector Filter:
dB
Accuracy
Position Magnitude
(direct):
Within 0.33% of full scale typical, 1.0% maximum
Gap:
1X Amplitude:
2X Amplitude:

Pk-Pk Amplitude:
158
Not 1X Amplitude:
Within 3.0% of full scale typical
Position Crank
Angle:
Within 1 typical, 3 maximum
Rod Position Angle

(paired only):
Within 1 typical, 3 maximum
8.5
Rod Drop:
Frequency Response:
Average Piston
Position (direct):
Average Gap:
-3 dB at 0.09 Hz
Accuracy
Average Piston
Position (direct):
Average Gap:
Instantaneous
Piston Position:
Instantaneous
Probe Gap:
8.6
Hyper-Channel:
Frequency Response:
Note: 1X and 2X vector and Not 1X parameters are valid for machine operation
of 60 cpm to 2,000 cpm.
Peak-Peak Filter:
Gap Filter:
-3 dB at 0.09 Hz
Not 1X Filter:
Constant Q notch filter with minimum rejection in stop-band
of 34.9 dB over frequency range of 60 cpm to 15.8 times
running speed.
1X Vector Filter:
dB
2X Vector Filter:
dB
159
Accuracy
Peak-Peak
Magnitude (direct):
Gap:
1X Amplitude:
2X Amplitude:

Not 1X Amplitude:
Within 3.0% of full scale typical
8.7
Alarms
Alarm Setpoint Values:
Alert levels can be set for each value measured by the
monitor. In addition, Danger setpoint values can be set for
any two of the values measured by the monitor. All alarm
setpoint values are set using software configuration. Alarms
are adjustable and can be set from 0 to 100% of full-scale
for each measured value. Accuracy of an alarm setpoint is
to within 0.13% of the desired value.
Alarm Time Delays:
Alarm delays can be programmed using software, and can
be set as follows:
Alert:
From 1 to 60 seconds in 1 second intervals.
Danger:
From 1 to 60 seconds in 1 second intervals or 0.1 seconds
(nominal)
Timed OK Channel
Defeat:
Ok Channel defeat is disabled for all rod position
configurations. When used as a hyper-compressor monitor
the action of both transducers going not OK will cause the
immediate issue of a danger alarm.
8.8
Environmental Limits
Operating Temperature:
-30C to +65C (-22F to +150F) when used with
Internal/External Termination Proximitor/Seismic I/O Module
Operating Temperature:
0C to +65C (32F to +150F) when used with
Proximitor/Seismic Internal Barrier I/O Module (Internal
Termination)
Storage Temperature:
-40C to +85C (-40F to +185F)
160
Humidity
95%, non-condensing
8.9
CE Mark Directives
EMC Directives
EN50081-2
Radiated Emissions
EN 55011, Class A
Conducted
Emissions
EN 55011, Class A
EN50082-2
Electrostatic
Discharge
EN 61000-4-2, Criteria B
Radiated
Susceptibility
ENV 50140, Criteria A
Conducted
Susceptibility
ENV 50141, Criteria A
Electrical Fast
Transient
Surge Capability
Magnetic Field
EN 61000-4-8, Criteria A
Power Supply Dip
Radio Telephone
ENV 50204, Criteria B
CE Mark Low Voltage Directives

EN 61010-1
Safety Requirements
8.10
Hazardous Approvals
CSA/NRTL/C:
When used with Internal/External Termination I/O Module:
Class I, Division 2, Groups A through D
When used with Internal Barrier I/O Module, refer to
specification sheet 141495-01 for approvals information.
161
8.11
Physical
Monitor Module
Dimensions (Height x
Width x Depth)
241.3 mm x 24.4 mm x 241.8 mm (9.50 in x 0.96 in x 9.52
in)
Weight
0.91 kg (2.0 lbs.).
I/O Modules (non-barrier)

Width x Depth)
241.3 mm x 24.4 mm x 99.1 mm (9.50 in x 0.96 in x 3.90 in)
Weight
0.20 kg (0.44 lb.).
I/O Modules (barrier)

Width x Depth)
241.3 mm x 24.4 mm x 163.1 mm (9.50 in x 0.96 in x 6.42
in)
Weight
0.46 kg (1.01 lbs.).
Rack Space Requirements

Monitor Module
1 full-height front slot
I/O Modules
1 full-height rear slot
162

6479A1 3500-72 Rodrop

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Part number 146479-01

Revision A, April 2004

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Copyright 2001 - 2004 Bently Nevada, LLC

1631 Bently Parkway South

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Receiving and Handling .............................................................. 1

General Information ..................................................................... 3

I/O Module Descriptions ............................................................ 55

6.2 LED Fault Conditions ......................................................................................142

Ordering Information ............................................................... 155

Specifications .......................................................................... 157

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Section 1 Receiving and Handling

Receiving and Handling

Handling and Storing Considerations

Personnel must be grounded with a suitable grounding strap (such as 3M

Transport and store circuit boards in electrically conductive bags or foil.

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Section 2 General Information

3300XL 8mm and 11mm

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

(1) Main module front view.

Section 2 General Information

The primary purpose of the 3500/72M monitor is to provide 1) machinery

Triple Modular Redundant Description

Monitor Configuration Fault

Monitor Special Alarm Inhibit

Module Hardware Failure

Node Voltage Failure

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Special Alarm Inhibit

The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

A Channel Special Alarm Inhibit software switch is enabled.

Channel Special Alarm

Section 2 General Information

The monitor has detected a serious internal fault.

A software switch is bypassing any channel alarming function.

Special Alarm Inhibit

The Alarm Inhibit contact (INHB/RET) on the I/O Module is closed

Software Special Channel Alarm Inhibit is active.

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Section 2 General Information

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Section 3 Configuration Information

Software Configuration Options

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Recip Rod Position Monitor Configuration Options

Slot Input/Output Module Type

Section 3 Configuration Information

Prox/Velom Internal I/O

Prox/Velom External I/O

Prox/Accel Internal Barrier I/O

Rod Position Single

Rod Position Pair

3500/72M Recip Rod Position Monitor Operation and Maintenance Manual

Section 3 Configuration Information

Rod Position Single Channel Configuration

Rod Position Single Channel Configuration Considerations

When NO Keyphasor is selected, the Design Speed is used to calculate

If a Keyphasor Channel is selected, a Keyphasor Module must be installed in

Setpoints may only be set on proportional values which are enabled.

Monitors must be configured in channel pairs. Channels 1 and 2 must be