OPERATION MANUAL CMCP525(A) CMCP530(A)

OPERATION MANUAL  CMCP525(A) CMCP530(A)
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OPERATION MANUAL
Vibration Input
Transmitters and Monitors
CMCP525(A)
CMCP530(A)
CMCP535(A)
CMCP540(A)
CMCP590(A)
NOTICE!
This equipment is suitable
for use in Class I, Division 2, Groups B-D
IMPORTANT!
After installation of this unit, no connections are to
be made or broken while any connection on the unit is powered up.
CMCP500 Series AC V2.0 6/2009 Page 1 of 11
Table of Contents
1.0
2.0
3.0
4.0
General:
1.1
Model Description
1.2
Power
1.3
Opening the Case
1.4
Dimensions and Mounting
Transmitter:
2.1
Transducer
2.2
Transducer Cable
2.3
Transducer OK Circuit
2.4
Full Scale Range
2.5
4-20 mA Output
2.6
Buffered Output
2.7
Filter Selection and Installation
2.8
Transmitter Jumper Selection
Monitor Alarm Module:
3.1
Alert and Danger Setpoints
3.2
Alert and Danger Delay Adjustment
3.3
Latching/Non-Latching Alarms
3.4
Trip Multiply
3.5
Alarm Relays
3.6
Alarm Module Jumper Selection
Test and Calibration Setup:
4.1
Test Setup
4.2
Zero Calibration
4.3
Full scale (Span) Calibration
CMCP500 Series AC V2.0 6/2009 Page 2 of 11
1.0
General
1.1
Model Description:
The CMCP500 Series Transmitters are 4-20mA Output Transmitters. They are ordered and factory
configured for use with a low-impedance accelerometer, low-impedance velocity transducer, electromechanical velocity transducer or eddy probe. The input signal is processed to determine its overall vibration
level in the selected engineering terms. The output is a standard 4-20mA current proportional to the full scale
range selected. The 4-20 mA output is suitable for direct connection to a Programmable Logic Controller
(PLC) or Distributed Control System (DCS). A BNC connector on the front of the unit provides buffered
access to the transducer signal for use with portable analysis instruments.
The CMCP500 Series Transmitters can be also ordered as a standalone Monitor by adding the suffix "A" to
the basic model number, i.e.: CMCP5XXA. When ordered in this configuration, the unit includes an alarm
module that provides independent set point alarms for both ALERT (A) and DANGER (D) levels. Each set
point has a corresponding adjustment potentiometer, a LED indicator on the alarm module front panel, and
an output relay that can be configured for either latching or non-latching operation. The alarm LED will turn
"ON" and the corresponding relay will actuate whenever overall vibration levels exceed the corresponding
set point for more than a preset (jumper selectable) delay time. The alarm module has a front panel
accessible BNC connector and associated selector switch for reading the current vibration level (CV) or
alarm set points (A or D) with a standard digital volt-meter. The alarm module also provides a transducer
"OK" relay, and a Trip-Multiply function. Trip multiply allows the alarm levels to be temporarily increased by a
factor of two or three during machine start-up. Both monitors and transmitters mount on standard DIN rail.
1.2
Power:
The CMCP500 Series require externally supplied DC power. The power supply should have a nominal
output of +24Vdc and be capable of supplying a minimum of 50mA for each CMCP500 Series Transmitter in
the system, or 100 mA for each CMCP500A Series Monitor in the system. A power-supply dedicated to the
vibration monitoring system is recommended. It is also recommended that connections between the powersupply and the monitors be made with twisted-shielded instrument cable. The cable shield should float at
the monitor / transmitter installation, and connect to common at the power-supply / system common end
only. The CMCP500 Series Transmitters and Monitors regulate dc power internally to prevent a fault on the
output of one channel from affecting other channels. When power is first applied to a monitor or transmitter
after connecting the transducer, there will be a delay of approximately 30 seconds before the "OK" LED turns
"ON".
CMCP500 Series AC V2.0 6/2009 Page 3 of 11
1.3
Opening the Case:
Opening the case is best done with a small flat-blade screwdriver. On transmitters (1" wide units) insert the
tip of the screwdriver between the right-side cover (as viewed from the front of the unit) and the DIN rail
mounting foot at the back of the unit and gently leverage the blade to begin separating the cover from the
rest of the unit. Carefully work your way around to the front of the unit to complete removal of the cover,
exposing the circuit board components. On Monitors (1.6" wide units), you must first CAREFULLY separate
the two halves of the unit at the center. The sides do not need to be removed. This is done by working the
screwdriver around the middle of the unit in the same general manner described above. As the two halves
start to become separated, you will see that they are still attached by a short ribbon cable inside. This cable
can be carefully removed by pulling it away from the left hand side of the unit. The cable stays with the right
hand side permanently. CAUTION: When re-installing this cable, make sure it is properly connected to the
mating connector, and that the bend in the cable goes towards the front panel side of the unit. IF THE UNIT
IS CLOSED WITH THE BEND TOWARDS THE BACK, THE RIBBON CABLE CAN BE DAMAGED. Also,
make sure the ribbon cables' connector does not catch on the relays when pressing the unit back together.
1.4
Dimensions and Mounting:
CMCP500 Series Transmitters and Monitors are designed to be mounted on Din Standard 35 mm “T” Rail or
“G” Rail. They simply snap in place by aligning the top of the mount on the track and pressing down. To
remove insert a screwdriver in the tab at the bottom and pull down and out slightly.
CMCP500 Series AC V2.0 6/2009 Page 4 of 11
2.0
Transmitter
2.1
Transducer:
The CMCP500 Series is factory configured for use with one of four transducer types. The specific type is
identified by a dash number immediately following the basic part number on the side label. This number is
the transducer sensitivity in mV/g, mV/in/sec or mv/mil, followed by an "A" for low-impedance accelerometers
(mV/g), "V" for a low-impedance velocity transducers (mV/in/second) or "EV" for electro-mechanical, selfgenerating velocity transducers (mV/in/sec) or no suffix for eddy probes.
2.2
Transducer Cable:
The CMCP500 Series provides power for low-impedance type accelerometers via a nominal 4.4 mA
constant current source. This is generally enough current to allow operation with transducer cables
extending up to about 150 ft. -24 VDC powered eddy probes must be powered with a external power supply.
It is strongly recommended that the monitor / transmitter be mounted as close as practical to the associated
transducer. This will prevent signal distortion associated with current drive limitations, and will minimize
interference from external electro-magnetic noise sources (EMI). A well shielded, properly installed
transducer cable is absolutely necessary to obtain reliable operation. Twisted-shielded pair or triad cables
designed and pre-fitted with the proper transducer connector, and sold for this specific purpose are highly
CMCP500 Series AC V2.0 6/2009 Page 5 of 11
recommended. The cable shield should be open at the transducer end, and connected to common (xdcr "-"
terminal) at the monitor/transmitter input only. The cable should be routed as far away from other electrical
circuits as possible, and run in metal bonded conduit.
2.3
Transducer OK Circuit:
The CMCP500 Series incorporates a transducer "OK" circuit. This feature continuously monitors the
transducer bias and signal voltage. If this voltage exceeds (over or under) pre-set limits, the 4-20 mA output
current is reduced to less than 2 mA (typically 0 mA) to allow detection of the fault condition at the
associated PLC or DCS system. A green “OK" LED on the front of the unit ("ON" in an "OK" condition)
turns "OFF" to provide a local indication of the fault condition. This circuit will effectively detect open,
shorted, or reversed transducer connections. If a fault is detected that subsequently is repaired or goes
away, there will be a delay of approximately 30 seconds before the unit returns to the "OK" condition and the
"OK" LED turns back "ON". The detected fault will also disable the "ALERT" and "DANGER" alarms/relays
until the fault is removed and an "OK" condition exists. NOTE: When configured for use with an electromechanical transducer ("EV"), the "OK" circuit will only detect an open circuit condition of the transducer /
cable.
2.4
Full Scale Range:
The CMCP500 Series is supplied factory calibrated for the full-scale range specified at the time of order.
Other ranges may be implemented (see table below) by changing the positions of internal jumpers as
indicated in the table below. See "Opening the case" to gain access to these jumpers. Changing range
jumpers without further re-calibration will introduce an additional reading error of 2% maximum. For greater
accuracy the unit must be re-calibrated. (See Section 2.8: “Transmitter Jumper Settings) The factory
calibrated range is listed on the side label as a dash number. Custom ranges are available.
Range
-01
-02
-03
-04
-05
2.5
CMCP525
0-5.0 g’s
0-10.0 g’s
0-15.0 g’s
0-20.0 g’s
0-25.0 g’s
CMCP530
0-0.5 in/sec (0-25.4 mm/sec)
0-1.0 in/sec (0-50.8 mm/sec)
0-1.5 in/sec (0-76.2 mm/sec)
0-2.0 in/sec (0-101.6 mm/sec)
0-2.5 in/sec (0-127.0 mm/sec)
CMCP535/540
0-5.0 mils (0-127.0 microns)
0-10.0 mils (0-254.0 microns)
0-15.0 mils (0-381.0 microns)
0-20.0 mils (0-508.0 microns)
0-25.0 mils (0-635.0 microns)
4-20 mA Output:
The primary output of the monitor/transmitter is the 4-20 mA current output which is proportional to the full
scale range of the unit. IE: If the range is 0 – 1.0, then 4 mA indicates a reading of 0.0 and 20 mA indicates
a reading of 1.00. This output is intended to drive a maximum resistive load of 600 Ohms with respect to
system common at the PLC/DCS input. A precision 250 Ohm resistor is the recommended load if the IO
Module is not equipped. This will convert the 4-20 mA current reading into a 1-5 Vdc reading for the
PLC/DCS. A short to ground (common) on this output will not damage it.
2.6
Buffered Output:
The CMCP500 Series provides buffered access to the transducer signal via a BNC connector on the front of
the unit. This output has the same sensitivity, units, and bias voltage as the transducer itself. i.e.: mV/g for
an accelerometer or mV/in/sec for a velocity transducer. This output can be connected to portable analysis
instruments, or can be used to check the bias-output-voltage (BOV) of low-impedance transducers using a
digital volt-meter. The Buffered output is un-filtered. The buffered output signal is also available on a screw
terminal at the top of the unit. Buffered output for -24 VDC eddy probes is flipped and will be a +VDC value.
NOTE: For electro-mechanical velocity transducers only: The buffered transducer output will have one-half
the standard sensitivity of the transducer. i.e.: a 100 mV/in/sec transducer will have a buffered output (BNC)
sensitivity of 50 mV/in/sec.
CMCP500 Series AC V2.0 6/2009 Page 6 of 11
2.7
Filter Selection and Installation:
Filters for use with the CMCP500 series transmitters and monitors are modular and may be factory or field
installed. Filter modules have a 4-pole Butterworth response which attenuates frequencies beyond the
specified corner frequency by approximately -24dB/octave. The Corner frequency as defined by standard
convention is the frequency at which the filter attenuates the signal by -3dB, or approximately 30%. For
Low-Pass filters, signals frequencies less than 60% of the specified corner frequency are attenuated less
than 1%, and for frequencies less than 75% of the corner, attenuation due to the filter is less than 5%. For
High-Pass filters the numbers translate to 1.66 times the corner, and 1.33 times the corner for 1% and 5%
attenuations respectively. Filters modules can be ordered with corner frequencies from as low as 5 Hz (300
RPM) to 2000 Hz (120,000 RPM). High-Pass and Low-Pass filters can be cascaded to form a Band-Pass
response but care must be taken to assure that the specified corner frequencies are far enough apart to
minimize attenuation due to corner interaction in the Pass-Band. Usually a factor of 5 or more between
corners will work. When installing filters, you will be working in direct contact with sensitive electronic
components. To assure your safety and to avoid damaging the unit you must first disconnect and remove
the unit from its installation. You must also make sure you do not accidentally cause a static discharge to
any part of the unit. This is best accomplished by wearing an anti-static ground strap around your wrist while
working on the unit. At a minimum, touch a grounded metal object to discharge yourself prior to handling the
open unit.
Step 1: To install filter modules you must first open the monitor/transmitter. Refer to Section 1.3
"Opening The Case".
Step 2: With the cover removed you will notice two 16-pin sockets near the rear of the printed circuit
board. These are where you will install the filter modules. You should also locate jumpers E1 and E5
which are next to the sockets. (CAUTION: TO AVOID DAMAGING THE UNIT, DO NOT TOUCH
ANY CIRCUIT BOARD COMPONENTS OTHER THAN THOSE INDICATED BELOW).
Step 3: To install a High-Pass filter module, first remove jumper E5, then install the filter module in
the socket marked U12 (this is the socket in the corner). Use care to assure that you align pin 1 of the
module (indicated on its label) with pin 1 of the socket (the pin next to the U12 marking). Note: Filters
only have 5 pins.
Step 4: To install a Low-Pass filter module, first remove jumper E1, then install the filter module in the
socket marked U9 (this is the socket closest to the center-rear of the circuit board). Use care to
assure that you align pin 1 of the module (indicated on its label) with pin 1 of the socket (the pin next
to the U9 marking).
Step 5: Re-assemble the unit.
CMCP500 Series AC V2.0 6/2009 Page 7 of 11
2.8
Transmitter Jumper Selection:
CMCP525/530 RMS Range Selections
CMCP525/530/535/540 Peak Range Selections
CMCP590 Jumper Selections
CMCP500 Series AC V2.0 6/2009 Page 8 of 11
3.0
Monitor Alarm Module (If Equipped):
3.1
Alert and Danger Alarm Set-Point Adjustment:
The Alert and Danger alarm set-points can be independently set in the field by turning the front panel
selector switch to the associated position (A or D) and adjusting the associated front-panel potentiometer
until the correct DC voltage is measured at the BNC connector located directly above the selector switch.
Adjusting the set-point requires the use of a digital volt-meter, knowledge of the full scale range of the
monitor, and the desired set-point as a percentage of the full scale range. The voltage measured at the
BNC will vary between 0 Vdc and 5 Vdc, corresponding to 0 to Full-scale. i.e.: 2.5 Vdc represents 50% of
full scale, 3.75 Vdc represents 75% of full scale. To calculate the required set point voltage if the unit is not
equipped with a display, use the equation, 5(.xx) where .xx is the desired percentage expressed as a
decimal fraction of the full scale range. i.e.: 5(.60) = 3.00 Vdc for a set-point of 60% of the full scale range.
Turning the potentiometer clockwise increases the set point voltage.
3.2
Alert and Danger Alarm Delay Adjustment:
The Alert and Danger alarm delays can be independently set by internal jumper selection to 0.1, 1.0, 3.0,
6.0, or 10.0 seconds. The purpose of the delay is to reduce nuisance alarms caused by external electrical
noise and/or transient vibration events. Both the Alert and Danger delay are factory set to the 3 second
position. To change the delay, open the unit and move the delay jumpers to the proper position (Refer to
Section 3.6 “”Alarm Module Jumper Settings”).
3.3
Latching/Non-Latching Alarms:
The Alert and Danger alarms are factory set for NON-LATCHING operation. This means that whenever the
vibration level drops below the associated set-point for more than about 1 second, the associated relay will
de-energize and the alarm LED will turn off. The alarms can also be set for LATCHING operation by
installing shunts on jumpers E1 and E2 respectively on the Alarm module circuit board (See: CMCP500
SERIES ALARM MODULE JUMPER LOCATIONS, at the back of this manual). Latched alarms may be
reset by closing the RESET (RST) and COMMON (COM) contacts at the top of the unit. This may be done
with an external switch, dry contact relay, or by shorting the terminals together by hand. DO NOT APPLY
CMCP500 Series AC V2.0 6/2009 Page 9 of 11
VOLTAGE TO EITHER THE “RST” or "COM" TERMINALS. If several monitors are mounted together, the
"RST" terminals may be daisy-chained together.
3.4
Trip Multiply:
The alarm module provides a trip multiply feature. This feature allows the user to temporarily double
(standard) or triple (jumper selectable) the normal set points during periods of normal high vibration such as
start-ups. To actuate the trip multiply feature, the Tx terminal at the top of the alarm module must be closed
to the adjacent "COM" terminal. This may be done with an external switch, dry contact relay, or by shorting
the terminals together by hand. DO NOT APPLY VOLTAGE TO EITHER THE “Tx” or "COM"
TERMINALS. If several monitors are mounted together, the "Tx" terminals may be daisy-chained together
and switched to "COM" (system common) as a group.
3.5
Alarm Relays:
The Alert Danger and OK relays are independent, single-pole-double throw relays. NO, ARM, and NC
contacts are available via plugable screw-connector at the bottom of the monitor. OK relay contacts are
available on fixed screw terminals at the bottom front of the alarm module (Refer to Section 3.0 “Monitor
Alarm Module). Relay contacts are rated 5 Amps at 30 Vdc or 125 Vac, resistive load. This rating includes
any inrush current that the load draws. For loads that are not purely resistive the contact switching capability
will need to be considered carefully in terms of this inrush current. The entire subject of relay application is
too large to address here, so the user is cautioned to use care in the application of the relays. The factory
intended purpose of providing relay contacts is to operate relatively low power alarm annunciators, act as a
dry or low dc voltage contact closure input to other systems, or act to actuate an appropriately sized slave
relay for larger loads such as shutting down a motor. Relays are socketed and can be replaced.
3.6
Alarm Module Jumper Selection:
CMCP500 Series AC V2.0 6/2009 Page 10 of 11
4.0
Test and Calibration:
4.1
Test Setup
The test equipment listed below is required to perform Zero and span calibration:
(1) +24 Vdc linear regulated power supply
(1) Variable DC power supply with floating output (for simulating BOV).
(1) 4.5 digit DC/True RMS reading digital volt/current meter. Fluke 87 or better
(1) Sine wave AC signal generator with floating output.
4.2
Zero Calibration:
Zero output has been factory calibrated and should not need further adjustment under normal use. However,
should adjustment become necessary, complete the following steps.
1. Connect the test instruments listed above as shown on the Test/Calibration drawing.
2. With the signal generator OFF, measure the output current from the mA terminal, using digital currentmeter.
3. Wait until the output has completely settled to a stable value, and then adjust potentiometer (farthest from
the circuit board edge) until the output is 4.00 +/- .05 mA.
4.3
Full-Scale (SPAN) Calibration:
The full-scale output has been factory calibrated. It should only need to be checked or adjusted once every
two years under normal use. However, should adjustment become necessary (such as with a range change)
complete the following steps.
1.
2.
3.
Connect the test instruments listed above as shown on the Test/Calibration drawing.
Calculate the proper full-scale test input voltage from the following options:
Turn on the signal generator, set the correct frequency and amplitude for the appropriate full scale
RMS or Peak voltage as measured with a True-RMS digital volt-meter directly at the + transducer
input terminal. Measure the output current using the digital current-meter. Wait until the output
has settled to a stable value, and then adjust potentiometer (closest to the circuit board edge) until
the output is 20.00 mA +/- .05 mA. Turning the potentiometer clockwise increases the output.
(Note: CMCP590(A) gE Transmitter must be Factory Calibrated.)
CMCP500 Series AC V2.0 6/2009 Page 11 of 11
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