2505 VIBRATION SENSOR INTERFACE MODULE INSTALLATION AND OPERATION GUIDE

2505 VIBRATION SENSOR INTERFACE MODULE INSTALLATION AND OPERATION GUIDE
2505
VIBRATION SENSOR INTERFACE MODULE
INSTALLATION AND OPERATION GUIDE
Version 1.2
CTI Part # 062-00353-012
*062-00353-012*
2505IOG 120105
$25
Copyright © 2005 Control Technology Inc.
All rights reserved.
This manual is published by Control Technology Inc., 5734 Middlebrook Pike, Knoxville, TN
37921. This manual contains references to brand and product names which are tradenames,
trademarks, and/or registered trademarks of Control Technology Inc. Siemens® and SIMATIC®
are registered trademarks of Siemens AG. Other references to brand and product names are
tradenames, trademarks, and/or registered trademarks of their respective holders.
DOCUMENT DISCLAIMER STATEMENT
Every effort has been made to ensure the accuracy of this document; however, errors do
occasionally occur. CTI provides this document on an “as is” basis and assumes no responsibility
for direct or consequential damages resulting from the use of this document. This document is
provided without express or implied warranty of any kind, including but not limited to the
warranties of merchantability or fitness for a particular purpose. This document and the products
it references are subject to change without notice. If you have a comment or discover an error,
please call us toll-free at 1-800-537-8398 or email us at [email protected]
REVISION HISTORY
Version 1.0
Version 1.1
12/5/03
8/12/04
Version 1.2
12/1/05
ii
Original Release
Incorporated SPQ393 (velocity probe leakage current) and
SPQ396 (displacement probe used as tach source) into Board Rev D.
CTI 2505 Installation and Operation Guide
PREFACE
This Installation and Operation Guide provides installation and operation instructions for the
CTI 2505 4-Channel Vibration Sensor Interface Module for Simatic® 505 programmable
controllers. We assume you are familiar with the operation of Simatic® 505 programmable
controllers. Refer to the appropriate user documentation for specific information on the Simatic®
505 programmable controllers and I/O modules.
This Installation and Operation Guide is organized as follows:
Chapter 1 provides a description of the module.
Chapter 2 covers hardware configuration.
Chapter 3 looks at software configuration.
Chapter 4 is a guide to troubleshooting.
Appendix A provides a jumper/dip settings log sheet.
Appendix B gives sample ladder logic for programming purposes.
Appendix C shows the configuration of status and timing for command/acknowledge
The 2505 4-Channel Vibration Sensor Interface Module
CTI 2505 Installation and Operation Guide
iii
USAGE CONVENTIONS
NOTE:
Notes alert the user to special features or procedures.
CAUTION:
Cautions alert the user to procedures that could damage equipment.
WARNING:
Warnings alert the user to procedures that could damage equipment and endanger the user.
iv
CTI 2505 Installation and Operation Guide
TABLE OF CONTENTS
PREFACE ...................................................................................................................................... iii
USAGE CONVENTIONS ............................................................................................................. iv
TABLE OF CONTENTS ................................................................................................................ v
TABLE OF FIGURES .................................................................................................................. vii
CHAPTER 1. OVERVIEW............................................................................................................. 1
1.0. Product Summary ................................................................................................................. 1
1.1. Operation .............................................................................................................................. 1
1.2. User-Configurable Options................................................................................................... 2
1.3. Front Panel Description ........................................................................................................ 3
1.3.1. Module Status LED........................................................................................................ 3
1.3.2. Analysis Data Ports ........................................................................................................ 3
1.3.3. Output BNC Connectors for Channels A-D and Tachometer ........................................ 4
1.3.4. Tachometer and Channel Sensor LEDs ......................................................................... 4
1.3.5. Input Connector for Channels A-D and Tachometer ..................................................... 4
1.4. Asynchronous Operation ...................................................................................................... 5
1.5. Product Selections................................................................................................................. 5
CHAPTER 2. HARDWARE CONFIGURATION ......................................................................... 6
2.1. Planning the Installation ....................................................................................................... 6
2.1.1. Calculating the I/O Base Power Budget......................................................................... 6
2.1.2. Wiring Consideration ..................................................................................................... 6
2.2. Unpacking the Module.......................................................................................................... 7
2.3. Configuring the Module for Operation ................................................................................. 8
2.3.1. Selecting High-pass Filter Value.................................................................................... 9
2.3.2. Selecting the Gain Range and Value............................................................................ 10
2.3.3. Setting the Sensor Configuration Switchblock ............................................................ 12
2.3.4. Selecting the Integration and Sensor Type................................................................... 13
2.3.5. Selecting the Tachometer options: Input mode............................................................ 14
2.3.6. Selecting the Tachometer options: Tach Source .......................................................... 14
2.3.7. Selecting the Tachometer options: Signal Type........................................................... 15
2.3.8. Selecting the Port Type ................................................................................................ 17
2.3.9. Selecting the Module Address...................................................................................... 17
2.3.10. Selecting the Write Configuration.............................................................................. 17
2.3.11. Setting Dip switches to match the hardware settings ................................................. 19
2.4. Inserting the Module in the I/O Base.................................................................................. 20
2.5. Wiring the Module.............................................................................................................. 20
2.5.1. Serial connector............................................................................................................ 20
2.5.2. High Speed Communications connector ...................................................................... 20
2.5.3. BNC connectors ........................................................................................................... 21
2.5.4. Signal input connector.................................................................................................. 20
2.6. Checking Module Operation............................................................................................... 22
CHAPTER 3. SOFTWARE CONFIGURATION......................................................................... 22
3.1. Intrinsic Safety Barrier Attenuation Factor......................................................................... 22
3.2. Output Scale Factor ............................................................................................................ 22
3.3. Units of Measurement......................................................................................................... 23
3.4. Input Scale Factor ............................................................................................................... 23
3.5. Reporting Mode .................................................................................................................. 24
CTI 2505 Installation and Operation Guide
v
3.6. Trip Multiply Value ............................................................................................................ 24
3.7. Probe Sensitivity ................................................................................................................. 26
3.8. Alert / Danger Setpoints and Time Delays ......................................................................... 26
3.9. Displacement Probe Response Curve ................................................................................. 28
3.10. Gap Over/Under and Bias High/Low Alarm Setpoints .................................................... 29
3.11. Parameters that apply to All Channels.............................................................................. 29
CHAPTER 4. TROUBLESHOOTING ......................................................................................... 33
SPECIFICATIONS ....................................................................................................................... 35
APPENDIX A. JUMPER/DIP SETTINGS LOG SHEET ............................................................ 37
APPENDIX B. SAMPLE LADDER LOGIC................................................................................ 39
APPENDIX C. CONFIGURATION: STATUS AND TIMING FOR
COMMAND/ACKNOWLEDGE.................................................................................................. 51
LIMITED PRODUCT WARRANTY ........................................................................................... 54
REPAIR POLICY ......................................................................................................................... 55
vi
CTI 2505 Installation and Operation Guide
TABLE OF FIGURES
Figure 1.1 CTI 2505 Front Panel...........................................................................................................3
Figure 1.1.a CTI 2505 Wiring Connector…………………………………………………………….4
Figure 1.2. Relation of Update Time Change in Signal Input...............................................................5
Figure 2.1. Jumper and Switch locations...............................................................................................8
Figure 2.3. Selecting High-Pass Filter Value ........................................................................................9
Figure 2.4. Selecting the Gain Range and Value.................................................................................11
Figure 2.5. Selecting the Integration and Sensor Type........................................................................13
Figure 2.6. Bipolar gear tooth example ...............................................................................................15
Figure 2.7. Selecting Tachometer Options ..........................................................................................16
Figure 2.8. Selecting the Port Type, Module Address, and Write Configuration ...............................18
Figure 2.9. Jumper Settings for Future Reference...............................................................................19
Figure 2.10. I/O signal connectors ......................................................................................................20
Figure 2.11. I/O Configuration Chart .................................................................................................22
Figure 3.1. Alarm & Danger levels, Time Delay example chart.........................................................26
Figure 3.2. Displacement probe example chart ...................................................................................28
Figure 3.3. Time to Sample Correlation Chart ....................................................................................30
Figure 3.4. WX/WY Summary Chart..................................................................................................31
Figure 4.1 Troubleshooting Matrix ....................................................................................................33
CTI 2505 Installation and Operation Guide
vii
viii
CTI 2505 Installation and Operation Guide
CHAPTER 1. OVERVIEW
1.0. Product Summary
The CTI 2505 Four Channel Vibration Sensor Interface Module is a member of Control
Technology's family of I/O modules compatible with Simatic® 505 programmable controllers.
The 2505 is designed to translate millivolt-level analog signals from velocity, accelerometer,
and/or proximity sensors into digital words for a Simatic® 505 programmable controller (PLC).
1.1. Operation
The 2505 Vibration Sensor Interface Module is a double-wide module. It logs in as 18WX and
22WY words. In operation the 2505 converts the signal coming from a vibration sensor into
three pieces of information: the overall RMS vibration, the maximum reading (True Peak-toPeak), and the DC bias of the probe circuit. There are four vibration input channels which are
individually configurable for either an accelerometer, velocity sensor, or displacement probe. An
additional input channel interfaces to a speed sensor; this can be either single or multiple-pulses
per revolution.
The first step in using the 2505 is to configure the hardware. Several jumpers and switches must
be set for each channel to select the type of probe, the gain, the high-pass filter setting, and
whether the hardware integration will be enabled. Jumpers must also be set to select the type of
electrical interface for the tachometer circuitry.
The next step is software configuration. The WY output words contain the parameters for each
channel’s configuration. These are downloaded to the 2505 module one channel at a time using
handshake bits to select the channel. Care should be taken to ensure the software parameters
agree with the hardware settings; the module can check syntax on several of these. Parameters
that can be specified include probe sensitivity, input and output scale factors, Alert and Danger
setpoints and time delays, and the low-pass filter setting. All of these parameters are downloaded
from the controller to the module via the WY output words.
Once the 2505 hardware and software has been configured, the WX input words can be
monitored for RMS, Peak-to-Peak, and DC bias on each vibration channel, and the speed from
the tachometer (tach). Status bits offer quick identification of alarm levels (Alert, Danger, Probe
Circuit status), tach status, Analog-Digital Converter (ADC) over-range conditions, and out-ofrange for reported values.
Note: Throughout this manual WX and WY are referenced as starting at a PLC log-in value of
address 1; this is portrayed as WX(1) where the parentheses are used to indicate this is for
reference only. These addresses must be changed to agree with the actual I/O addressing for each
installation.
CTI 2505 Installation and Operation Guide
1
1.2. User-Configurable Options
The following is a summary of user-configurable options:
Probe type - accelerometer, velocity, or displacement
Gain - interacts with maximum expected signal (full-scale reading) and probe sensitivity; sets
resolution for channel
Integration - accelerometer reports ips, or velocity reports mils
Tachometer - single or multiple pulses per revolution, wide range of electrical pickups
High-pass filter - seven steps between 1Hz to 100Hz
Low-pass filter - sixteen steps between 1.5Hz to 50kHz; interacts with Number of Samples (lines
of resolution) to determine how long it takes to sample the input channels
I.S. barrier factor - compensates for attenuation introduced by external Intrinsic Safety barrier
Units of measurement - either English or Metric
Input and Output Scale factor - multipliers to achieve higher resolution
Report mode - either mV or engineering units (g, ips, mils)
Trip Multiply value - factor to multiply alarm levels
Alert and Danger alarms - setpoints and time delays
Bias alarms - upper and lower setpoints on the probe’s DC bias
Displacement response curve - specification enables module to report displacement in mils or mV
Port options - serial or parallel ports to access raw waveform data for analysis
2
CTI 2505 Installation and Operation Guide
1.3. Front Panel Description
Module status
and transmit/
receive LEDs
High speed parallel
communication port
Serial port
interface
Output BNC connectors for
Channels A-D and
Tachometer
Bi-color (red/green)
channel and
tachometer LEDs
Input connector for
channels A-D and
tachometer
Figure 1.1. CTI 2505 Front Panel
1.3.1. Module Status LED
The green Module Status LED will be illuminated when the module is functioning normally. If
the Status LED is not lit, the module has not completed power up diagnostics, it is not powered,
or a serious problem exists with the module. Refer to Chapter 4 for troubleshooting.
1.3.2. Analysis Data Ports
The 9-pin serial port interfaces with a software program available from CTI / MAARS which
takes “snapshot” data from the module and provides the time-domain waveforms and frequencydomain spectrum on a PC. This port requires significant attention from the on-board
microprocessor (e.g. 10 seconds to download maximum data from all four channels) so is not
recommended for frequent usage, especially in a critical application.
CTI 2505 Installation and Operation Guide
3
The parallel port is provided for future use with a high-speed data interface. This port is much
faster than the serial port and will not interfere with the normal scanning of the inputs.
1.3.3. Output BNC Connectors for Channels A-D and Tachometer
Five individual BNC connectors for channels A-D and the tachometer signal are available for use
with external analysis equipment. These are buffered but the signal output is not filtered.
1.3.4. Tachometer and Channel Sensor LEDs
The bi-color (green and red) channel LEDs show the following operating modes:
Solid green = channel configured and operating within limits
Not lit = channel not configured or bad configuration
Flashing green = Alert setpoint and time delay exceeded
Flashing red = Danger setpoint and time delay exceeded
Solid red = probe circuit fault (takes precedence over Alert or Danger indications)
The single color (green) tachometer LED flashes in relation to speed of input signal.
1.3.5. Input Connector for Channels A-D and Tachometer
This connector provides wiring terminals for channels A-D and for a tachometer signal. The
wiring connector accepts 14-26 AWG wire.
PWR
SIGNAL
COMM
Accelerometer
SHIELD
PWR
SIGNAL
COMM
C
H
C
H
A
B
C
H
C
H
C
D
SHIELD
(+)
(-)
SHIELD
NOT USED
T
A
C
H
PWR
SIGNAL
COMM
SHIELD
Proximity probe
PWR
SIGNAL
COMM
SHIELD
NOT USED
NOT USED
NOT USED
NOT USED
Velocity transducer
Figure 1.1.a. CTI 2505 Wiring Connector
4
CTI 2505 Installation and Operation Guide
1.4. Asynchronous Operation
The module operates asynchronously with respect to the PLC so that a scan of the PLC and a
module output scan cycle do not occur at the same time. Note also that how an output signal
change is dependent on the update time of the module. The following figure illustrates this
relationship:
Figure 1.2. Relation of Update Time Change in Signal Input
1.5. Product Selections
On-board switch/jumpers selections include:
Address selection switch - choose address 1 through E (not used except with parallel port).
Write Protect Switch - when set, the module will accept only one download of configuration
parameters for each channel from the PLC. Changing parameters
again will require power cycling of the module.
Tach section
Tachometer Input mode – Open Collector or Normal
Tach Signal Type – Positive, Negative, or Bipolar
Tach Master switch – select which module has the Tach signal input which will
be sent to other 2505 modules across the high-speed bus.
Tach Input – local or bussed master
Analog input section (four channels)
Gain - jumper select one of: 1, 1.25, 2.5, 5, 10, 25
Hardware Integration - jumper select to enable or disable
High-pass filter value - jumper select one of: 1, 2, 5, 10, 20, 50, or 100 Hz
Probe type selection - switch select of : Proximity Probe or Accelerometer/Velocity
Probes and/or Probe bias
CTI 2505 Installation and Operation Guide
5
CHAPTER 2. HARDWARE CONFIGURATION
The installation of the Vibration Sensor Interface Module involves the following steps:
1.
2.
3.
4.
5.
Planning the installation
Unpacking the module
Configuring the module
Wiring the module
Checking module operation
The steps listed above are explained in detail in the following pages.
2.1. Planning the Installation
Planning is the first step in the installation of the module. This involves calculating the I/O base
power budget and routing the input signal wiring to minimize noise. The following sections
discuss these important considerations.
2.1.1. Calculating the I/O Base Power Budget
The 2505 requires 14 watts of +5 VDC power from the I/O base. Before inserting the module into
the I/O base, ensure that the I/O base power supply capacity is not exceeded. The power supply
should be a single voltage, 20-28 VDC nominal 2.0 amp, UL Class 2 device. The drive voltage
and current are specified at 24 VDC.
2.1.2. Wiring Consideration
Power, communication, and signal wiring must be separated to prevent noise in the signal wiring.
Input signal wiring must be shielded, twisted-pair cable, with 14 to 26 gauge stranded conductors.
The cable shield should always be terminated to earth ground at the I/O base. It should not be
terminated at the output connector. Use the following guidelines when wiring the module:
•
•
•
•
•
•
•
6
Always use the shortest possible cables
Avoid placing power supply wires and signal wires near sources of high energy
Avoid placing low voltage wire parallel to high energy wire (if the two wires must meet,
cross them at a right angle)
Avoid bending the wires into sharp angles
Use wireways for wire routing
Be sure to provide a proper earth ground for the cable shield at the I/O base
Avoid placing wires on any vibrating surfaces
CTI 2505 Installation and Operation Guide
2.2. Unpacking the Module
Open the shipping carton and remove the special anti-static bag which contains the module.
CAUTION:
HANDLING STATIC SENSITIVE DEVICES
The components on the 2505 module printed circuit card can be damaged by static
electricity discharge. To prevent this damage, the module is shipped in a special anti-static
bag. Static control precautions should be followed when removing the module from the
bag, when opening the module, and when handling the printed circuit card during
configuration.
After discharging any static build-up, remove the module from the static bag. Do not discard the
static bag. Always use this bag for protection against static damage when the module is not
inserted into the I/O backplane.
WARNING:
Ensure that the power supply is turned OFF before connecting the wires to the I/O base.
CTI 2505 Installation and Operation Guide
7
2.3. Configuring the Module for Operation
The 2505 must be configured for a high-pass filter setting, gain range and value, sensor
configuration, integration and transducer type, input mode, tachometer input and status, signal
type, port type, module address, and write configuration before inserting the module into the I/O
base. As shipped, all input channels are configured for 1Hz high pass filter, a gain range and
value of 1.0, accelerometer with (+) bias, integration disabled, tachometer input from local source
and ‘is master’ disabled, bipolar signal type, serial port type, module address of 0001, write
configuration enabled, and normal input mode.
Configuring the 2505 for operation consists of the following steps. Following this list are sections
which describe these selections in detail.
1. High-pass frequency input.
2. Gain range and value.
3. Sensor configuration.
4. Integration and transducer type.
5. Tachometer: input mode.
6. Tachometer source.
7. Signal type.
8. Port type.
9. Module address.
10. Write configuration.
11. Dip switches to match the hardware settings.
Figure 2.1. Jumper and Switch locations
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CTI 2505 Installation and Operation Guide
2.3.1. Selecting High-pass Filter Value
The 2505 allows high-pass filter values to be set for each of the four channels. This value must
match the WY configuration in the PLC. For each channel, the high-pass filter must be set in
three places: two hardware jumpers and a switch bank. The jumpers are on the field side of the
circuitry and the switch bank is on the digital logic side of the isolation barrier. As shipped, the 1
Hz filter value is selected. Refer to the diagram below for the correct settings for a 5Hz example.
High-pass
Filter
WY(20)
Transducer Type
& Integration
Gain
nibble 1
nibble 2
0, 1, 2, 3, 4, 5, 6
nibble 3
Not Defined
nibble 4
Figure 2.3. Selecting High-Pass Filter Value
CTI 2505 Installation and Operation Guide
9
2.3.2. Selecting the Gain Range and Value
The Gain settings of ‘Range’ and ‘Value’ must be set in three places for each channel of the
module: two jumpers and a switch bank. The corresponding value must also be entered in the
WY(20) nibble 2 configuration word. Use the table below to correlate these two values and
choose a gain setting for the channel.
When the module is operating, status bits WX(15.13) through WX(15.16) can be monitored to
check for an Analog-Digital Converter (ADC) over-range condition. If the bit is ON, that
indicates the gain setting is set too high for that channel, i.e. the ADC is getting too much voltage
from the vibration sensor. A graphical picture would show the input signal clipping. Move the
gain to a lower setting if this occurs.
ADC
max
5V
4V
2V
1V
500mV
200mV
10
WY(20)
nibble 2
0
1
2
3
4
5
Resolution
in mV
2.441
1.953
0.976
0.488
0.244
.0976
Gain
1
1.25
2.5
5
10
25
Probe Sensitivity (specified by manufacturer)
50mV
100mV
200mV
500mV
100
50
25
10
80
40
20
8
40
20
10
4
20
10
5
2
10
5
2.5
1
4
2
1
0.4
Full Scale Range
CTI 2505 Installation and Operation Guide
Gain
WY(20)
Transducer Type
& Integration
nibble 1
0, 1, 2, 3, 4, 5
nibble 2
High-pass
Filter
Not Defined
nibble 3
nibble 4
Figure 2.4. Selecting the Gain Range and Value
CTI 2505 Installation and Operation Guide
11
2.3.3. Setting the Sensor Configuration Switchblock
The sensor configuration switchblock sets the field-side circuitry to provide the correct probe bias
voltage (if necessary) and the appropriate signal sensing path. The accompanying logic-side
information is provided in WY(20) nibble 1, along with the Integration option (see next section).
Settings for Accelerometers with Positive bias (typical)
C1
C2
C3
C4
The gray portion of the switch
is the depressed side.
Accelerometer bias polarity in
positive position (most probes)
Note: Switch C1 is not read if an
accelerometer is used. If the
accelerometer requires negative bias,
set C2 to the “up” position (relative
to the backplane of the board). C3
and C4 must be in the “down”
position.
Settings for Displacement Probes with Negative bias (typical)
C1
C2
C3
C4
The gray portion of the switch
is the depressed side.
Note: Switch C2 is not read if a
displacement probe is used. If the
displacement probe requires positive
bias, set C1 to the “down” position
(relative to the backplane of the
board). C3 and C4 must be in the
“up” position.
Displacement probe bias polarity in
negative position (most probes)
Settings for Velocity Probes (typically passive => no bias)
C1
C1
C2
C2
C3
C3
C4
C4
The jumper in the top position
is NORMAL (no leakage
current).
Note: Switches C1 and C2 are not
read if a velocity probe is used. The
internal circuitry reads the probe as a
displacement probe without bias
voltage. C3 and C4 must be in the
“up” position.
Settings for Velocity Probes with Open Probe Detection
C1
C2
C3
C4
The jumper in the bottom
position outputs 0.5mA of
leakage current.
The jumper for Channel 1 is located above the switchblock; the left
position is NORMAL and the right position is LEAKAGE CURRENT.
12
Note: For Open Probe detection, the
switches must be configured as an
accelerometer even though a
velocity probe is being used. The
“Probe Circuit Bias Voltage” word
reported to the PLC will show a
small voltage if the probe circuit is
good. (This is the equivalent of
SPQ393.)
CTI 2505 Installation and Operation Guide
2.3.4. Selecting the Integration and Sensor Type
As shipped, the sensor type “Accelerometer” is selected. A jumper setting on the module selects
whether the channel’s input will be integrated. Integration is a function that can be done at the
board level which allows the module to report in different units. For instance, in the case of an
accelerometer the module will report the velocity measurement of ‘inches per second’ (“ips”)
instead of ‘gravities’ (“g”), which is the typical accelerometer measurement unit. Likewise, a
velocity probe will report ‘milli-inches’ (“mils”) instead of “ips”, the common velocity
measurement. See the diagram below for the jumper position and the settings for the switch
banks. If integration is selected, the MSB of WY(20) nibble 1 should be set to a 1. If there is no
integration, this value should be 0.
Transducer Type
& Integration
WY(20)
Accel = 8 or 0
Velocity = 9 or 1
Displacement = 4
nibble 1
Gain
nibble 2
High-pass
Filter
nibble 3
Not Defined
nibble 4
Figure 2.5. Selecting the Integration and Sensor Type
CTI 2505 Installation and Operation Guide
13
2.3.5. Selecting the Tachometer options: Input mode
The input signal for the 2505 tachometer circuit can come from either the input connector or from
Channel 1 (Channel A on the input connector). If the tach source is from a mag pickup or other
such device, the input connector should be wired directly to the device. Alternatively, the input
source could be a displacement transducer which is sensing a keyslot or a drilled hole in a shaft.
In this case the source will come from the Channel 1 input circuit. The advantage of using a
displacement transducer is that it can be monitored for probe circuit status since it is a powered
probe. A mag pickup is a passive device therefore the difference between an open circuit or a
non-moving object cannot be detected; both report a 0 input.
Jumper JP95 selects whether the tach circuit will receive its signal from Channel 1 or from the
input connector. If Channel 1 is selected, the input voltage threshhold is raised by an order of
magnitude to remove the “noise” of the vibration signal. The actual tach pulse is a comparatively
high voltage level so the gain for Channel 1 should be set to its lowest value of 1. The Channel 1
input circuit removes the DC bias from the sensor’s input signal before sending it over to the tach
circuit. (Note: This was first implemented as SPQ396 which used Channel 4 for the input.)
The connector input can be a single pulse per revolution, multiple pulses per revolution such as
blades on a fan or teeth on a gear, or a TTL pulse train (either + or -). The tach circuitry can
sense voltages from 140mV to 50V from normal or open collector circuits, with a frequency
resolution of 1Hz (maximum 65kHz). If the tach is a single pulse per revolution, this signal can
be used as a synchronization mark in analyzing the vibration waveforms since all channels on a
single 2505 are obtained synchronously. In addition, the tach signal can be bussed across the
high speed parallel port interface between multiple 2505 modules to provide a common reference.
The type of tach input (normal or open collector) is set by jumper JP17. Normal is the default
setting. Open Collector input is connected internally through a 10kΩ resistor to +15Vdc; no
external pull-up resistor or power supply is needed.
The status of the tachometer circuitry is available in WX(15). Bit 2 indicates a tach overrange
condition; this means the pulses are exceeding 65535 counts. This could occur if a toothed gear
is used at a high speed. Bit 3 is the tach underrange status bit; this means the speed is less than
2Hz. After 10 seconds without pulses, the No Tach (bit 4) will be set.
2.3.6. Selecting the Tachometer options: Tach Source
If multiple 2505 modules are connected using the high speed parallel port interface, the tach
signal can be sourced from any 2505 and bussed to the other modules. The selection of whether
the tach is used locally only or as the master tach is made using switch block SW5. The options
are:
Local tach only – tach source is connected to this 2505 and is not bussed to other modules
Local tach is Master – tach source is connected to this 2505 and is bussed to other modules
Use Master tach – tach source is on another 2505 and is bussed to this module
14
CTI 2505 Installation and Operation Guide
2.3.7. Selecting the Tachometer options: Signal Type
Signal type (positive, negative, or bipolar) is set by jumpers J1, J2, or J3. A negative signal type
is used when devices generate a negative pulse relative to ground, a positive setting is for devices
that generate a positive pulse relative to ground, and bipolar is used for devices that generate a
sinusoidal or bipolar (square wave) output. A gear tooth or blade pass waveform uses the bipolar
setting. See figure below for correct signal polarity.
Magnetic pickup
Output waveform
approaching
departing
parallel
to pickup
Teeth on gear
Figure 2.6. Bipolar gear tooth example
Configuration word WY(40) determines whether the tach pulses coming from the hardware
circuitry are counted as once per revolution or as multiple pulses per revolution.
If WY(40) is set to 0, the speed as sensed from the tach is reported to the PLC WX(14) in Hertz;
an RPM selection is not possible. If WY(40) is set to 1, that equates to a single pulse per
revolution. The choice of speed reporting is made by setting WY(19.6) to 1 for Hertz or 0 for
RPM. For teeth on a gear or blade passes, set WY(40) equal to the number of teeth on the gear (or
vanes on the fan).
CTI 2505 Installation and Operation Guide
15
INPUT MODE:
NORMAL = typical setting
OPEN COLLECTOR = input is
connected thru a 10kOhm
resistor to +15Vdc; no
external pull-up or power
source needed.
INPUT SOURCE:
CH1 TACH = Channel 1 sensor
NORMAL = input connector pins
SIG TYPE:
NEG = devices that generate a negative pulse relative to ground
POS =
“
“
“
“ positive
“
“
“
“
BIP =
“
“
“
“ sinusoidal or bipolar (square wave)
oupu
Figure 2.7. Selecting Tachometer Options
16
CTI 2505 Installation and Operation Guide
2.3.8. Selecting the Port Type
The port type can either be parallel or serial and is selected on jumpers JP88 and JP89 (see Figure
2.8. on next page). If the 2505 is not paired with a 2506 Vibration Sensor Analysis Module
(available mid-2004), then the serial port should be selected. This enables the DB9 serial port on
the front of the module. A software package is available from CTI / MAARS which is capable of
downloading waveform data from the serial port in a “snapshot” mode. This data can be
portrayed as a time domain waveform or as a frequency domain spectrum. The historical
trending and analysis features of the 2506 Vibration Sensor Analysis Module are not available in
this mode. The 2505 stops processing vibration input data during this download process so it is
recommended that this capability not be used frequently if the module is monitoring critical
machinery for shutdown purposes.
The purpose of the parallel port interface is to connect the 2505(s) to the 2506 Vibration Sensor
Analysis Module. This bus transfers waveform data at a speed which does not interfere with the
ability of the 2505 to continuously monitor the vibration signals.
The status of the port activity is available in WX(15). Bit 11 indicates if the processor on the
2505 has been halted due to activity on either the serial or parallel port. Bit 12 indicates a timeout
condition due to a failure of the 2506 to respond to a signal from the 2505.
2.3.9. Selecting the Module Address
The module address is set via switchblock SW10 (see Figure 2.8. on next page). It is only used
when the 2506 Vibration Sensor Analysis Module (available mid-2004) is in the system. Two
addresses are reserved: address 0 is always the 2506, and an address of F (hex) is used for the
2506 to broadcast to all 2505s. The 2505 can therefore be address 1 through E (hex) and is
shipped with the 0001 address.
2.3.10. Selecting the Write Configuration
The Write Configuration is set via jumper JP20 (see Figure 2.8. on next page). In the Enable
position, the 2505 can be dynamically configured from the PLC at any time. In this mode,
changes can be made to one channel’s parameters, e.g. Alarm Delay Time, without affecting the
operation of any other channel. If the application is sensitive or perhaps subject to agency
regulation, the jumper can be set to Disable. In this mode, only one set of configuration
parameters can be downloaded to each channel. Dynamic changes are not accepted by the 2505.
To effect a change, the module must be power cycled, then another set of parameters will be
accepted.
CTI 2505 Installation and Operation Guide
17
Figure 2.8. Selecting the Port Type, Module Address, and Write Configuration
18
CTI 2505 Installation and Operation Guide
2.3.11. Setting Dip switches to match the hardware settings
Once the hardware jumpers are selected this information needs to be reported to the
microcomputer. The information is reported via DIP switches SW6, 7, 11, and 12. Each channel
uses 8 rocker switches with a BCD code to indicate the state of the hardware jumpers. The 2505
compares the state of these switches to the configuration word WY(20) which comes from the
user’s program in the PLC. Because of the need to isolate the field-side circuitry from the logicside, there is no physical check to make sure the module is configured the same as the PLC
“thinks” it is. These switches are simply a step to help ensure there are no setup mis-matches.
Channel Dip
Position(s)
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
4-6
4-6
4-6
4-6
4-6
4-6
4-6
4-6
7
7
8
BCD code
Corresponding Value
000
100
010
110
001
101
110
111
000
100
010
110
001
101
011
111
0
1
0
8
1
Gain = 1.0
Gain = 1.25
Gain = 2.50
Gain = 5
Gain = 10
Gain = 25
N/A
N/A
High Pass Filter = 1Hz
High Pass Filter = 2 Hz
High Pass Filter = 5 Hz
High Pass Filter = 10 Hz
High Pass Filter = 20 Hz
High Pass Filter = 50 Hz
High Pass Filter = 100 Hz
N/A
Integrator Value = Disabled
Integrator Value = Enabled
Sensor type =
Accelerometer or Velocity
Probe
Sensor type = Displacement
Probe
Figure 2.9. Jumper Settings for Future Reference
See “Appendix A. Jumper Settings Log Sheet” to document individual channel settings after
making copies for each of the four channels.
CTI 2505 Installation and Operation Guide
19
2.4. Inserting the Module in the I/O Base
Insert the module into the I/O base by carefully pushing the module into the slot. When the
module is fully seated in the slot and backplane connector, tighten the captive screws at the top
and bottom to hold the module in place. To remove the module from the I/O base loosen the
captive screws then remove the module from the I/O base.
2.5. Wiring the Module
Input and output signals travel through a variety of connectors accessible on the front panel of the
module: a 9-pin serial connector, a high speed 24-pin communications connector with latches, a
group of five BNC connectors, and a dual row 24-pin connector. Each connector type and its
function is described below.
2.5.1. Serial connector
The 9-pin D-SUB serial connector interfaces with a software program available from
CTI/MAARS which takes “snapshot “ data from the module and provides the time-domain
waveforms and frequency-domain spectrum on a PC. This port requires significant attention
from the on-board microprocessor (e.g. 10 seconds to download maximum data from all four
channels) so is not recommended for frequent usage, especially in a critical application.
2.5.2. High Speed Communications connector
The 24-pin connector acts as a high speed communication connector to transfer signals between
the 2505 and a vibration data analysis program. This port is much faster than the serial port and
will not interfere with the normal scanning of the inputs.
2.5.3. BNC connectors
Five individual BNC connectors for channels A-D and the tachometer signal are available for use
with external analysis equipment. These are buffered but the signal output is not filtered.
2.5.4. Signal input connector
This connector provides wiring terminals for channels A-D and for a tachometer signal. The
wiring connector accepts 14-26 AWG solid or stranded wire.
20
CTI 2505 Installation and Operation Guide
2.6. Checking Module Operation
First turn on the base supply power. If diagnostics detects no problems, the front panel module
status indicator will light. If the indicator does not light (or goes out during operation), the base
power is not available or the module has detected a different failure. For information on viewing
failed module status, refer to your SIMATIC® TISOFT Programming Manual. To diagnose and
correct a module failure, refer to the next section on troubleshooting.
You must also check that the module is configured in the memory of the PLC. This is important
because the module will appear to be functioning regardless of whether it is communicating with
the PLC. To view the PLC memory configuration chart listing all slots on the base and the inputs
or outputs associated with each slot, refer to your SIMATIC® TISOFT Programming Manual. An
example chart is shown in the following figure.
In this example, the 2505 Module is inserted in slot 1 in I/O base 0. For your particular module,
look in the chart for the number corresponding to the slot occupied by the module. If word
memory locations appear on this line, then the module is registered in the PLC memory and the
module is ready for operation.
I/O Module Definition for Channel…….1 Base..…..00
Number of Bit and Word I/O
I/O Address
Slot
1
2
.
.
15
16
0001
0000
.
.
0000
0000
X
00
00
.
.
00
00
Y
00
00
.
.
00
00
WX
18
00
.
.
00
00
WY
22
00
.
.
00
00
Special
Function
NO
NO
.
.
NO
NO
Figure 2.11. I/O Configuration Chart
If the line is blank or erroneous, re-check the module to ensure that it is firmly seated in the slots.
Generate the PLC memory configuration chart again. If the line is still incorrect, contact your
local distributor or CTI at 1-800-537-8398 for further assistance.
NOTE:
In the event a CTI analog module detects an onboard module failure, the module will assert
the module fail line and report the module failure in the I/O Status Word, which is reported to
the PLC CPU. CTI strongly recommends the user application monitor the I/O Module Status
Words which are Status Words 11-26 and apply to SIMATIC® Controllers TI/545, TI/555,
TI/560 & 565, and the TI/575. The I/O Module Status Word can be used to report a module
failure for an I/O Module in any of theSimatic® 505 I/O slots. Please refer to Siemens®
SIMATIC® TI505 Programming Reference Manual for more information. If a module failure
is reported by the status word, the module should be replaced with a working unit and the
failed module sent in for repair.
CTI 2505 Installation and Operation Guide
21
CHAPTER 3. SOFTWARE CONFIGURATION
In addition to the module hardware configuration settings noted in Chapter 2, a number of other
items are addressed in regards to vibration monitoring. They are:
1. Intrinsic Safety Barrier Attenuation Factor
2. Output Scale Factor
3. Units of Measurement
4. Input Scale Factor
5. Reporting Mode
6. Trip Multiply Value
7. Probe Sensitivity
8. Alert / Danger Setpoints and Time Delays
9. Displacement Probe Response Curve
10. Gap Over/Under and Bias High/Low
11. Parameters that apply to All Channels
12. Analog Values and Status Bits
3.1. Intrinsic Safety Barrier Attenuation Factor
The module can automatically compensate the readings it reports to the PLC if an Intrinsic Safety
barrier is present. It uses the value of WY(21) to adjust the reported reading. For instance, if an
IS barrier is used which attenuates the signal 9%, set WY(21)=9. An actual input value of 91mV
will be reported to the PLC as 100mV, thus compensating for the 9% decrease in sensed voltage
due to the barrier. Alert and Danger Setpoints should be set to the levels that would be seen if
there were no IS barrier present. A value of 0 in WY(21) means there is no attenuation
compensation (i.e. no IS barrier).
WY(21)
Intrinsic Safety barrier attenuation value
3.2. Output Scale Factor
The output of a typical vibration sensor is a very low mV level. Since the PLC cannot display
decimal point values (and it is inconvenient to use floating point numbers), Scaling will normally
be needed. The value of WY(22) is the power of 10 by which the reported value is multiplied. If
no scaling is used, this is 100 or multiply by 1. A value of 1 is equivalent to 101 or multiply by
10; an actual vibration of 0.13g RMS would be reported as 0 (no decimal values). A value of 2
(102 or multiply by 100) will be typical; vibration of 0.13g RMS will be reported as 13. It is
possible to reduce the reading by using negative powers; these are converted into Hex as one’s
complement numbers. A value of –1 (10-1 or divide by 10) is FF in Hex.
Output Scale Factor
WY(22)
22
FC, FD, FE, FF, 0, 1, 2, 3,
4
CTI 2505 Installation and Operation Guide
3.3. Units of Measurement
A vibration sensor can be specified in either English or Metric units. It may be that a Metric
sensor is used in an application where English output units are desired. WY(23) makes it
possible to accommodate any of these cases. The first number specifies the Input spec of the
sensor and the second number determines the Output mode. A value of “0” is English units, and
“1” is Metric.
00
11
01
10
(0) = English units on Input and Output
(g, ips, mils)
(3) = Metric units on Input and Output
(m/s2, mm/s, µm)
(1) = English units on Input, Metric units on Output
(2) = Metric units on Input, English units on Output
Most applications will have a value of “0” in this location.
Units of Measurement
WY(23)
0, 3, 1, 2
3.4. Input Scale Factor
Just as the reported value output to the PLC can be scaled, the actual input reading can also be
scaled. The value of WY(24) is the power of 10 by which the actual reading is multiplied. The
computations are the same as used in the Output Scale Factor. It is anticipated that most
applications will not require Input Scaling and therefore this value should be “0”. See the
paragraph on Probe Sensitivity for an example where this is useful.
Input Scale Factor
WY(24)
FC, FD, FE, FF, 0, 1, 2, 3,
4
CTI 2505 Installation and Operation Guide
23
3.5. Reporting Mode
The module receives a mV signal input from the vibration sensor and translates this into the
equivalent vibration reading based on the sensor specifications and other variables. In some cases
it may be desired to know the actual voltage reading instead of the vibration value. WY(25)
chooses whether the reported value is in Engineering Units or the raw mV. There is also a choice
of type of output:
RMS is normally used and is an “average” of the input readings.
Peak is a computed value equal to the RMS value times 1.4.
Peak-Peak is a computed value equal to the Peak value times 2. Do not confuse this with
the True Peak-to-Peak value which the module also reports.
0 = RMS raw mV
2 = peak raw mV
4 = p-p raw mV
1 = RMS engineering units
3 = peak engineering units
5 = p-p engineering units
Reporting Mode
WY(25)
0, 1, 2, 3, 4, 5
It is possible to select a mode that exceeds the range of a signed integer data type (-32765 to
32767), yet have an actual vibration level that is OK. For example: Output Scale of 100 reporting
in RMS engineering units gives an acceptable reading. Changing the Scale factor or the Report
Mode may cause the reported value to exceed +32767. Always check the WX(15.10) Math
Overflow status bit to ensure the reported value is legitimate.
3.6. Trip Multiply Value
If the module is calculating the Alarm and Danger Setpoints, then it can go into Trip Multiply
mode where the setpoints are raised by the factor specified in WY(26). This Trip Multiply Value
can be set on a per-channel basis and is activated when the module receives the WY(19.8)
command bit from the PLC. Trip Multiply mode is maintained until the command bit is lowered.
For instance, an alarm setpoint of 2 g’s can be raised to 3 g’s during startup or coastdown to avoid
harmonic regions and spurious alarms. The value of WY(26) would be set to “1” indicating a
50% increase in setpoint. The possible values for WY(26) are:
0 = no change in Setpoint
1 = 50% increase in Setpoint
2 = 100% increase
4 = 150% increase
8 = 200% increase
WY(26)
24
Trip Multiply Value
CTI 2505 Installation and Operation Guide
3.7. Probe Sensitivity
The sensitivity of a vibration probe is specified by the manufacturer and is typically a nominal
value such as 100mV/g (accelerometer) or 200mV/mil (displacement probe). The 2505 expects
this parameter to be expressed in terms of RMS. This is normal for accelerometers however
velocity transducers are often specified as 145mV/ips peak. This value needs to be converted to
RMS (by dividing by 1.414) which yields 102.6mv/ips RMS. This can in most instances be
approximated as a sensitivity of 100. The module can go a step further and accept the more
accurate calibrated value if it is known. It can also accept Metric inputs with decimal values; the
WY(24) Input Scale Factor is used. For example:
200mV/mil prox probe Î WY(27) = 200
WY(24) = 0
7.87mV/µm prox probe Î WY(27) = 787
WY(24) = FE (10-2)
10.2mV/m/s2 accelerometer Î WY(27) = 102
WY(24) = FF (10-1)
102mV/g calibrated accel Î WY(27) = 102
WY(24) = 0
WY(27)
Probe Sensitivity
3.8. Alert / Danger Setpoints and Time Delays
The next four configuration words (WY(28) through WY(31)) specify the Alarm and Danger
levels, and Time Delays. If the module is not calculating alarms (control bit WY(19.5) is ON)
then no values need to be entered. Note: If setpoints are not entered and Alarm Control = 1,
then the front panel LEDs will always remain at solid green. For applications where alarm
calculations are desired, refer to the following figure for assistance in determining appropriate
values.
Voltage
Gap Over or
Bias High
Danger Setpoint
Alert Setpoint
Nominal DC
bias voltage
True
Peak-to-Peak
Gap Under or
Bias Low
Time
Figure 3.1. Alarm & Danger levels, Time Delay example chart
CTI 2505 Installation and Operation Guide
25
The 2505 allows several options in how vibration levels are alarmed. The first choice is whether
to alarm on a level that is calculated or on the True Peak-to-Peak. As a vibration signal comes
into the 2505, it is transformed by the analog-to-digital (ADC) converter into a digital
representation. A math process converts the raw data points into an RMS (Root Mean Square)
value. This is often called the Overall Vibration value and is very roughly analogous to the
average of all the data values. Since the math process is an averaging function, the effect of a
single peak on the overall value is reduced. From this RMS value, two other representations are
possible: the calculated Peak (1.4 x RMS) and the calculated Peak-to-Peak (1.4 x RMS x 2). It is
important to distinguish that these are calculated values. If the vibration waveform is a true sine
wave, then the calculated values would correlate exactly with the actual peak and peak-to-peak
measurements. Since vibration is never a perfect sine wave, these are therefore approximations
based on calculated values.
The 2505 does give the option of alarming on the True Peak-to-Peak. This is demonstrated
graphically in Figure 3.1, and is obtained by adding the maximum positive value out of the ADC
to the absolute value of the maximum negative value. These maximum values are not necessarily
caused by the same physical condition. In other words, the maximum positive value could be
caused by misalignment whereas the maximum negative value is due to oil whirl. Whether or not
that is possible, the point is that there may not be any correlation in the timing of the max positive
peak and the max negative peak. This value is the maximum vibration (physical movement)
experienced and therefore is often monitored on proximity probes. The RMS value is a more
accurate representation of the overall vibration and is often used as a trend variable to detect
increasing vibration levels over time.
Alert and Danger setpoints are specified in engineering units and are subject to the Output Scale
Factor. Reference WY(19.13~15) for data source (calculated or true p-p), WY(25) for calculated
mode (RMS, peak, p-p), and WY(25) for units (English = g, ips, mils; Metric = m/s2, mm/s, µm).
Input signals that exceed these setpoints are subject to the specified Time Delays and are reported
as Status Bits, e.g. WX(1.5) and WX(1.6).
For example:
Accelerometer input, Alarm level of 0.4g RMS with Output Scale Factor of 2 Î WY(28)=40
Same input and Alarm level, but Output Scale Factor of 1 Î WY(28) = 4
Time Delays require the input to be above the Alarm / Danger Setpoint for the specified time
before the Alarm or Danger status bit is triggered. If the input level dips below the Setpoint
during the Time Delay, the count is reset. Time Delays are specified in seconds x 10. For a
delay of 3 seconds, WY(29) = 30.
26
WY(28)
Alert Setpoint
WY(29)
Alert Time Delay
WY(30)
Danger Setpoint
WY(31)
Danger Time Delay
CTI 2505 Installation and Operation Guide
Once an alarm has been triggered, it remains on until the input signal returns to a level below the
Setpoint. It is therefore possible for an alarm to be triggered for only one scan and then to reset.
Logic in the PLC should be used to capture the alarms.
CTI 2505 Installation and Operation Guide
27
3.9. Displacement Probe Response Curve
The next four configuration parameters (WY(32) through WY(35)) are used only for
displacement probes. They specify the slope of the response curve for the probe. Accurately
filling in these values allow the module to report displacement probe vibration values in mils.
Without this information, the module can only report the mV signal levels it gets from the probe.
These parameters are also useful when calibrating the probe during installation (gapping the
probe) on the machine to be monitored. If any of these values are zero, the module will report
mV. Refer to the following figure for an example of WY(32) through WY(35) parameters.
-24
-22
-20
B
Output (volts)
-18
-16
-14
-12
-10
-8
-6
A
-4
-2
0
0
10
20
30
40
50
60
70
80
90
100
Gap (mils)
Figure 3.2. Displacement probe (200mV/mil) chart example
At point A, the DC output voltage equals –3.98V and gap distance is 20 mils.
At point B, the DC output voltage equals –18V and gap distance is 90 mils.
WY32 is the gap voltage specified as V x 100 Î WY(32) = -398, and WY(34) = -1800.
The gap distance values are specified in mils Î WY(33) = 20 and WY(35) = 90.
28
WY(32)
Gap Voltage at Point A
WY(33)
Gap Distance at Point A
WY(34)
Gap Voltage at Point B
WY(35)
Gap Distance at Point B
CTI 2505 Installation and Operation Guide
3.10. Gap Over/Under and Bias High/Low Alarm Setpoints
The last two parameters are measurements of the DC voltage component of the sensor’s output.
The AC voltage component is the vibration measurement which is reported in WX(2) and WX(3)
for Channel A, etc. For an accelerometer this DC component is called Bias High/Low. For a
displacement probe it is Gap Over/Under. A velocity transducer is typically a self-powered
sensor so it does not have a bias voltage, but a small current can be run through the sensor to
ascertain circuit continuity (call CTI for information on Special Product Quote 393). This DC
component is an important measure of the integrity of the probe circuit and is reported separately
in WX(4) for Channel A, etc. A separate status bit is also reported (WX(1.7) for Channel A, etc.)
if either one of these setpoints are exceeded. There are no Time Delays associated with these DC
measurements. The values are specified in Volts and are scaled between 0 and ±2400.
Accelerometer values are typically positive voltages and displacement sensors are negative
voltages. Refer to the figure on Alarm and Danger levels for assistance in setting these
parameters.
For displacement probes: if the Probe Response Curve has been specified (WY(32~35)), the
value reported in WX(4) is the displacement distance not the voltage. The Gap Over/Under alarm
still measures the bias voltage even though it is not being reported. Gapping the probe is
normally done using voltage, but the 2505 module allows distance to be used if desired.
Important note: when dealing with negative values, the more negative value is considered to be
lower than the less negative value. Format WY(36) and WY(37) as signed integers in the PLC.
For example, if the desired setpoints are –20V and -10V, then
Gap Over setpoint is –10 Î WY(36) = -1000, and Gap Under setpoint is –20 Î WY(37) =
-2000. Remember these are scaled between 0 and ±2400.
WY(36)
Gap Over or Bias High Alarm Setpoint
WY(37)
Gap Under or Bias Low Alarm Setpoint
3.11. Parameters that apply to All Channels
These last three words only need to be written to the module one time. In the RLL example
program in Appendix B, they are written along with each channel’s individual configuration
parameters but the only download that matters is the last one.
Fmax = WY(38)
(Note: This value sets the low-pass filter for the module.)
Number of samples = WY(39)
Refer to figure below to correlate these two values with the amount of time the module will take
to process each sample. All channels are sampled simultaneously so this value applies to the
CTI 2505 Installation and Operation Guide
29
module. The “# of lines” is used in vibration analysis; it refers to the number of discrete
frequency values in the spectrum. It is directly correlated to the “# of samples” in that more
samples are necessary to display greater spectral detail, and enough samples must be taken to
avoid aliasing (Nyquist theorem). Not all the cells contain a value because these were empirically
determined; cells in the same row to the left of a specified value will be greater and cells to the
right will be less. The purpose is to show the limits where the module complies with the API670
specification which states that the module must be able to sense a vibration level in excess of a
threshold in less than 100ms. (The rest of the spec requires a response time of between 1 and 3
seconds.)
WY(38)
F
Hz fmax
50000
E
Time to Sample (in sec)
4.1
25000
D
C
B
A
9
8
7
6
1.2
0.6
0.35
0.6
2.05
12000
0.6
6000
0.6
3000
0.6
1500
0.8
0.4
800
1.05
0.55
400
0.8
0.4
200
1.3
0.65
0.35
1.15
0.60
100
5
50
4
1.1
25
# of lines
# of samples
WY(39)
0.55
1.1
0.55
3200
1600
800
400
200
100
50
25
12.5
8192
4096
2048
1024
512
256
128
64
32
F
E
D
C
B
A
9
8
7
Figure 3.3. Time to Sample Correlation Chart
(cells in the shaded area indicate API670-compliant region)
WY(38)
WY(39)
Fmax (0 through F)
# of samples
(7 through F)
Speed Sensing = WY(40)
If using a toothed gear, WY(40) = # of teeth (max of 255)
If sensing a single pulse per revolution, WY(40) = 1
Note: If WY(40) = 0, then speed is reported to PLC in Hz; RPM not possible.
WY(40)
Speed sensing
(0, 1, or 2-255)
Rfer to Figure 3.4. on the next page for a detailed WX/WY summary.
30
CTI 2505 Installation and Operation Guide
I/O login
1
WX/WY Summary
1
WX
1
WX
2
WX
3
WX
4
Ch A
WX
5
WX
6
2
3
4
5
6
Configuration acknowledge
Ch B
Ch C
Ch D
7
8
Channel A
11
12
13
14
Channel C
15
16
Channel D
Alert Danger Probe Alert Danger Probe Alert Danger Probe Alert Danger Probe
Channel A
True Peak-to-Peak vibration
Probe circuit bias voltage
Calculated vibration (RMS, Peak, Peak-Peak)
Channel B
True Peak-to-Peak vibration
7
Probe circuit bias voltage
WX
8
Calculated vibration (RMS, Peak, Peak-Peak)
WX
9
WX
10
Channel C
True Peak-to-Peak vibration
Probe circuit bias voltage
WX
11
WX
12
WX
13
WX
14
WX
15 Module
Calculated vibration (RMS, Peak, Peak-Peak)
Channel D
True Peak-to-Peak vibration
Probe circuit bias voltage
Tachometer reading
status
Tach
Over
Tach
Under
No
Tach
Configuration status
Ch A
Ch B
WX
16
Channel A Syntax Error (in hex)
WX
17
Channel C Syntax Error (in hex)
WX
18
WY
19
Ch C Ch D
Not
defined
ADC overrange
Math Port Parallel
Ch A Ch B Ch C Ch D
port
over stop
Channel B Syntax Error (in hex)
Channel D Syntax Error (in hex)
Not defined
Configuration command
Ch A
20
10
Calculated vibration (RMS, Peak, Peak-Peak)
WX
WY
9
Channel B
Ch B
Ch C
Ch D
Alarm
master
Speed
report
Module
inhibit
0=alarm
0=RPM
0=run
Transducer type & integration
Trip
Multiply
Not defined
Ch A
Gain
WY
21
Intrinsic safety barrier attenuation value
WY
22
Output scale factor
1
2
RMS / True P-P
alarm control (0=RMS)
High-pass filter value
3
-1
Ch B
Ch C Ch D
Not defined
-2
(1 = 10 , 2 = 10 , 3 = 10 , FF = 10 , FE = 10 )
WY
23
Units of measure
(0 = English in/out, 3 = Metric in/out, 1 = English in, Metric out, 2 = Metric in, English out)
WY
24
Input scale factor
(1 = 10 , 2 = 10 , 3 = 10 , FF = 10 , FE = 10 )
WY
25
Report Mode
(0 = mV
WY
26
Trip Multiply value
(1 = 50% increase, 2 = 100% increase, 4 = 150% increase)
WY
27
Probe Sensitivity
WY
28
Alert Setpoint
WY
29
Alert Time Delay
(10 = 1 sec)
WY
30
Danger Setpoint
(x 10
WY
31
Danger Time Delay
(10 = 1 sec)
WY
32
Gap Voltage at A
(scaled 0 to +/- 2400)
WY
33
Gap Distance at A
(in mils)
WY
34
Gap Voltage at B
(scaled 0 to +/- 2400)
WY
35
Gap Distance at B
(in mils)
WY
36
Gap Over or Bias High Alarm Setpoint
(scaled 0 to +/- 2400)
WY
37
Gap Under or Bias Low Alarm Setpoint
(scaled 0 to +/- 2400)
WY
38
F max
(F = 50k, E = 25k, D = 12k, C = 6k, B = 3k, A = 1.5k, 9 = 800, 8 = 400, 7 = 200)
WY
39
Number of Samples
(F = 8192, E = 4096, D = 2048, C = 1024, B = 512, A = 256, 9 = 128, 8 = 64)
WY
40
Number of Teeth
1
2
3
-1
-2
1 = eng units)
WY22
(x 10
)
WY22
)
Figure 3.4. WX/WY Summary Chart
CTI 2505 Installation and Operation Guide
31
32
CTI 2505 Installation and Operation Guide
CHAPTER 4. TROUBLESHOOTING
Symptom
Module status LED is not lit.
Module XMT/RCV LEDs are
not blinking
•
•
Probable Cause
Base or PLC power is off.
Module has not completed
power up diagnostics.
•
•
Corrective Action
Turn base or PLC on.
Wait for power up
diagnostics to be
completed.
Return module to CTI for
repair.
•
Serious problem with
module exists.
•
•
If serial or high speed
comm. Port is not
populated, then module is
operating properly.
Comm. problem exists
between module/PC.
•
N/A
•
Try to reseat
communication cables
between modules/PC.
•
Single channel stopped
reporting
•
Spike in incoming voltage
exceeding fuse value.
•
Replace removable SMT
fuse with Littelfuse
154.062 or equivalent.
Individual channel LED not lit
•
•
Channel not configured.
Channel has bad
configuration.
•
•
Configure channel.
Check channel
configuration; change
necessary values.
•
Probe circuit fault.
•
Check probe driver (where
applicable) and probe for
damage/proper functioning.
Continuous Red channel LED
Figure 4.1 Troubleshooting Matrix
When it is inconvenient to visually check the status indicator, use the TISOFT "Display Failed
I/O" or "Show PLC Diagnostics" support functions. Note that if the module power supply (user
supply) fails, the module will still be logged into the PLC even though it is not operating.
If after consulting the chart above and you are unable to diagnose or solve the problem, contact
CTI at 1-800-537-8398 for further assistance.
CTI 2505 Installation and Operation Guide
33
34
CTI 2505 Installation and Operation Guide
SPECIFICATIONS
Input Channels:
4 input channels plus tachometer
Sensor Types:
Accelerometer, Velocity, and Proximity
Response Time:
4 mSec total module (includes settling time)
Gain settings:
1, 1.25, 2.5, 5, 10, 25
High-pass filter values:
1, 2, 5, 10, 20, 50, 100 Hz
PLC Reporting of:
Overall RMS vibration level
Peak-to-Peak value
DC bias voltage of probe circuit
Speed (in RPM or Hz)
Probe Circuit Fault status bit
Alarm/Danger status bits
Module status word
Reporting units:
mils, i.p.s., g’s, meters, m/s, m/s2
Isolation:
1500 VDC channel-to-PLC
Backplane Power Consumption:
up to 14.0 Watts
Module Size:
Double-wide
Module (Packed) Weight:
2.0 lbs (0.9 kg)
Operating Temperature:
0° to 60°C (32° to 140°F)
Storage Temperature:
-40° to 85°C (-40° to 185°F)
Humidity, Relative:
5% to 95% non-condensing
Agency Approvals Pending:
UL, UL-C, FM (Class 1, Div 2), CE
Specifications subject to change without notice.
CTI 2505 Installation and Operation Guide
35
36
CTI 2505 Installation and Operation Guide
APPENDIX A. CONFIGURATION LOG SHEET
These two pages are provided for an easy record of each channel’s configuration setup. Make
copies for each channel that is configured differently.
Channel ___
Sensor type (accelerometer
velocity
displacement)
Integrated (Yes No)
Sensitivity __________________
Gain (1 1.25
2
5
10 25)
High-pass filter setting (1 2 5 10 20 50 100)
Report (RMS Peak Peak-Peak True P-P)
Alarm on (none RMS True P-P)
Parameters stored in V-memory at V________
Parameters stored in K-memory at K________
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
WY__
Hex
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Sint
Hex
Hex
Sint
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
CTI 2505 Installation and Operation Guide
Transducer Type & Integ. / Gain / HP Filter
Intrinsic Barrier Attenuation Factor
Output Scale Factor
Units of Measurement
Input Scale Factor
Reporting Mode
Trip Multiply Value
Probe Sensitivity
Alert Setpoint
Alert Time Delay
Danger Setpoint
Danger Time Delay
Gap Voltage at A
Gap Distance at A
Gap Voltage at B
Gap Distance at B
Gap Over or Bias High Alarm Setpoint
Gap Under or Bias Low Alarm Setpoint
Fmax
# of samples
# of gear teeth
37
38
CTI 2505 Installation and Operation Guide
APPENDIX B. SAMPLE LADDER LOGIC
| LAD Network 1 Address 1
|The configuration parameters are stored in K-memory (non-volatile)
|then moved into V-memory. The trigger contact for this Move Word
|command is latched so any parameter changes only need to be made once
|in K-memory and are automatically moved into V-memory.
|For this sample program:
|K1-21 ==> V1-21
Channel A (proximity probe; also used as Tach source)
|K31-51 ==> V31-51
Channel B (velocity transducer w. Open Probe detection)
|K61-81 ==> V61-81
Channel C
(accelerometer)
|K91-111 ==> V91-111 Channel D (proximity probe in axial (thrust) orientation)
|
| MoveK_to_V
+-------------------------+
MoveK_to_V
|
| MOVE WORD
|
|
C17
|
|
C17
[------] [-----]
[--------------------( / )---|
| A:
K1|
|
|
|
|
|
A_Transduce|
|
|
r_Gain_HP |
|
| B:
V1|
|
|
|
|
|
|
|
| N:
120|
|
|
|
|
|
|
|
+-------------------------+
|
| LAD Network 2 Address 7
|This is the test for Channel A at power-up. ConfigStatus for all
|channels will be OFF, so Channel A will be configured first.
|
| A_ConfigSta
B_ConfigSta
C_ConfigSta
D_ConfigSta
A_InitialCo
| tus
tus
tus
tus
nfig
|
WX15.5
WX15.6
WX15.7
WX15.8
C1
[------]/[-----------]/[-----------]/[-----------]/[----------(
)---|
|
| LAD Network 3 Address 20
|This is the Dynamic re-configuration for Channel A. If any parameters
|have been changed in K-memory, this Command Bit will force a re-load to
|Channel A.
|
| A_ReConfig
A_DynamicCo
|
nfig
|
C13
5
C81
[------] [----------] ^ [-------------------------------------(
)---|
CTI 2505 Installation and Operation Guide
39
|
| LAD Network 4 Address 23
|This Move Word takes configuration parameters for Channel A from
|V-memory to WY, then sets the Channel A configuration command bit (WY19.1).
|Either the initial power-up or the dynamic reconfiguration can trigger this
|command. The Configuration Acknowledge bit (WX1.1) is tested to keep the
|command from executing more than once per download operation.
|
| A_InitialCo
A_Config_X
+-------------------------+ A_Config_Y
| nfig
| MOVE WORD
|
|
C1
WX1.1
|
A_Transduce|
WY19.1
[------] [----+------]/[-----]
r_Gain_HP [------(
)---|
|
| A:
V1|
| A_DynamicCo |
|
|
| nfig
|
|
Transducer_|
|
C81
|
|
Gain_HP
|
[------] [----]
| B:
WY20|
|
|
|
|
| A_Config_Y |
|
|
|
|
| N:
21|
|
WY19.1
|
|
|
[------] [----+
|
|
|
+-------------------------+
|
| LAD Network 5 Address 38
|This is the test for Channel B at power-up. ConfigStatus for Channel A
|will be ON, but Channel B, C, and D will still be OFF.
|
| A_ConfigSta
B_ConfigSta
C_ConfigSta
D_ConfigSta
B_InitialCo
| tus
tus
tus
tus
nfig
|
WX15.5
WX15.6
WX15.7
WX15.8
C2
[------] [-----------]/[-----------]/[-----------]/[----------(
)---|
|
| LAD Network 6 Address 51
|This is the Dynamic re-configuration for Channel B. If any parameters
|have been changed in K-memory, this Command Bit will force a re-load to
|Channel B.
|
| B_ReConfig
B_DynamicCo
|
nfig
|
C14
6
C82
[------] [----------] ^ [-------------------------------------(
)---|
|
| LAD Network 7 Address 54
|This Move Word takes configuration parameters for Channel B from V-memory
|to WY, then sets the Channel B configuration command bit (WY19.2). Either
|the initial power-up or the dynamic reconfiguration can trigger this command.
|The Configuration Acknowledge bit (WX1.2) is tested to keep the command
|from executing more than once per download operation.
| B_InitialCo
B_Config_X
+-------------------------+
B_Config_Y
| nfig
| MOVE WORD
|
|
C2
WX1.2
|
B_Transduce|
WY19.2
[------] [----+------]/[-----]
r_Gain_HP [------(
)---|
|
| A:
V31|
| B_DynamicCo |
|
|
| nfig
|
|
Transducer_|
|
C82
|
|
Gain_HP
|
[------] [----]
| B:
WY20|
|
|
|
|
| B_Config_Y |
|
|
|
|
| N:
21|
|
WY19.2
|
|
|
[------] [----+
|
|
|
+-------------------------+
40
CTI 2505 Installation and Operation Guide
|
| LAD Network 8 Address 69
|This is the test for Channel C at power-up. ConfigStatus for Channel A
|and B will be ON, but Channel D will still be OFF.
|
| A_ConfigSta
B_ConfigSta
C_ConfigSta
D_ConfigSta
C_InitialCo
| tus
tus
tus
tus
nfig
|
WX15.5
WX15.6
WX15.7
WX15.8
C3
[------] [-----------] [-----------]/[-----------]/[----------(
)---|
|
| LAD Network 9 Address 82
|This is the Dynamic re-configuration for Channel C. If any parameters
|have been changed in K-memory, this Command Bit will force a re-load to
|Channel C.
|
| C_ReConfig
C_DynamicCo
|
nfig
|
C15
7
C83
[------] [----------] ^ [-------------------------------------(
)---|
|
| LAD Network 10 Address 85
|This Move Word takes configuration parameters for Channel C from V-memory to
|WY, then sets the Channel C configuration command bit (WY19.3). Either the
|initial power-up or the dynamic reconfiguration can trigger this command.
|The Configuration Acknowledge bit (WX1.3) is tested to keep the command
|from executing more than once per download operation.
|
| C_InitialCo
C_Config_X
+-------------------------+ C_Config_Y
| nfig
| MOVE WORD
|
|
C3
WX1.3
|
C_Transduce|
WY19.3
[------] [----+------]/[-----]
r_Gain_HP [------(
)---|
|
| A:
V61|
| C_DynamicCo |
|
|
| nfig
|
|
Transducer_|
|
C83
|
|
Gain_HP
|
[------] [----]
| B:
WY20|
|
|
|
|
| C_Config_Y |
|
|
|
|
| N:
21|
|
WY19.3
|
|
|
[------] [----+
|
|
|
+-------------------------+
|
| LAD Network 11 Address 100
|This is the test for Channel D at power-up. ConfigStatus for all other
|channels will be ON, but Channel D will still be OFF.
|
| A_ConfigSta
B_ConfigSta
C_ConfigSta
D_ConfigSta
D_InitialCo
| tus
tus
tus
tus
nfig
|
WX15.5
WX15.6
WX15.7
WX15.8
C4
[------] [-----------] [-----------] [-----------]/[----------(
)---|
|
| LAD Network 12 Address 113
|This is the Dynamic re-configuration for Channel D. If any parameters
|have been changed in K-memory, this Command Bit will force a re-load to
|Channel D.
|
| D_ReConfig
D_DynamicCo
|
nfig
|
C16
8
C84
[------] [----------] ^ [-------------------------------------(
)---|
CTI 2505 Installation and Operation Guide
41
|
| LAD Network 13 Address 116
|This Move Word takes configuration parameters for Channel D from V-memory
|to WY, then sets the Channel D configuration command bit (WY19.4). Either
|the initial power-up or the dynamic reconfiguration can trigger this command.
|The Configuration Acknowledge bit (WX1.4) is tested to keep the command
|from executing more than once per download operation.
|
| D_InitialCo
D_Config_X
+-------------------------+
D_Config_Y
| nfig
| MOVE WORD
|
|
C4
WX1.4
|
D_Transduce|
WY19.4
[------] [----+------]/[-----]
r_Gain_HP [------(
)---|
|
| A:
V91|
| D_DynamicCo |
|
|
| nfig
|
|
Transducer_|
|
C84
|
|
Gain_HP
|
[------] [----]
| B:
WY20|
|
|
|
|
| D_Config_Y |
|
|
|
|
| N:
21|
|
WY19.4
|
|
|
[------] [----+
|
|
|
+-------------------------+
|
| LAD Network 14 Address 131
|This AlarmMode command bit chooses whether the module performs the alarm tests.
|The default value of 0 tells the module to test the channels for alarm levels
|and set the appropriate status bits in WX1. If AlarmControl is set to 1,
|the module ignores any alarm settings; status bits remain at 0 and the
|front panel LEDs do not indicate alarm status.
|
| AlarmMode
AlarmContro
|
lBit
|
C5
WY19.5
[------] [----------------------------------------------------(
)---|
|
| LAD Network 15 Address 135
|SpeedReport command bit chooses whether the Tach value reported in WX14
|is in Hz or RPM. Default of 0 is RPM; 1 chooses Hz (RPM / 60). The
|notted contact in this sample program is indicating Hz.
|
| SpeedReport
TachReportM
|
ode
|
C6
WY19.6
[------]/[----------------------------------------------------(
)---|
|
| LAD Network 16 Address 139
|The ModuleInhibit bit (WY19.7) forces the module to cease all processing;
|WX data words will be held at last value. This rung is conditioning the
|ModuleInhibit by Module Status, e.g. the module must be functioning to be
|inhibited. The default of 0 is the Run condition.
|
| ModuleInhib
ModuleStatu
Inhibit
| it
s
|
C7
WX15.1
WY19.7
[------] [-----------] [--------------------------------------(
)---|
|
| LAD Network 17 Address 146
|The TripMultiply command bit from the PLC / operator tells the module
|to take each channel’s alarm levels to the Trip Multiply settings
|specified in the channel’s configuration parameters. When TripMultiply
|is released (back to 0 value) then each channel reverts to normal alarm levels.
|
| TripMultipl
TripMultipl
| yCtrl
y
|
C8
WY19.8
[------] [----------------------------------------------------(
)---|
42
CTI 2505 Installation and Operation Guide
|
| LAD Network 18 Address 150
|This command bit for Channel A chooses whether processing of the alarm
|values for Alert and Danger specified in the configuration parameters
|is done on the RMS value (reported in WX2) or the True Peak-Peak value
|(reported in WX3). Default of 0 is RMS.
|
| A_PeakPeak
A_AlarmChoi
|
ce
|
C9
WY19.13
[------] [----------------------------------------------------(
)---|
|
| LAD Network 19 Address 154
|This command bit for Channel B chooses whether processing of the alarm
|values for Alert and Danger specified in the configuration parameters
|is done on the RMS value (reported in WX5) or the True Peak-Peak value
|(reported in WX6). Default of 0 is RMS.
|
| B_PeakPeak
B_AlarmChoi
|
ce
|
C10
WY19.14
[------] [----------------------------------------------------(
)---|
| LAD Network 20 Address 158
|This command bit for Channel C chooses whether processing of the alarm
|values for Alert and Danger specified in the configuration parameters
|is done on the RMS value (reported in WX8) or the True Peak-Peak value
|(reported in WX9). Default of 0 is RMS.
|
| C_PeakPeak
C_AlarmChoi
|
ce
|
C11
WY19.15
[------] [----------------------------------------------------(
)---|
|
| LAD Network 21 Address 162
|This command bit for Channel D chooses whether processing of the alarm
|values for Alert and Danger specified in the configuration parameters
|is done on the RMS value (reported in WX11) or the True Peak-Peak value
|(reported in WX12). Default of 0 is RMS.
|This example program has a proximity probe in an axial orientation to
|measure the shaft movement due to thrust. The AC component of vibration
|is not as critical as the true movement, so the True Peak-to-Peak value
|is selected for alarming.
|
| D_PeakPeak
D_AlarmChoi
|
ce
|
C12
WY19.16
[------]/[----------------------------------------------------(
)---|
|
| LAD Network 22 Address 166
|This rung is continually testing for axial shaft movement due to thrust.
|Assume the shaft at rest was gapped to -10V with a 200mV/mil proximity probe.
|Test the DC Probe bias voltage for Channel D (WX13) for movement of 20mils
|(4V change) in positive direction and 10mils (2V change) in negative direction.
|
|
+--A > B------------------+
AxialThrust
|
|D_ProbeCirc
|
Alarm
|
C25
|uitVoltage
|
C26
[------]/[---+-] A:
WX13
B:
-14[-+-------------------(
)---|
| +-------------------------+ |
|
|
|
|
| +--A < B------------------+ |
|
| |D_ProbeCirc
| |
|
| |uitVoltage
| |
|
+-] A:
WX13
B:
-8[-+
|
+-------------------------+
|
|
+-------------+
[---------------------------+ PROGRAM END +---------------------------|
+-------------+
CTI 2505 Installation and Operation Guide
43
REGISTERS
V REGISTERS: V1 - V50120
Address
Value
Tag
Address
Value
V1
00768
V26
00000
V2
00000
V27
00000
V3
00000
V28
00000
V4
00000
V29
00000
V5
00000
V30
00000
V6
00000
V31
00768
V7
00000
V32
00000
V8
00100
V33
00000
V9
00030
V34
00000
V10
00030
V35
00000
V11
00040
V36
00000
V12
00040
V37
00000
V13
00000
V38
00100
V14
00000
V39
00030
V15
00000
V40
00030
V16
00000
V41
00040
V17
01500
V42
00040
V18
00800
V43
00000
V19
00004
A_Transduce
r_Gain_HP
A_IS_Barrie
r
A_OutputSca
leFactor
A_UnitsOfMe
asure
A_InputScal
eFactor
A_ReportMod
e
A_TripMulti
plyValue
A_ProbeSens
itivity
A_AlertSetp
oint
A_AlertTime
Delay
A_DangerSet
point
A_DangerTim
eDelay
A_GapVoltag
eA
A_GapDistan
ceA
A_GapVoltag
eB
A_GapDistan
ceB
A_GapOver_B
iasHigh_Ala
A_GapUnder_
BiasLow_Ala
A_Fmax
V44
00000
V20
00007
V45
00000
V21
00025
A_NumberOfS
amples
A_NumberOfT
eeth
V46
00000
V22
00000
V47
01500
V23
00000
V48
00800
V24
00000
V49
00010
V25
00000
V50
00013
44
Tag
B_Transduce
r_Gain_HP
B_IS_Barrie
r
B_OutputSca
leFactor
B_UnitsOfMe
asure
B_InputScal
eFactor
B_ReportMod
e
B_TripMulti
plyValue
B_ProbeSens
itivity
B_AlertSetp
oint
B_AlertTime
Delay
B_DangerSet
point
B_DangerTim
eDelay
B_GapVoltag
eA
B_GapDistan
ceA
B_GapVoltag
eB
B_GapDistan
ceB
B_GapOver_B
iasHigh_Ala
B_GapUnder_
BiasLow_Ala
B_Fmax
B_NumberOfS
amples
CTI 2505 Installation and Operation Guide
REGISTERS
V REGISTERS: V51 - V100
Address
Value
Tag
Address
Value
Tag
V51
00025
B_NumberOfT
eeth
V76
00090
V52
00000
V77
65436
V53
00000
V78
64036
V54
00000
V79
00010
C_GapDistan
ceB
C_GapOver_B
iasHigh_Ala
C_GapUnder_
BiasLow_Ala
C_Fmax
V55
00000
V80
00013
V56
00000
V81
00025
V57
00000
V82
00000
V58
00000
V83
00000
V59
00000
V84
00000
V60
00000
V85
00000
V61
16384
V86
00000
V62
00000
V87
00000
V63
00000
V88
00000
V64
00000
V89
00000
V65
00000
V90
00000
V66
00000
V91
16384
V67
00000
V92
00000
V68
00200
V93
00000
V69
00015
V94
00000
V70
00030
V95
00000
V71
00020
V96
00000
V72
00040
V97
00000
V73
65138
V98
00200
V74
00020
V99
00015
V75
63736
V100
00030
C_Transduce
r_Gain_HP
C_IS_Barrie
r
C_OutputSca
leFactor
C_UnitsOfMe
asure
C_InputScal
eFactor
C_ReportMod
e
C_TripMulti
plyValue
C_ProbeSens
itivity
C_AlertSetp
oint
C_AlertTime
Delay
C_DangerSet
point
C_DangerTim
eDelay
C_GapVoltag
eA
C_GapDistan
ceA
C_GapVoltag
eB
CTI 2505 Installation and Operation Guide
C_NumberOfS
amples
C_NumberOfT
eeth
D_Transduce
r_Gain_HP
D_IS_Barrie
r
D_OutputSca
leFactor
D_UnitsOfMe
asure
D_InputScal
eFactor
D_ReportMod
e
D_TripMulti
plyValue
D_ProbeSens
itivity
D_AlertSetp
oint
D_AlertTime
Delay
45
REGISTERS
V REGISTERS: V101 - V120
Address
Value
Tag
V101
00020
V102
00040
V103
65138
V104
00020
V105
63736
V106
00090
V107
65436
V108
64036
V109
00008
D_DangerSet
point
D_DangerTim
eDelay
D_GapVoltag
eA
D_GapDistan
ceA
D_GapVoltag
eB
D_GapDistan
ceB
D_GapOver_B
iasHigh_Ala
D_GapUnder_
BiasLow_Ala
D_Fmax
V110
00008
V111
00025
V112
00000
V113
00000
V114
00000
V115
00000
V116
00000
V117
00000
V118
00000
V119
00000
V120
00000
46
D_NumberOfS
amples
D_NumberOfT
eeth
CTI 2505 Installation and Operation Guide
DOCUMENTATION
Addr
C1
Tag
A_InitialCo
nfig
C2
B_InitialCo
nfig
C_InitialCo
nfig
C3
Addr
WX1.5
Tag
A_Alert
Addr
WX12
Tag
D_TruePeak_
peak
WX1.6
A_Danger
WX1.7
A_ProbeFaul
t
WX13
D_ProbeCirc
uitVoltage
WX1.8
B_Alert
WX14
TachData
WX1.9
B_Danger
WX15
Module_stat
us_word
WX1.10
B_ProbeFaul
t
WX15.1
ModuleStatu
s
WX15.2
TachOverran
ge
WX15.3
TachUnderra
nge
WX15.4
NoTach
WX15.5
A_ConfigSta
tus
C4
D_InitialCo
nfig
C5
AlarmMode
C6
SpeedReport
WX1.11
C_Alert
C7
ModuleInhib
it
WX1.12
C_Danger
WX1.13
C_ProbeFaul
t
WX1.14
D_Alert
WX1.15
D_Danger
WX1.16
D_ProbeFaul
t
WX15.6
B_ConfigSta
tus
C8
TripMultipl
yCtrl
C9
A_PeakPeak
C10
B_PeakPeak
C11
C_PeakPeak
C12
D_PeakPeak
WX2
A_RMS
WX15.7
C_ConfigSta
tus
C13
A_ReConfig
WX3
A_TruePeak_
peak
WX15.8
C14
B_ReConfig
D_ConfigSta
tus
C15
C_ReConfig
A_ProbeCirc
uitVoltage
WX15.10
MathOverflo
w
C16
D_ReConfig
WX5
B_RMS
WX15.11
PortStop
C17
MoveK_to_V
WX6
B_TruePeak_
peak
WX15.12
C26
AxialThrust
Alarm
ParallelPor
tTimeout
B_ProbeCirc
uitVoltage
WX15.13
A_ADC_Overr
ange
WX15.14
B_ADC_Overr
ange
WX15.15
C_ADC_Overr
ange
WX15.16
D_ADC_Overr
ange
WX4
WX1
WX7
ConfigAcks_
AlarmBits
WX8
C_RMS
WX1.1
A_Config_X
WX9
C_TruePeak_
peak
WX1.2
B_Config_X
WX10
C_ProbeCirc
uitVoltage
WX11
D_RMS
WX1.3
C_Config_X
WX1.4
D_Config_X
CTI 2505 Installation and Operation Guide
47
DOCUMENTATION
Addr
WX16
Tag
A_B_SyntaxE
rror
Addr
WY20
Tag
Transducer_
Gain_HP
Addr
WY39
Tag
NumberOfSam
ples
WX17
C_D_SyntaxE
rror
WY21
IS_Barrier
WY40
NumberOfTee
th
WY22
WX19.5
AlarmContro
l
OutputScale
Factor
WY23
WX19.6
SpeedReport
Mode
UnitsOfMeas
ure
WY24
WX19.7
RunMode
InputScaleF
actor
WX19.8
TripMultipl
yMode
WY25
ReportMode
WY26
WY19
ConfigCmd_M
oduleContro
l
TripMultipl
yValue
WY27
ProbeSensit
ivity
WY28
AlertSetpoi
nt
WY29
AlertTimeDe
lay
WY30
DangerSetpo
int
WY31
DangerTimeD
elay
WY32
GapVoltageA
WY33
GapDistance
A
WY19.1
A_Config_Y
WY19.2
B_Config_Y
WY19.3
C_Config_Y
WY19.4
D_Config_Y
WY19.5
AlarmContro
lBit
WY19.6
TachReportM
ode
WY19.7
Inhibit
WY19.8
TripMultipl
y
WY34
GapVoltageB
WY19.13
A_AlarmChoi
ce
WY35
GapDistance
B
B_AlarmChoi
ce
WY36
GapOver_Bia
sHigh_Alarm
C_AlarmChoi
ce
WY37
GapUnder_Bi
asLow_Alarm
D_AlarmChoi
ce
WY38
F_max
WY19.14
WY19.15
WY19.16
48
CTI 2505 Installation and Operation Guide
APPENDIX C. CONFIGURATION: STATUS AND TIMING FOR
COMMAND/ACKNOWLEDGE
Power up self diags
WX15.5
WY19.1
Config command
Config acknowledge
WX1.1
A
A:
B:
C:
D:
Configuration successful
Configuration status: Ch A not configured
B
C
D
Power up self diagnostics passed; channel configuration status = 0 indicates no
parameters loaded for that channel. PLC program sets configuration command control
bit (WY19.1=1) which initiates transfer of parameters (WY20~40) to module.
Module responds by setting configuration acknowledge (WX1.1=1) when data has been
checked for valid syntax and database successfully updated. If syntax check fails, the
acknowledge bit is not set and the word that caused the error is reported in Syntax Error
(WX16 high byte for Ch A).
PLC program resets configuration command bit (WX19.1=0).
Module responds by resetting configuration acknowledge bit (WX1.1=0) and setting
configuration status (WX15.5=1) to indicate successful configuration. Note that the
parameters can be reloaded at anytime even though configuration status is set.
WX15.5
WY19.1
WX1.1
Ch A Configuration Status
Configuration Command
Configuration Acknowledge
WX15.6
WY19.2
WX1.2
Ch B Configuration Status
Configuration Command
Configuration Acknowledge
WX15.7
WY19.3
WX1.3
Ch C Configuration Status
Configuration Command
Configuration Acknowledge
WX15.8
WY19.4
WX1.4
Ch D Configuration Status
Configuration Command
Configuration Acknowledge
CTI 2505 Installation and Operation Guide
49
Status Words
WX1
bits 1~4
bits 5~7
bits 8~10
bits 11~13
bits 14~16
WX15 bit 1
bit 2
bit 3
bit 4
bit 5
bit 6
bit 7
bit 8
bit 9
bit 10
bit 11
bit 12
bit 13
bit 14
bit 15
bit 16
WX16 high byte
low byte
WX17 high byte
low byte
50
Configuration acknowledge for Channels A~D
Alarm status bits for Channel A
Alarm status bits for Channel B
Alarm status bits for Channel C
Alarm status bits for Channel D
Module status bit
1 = passed self-diags [Module LED solid Green]
0 = failed self-diags [Module LED off]
Tachometer Overrange
1 = tach input signal > 65535 Hz
Tachometer Underrange
1 = tach input < 2Hz
No Tach
1 = no input pulses within 10 seconds
Channel A configuration status bit
1 = configuration downloaded & syntax OK [Channel LED solid Green]
0 = not configured or configuration bad [Channel LED off]
Channel B
Channel C
Channel D
Not defined
Math Overflow
1 = a reported value is outside the signed integer range
Port Stop
1 = either Serial or Parallel port stopped the data acquisition process
Parallel Port Timeout
1 = 2506 failed to respond to STROBE or a BUS_BUSY signal
Channel A Analog-Digital Converter overrange bit
1 = set when input reading saturates ADC => Gain setting too high
Channel B
Channel C
Channel D
Channel A syntax error; displays (in hex) WY word that caused syntax
error
e.g. 20xx = error in WY20 … first configuration Word
Note: These are referenced to WY20 even though I/O login may be
different.
Channel B syntax error
Channel C syntax error
Channel D syntax error
CTI 2505 Installation and Operation Guide
Control Bits
WY19 bit 1
bit 2
bit 3
bit 4
bit 5
bit 6
bit 7
bit 8
bit 9
bit 10
bit 11
bit 12
bit 13
bit 14
bit 15
bit 16
Channel A configuration command bit
1 = initiate download of parameters from PLC to module
Channel B
Channel C
Channel D
Alarm Master
0 = module calculates Alert / Danger; provides analog values and status
to PLC
1 = module provides analog values only
Speed Report
1 = report speed in Hz (max of 65k)
0 = report speed in RPM
Module Inhibit
1 = do not process input signals & freeze outputs at current levels
Trip Multiply
1 = process alarms at Setpoint value x Trip Multiply value
Not defined
Not defined
Not defined
Not defined
Channel A RMS or True P-P alarm choice
1 = process alarms on value contained in WX3 (True Peak-to-Peak)
0 = process alarms on value contained in WX2 (Calculated RMS)
Channel B
Channel C
Channel D
Analog Values
WX2
Channel A calculated vibration
* in mVolts or eng units (dependent on value in WY25)
WX3
Channel A True Peak-to-Peak vibration
* in mVolts or eng units (dependent on value in WY25)
WX4
Channel A Probe circuit bias voltage
* DC voltage of probe circuit (scaled from 0 to ±2400)
* if Displacement probe and WY32~35 are non-zero: displacement in mils or um
(Scaled to WY22) (Note: Probe Bias Alarm still operates on bias voltage.)
WX5 ~ 7
WX8 ~ 10
WX11 ~ 13
WX14
Channel B
Channel C
Channel D
tachometer input in RPM or Hz (dependent on WY19.6)
CTI 2505 Installation and Operation Guide
51
LIMITED PRODUCT WARRANTY
CTI warrants that this CTI Industrial Product shall be free from defects in material and
workmanship for a period of one (1) year after purchase from CTI or from an authorized CTI
Industrial Distributor. This CTI Industrial Product will be newly manufactured from new and/or
serviceable used parts which are equal to new in the Product.
Should this CTI Industrial Product fail to be free from defects in material and workmanship at
any time during this (1) year warranty period, CTI will repair or replace (at its option) parts or
Products found to be defective and shipped prepaid by the customer to a designated CTI service
location along with proof of purchase date and associated serial number. Repair parts and
replacement Product furnished under this warranty will be on an exchange basis and will be either
reconditioned or new. All exchanged parts or Products become the property of CTI. Should any
Product or part returned to CTI hereunder be found by CTI to be without defect, CTI will return
such Product or part to the customer.
This warranty does not include repair of damage to a part or Product resulting from: failure to
provide a suitable environment as specified in applicable Product specifications, or damage
caused by an accident, disaster, acts of God, neglect, abuse, misuse, transportation, alterations,
attachments, accessories, supplies, non-CTI parts, non-CTI repairs or activities, or to any damage
whose proximate cause was utilities or utility like services, or faulty installation or maintenance
done by someone other than CTI.
Control Technology Inc. reserves the right to make changes to the Product in order to improve
reliability, function, or design in the pursuit of providing the best possible Product. CTI assumes
no responsibility for indirect or consequential damages resulting from the use or application of
this equipment.
THE WARRANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY
CTI GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED
GUARANTY OR WARRANTY ON CTI PRODUCTS, INCLUDING WITHOUT
LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE AND IS IN LIEU OF ALL OBLIGATIONS OR LIABILITY OF CTI
FOR DAMAGES IN CONNECTION WITH LOSS, DELIVERY, USE OR PERFORMANCE
OF CTI PRODUCTS OR INTERRUPTION OF BUSINESS, LOSS OF USE, REVENUE OR
PROFIT. IN NO EVENT WILL CTI BE LIABLE FOR SPECIAL, INCIDENTAL, OR
CONSEQUENTIAL DAMAGES.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS, SO THE ABOVE
LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE.
52
CTI 2505 Installation and Operation Guide
REPAIR POLICY
In the event that the Product should fail during or after the warranty period, a Return Material
Authorization (RMA) number can be requested orally or in writing from CTI main offices.
Whether this equipment is in or out of warranty, a Purchase Order number provided to CTI when
requesting the RMA number will aid in expediting the repair process. The RMA number that is
issued and your Purchase Order number should be referenced on the returning equipment's
shipping documentation. Additionally, if the product is under warranty, proof of purchase date
and serial number must accompany the returned equipment. The current repair and/or exchange
rates can be obtained by contacting CTI's office at 1-800-537-8398.
When returning any module to CTI, follow proper static control precautions. Keep the module
away from polyethylene products, polystyrene products and all other static producing materials.
Packing the module in its original conductive bag is the preferred way to control static problems
during shipment. Failure to observe static control precautions may void the warranty. For
additional information on static control precautions, contact CTI's office at 1-800-537-8398.
CTI 2505 Installation and Operation Guide
53
54
CTI 2505 Installation and Operation Guide
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