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Symphony Plus

S+ Turbine: Machinery Condition Monitoring MCM800


Product Guide

Symphony Plus

S+ Turbine: Machinery Condition Monitoring MCM800


Product Guide

NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be
liable for incidental or consequential damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be reproduced or copied without written permission
from ABB, and the contents thereof must not be imparted to a third party nor used
for any unauthorized purpose.
The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license.
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright 2010 by ABB.
All rights reserved.
Release: Dec 2010
Document number: 2VAA000341

TRADEMARKS
All rights to other trademarks reside with their respective owners.

0BABOUT THIS BOOK

8BOverview

ABOUT THIS BOOK................................................................................................. 8


1.1

Overview ..............................................................................................................8

1.2

Use of Warnings, Caution, Information, and Tip Icons ....................................9

1.3

Terminology .........................................................................................................9

1.4

Related Documentation ......................................................................................9

2.

INTRODUCTION............................................................................................ 10
2.1

Product Overview ..............................................................................................10

2.1.1 MPM810 Overview .........................................................................................10


2.1.2 TBU850 Overview ..........................................................................................10
2.2

MCM800 Details .................................................................................................10

2.2.1 MPM810 Module ............................................................................................10


2.2.2 Termination Base Unit (TBU850) ...................................................................10
2.3

Prerequisites and Requirements......................................................................10

2.4

Product Features ...............................................................................................11

2.4.1 Field I/O Capabilities ......................................................................................11


2.4.2 Communication ..............................................................................................11

3.

INSTALLATION............................................................................................. 12
3.1

Cabinet Installation ...........................................................................................12

3.2

Termination Base Unit (TBU850)......................................................................12

3.3

Termination Base Unit Connections................................................................12

3.4

Module (MPM810) ..............................................................................................12

3.5

Module Interconnection ....................................................................................13

3.6

Power Supply Installation.................................................................................13

3.7

Redundant Power Supply Configuration.........................................................14

3.8

Power Distribution and Grounding ..................................................................14

4.

CONFIGURATION......................................................................................... 15
4.1

Before You Start ................................................................................................15

2VAA000341

8BOverview

4.2

0BABOUT THIS BOOK

Termination Base Units ....................................................................................15

4.2.1 Signal Input Configuration ..............................................................................17


4.2.2 Relay Output Configuration ............................................................................18
4.2.3 Event Marker Input Configuration...................................................................19
4.3

DIP Switch Configuration .................................................................................20

4.3.1 Profibus/Modbus Dipswitch ............................................................................20


4.3.2 Profibus/Modbus Address ..............................................................................21
4.3.3 Option Dipswitch ............................................................................................21
4.3.4 Profibus Termination Dipswitch (S3) ..............................................................22
4.3.5 MPM810.........................................................................................................22
4.4

MCM800 Configuration via Profibus & Ethernet .............................................23

4.4.1 Module Specific Parameters sent to MCM800 ...............................................23


4.4.2 Channel Specific Parameters sent to MCM800..............................................24
4.4.3 Active Data Sent To the MCM800..................................................................26
4.4.4 Active Data Reported By the MCM800 ..........................................................28

5.

OPERATION.................................................................................................. 33
5.1

General Description ..........................................................................................33

5.2

I/O Conditioning Functions ..............................................................................33

5.2.1 Signal Inputs ..................................................................................................33


5.2.2 Event Marker Inputs .......................................................................................33
5.2.3 Relay Outputs ................................................................................................34
5.3

Functions ...........................................................................................................35

5.3.1 Vibration .........................................................................................................35


5.3.2 Eccentricity.....................................................................................................36
5.3.3 Thrust (Rotor) Position ...................................................................................36
5.3.4 Differential Expansion ....................................................................................37
5.3.5 Case Expansion .............................................................................................38
5.3.6 Dual Probe .....................................................................................................38
6

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0BABOUT THIS BOOK

8BOverview

5.3.7 SMAX .............................................................................................................39


5.3.8 Complementary Position ................................................................................39
5.3.9 Waveform Capture Settings ...........................................................................40

6.

MAINTENANCE............................................................................................. 41
6.1

Preventive Maintenance....................................................................................41

6.2

Hardware Indicators ..........................................................................................41

6.2.1 MPM810 I/O Module LEDs.............................................................................41


6.3

Troubleshooting ................................................................................................42

6.4

Diagnostics ........................................................................................................43

6.5

Module Replacement.........................................................................................43

6.5.1 General ..........................................................................................................43


6.5.2 Replacement ..................................................................................................43
6.5.3 Returning a Module ........................................................................................44
6.6

7.

SPECIFICATIONS ......................................................................................... 45
7.1

8.

Firmware Upgrade .............................................................................................44

MCM800 Product Specifications ......................................................................45

REVISION HISTORY ..................................................................................... 46

2VAA000341

8BOverview

0BABOUT THIS BOOK

ABOUT THIS BOOK


1.1 Overview
This book provides a description of the MCM800 modules and termination units. It provides instructions for installation,
start-up, and information regarding capacity and performance. This book is not intended to be the sole source of
instruction for the MCM800 Machinery Condition Monitoring.
This section provides introductory and background information including guidelines about how to find information in the
manual related documentation.
The Introduction section provides a product and functional overview.
The Installation section provides installation guidance.
The Configuration section provides details for customizing the units to meet the requirements of individual
applications. The main information is structured as follows:

Design considerations and guidelines.


Capacity and performance.

The Operation section describes the various start modes and operating modes available for each installation.
The Maintenance section focuses on detecting faults using built-in diagnostics. It explains system status displays in
operator stations and LEDs on modules.
In the Specifications section you will find a data sheet that lists the capacities of all of the components of the MCM800
module.

2VAA000341

0BABOUT THIS BOOK


K

9BUse of Warnings, Caution, Information, and Tip Icons

1.2 Use of Warnings, Caution, Information, and Tip Icons


This publication includes Warning, Caution, and Information statements where appropriate to point out safety related
or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols
should be interpreted as follows:
An electrical warning icon indicates the presence of a hazard, which
could result in electrical shock.

A warning icon indicates the presence of a hazard, which could result


in personal injury.

A caution icon indicates important information or a warning related to


the concept discussed in the text. It might indicate the presence of a
hazard, which could result in corruption of software or damage to
equipment/property.
An information icon alerts the reader to pertinent facts and conditions.

A tip icon indicates advice on, for example, how to design your project
or how to use a certain function.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or
property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance, leading to personal injury or death. Therefore, comply fully with all
Warning and Caution notices.

1.3 Terminology
The following is a list of terms associated with the MCM800 that you should be familiar with. The list contains terms and
abbreviations that are unique to ABB or have a usage or definition that is different from standard industry usage.
Term

Description

MPM810

MCM Processor Module for the MCM800

TBU850

Terminal Base Unit for the MPM810

VAC

Alternating Current Voltage (value is rms unless otherwise stated)

VDC

Direct Current Voltage

1.4 Related Documentation


The following is a listing of all documentation related to the I/O system.
Title

Description

3BUA000258R5 ABB Site Planning Guide

2VAA000341

12BProduct Overview

1BINTRODUCTION

2. INTRODUCTION
This documentation contains the description of the Machinery Condition Monitoring Module MCM800, which provides a
complete set of functions for comprehensive Rotating Machinery Diagnostics. These functions include:

Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.

The MCM800 system is part of a distributed modular I/O system. The MCM800 components provide easy installation
and reliable performance using advanced control technology.

2.1

Product Overview
The MCM800 is comprised of a Processing Module (MPM810) and a Termination Mounting Unit (TBU850).
Its main function is to provide rotating machinery monitoring and protection capability independent from any master
DCS or PLC. This independence results in higher reliability and faster response time.
The MCM800 system implements widely used monitoring and protection algorithms available in the industry. Each
function also has a set of software configuration parameters.
The MCM800 system has a built-in Profibus-DP Communication Interface to facilitate integration with external control
systems or other Profibus compatible devices.

2.1.1 MPM810 Overview


The Processor Module (MPM810) plugs into the slot of the Termination Base Unit (TBU850).
The MPM810 performs the following functions:

Executes the selected functions of the MCM800 system.

Communicates to the control system via Profibus DP or Modbus RTU.

2.1.2 TBU850 Overview


The TBU850 contains terminals for power, field connections, and communication. It houses the MPM810 module.

2.2

MCM800 Details

2.2.1 MPM810 Module


The MPM810 resides in an open ventilated plastic enclosure. On the front of the MPM810 module there are eleven
LEDs indicating the module and I/O status. Refer to Section 6.2.1 MPM810 I/O Module LEDs for the status indication of
the LEDs.
MPM810 module can be easily replaced in a fully operational I/O station. The design of the module and TBUs protect
the module from being damaged by excessive voltage or current.

2.2.2 Termination Base Unit (TBU850)


The Termination Base Unit (TBU850) is an active base unit that receives and conditions the analog signals for use by
the MPM810. It contains the power and field I/O terminals, Profibus communication connectors, serial interface ports,
and relay output terminals.
The TBU850 can be mounted on a standard DIN rail. It has a mechanical latch to lock the TBU850 to the DIN rail. The
latch can be released with a screwdriver.

2.3

Prerequisites and Requirements


Before operation a complete set of parameters must be downloaded using Profibus DP or the Ethernet Configuration
tool. The Profibus master must configure the module before operation can occur.

10

2VAA000341

1BINTRODUCTION

2.4

15BProduct Features

Product Features

2.4.1 Field I/O Capabilities


Power Input
+24VDC, -24VDC, Common.
Parallel terminals for use in daisy-chaining modules.
Analog Inputs
Channels 1-4

System Power: +24VDC, -24VDC current limited to 30mA.


Voltage Inputs range from +20 volts to -20 volts AC or DC.
Current Inputs range from 4 to 20 milliamps.
Constant current 4.7mA available for +24VDC.

Event Marker Input


System Power: -24 VDC current limited to 30mA.
Relay Outputs
Alert

Dry Contact (Form C)

Danger

Dry Contact (Form C)

2A @ 24 VDC / VAC (resistive load)


Normally de-energized/energized
selectable
2A @ 24 VDC / VAC (resistive load)
Normally de-energized/energized
selectable

DIP Switches
Profibus Address

Seven switches for address selection; one for mode selection.

Option Switch

Used for calibration, startup mode, diagnostics, and power option.

Profibus termination

Two switches for termination of Profibus line A and line B.

2.4.2 Communication
RS-485
Profibus DP V1

Configuration, Control, and Reporting Values.

Modbus

Reporting Values.

Ethernet
10/100 BaseT TCP/IP

Configuration, Control, and Reporting Values.


Transmission of machinery diagnostic information.
Firmware Upgrades.

RS-232
Debug
Note: a special cable is required.

2VAA000341

Debugging and Firmware Upgrades.

11

16BCabinet Installation
on

2BINSTALLATION

3. INSTALLATION
3.1

Cabinet Installation
Refer to the ABB Site Planning Guide (3BUA000258R5001) and the MCM800 Installation Guide for more information
about cabinet installation.

3.2

Termination Base Unit (TBU850)


The Termination Base Unit (TBU850) is designed to connect to a standard 35mm DIN rail. First verify that the locking
mechanism is set to the unlocked position. Use a flat head screwdriver if necessary to set the locking mechanism to the
unlocked position.

Figure 3-1 TBU850 Locking Mechanism


Then insert the edge of the DIN rail into the angled tabs located on the metal base. Once inserted, apply pressure on
the TBU850 so the metal cover lies flat against the DIN rail. While holding in place, use the flat head screwdriver to set
the locking mechanism to the sliding position by turning the device clockwise 90 degrees. Position the TBU850 to the
desired location and set the locking mechanism to the locked position by turning another 90 degrees.
Although the locking mechanism is in the locked position, it is possible that the unit
may slide given enough force, especially if mounted on a vertical DIN rail. To
further secure the modules, it is recommended to install a DIN rail end-bracket, or
place machine screws through the secure tabs on the TBU850.

3.3

Termination Base Unit Connections


A TBU850 provides a slot for the MPM810 module.
Two DSUB9 connectors are located on the right and left side of the TBU for Profibus and Modbus communication.

A standard Profibus or Modbus connector for line A (PA1) is connected on the left side of the unit and line B
(PB2) on the right side. The TBUs are designed to connect together passing the communication through the
system and out the opposite port.

The RJ-45 connector on the front of the unit provides proprietary Ethernet communication using TCP/IP protocol.

3.4

Module (MPM810)
Install module by aligning the connectors of the TBU and module, and then pushing the units together.
Ensure that the module is fully engaged into the TBU. Partial engagement may
produce unexpected results

After connection to the TBU, lock the I/O module in place using the I/O Module Locking device.

12

2VAA000341

2BINSTALLATION

3.5

20BModule Interconnection

Module Interconnection
On each side of the TBU are two DSBU9 connectors. The TBU is designed to plug together. Place the TBUs on the
DIN rail and slide the TBUs together until they are fully engaged. Use a screwdriver to turn the latch to secure the TBUs
in place.

Figure 3-2 MCM800 Module Interconnection

3.6

Power Supply Installation


The terminals of the TBU850 provide the connections for power of the MCM800. Table 3-1 lists the terminals used by
the MCM800 for the power connection. Figure 2-3 shows a typical power supply configuration. Refer to the MCM800
Installation Guide for more information.

Terminal

Description

+24VDC Power (in)

Power Common (in)

-24VDC Power (in)

+24VDC Power (out)

Power Common (out)

-24VDC Power (out)


Table 3-1 TBU850 Power Terminals

Figure 3-3 Typical Power Connection


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13

22BRedundant Power Supply Configuration

3.7

2BINSTALLATION

Redundant Power Supply Configuration


To configure the power supplies for redundancy, two voting units are required.
Note: There is a positive and a negative voting unit one for +24VDC and the other for -24VDC.

Figure 3-4 Redundant Power Supply Configuration

3.8

Power Distribution and Grounding


It is important to provide proper power distribution and grounding to the MCM800 module. Since the MCM800 monitors
frequencies related to the AC power it is necessary to eliminate any line frequency noise from the system.
The MCM800 requires +24VDC and -24VDC. The -24VDC is often confused with
Common. Care must be taken such that the -24VDC is not connected to the
Common.

Figure 3-5 Power Distribution and Grounding


14

2VAA000341

3BCONFIGURATION
FIGURATION

24BBefore You Start

4. CONFIGURATION
4.1

Before You Start


Read this manual thoroughly before landing wires to the Termination
Unit and applying power to the modules.

4.2

Termination Base Units


The Termination Base Unit (TBU850) has several connectors for power and field inputs. The figure below shows the
relative position and numbering of connectors on the TBU850.

Figure 4-1 Connector Positions


There are four input channels that can handle a wide variety of sensors. Table 3-1 describes the use of each of the
terminals.

Terminal

Description

Transducer Power (+24) (out)

Constant Current (4.7mA)

Transducer Common

Transducer Signal

Transducer Power (-24) (out)

Earth Ground (Shield)

Table 4-1 TBU850 Signal Terminals Channels 1- 4

2VAA000341

15

25BTermination Base
e Units

3BCONFIGURATION

The Event Marker Terminal is used for the once per revolution phase marker. It is intended to be used with proximity
probes as the input sensor. This signal is common to each of the four input channels used to determine the various
orders calculations of vibration and it is used to report the speed of the shaft. The signal may be daisy chained to other
MCM800 modules or may drive a TTL signal for third part devices that can not handle proximity probe inputs.

Terminal

Description

EM Out (+) TTL

EM Out (-) TTL

Transducer Common

EM Signal (out)

EM Common (out)

EM Signal (in)

EM Common (in)

Transducer Power (-) (out)

Earth Ground (Shield)

Table 4-2 TBU850 Event Marker Terminals


There are two on-board relays that may be used for Alert and Danger indication. Each relay has a Normally Open (NO)
and Normally Closed (NC) contact. Any alarm from the four input channels may activate the relays using an OR
function.
These relays are not intended to drive high voltage, high current or
inductive loads, so an interposing relay may be required for these
applications.

Terminal

Description

Alert Normally Closed

Alert Common

Alert Normally Open

Danger Normally Closed

Danger Common

Danger Normally Open


Table 4-3 TBU850 Relay Contacts

16

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3BCONFIGURATION

25BTermination Base Units

4.2.1 Signal Input Configuration


The MCM800 signal input terminals are designed to interface to a variety of sensors. Figures 3-2 through 3-5 show the
different TBU850 wiring configurations associated with the different type of sensor.

Figure 4-2 Eddy Current Probe Configuration

Figure 4-3 Piezoelectric velocity probes and accelerometers

Figure 4-4 Moving Element Velocity Probes

2VAA000341

17

25BTermination Base Units

3BCONFIGURATION

Figure 4-5 DC LVDTs

4.2.2 Relay Output Configuration


The MCM800 relay output terminals are designed to interface directly to low power switching configurations or high
power switching devices using interposing relays. Figure 3-6 shows the TBU850 configuration for the on-board relay
contacts.

Figure 4-6 Relay Terminal Connections

18

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3BCONFIGURATION

25BTermination Base Units

4.2.3 Event Marker Input Configuration


The TBU850 has an Event Marker input which typically is used to interface to an eddy current probe. Figures 3-7 and
3-8 show the TBU850 wiring configurations associated with these probes.

Figure 4-7 Event Marker with single TBU850

Figure 4-8 Event Marker with multiple TBU850s

2VAA000341

19

26BDIP Switch Configuration

4.3

3BCONFIGURATION

DIP Switch Configuration


The TBU850 requires proper Dipswitch setting prior to operation.

4.3.1 Profibus/Modbus Dipswitch


Determine the Profibus/Modbus address of the module and set Dipswitch S1 to the proper address. Valid Profibus
addresses range from 0 to 125; however addresses 0 & 1 are reserved for the Profibus Master. Therefore, valid
MCM800 addresses range from 2 to 125.
Note: System Redundancy requires a slave backup address to be n+64; therefore the highest possible primary
address with System Redundancy enabled is 61 for a backup address of 125.
Table 4-4 shows the switch settings for addresses 0 63. The switch settings for addresses 64 127 correspond to
the first 63 settings in the table, with switch 2 (S1) set to the 1 position.

Switch
2345678

Profibus
Address

Switch
2345678

Profibus
Address

Switch
2345678

Profibus
Address

Switch
2345678

Profibus
Address

0000000

0010000

16

0100000

32

0110000

48

0000001

0010001

17

0100001

33

0110001

49

0000010

0010010

18

0100010

34

0110010

50

0000011

0010011

19

0100011

35

0110011

51

0000100

0010100

20

0100100

36

0110100

52

0000101

0010101

21

0100101

37

0110101

53

0000110

0010110

22

0100110

38

0110110

54

0000111

0010111

23

0100111

39

0110111

55

0001000

0011000

24

0101000

40

0111000

56

0001001

0011001

25

0101001

41

0111001

57

0001010

10

0011010

26

0101010

42

0111010

58

0001011

11

0011011

27

0101011

43

0111011

59

0001100

12

0011100

28

0101100

44

0111100

60

0001101

13

0011101

29

0101101

45

0111101

61

0001110

14

0011110

30

0101110

46

0111110

62

0001111

15

0011111

31

0101111

47

0111111

63

A 1 corresponds to the switch position labeled ON or CLOSED.


Table 4-4 Profibus/Modbus Address Selection

Figure 4-9 Address and Option Dipswitch

20

2VAA000341

3BCONFIGURATION
URATION

26BDIP Switch Configuration

4.3.2 Profibus/Modbus Address


Switch 1 of Dipswitch S1 is used to determine the Profibus redundancy format used by the MCM800.

Setting Description
0

System Redundancy Disabled

System Redundancy Enabled

4.3.3 Option Dipswitch


Operating Mode
Switches 1 & 2 of Dipswitch S2 set the start-up and operating mode of the MCM800.

Switch 1 Switch 2 Description

Normal Mode

Diagnostic Mode

Low Speed Mode

Calibration Mode

Normal Mode should be selected for most applications.


Diagnostic mode is used to run diagnostics on the MCM800 module.
Low Speed Mode is used for slower applications such as Hydro Turbines.
Calibration Mode is used to calibrate the module.
The MCM800 has a level of Ethernet security that reduces the risk of unauthorized
access to the module. The security may make it more difficult to troubleshoot the
Ethernet connection. To lower the Ethernet security for troubleshooting, set the
option dipswitch to Diagnostic Mode.

Configuration Retention
Switch 3 determines if the MCM800 retains its configuration on restart or resets all configurations to the default settings.

Switch 3 Description
0

Use and store Default settings at start-up.

Store configuration and use at start-up.

Reset IP Address
To reset the IP address to the default (192.168.222.111) set Switch 3 to 0 and the Address switch (S1) to 127 and the
redundancy to 0 (S1 = 01111111).

2VAA000341

21

26BDIP Switch Configuration

3BCONFIGURATION

Module Communication Protocol


Switch 4 determines the communication protocol for ports PA 1 & 2 and PB 1 & 2.

Switch 4 Description
0

Modbus RTU protocol.

Profibus DP-V1 protocol.

Modbus Baud Rate Selection


When the Modbus Protocol is selected (Switch 4 of S2 = 0), switch 1 of S1 determines the baud rate.

Switch 1 Description
0

38400 Baud

19200 Baud

4.3.4 Profibus Termination Dipswitch (S3)


The Profibus Termination Dipswitch (S3) is used to terminate the Profibus bus. There is a switch for Line A and one
from Line B.

Figure 4-10 Terminate Profibus Lines

4.3.5 MPM810
There are no configurable settings on this board.
22

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3BCONFIGURATION

4.4

27BMCM800 Configuration via Profibus & Ethernet

MCM800 Configuration via Profibus & Ethernet


The MCM800 system uses Profibus DP for communication with the control system
Refer to the Profibus Users Guide for more information.

4.4.1 Module Specific Parameters sent to MCM800


Description

Range

Units

Type

IP Address NNN.xxx.xxx.xxx

0 to 255

None

IP Address xxx.NNN.xxx.xxx

0 to 255

None

IP Address xxx.xxx.NNN.xxx

0 to 255

None

IP Address xxx.xxx. xxx.NNN

0 to 255

None

Subnet Mask NNN.xxx.xxx.xxx

0 to 255

None

Subnet Mask xxx.NNN.xxx.xxx

0 to 255

None

Subnet Mask xxx.xxx.NNN.xxx

0 to 255

None

Subnet Mask xxx.xxx. xxx.NNN

0 to 255

None

English/Metric EU

0, 1

None

Angular Position of Event Marker


probe

-360 to 360

Degrees

Event Marker Detect Voltage

0 to 15

Volts

Normal Alert relay state

0,1

None

Normal Danger relay state

0,1

None

IP Address and Subnet Mask The IP Address and Subnet Mask is required for the module to communicate over
Ethernet. It is a unique address for a specific network. The default values are 192.168.222.111 and 255.255.0.0. The
configuration tools will allow a new address to be set. Once set the user must switch to the new address for proper
communication.
English/Metric Set this value to a 0if the engineering units are English and a 1 if they are in metric.
Angular Position of Event Marker probe This value is the angular position of the Event Marker from a fixed
reference point, typically vertical.

Event Marker Detect Voltage This value is the minimum pulse height (pk-pk) of the Event Marker pulse.

2VAA000341

23

27BMCM800 Configuration via Profibus & Ethernet

3BCONFIGURATION

Normal Alert/Danger relay state Set to 0 for Normally De-energized (energize to activate relay), and 1 for Normally
Energized (de-energize to activate relay).

4.4.2 Channel Specific Parameters sent to MCM800

24

Description

Range

Units

Type

Channel type
This value specifies the operation of the channel.
0 = None (Valid for all channels)
1 = Vibration (Channels 1-4 only)
2 = Eccentricity (Channels 1-4 only)
3 = Thrust (Rotor) Position (Channels 1-4 only)
4 = Differential Expansion (Channels 1-4 only)
5 = Case Expansion (Channels 1-4 only)
6 = Dual Probe - Relative (Channels 1 & 3 only)
7 = Dual Probe Seismic (Channels 2 & 4 only)
8 = Dual Probe Absolute (Channels 5 & 6 only)
For channel 5, channel 1 must be set to Relative (6), and
channel 2 must be set to Seismic (7).
For channel 6, channel 3 must be set to Relative (6), and
channel 4 must be set to Seismic (7).
9 = SMAX (Channels 5-7only)
For channel 5, channel 1 & 2 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 6, channel 3 & 4 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 7, channels 5 & 6 must be set to Dual Probe
Absolute.
10 = Complementary Position (Channels 5 & 6 only)
For channel 5, channel 1 & 2 must be set to Thrust (3) or
Differential Expansion (4).
For channel 6, channel 3 & 4 must be set to Thrust (3) or
Differential Expansion (4).

0 to 10

None

Block output select


Value of the output (valid for all channels).
0 = Peak-to-Peak.
1 = Peak.
2 = RMS.
3 = Average.
4 = Calculated Peak-to-Peak.
5 = Calculated Peak.

0 to 5

None

Probe type
Type of probe (valid for channels 1 - 4 only).
0 = None.
1 = Proximity Probe.
2 = DC LVDT.
3 = Accelerometer.
4 = Moving Element velocity probe.
5 = Piezoelectric velocity probe.

0 to 8

None

2VAA000341

3BCONFIGURATION

Description

27BMCM800 Configuration via Profibus & Ethernet

Range

Units

Type

Probe Sensitivity
Sensitivity of the probe in mv/EU (valid for channels 1 - 4 only)

Full

mv/EU

Integration
Sets the type of integration (valid for channels 1-4 only).
0 = None.
1 = Velocity to displacement (velocity probes only).
2 = Acceleration to velocity (accelerometers only).

0 to 2

None

Angular Position of Probe (see note pg 26)

-360 to 360

Degrees

Ramp Angle (see note pg 26)

0 to 90

Degrees

Probe DC Voltage High Failure Threshold (see note pg 26)

-24 to +24

Volts

Probe DC Voltage Low Failure Threshold (see note pg 26)

-24 to +24

Volts

N for Nth Order


User defined order calculation from 3 to 10

3 to 10

None

Dual Vote Enable

0,1

None

6 = Complementary proximity probe.


7 = Ramped proximity probe.
8 = Ramped complementary proximity probe.

Angular Position of probe This value is the angular position of the probe from a fixed reference point, typically
vertical.

Ramp Angle This value specifies the ramp angle for ramped differential expansion.

Probe DC Voltage High/Low Failure Thresholds This value is the voltage beyond which the module will report bad
quality for that channel. The High Failure Limit should be set to approximately one volt less than the upper limit of the
linear range. Likewise, the Low Failure Limit should be set to approximately one volt greater than the lower limit of the
linear range.

2VAA000341

25

27BMCM800 Configuration via Profibus & Ethernet

3BCONFIGURATION

Note: Non-Linear Correction X1-X5, Y1-Y5 are pairs of values are used to correct for non-linearity effects of probes are
for Future Use.

4.4.3 Active Data Sent To the MCM800

26

Description

Range

Units

Type

Shaft Rotational Direction


Indicates the rotation of the shaft.
0 = Clockwise.
1 = Counter-clockwise.

0,1

None

Set Alert Relay


Forces the relay to the active state.
0 = Normal operation.
1 = Force relay active.

0,1

None

Set Danger Relay


Forces the relay to the active state.
0 = Normal operation.
1 = Force relay active.

0,1

None

Reset Diagnostic Function


A transition from 0 to 1 forces a reset of the Ethernet
communication interface.
0 = Normal Operation.
1 = Forces Ethernet Network close and restart.

0,1

None

High Danger Threshold


The values determine the point above which the corresponding
action will occur. (Valid for all channels).

Full

EU

High Alert Threshold


The values determine the point above which the corresponding
action will occur. (Valid for all channels).

Full

EU

Low Alert Threshold


The values determine the point below which the corresponding
action will occur. (Valid for all channels).

Full

EU

Low Danger Threshold


The values determine the point below which the corresponding
action will occur. (Valid for all channels).

Full

EU

Alert Delay
Determines the delay in seconds the condition must exist before
activating Alert status. Note: If the value exceeds the Danger set
point before the Alert delay expires, the module will immediately
set the Alert status. (Valid for all channels).

0.1 to 300

Seconds

2VAA000341

3BCONFIGURATION

27BMCM800 Configuration via Profibus & Ethernet

Description

Range

Units

Type

Danger Delay
Determines the delay in seconds the condition must exist before
activating Danger status. Note: If the value exceeds the Danger
set point before the Alert delay expires, the module will
immediately set the Alert status. (Valid for all channels).

0.1 to 300

Seconds

Alert Enable
Enables the alert action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.

0,1

None

Danger Enable
Enables the danger action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.

0,1

None

Filter Low Cutoff Frequency


Sets the cutoff frequency below which the signal is attenuated.
The value specified is the -3dB point of a 4-pole Butterworth filter.
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types).

1 to 1,000

Hz

Filter High Cutoff Frequency


Sets the cutoff frequency above the signal is attenuated. The
value specified is the -3dB point of a 4-pole Butterworth filter.
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types).

30 to
15,000

Hz

Null Position in Engineering Units


The null or zero point of a position measurement. It is a known
starting point of the shaft from which the shaft will deviate either
from thermal growth or load conditions. Typically it is determined
when the shaft is cold or a no load condition. This value can be
set to zero or some measured value. (Valid for channels 1 - 4,
Thrust, Differential or Case Expansion channel types).

Full

EU

Null Position Voltage


The voltage of the null or zero point of a position measurement
describe above. When the voltage measured by the probe is
equal to this value the output will display the Null Position set in
Engineering Units. When the voltage changes the output value
will change based on the Sensitivity parameter. (Valid for
channels 1 - 4, Thrust, Differential or Case Expansion channel
types).

-24 to +24

Volts

0,1

None

Waveform Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.

0,1

None

Run-up Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.

0,1

None

Set Null Position Voltage


Forces the MCM to set the internal NVRAM to correspond to the
Null Position EU and Voltage. (The MCM uses the locally stored
values to determine position.)
0 = Normal operation.

1 = Set Null Position.

2VAA000341

27

27BMCM800 Configuration via Profibus & Ethernet

3BCONFIGURATION

Description

Range

Units

Type

Rundown Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.

0,1

None

Event Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.

0,1

None

4.4.4 Active Data Reported By the MCM800

28

Description

Range

Units

Type

Module Alert
Indicates the Alert alarm status.
0 = Normal.
1 = Alert / Danger Active.

0,1

None

Module Danger
Indicates the Danger alarm status.
0 = Normal.
1 = Alert / Danger Active.

0,1

None

Dual Vote Alert Ch 1&2


Indicates if both channels are active when Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).

0,1

None

Dual Vote Danger Ch 1&2


Indicates if both channels are active when Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).

0,1

None

Dual Vote Alert Ch 3&4


Indicates if both channels are active when Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).

0,1

None

Dual Vote Danger Ch 3&4


Indicates if both channels are active when Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).

0,1

None

Dual Vote Alert Ch 5&6 Indicates if both channels are active when
Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).

0,1

None

Dual Vote Danger Ch5&6


Indicates if both channels are active when Dual Voting is enabled.
0 = Normal
1 = Alert / Danger Active (Both channels).

0,1

None

2VAA000341

3BCONFIGURATION

27BMCM800 Configuration via Profibus & Ethernet

Description

Range

Units

Type

MCM Mode
Reflects the operational mode of the MCM800 based on Dipswitch
S2.
0 = Normal.
1 = Low Speed.

0,1

None

Calibration Active
Calibration status.
0 = Not calibrating (Normal).
1 = Module is calibrating.

0,1

None

Diagnostic Error
Indicates the diagnostic status.
0 = Diagnostics successfully passed.
1 = Diagnostics failed.

0,1

None

Orders Active
Orders are being calculated.
0 = Orders are not being calculated.
1 = Orders are being calculated.

0,1

None

Event Marker Status


Indicates Event Marker Status.
0 = Event Marker Failed.
1 = Event Marker OK.

0,1

None

Zero Speed Indicator


Indicates if shaft has stopped.
0 = Speed is >= 1 RPM or bad quality (Event Marker Status = 0).
1 = Speed is < 1 RPM and good quality (Event Marker Status = 1).

0,1

None

Invalid IP Address
Indicates if the IP address or subnet mask is invalid.
0 = IP Address and Subnet mask are valid.
1 = IP Address or Subnet mask is invalid.

0,1

None

Profibus Active
Indicates a Profibus Master is communicating.
0 = Profibus not communicating.
1 = Profibus is communicating.

0,1

None

Software Version Major


Indicates the software major version.

0 to 255

None

Software Version Minor


Indicates the software minor version.

0 to 255

None

Software Version Revision


Indicates the software version revision.

0 to 255

None

Software Version Pre-Release


Indicates the software version pre-release.

0 to 255

None

Speed
The current speed in RPM.

0 to 30,000

RPM

Overall Output
The overall movement or position in Engineering Units according
to channel type. (Valid for all channels).

Full

EU

2VAA000341

29

27BMCM800 Configuration via Profibus & Ethernet

30

3BCONFIGURATION

Description

Range

Units

Type

DC Voltage
The current DC component of the output value in Volts. (Valid for
channels 1 - 4).

-24 to +24

Volts

DC Relative Gap
The current DC component of the output value in Engineering
Units according to channel type. (Valid for channels 1 4,
Ethernet Only).

Full

EU

Order 0.5x Amplitude


Half Order Vibration component in Engineering Units. (Valid for
channels 1 6, Vibration only).

Full

EU

Order 0.5x Phase


Half Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).

0 to 359

Degrees

Order 1x Amplitude
First Order Vibration component in Engineering Units. (Valid for
channels 1 6, Vibration only).

Full

EU

Order 1x Phase
First Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).

0 to 359

Degrees

Order 2x Amplitude
Second Order Vibration component in Engineering Units. (Valid
for channels 1 6, Vibration only).

Full

EU

Order 2x Phase
Second Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).

0 to 359

Degrees

Order Nx Amplitude
Indicates the Nth Order Vibration component in Engineering Units.
(Valid for channels 1 6, Vibration only).

Full

EU

Order Nx Phase
The Nth Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).

0 to 359

Degrees

Order Not1x Amplitude


Not First Order Vibration components in Engineering Units. (Valid
for channels 1 6, Vibration only).

Full

EU

N for Nth Order


The Nth Order phase angle in degrees. (Valid for channels 1-6,
Vibration only).

0 to 359

Degrees

Critical Error
Any module error detected by the system.
0 = Normal.
1 = Error.

0,1

None

Configuration Error
A channel is configured improperly.
0 = Normal.
1 = Error.

0,1

None

Probe Voltage Error


The channels DC voltage is out of limits.
0 = Normal.
1 = Error.

0,1

None

2VAA000341

3BCONFIGURATION

27BMCM800 Configuration via Profibus & Ethernet

Description

Range

Units

Type

Bad Data
The overall value is out of the specified limits.
0 = Normal.
1 = Bad Quality.

0,1

None

Suspect Data
The Overall value is within 5% of the specified limit.
0 = Normal.
1 = Suspect Quality.

0,1

None

Alert Active
The Overall value has exceeded the specified range.
0 = Normal.
1 = Alert.

0,1

None

Alert Low Active


The Overall value has exceeded the specified range.
0 = Normal.
1 = Alert.

0,1

None

Alert High Active


The Overall value has exceeded the specified range.
0 = Normal.
1 = Alert.

0,1

None

Danger Active
The Overall value has exceeded the specified range.
0 = Normal.
1 = Danger.

0,1

None

Danger Low Active


The Overall value has exceeded the specified range.
0 = Normal.
1 = Danger.

0,1

None

Danger High Active


The Overall value has exceeded the specified range.
0 = Normal.
1 = Danger.

0,1

None

Time Waveform Buffer Full


Indicates Capture buffer is full.
0 = Normal.
1 = Buffer Full.

0,1

None

Time Waveform Capture Complete


Indicates a single capture has completed.
0 = Normal.
1 = Complete.

0,1

None

0,1

None

Time Waveform Run-up Active


The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.

2VAA000341

31

27BMCM800 Configuration via Profibus & Ethernet

Description
Time Waveform Rundown Active
The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.
Time Waveform Event Log Active
The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.

32

3BCONFIGURATION

Range

Units

Type

0,1

None

0,1

None

2VAA000341

4BOPERATION

28BGeneral Description

5. OPERATION
5.1

General Description
The MCM800 system is part of ABBs Symphony Plus technology platform. Data exchange occurs between the
controller and the module. However, the MCM800 operates independently from the main DCS controller using its builtin processors. The functions of the MCM800 provide dedicated monitoring and protective features, including:
Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.
The MCM800 System is comprised of an MPM810 and a TBU850. The TBU850 conditions the field signals and passes
the conditioned signals to the MPM810 controller. The MPM810 uses the field data in the execution of its functions.
In the next sections of this manual, the MCM800 system is divided into three main functional areas for analysis
purposes:

I/O Functions

Protective Functions

Testing Functions.

These functions include both hardware and software components.

5.2

I/O Conditioning Functions


I/O Conditioning functions convert the field electrical signals into digital data, which is then transferred to the microcontroller in the MPM810.

5.2.1 Signal Inputs


The MCM800 can accept up to four signal inputs. They can range from approximately +20 volts to 20volts. They pass
through over-voltage protection devices then into a differential input to reduce common mode noise. The signal passes
through a four-pole low-pass anti-aliasing filter with a corner frequency of about 20 kHz. This filter reduces high
frequencies that may be falsely interpreted. Finally, the signal is passed to the MPM810 where it is processed.
Internally the signal is separated into an AC and a DC component. The AC component is used for vibration and
eccentricity measurements. The DC component is used for Thrust, Differential Expansion, Case Expansion, and for
Signal Quality.
The AC signal is filtered using the frequency parameters set by the user to reduce unwanted frequencies. The filters
used are digital 4-pole Butterworth high-pass and low-pass filters. The output of the filter may be integrated from
velocity to displacement or acceleration to velocity. The signal is finally analyzed and output as a peak, Peak-to-Peak,
RMS or average value.
The DC signal is filtered to remove the AC component providing a steady output value. For all type of configurations
the DC voltage provides ranging from +24 volts to 24 volts. This signal is used to determine signal quality as specified
by the user. It is also used for all position measurements. The position is determined from a null position previously
set.

5.2.2 Event Marker Inputs


The MCM800 accepts a once-per-revolution pulse with a minimum pulse height of 1.7 v and a minimum pulse width of
100 sec (larger signals are preferred). The Event Marker has two functions:
Shaft speed (in RPMs).
Orders calculations.
Speed is measured between 1 RPM and over 20,000 RPMs. When the speed goes below 1 RPM, the module
interprets this as zero speed. If the speed is suddenly lost above 20 RPMs the speed output is set to bad quality.
For orders calculations, the event marker is used to determine the running speed of the shaft. The
calculations produce an amplitude of 1 times running speed (1X), 2 times running speed (2X), one-half
times running speed (half-X), and N times running speed (NX). N is a number between 3 and 10 specified
by the user. In addition, a Not 1X value is calculated. A phase angle is produced for half-X, 1X, 2X, and
2VAA000341

33

29BI/O Conditioning Functions


nctions

4BOPERATION

NX.

5.2.3 Relay Outputs


For each signal channel there are up to four alarm levels available.
High Danger
High Alert
Low Alert
Low Danger
If enabled, the MCM800 will activate on-board relays indicating a problem exists. There is one relay for Alert and one
relay for Danger. Time delays of 0.1 to 300 seconds are available to avoid false alarms.
The relays are Form-C providing a Normally Open (NO) and Normally Closed (NC) contact. In addition, parameters
enable the user to specify normally energized and normally de-energized relays.

The features must be used carefully to ensure expected results.

34

2VAA000341

4BOPERATION

5.3

30BFunctions

Functions
The MCM800 System provides all the common rotating machinery diagnostic functions. These functions can be
individually configured for maximum flexibility. The sections below list typical parameter settings for the various
functions. Some parameters are application specific and may deviate from those listed. Not all parameters are used for
every function and are ignored. For those parameters, the default setting is recommended.

5.3.1 Vibration
This function measures shaft vibration.

Typical Vibration Configuration (valid for channels 1-4)


Channel Type
Output Select

Probe Type

Probe Sensitivity
Integration

1 = Vibration
0 = Peak-to-Peak
1 = Peak
2 = RMS
3 = Average
4 = Calculated Peak-to-Peak
5 = Calculated peak
1 = Proximity Probe
3 = Accelerometer
4 = Moving Element velocity probe
5 = Piezoelectric velocity probe
Millivolts / EU
0 = None
1 = Velocity to displacement (velocity probes only)
2 = Acceleration to velocity (accelerometers only)

Angular Position
of Probe

High Failure
Threshold

Low Failure
Threshold

N for Nth Order


Filter Low Cutoff
Frequency

2VAA000341

Typical settings
Proximity Probe = -0.5
Accelerometer = 20.0
Moving Element velocity probe = 20.0
Piezoelectric velocity probe = 20.0
Typical settings
Proximity Probe = -20.0
Accelerometer = 0.5
Moving Element velocity probe = -20.0
Piezoelectric velocity probe =0.5
3 10 (User specified)
User defined (recommendations listed below)
Proximity Probe = 1
Accelerometer = 10
Moving Element velocity probe = 10
Piezoelectric velocity probe = 10
Integrated signals with low frequency noise = 40
35

30BFunctions

4BOPERATION

Filter High Cutoff


Frequency

Shaft Rotation
Direction

User defined (recommendations listed below)


Low Speed (< 1000 RPM) = 200
Medium Speed (1000-5000 RPM) = 300 to 1000
1500/1800 RPM = 300
3000 RPM = 500
3600 RPM = 600
High Speed (> 5000 RPM) = up to 2000
Highest speed of interest in Hertz times 10
Shaft rotation is determined looking axially from the
driver to driven direction.
0 = Clockwise
1 = Counter-clockwise

5.3.2 Eccentricity
This function measures shaft eccentricity.

Typical Eccentricity Configuration (valid for channels 1 - 4)


Channel Type
Output Select
Probe Type
Probe Sensitivity

2 = Eccentricity
0 = Peak-to-Peak
1 = Proximity Probe
Millivolts / EU

Angular Position
of Probe

High Failure
Threshold
Low Failure
Threshold

Proximity Probe = -0.5


Proximity Probe = -20.0

5.3.3 Thrust (Rotor) Position


This function measures Thrust or Rotor Position.

Typical Thrust Configuration (valid for channels 1 - 4)


Channel Type
Probe Type
Probe Sensitivity
36

3 = Thrust
1 = Proximity Probe
6 = Complementary proximity probe
Millivolts / EU
2VAA000341

4BOPERATION

30BFunctions

High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage

Proximity Probe = -0.5


Proximity Probe = -20.0
User defined.
Set by user.

5.3.4 Differential Expansion


This function measures Differential Expansion. See Complementary Position for complementary applications

Typical Differential Expansion Configuration (valid for channels 1 - 4)


Channel Type
Probe Type

Probe Sensitivity
Ramp Angle

4 = Differential Expansion
1 = Proximity Probe
2 = DC LVDT
6 = Complementary proximity probe
7 = Ramped Complementary proximity probe
Millivolts / EU

(for probe type 7 only)

High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage
Non-linear
Correction

Proximity Probe = -0.5


DC LVDT = probe dependent
Proximity Probe = -20.0
DC LVDT = probe dependent
User defined.
Set by user.
User defined. This is intended to extend the usable
range of a probe. (For Future Use Only)
100
90
80
70
60
50
40
30
20
10
0
0

2VAA000341

10

15

20

37

30BFunctions

4BOPERATION

5.3.5 Case Expansion


This function measures Case Expansion.

Typical Case Expansion Configuration (valid for channels 1 - 4)


Channel Type
Probe Type
Probe Sensitivity
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage

5 = Case Expansion
1 = Proximity Probe
2 = DC LVDT
Millivolts / EU
Proximity Probe = -0.5
DC LVDT = probe dependent
Proximity Probe = -20.0
DC LVDT = probe dependent
User defined.
Set by user.

5.3.6 Dual Probe


This function measures shaft vibration using a Dual Probe.
The Dual Probe application combines a Relative Probe (channel 1) with a Seismic Probe (channel 2) producing an
Absolute signal (channel 5). Likewise, channel 3 (Relative) and channel 4 (Seismic) produces channel 6 (Absolute).
The individual hardware channels (1 - 4) are configured similar to the vibration settings.

Typical Dual Probe Configuration


Parameter
Channel Type
Output Select
Probe Type

Probe
Sensitivity
Integration

Seismic (2/4)

Absolute (5/6)

6 = Relative
0 = Peak-to-Peak
1 = Proximity Probe

7 = Seismic
0 = Peak-to-Peak
4 = Moving Element
velocity probe
5 = Piezoelectric
velocity probe
Millivolts / EU

8 = Absolute
0 = Peak-to-Peak
N/A

Millivolts / EU

N/A

0 = None

1 = Velocity to
displacement

N/A

Angular
Position of
Probe
High Failure
Threshold
Low Failure
Threshold

45

-45

N/A

Proximity Probe = -0.5

velocity probe = 20.0

N/A

Proximity Probe = -20.0

N for Nth
Order
Filter Low
Cutoff
Frequency

3 10 (User specified)

Moving Element velocity


probe = -20.0
Piezoelectric velocity
probe =0.5
Same as relative

Same as relative

Filter High
Cutoff
Frequency
38

Relative (1/3)

User defined
(recommendations
listed below)
1 to 10 Hz
User defined
(recommendations
listed below)
Low Speed (< 1000

User defined
(recommendations
listed below)
5 to 10 Hz
Same as relative

N/A

N/A

2VAA000341

4BOPERATION

30BFunctions

RPM) = 200
Medium Speed (10005000 RPM) = 300 to
1000
High Speed (> 5000
RPM) = up to 2000
Highest speed of
interest in Hertz times
10

5.3.7 SMAX
This function measures shaft vibration using two probes in an X/Y configuration.
displacement of the shaft by trigonometrically combining the two signals.

It determines the maximum

The SMAX application combines an X (channel 1) with a Y (channel 2) producing an SMAX signal (channel 5).
Likewise, channel 3 (X) and channel 4 (Y) produces channel 6 (SMAX). In addition, if two Dual Probes are placed in an
X/Y configuration SMAX is calculated using channel 7.
The X and Y designators are arbitrary. What is more important is the probe angles and direction of rotation.
Typical SMAX Configuration (valid channels 5 - 7)
Configure the X and Y channels as vibration channels or dual probes.

Channel Type
Output Select

9 = SMAX
0 = Peak-to-Peak
1 = Peak

5.3.8 Complementary Position


This function measures Thrust or Differential Expansion in a complementary position.
The Complementary Position application compares the signals from channels 1 and 2 to output channel 5, or channels
3 and 4 for channel 6.

Typical Complementary Position Configuration (valid channels 5 & 6)


Channel Type

10 = Complementary Position

Set Sensitivity for


channel 1 or 3 to
mV / EU and 2 or 4
to (-) mV /EU

Set Sensitivity for


channel 1 or 3 to
(-)mV / EU and 2 or
4 to mV /EU

Set Sensitivity for


channel 1 or 3 to
mV / EU and 2 or 4
to (-) mV /EU

2VAA000341

39

30BFunctions

4BOPERATION

Set Sensitivity for


channel 1 or 3 to
(-)mV / EU and 2 or
4 to mV /EU

The value of the Complementary output depends on the quality of each of the two hardware inputs. The quality is
based on the High and Low failure voltages. Refer to the section that explains the Probe Failure Voltage setting.
The two probes can be mounted in such a way that the probes are either overlapping or non-overlapping as shown
below. It is preferred to mount the probes such that their ranges overlap. If this is not possible due to longer shaft
movement the range in the middle of the shaft movement will report bad quality, as shown below.

5.3.9 Waveform Capture Settings


The MCM800 has 4 logic signals that control when time waveform data is captured. Controller logic can be written to
capture a single time waveform or capture a series of time waveforms during a run-up, a rundown or during an event
such as a plant trip.
Capture Waveform
On a transition from false to true the current waveform will be captured and transmitted to the Data Server. Once
captured, the Capture Time Waveform flag becomes true. At least 5 waveforms can be retained in a buffer to await
transfer. If the buffer fills, the Buffer Full flag becomes true and the MCM800 will not capture additional waveforms until
buffer space is available. If Capture Waveform remains true, no additional waveforms will be captured. While it is not
normally necessary, DCS logic can check the Capture Time Waveform and Buffer Full flags.
Run-up Capture
When Runup Capture is true, the current waveform will be stored every time speed increases by Delta RPM or more.
Runup Capture continues while the flag is true and there is enough storage on the MCM800. There is enough memory
to store up to 40 files, but files can be off-loaded to the Data Server while the data is being captured. Delta RPM is
specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally
necessary, DCS logic can check the Run-up Data flag.
Rundown Capture
Same as Run-up Capture except speed must decrease by Delta RPM or more.
Event Active
The Event Waveform file contains up to 40 waveforms. The MCM800 will retain a configurable amount of waveforms
from the Current Data Buffer at a configurable Skip-over Factor prior to Event Active. The purpose is to store data from
before and after an event such as a Danger alarm or a machinery trip. Construction of the Event Waveform file starts
when Event Active becomes true. Construction continues until 40 waveforms, including pre-event captures, are stored
or Event Active becomes false, constituting a file. When a file is complete, the Event Data flag becomes true until the
waveforms are uploaded to the Data Server. If Event Active remains true, no additional Event Waveform files will be
constructed. The Skip-over Factor and Number of Pre-trigger Waveforms are specified by means of ABB's Analyst
diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the
Event Data flag.

40

2VAA000341

5BMAINTENANCE

31BPreventive Maintenance

6. MAINTENANCE
6.1

Preventive Maintenance
Periodically (every six months) or during a plant shutdown, inspect modules and clean any dust accumulation with a
static safe vacuum cleaner.

6.2

Hardware Indicators

6.2.1 MPM810 I/O Module LEDs


LED

Description

R/F

Health LED. If module is OK the LED is GREEN. On failure, the LED is either RED or OFF.
During startup this LED may flash GREEN and RED while going through diagnostics.

RxTxA Profibus Bus A communication. The LED is AMBER if the module is communicating over Bus A.
RxTxB Profibus Bus B communication. The LED is AMBER if the module is communicating over Bus B.
The LED is GREEN when running normally, completed diagnostics, or completed calibration. It
STATUS is AMBER during startup, running diagnostics or calibration. It is RED if the module failed
startup, diagnostics or calibration
CH1

Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH2

Channel 2 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH3

Channel 3 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH4

Channel 4 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH5

Channel 5 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH6

Channel 6 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.

CH7

Channel 7 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
Table 6-1 MPM810 LEDs

2VAA000341

41

33BTroubleshooting

6.3

5BMAINTENANCE

Troubleshooting
Symptom

Possible Causes
Module is not plugged in correctly.

Module does not initialize.

Operating mode not set up correctly.


Hardware failure.
No power to module.

R/F LED is OFF.

R/F LED is RED.

Module is not plugged in correctly.


Hardware failure.
Module is not plugged in correctly.
Hardware failure.
Profibus not communicating.

RxTxA & RxTxB LEDs are OFF

Loose or disconnected.
Profibus not properly terminated.

STATUS LED is AMBER.


STATUS LED is RED.
CHn LED is OFF.

CHn LED is AMBER

CHn LED is RED


CHn LED is blinking AMBER
Channel status indicates a Critical
error, but no Configuration error.

MCM800 reporting incorrect


values.

Incorrect speed or phase

The module is on startup, calibration


or diagnostic mode.
Module failed startup.
Module failed diagnostic.
Module failed calibration.
Channel not configured.
Channel is in Alert condition.

Channel is in Danger condition.


There is a configuration error.
No configuration defined for channel.
Configuration not saved.

There are numerous possible causes


for incorrect values, some are listed
below.

Signal noise.

Poor connection.

Improper power and ground.

Improper shielding.

Incorrect sensitivity.

Incorrect filter values.

Improper calibration.

Malfunctioning hardware.

Noise on Event Marker input signal.


Hardware failure.

Improper actuation of termination


unit relays.

Noise on input signal.


Hardware failure.

42

Corrective Action
Re-adjust the module to fit properly.
Check Profibus Address Dipswitch.
Check Ethernet IP address.
Check option Dipswitch.
Replace the module.
Check +24 & -24 volt power supplies
and connector.
Re-adjust the module to fit properly.
Replace the module.
Re-adjust the module to fit properly.
TBU850 Power Failure.
Replace the module.
Check Profibus master and
configuration and addressing.
Check module Profibus address.
Check the cable for proper fitting.
Check Profibus termination Dipswitch
S3.
If LED does not turn green after
several minutes the module may be
faulty. Replace module.
Replace MPM810.
Replace MPM810 or TBU850.
Replace TBU850.
Check configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
Check configuration.
Configure channel using configuration
tool.
Re-configuration channel and set
dipswitch to save parameters.
The possible corrective actions are
just as numerous, some are listed
below.

Check signal path.

Check cable connections.

Check cable shielding.

Check sensitivity value.

Check or adjust filter


settings.

Recalibrate TBU850.

Verify module with known


input signal.

Replace MPM810 or
TBU850.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
2VAA000341

5BMAINTENANCE

6.4

34BDiagnostics

Diagnostics
The R/F LED will flash RED according to the table below if an error is detected. A Channel LED will light RED if the
corresponding component test fails.
Test
TBU850 Test

R/F
LED
X

Channel
LED

Error

Code

Faulty Voltage(s)
on TBU850
Faulty CPU

Solid RED

CPU access, instruction, register testing

Full DRAM Test

Stack RAM

Faulty access or
data
Faulty data

FPGA Load

Faulty FPGA

During any subsequent associated channel


testing the Status LED may RED light if a test
fails. Following all testing the Status LED will
flash RED three times and the continually
flash RED if an error was discovered.
Non-initialized DRAM Test

6.5

Status
LED

Faulty Test

Repetitive RED
Flashes
2 Repetitive
Flashes
4 Repetitive
RED Flashes
5 Repetitive
RED Flashes
Continuous
Flashing RED

Flash Test

Faulty access or
data
Bad CRC

Solid RED

Processor Test

Faulty CPU

Solid RED

FPGA Test

Faulty Signature

Solid RED

DSP Test

Faulty DSP

Solid RED

NVRAM Test

Faulty Parameters

Solid RED

Undefined

Program failure

Solid RED

Solid RED

Module Replacement

6.5.1 General
All I/O modules are designed for long, trouble-free service. If it is determined that the module is faulty, replace it with a
new one. DO NOT try to repair the module as replacing components may adversely affect the module's performance
and void the warranty. If it becomes necessary to replace any parts, contact the ABB Customer Service Department.
All I/O modules can be exchanged on-line with the process power supply connected. However, it is important to
understand the consequences of a module exchange on-line and how it affects the process. Replacement of an I/O
module affects all channels on the module. It sometimes also indirectly affects the outputs, via some application
function, on another module.

6.5.2 Replacement
Replace faulty or suspect I/O modules in the following way:
Provide access to the module by loosening the module locking device.
Grip the module firmly and extract the module.
Store extracted modules in envelopes.
Insert the new module carefully and completely.
Ensure that the module contacts mate properly with the contacts in the TBU and activate the locking
mechanism in place.
Modules initialize automatically and will begin to execute in a few seconds.

2VAA000341

43

36BFirmware Upgrade

5BMAINTENANCE

6.5.3 Returning a Module


When returning a module, first obtain a Return Material Authorization (RMA) number. Be sure to show this number
prominently on the outside of the shipping container, on the shipping label, and on the packing list.
Provide as much information as possible regarding the symptoms of the problem; include the part description, the part
number, and the serial number.

6.6

Firmware Upgrade
Occasionally firmware upgrades of the MCM800 will be available at which time an upgrade procedure will be available
with the firmware release.

44

2VAA000341

6BSPECIFICATIONS

37BMCM800 Product Specifications

7. SPECIFICATIONS
7.1

MCM800 Product Specifications


GENERAL

Microprocessors

MCF5282 @ 64 MHz PLL


MC56321 DSP @ 250 MHz PLL

System Communications

Profibus DP V1
Modbus RTU (Output Only)
Ethernet 10/100 Base T, TCP/IP

I/O Module Mounting

One slot in Modular Termination Unit (TBU850)

I/O Termination

Termination Base Unit (TBU850)

TBU Cabinet Mounting

Standard 35mm DIN Rail

TU Terminal Blocks

24A/250V

Compression: 0.14-1.5 / 0.14-1.5 / 28-16


solid[mm2] / stranded[mm2] / AWG
OPERATING

Positive Power

+24 VDC current limited 30 mA each

Negative Power

-24 VDC current limited 30 mA each

Constant Current

4.7 mA (for piezoelectric devices)

Digital Output (Alert / Danger)

Dry Relay Contact (Form C)

2A @ 24 VDC

ELECTRICAL
Module Operating

+24 / -24 VDC 5% @ 300 mA each (typical)

Module Consumption

7.5 W each supply (typical)

Field I/O

+24 / -24 VDC (fused @ 1/16 amp each)

2VAA000341

45

37BMCM800 Product Specifications

7BREVISION HISTORY

ENVIRONMENTAL
This product, when installed in a cabinet, was designed to comply with
the following Directives/Standards for CE Marking.
Emissions:
EN61000-6-2:2005
CIS 11:2003+A2:2006,EN55011:2007+A2:2007
EN61000-3-2:2006,EN61000-3-3:1995+A1:2001+A2 :2005
Immunity:
EN61131-2 :2007,
EN61000-4-2 :1995+A1 :1999+A2 :2001, EN61000-4-3 :2006,
EN6111-4-4 :2004, EN61000-4-5 :2005,EN61000-4-6 :2007 ,
EN6100-4-8 :1993+A1 :2001, EN61000-4-11 :2004

CE Mark
EMC Directive
2004/108/EC

Safety Requirements

EN61010-1 Safety Requirements for Electrical Equipment for


Measurement, Control and Laboratory Use - Part 1: General
Requirements

Ambient Temperature

0 to 55 C (32 to 131 F)

Humidity

5% to 90% RH (5%) up to 55C (non-condensing)


5% to 40% RH (5%) up to 70C (non-condensing)

Atmospheric Pressure

Sea level to 3 km (1.86 miles)

Air Quality

Non-corrosive

Installation Category

Category II per ANSI/ISA-S82.01-1994

8. REVISION HISTORY
Rev.
5.1

46

Date / Initial
Updated for the Version 5.1 release

05/2010 KD

2VAA000341

Notice
The information in this document is subject to change
without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility
for any errors that may appear in this document.
In no event shall ABB be liable for direct, indirect,
special, incidental or consequential damages of any
nature or kind arising from the use of this document,
nor shall ABB be liable for incidental or consequential
damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be
reproduced or copied without written permission from
ABB, and the contents thereof must not be imparted to
a third party nor used for any unauthorized purpose.
The software or hardware described in this document
is furnished under a license and may be used, copied,
or disclosed only in accordance with the terms of such
license.
This product meets the requirements specified in EMC
Directive 89/336/EEC and in Low Voltage Directive
72/23/EEC.
Copyright 2010 by ABB.
All rights reserved.
Release: June 2010

47

2VAA000341A5100_SPlus_MCM800 Product Guide.doc

Document Number 2VAA000341

ABB Ltd.
Business Unit Power Generation
P.O. BOX 8131
8050 Zrich
SWITZERLAND
Phone: +41 (0) 43 317-5380
Fax:
+41 (0) 43 317-5382
www.abb.com/powergeneration