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Reference Manual

RBMware® Online System
Installation
Model 4500 RBMconsultant® Manual

CSI Part # 97101 Rev. 3

Copyright
© 2002 by Computational Systems, Incorporated.
All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or
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This manual is provided for informational purposes.
COMPUTATIONAL SYSTEMS, INCORPORATED MAKES NO
WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND
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to change without notice and does not represent a
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Incorporated. The information in this manual is not allinclusive and cannot cover all unique situations.
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Should you have any comments on this documentation or questions concerning the Agreement on the
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Reference Manual
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License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMS AND CONDITIONS OF THIS
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Please contact CSI Customer Services for more information. • Mass updates that are released during that time. manuals. 2. update. Obsolete Hardware Although CSI will honor all contractual agreements and will make every effort to ensure that its software packages are “backward compatible. software diskettes. Call Product Support (see page 2) to obtain a return authorization number. what mode were you in? What steps did you go through? Try to determine before you call whether the problem is repeatable. Software Technical Support CSI provides technical support through the following for those under maintenance contracts: • Telephone assistance and communication via the Internet. etc. explain the exact nature of your problem.) When do they occur? Know what you were doing when the problem occurred. and other analyzers appears on the powerup screen that is displayed when the analyzer is turned on. modification. iv . For example. abuse. recalibration. Insure your package for return shipment. The version number for software operating under MS-DOS® appears at the top of every menu screen. Returning Items 1. correction. COD packages cannot be accepted and will be returned unopened.Hardware Technical Help 1. For example. Contact CSI’s Product Support Department for information concerning the current rates. CSI reserves the right to discontinue support for old or out-of-date hardware items. Enclose a note that describes the reason(s) you are returning the item(s). The version number for software operating under Windows® is displayed by selecting “About” under the Help menu bar item. The version of the firmware in CSI’s Model 2100 series. and maintenance for normal wear. Include cables. This service warranty includes hardware improvement. Please have the number of the current version of your firmware ready when you call. Hardware Repair CSI repairs and updates its hardware products free for one year from the date of purchase. For example. what are the error messages? (If possible. If returning for credit. If you have a problem. 4. Model 2400. each return of a CSI hardware product is subject to a minimum service fee. what mode were you in? What steps did you go through? Try to determine before you call whether the problem is repeatable. Please be at your computer when you call. neglect. return all accessories originally shipped with the item(s). 3. This service warranty excludes repair of damage from misuse. For example. If you have a problem. Please write it clearly and prominently on the outside of the shipping container. 3. we will call you with an estimate before performing any work. We can serve you better when we can work through the problem together. • Interim updates upon request.” to take advantage of advances in newer hardware platforms and to keep our programs reasonably small. or modification performed by anyone other than CSI. After the one year service warranty expires. Please have the number of the current version of your software ready when you call. carelessness. If the cost of repair exceeds this minimum fee. 2. make a printout of the error message. 2. what are the error messages? When do they occur? Know what you were doing when the problem occurred. Software Technical Help 1. Shipping costs and any losses during shipment are your responsibility. explain the exact nature of your problem.

Contents Chapter 1 • Introduction Special Emphasis · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-2 How to Use · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-3 Plant Appointed Project Manager · · · · · · · · · · · · · · · · · · · · · · · · ·1-3 Contractor · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-5 Supplemental Information · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-6 Where to Start · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-7 Chapter 2 • Pre-Installation Review Contractor Kickoff Meeting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-2 Final Walk-Through· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-3 System Component Review · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·2-4 Chapter 3 • System Documentation System Overview Drawings · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-2 System Layout Drawings · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-5 Cable Administration Charts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-6 Junction Box · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-7 4500R Enclosure· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-8 4500S Enclosure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-11 Documentation Storage· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·3-13 Chapter 4 • Install Instrumentation Description and Handling Instructions · · · · · · · · · · · · · · · · · · · · ·4-1 Required Tools & Parts· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·4-4 Surface Preparation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·4-6 A0322 Mounting Stud Installation (Stud Mounting Only) · · · · ·4-11 v .

A0322DS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-15 Description & Handling Instructions · · · · · · · · · · · · · · · · · · · · · 4-15 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-17 Surface Preparation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-20 AO322LC Sensor Mounting (without Quick-Connect) · · · · · · · 4-24 A0322LC with Quick-Connect Mounting Instructions · · · · · · · 4-26 A0322RM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-28 Description & Handling Instructions · · · · · · · · · · · · · · · · · · · · · 4-28 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-30 Surface Preparation · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-31 A0322RM Mounting Stud Installation (Stud Mounting Only) · 4-36 Sensor Mounting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-37 V425 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-38 Description & Handling· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-38 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-39 Choosing Proper Actuator (Target)· · · · · · · · · · · · · · · · · · · · · · · 4-40 Mounting Sensor Bracket · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-42 Mounting Sensor · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-43 Chapter 5 • Enclosure Mounting Description· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-1 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-4 Mounting Instructions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-5 Mount 4500R and 4500S Data Collection Units · · · · · · · · · · · · · · 5-6 Description· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-6 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-9 Mounting Instructions · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-10 Prepare 4500R or 4500S Cable Access Plate · · · · · · · · · · · · · · · · 5-11 Description· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-11 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-11 Determine Hole Size & Location · · · · · · · · · · · · · · · · · · · · · · · · 5-12 Chapter 6 • Cabling Requirements Pull Instrumentation Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-5 Required Tools & Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-7 vi .Sensor Mounting · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 4-12 A0322LC.

Installation· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-7 Pull A680 Bundled Cable from Junction Box/4500R or 4500S · ·6-9 Description · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-9 Required Tools & Parts· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-9 4500R or 4500S Enclosure · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-9 Guidelines for Dedicated 4500R or 4500S Network Segment · ·6-10 Description · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-10 4500R or 4500S Power Circuit Guidelines · · · · · · · · · · · · · · · · · ·6-11 Description · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·6-11 Chapter 7 • Wire Terminations Description · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-1 Required Tools & Parts· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-2 Terminate Instrumentation Wire · · · · · · · · · · · · · · · · · · · · · · · · · ·7-3 Terminate V680 Bundled Cable · · · · · · · · · · · · · · · · · · · · · · · · · ·7-5 Terminate 4500R Wiring · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-7 Description · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-7 Required Tools & Parts· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-8 Terminate Power · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·7-8 Appendix A • 4500R or 4500S Default Network Addressing Schema Appendix B • Additional 4500R Connections 4500R Proximity Probe Interconnetion Diagram · · · · · · · · · · · · B-2 4500R 4-20ma Current Loop Interconnection · · · · · · · · · · · · · · · B-3 Appendix C • AC-DC Power Converter Connecting and Maintaining the 4500R or 4500S unit · · · · · · · · C-2 Required Tools and Parts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · C-2 4500R (with duplex receptacle) · · · · · · · · · · · · · · · · · · · · · · · · · · C-3 4500R (without duplex receptacle) and 4500S · · · · · · · · · · · · · · C-3 Safe Operation of the 4500R or 4500S AC-DC Power ConverterC-3 Indicators · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · C-4 vii .

Power Output Connectors · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·C-5 Auxiliary sensor output connections· · · · · · · · · · · · · · · · · · · · · · ·C-5 Fan output connections · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·C-5 LED Indicators· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·C-6 Appendix D • Connection Parameters Specifications for equipment that supplies and receives energy:·D-2 Index viii .

you have been provided several manuals to assist in installing. learning. Along with your system hardware and software. 1-1 . This particular document is the RBMware Online System Installation. Note Normal installation for the Model 4500R or 4500S unit is in an orientation such that the front panels are vertical. This manual does not attempt to explain the operation or application of the CSI 4500R or 4500S online system nor does it cover hardware or software specifications.Chapter 1 Introduction Preface Congratulations on your purchase of the CSI 4500R or 4500S online monitoring system. and maintaining your system. The purpose of this document is to provide system installers specific requirements and instructions for the correct installation of the CSI 4500R or 4500S online monitoring system and accessories.

Read This First Special Emphasis These conventions are used throughout this manual to call attention to the adjacent text: Note A note indicates special comments or instructions. Caution! A caution indicates actions that may have a major impact on the system integrity. 1-2 Introduction . Warning! The Warning paragraph warns you of actions that could cause serious injury or death.

procuring bids from contractors. and the contractor. Warning! Power to the 4500R or 4500S AC-DC power converter PCB must include a remote disconnect switch or circuit breaker. it is important that each understand how to make use of this document. insulation voltage ratings. and supervising the system install. wire size. Warning! All wiring should be installed by a trained and qualified electrician. Therefore.How to Use There are two intended audiences for this manual: the plant appointed project manager. color codes. this manual is divided into sections: How to Use 1-3 . As such. Wiring must conform to all applicable local codes and regulations. The switch or circuit breaker must be in close proximity to the equipment and within easy reach of the operator. Caution! Use of the 4500R or 4500S AC-DC Power converter in a manner not specified by CSI may impair protection offered by the equipment. setting schedules. Furthermore. and any other standards must be followed. Local codes and regulations regarding wire type. Plant Appointed Project Manager The project manager will be involved in budgeting money for the installation work. it is important that the project manager understand the scope of work which is involved with an on-line system installation which can be properly estimated by reviewing each section of this manual.

This includes assigning labels. and filling out cable administration charts. System documentation is often neglected until an installation is completed. Particular attention should be paid to any “Notes” or “Cautions” within the document.• Pre-Installation Review • System Documentation • Install Instrumentation • Enclosure Mounting • Cabling Requirements • Wire Terminations. The project manager must be in charge of creating proper system documentation for the contractor before the installation begins. the project manager will have the important duty of performing an installation review and creating proper system documentation. which may include a “Contractor Kickoff Meeting” attended by a CSI online project manager. Apart from the installation manual. The installation review also requires the project manager to perform a final walk-through of the installation site and determine if the purchased hardware is adequate and if any additional hardware will be required. etc. creating system diagrams. Having the proper system documentation will make the contractor’s job easier and reduce the number of mistakes made. which are the most common causes of a poor installation. Each contractor should receive a copy of this manual and use that as a basis for their scope of work. Before the contractor begins work. When reviewing bids from contractors it is very important that each contractor’s scope of work is based on this installation manual and all exceptions are noted. is intended to educate everyone involved with the installation on requirements. Another important function of the project manager is to procure bids from contractors. The installation review. procedures. deadlines. 1-4 Introduction . all the contractor should need is a copy of the system proposal and any supplemental information for special purchases. Finally the project manager should use this installation manual to validate the work being performed by the contractor. These sections follow the natural progression of a system installation which should make it easier for the project manager to estimate schedules and budgets for the installation.

such as installing an AO322LC sensor. each performing a specific function.Contractor The contractor will use this manual for two purposes: preparing a bid for the system installation. How to Use 1-5 . then it will be assumed that the bid covers the scope of work as defined in the installation manual. can turn to that particular section and have a complete instruction set without referencing any other part of the manual. If the contractor takes no exceptions. When preparing a bid for the system installation. it is imperative that the contractor reviews all parts of the manual that are specific to the installation and list any exceptions to the manual within the bid. This should make it easier when many people are involved with the installation. The manual is written so a contractor when performing a certain action. and as a guide during the system installation. it is not necessary that the installer be familiar with the entire manual. As an installation guide.

Supplemental Information This installation manual covers the standard online system components. there will be non-standard components purchased with the online system. For specific customer installations. For each of these components. If a purchased component cannot be found in the installation guide. please contact your CSI project manager and request an installation guide supplement. an installation guide supplement will be prepared by CSI and included with the installation guide. 1-6 Introduction .

Chapter 3 System Documentation System documentation is prepared before the system installation begins. Chapter 4 Install Instrumentation The online system instrumentation includes the 322 family of accelerometers and the 425 tachometer. and pulling the online instrumentation cabling as well as the 680 bundled (multi-pair) cable from junction boxes to the 4500R or 4500S.Where to Start The chapters in this manual are intended to follow the natural progression of a system installation. The following is a brief summary of each chapter.” Contractors need to review Chapters 4-7 to fully understand the scope of work involved in the online system installation. required tools. wire tag designations. and examination of the delivered system components. Where to Start 1-7 . and filling out the cable administration charts. This involves assigning sensor names. Chapter 5 Enclosure Mounting The online system will have two types of enclosures: junction boxes (701 family and the 745) and the 4500R or 4500S enclosure. and the installation procedures for each piece of instrumentation. Chapter 2 Pre-Installation Review The pre-installation review could also be called installation preparation. enclosure names. network cabling guidelines. This involves a “contractor kickoff meeting. Chapter 6 Cabling Requirements This chapter covers conduit installation guidelines. power line specifications. This chapter covers the handling requirements.” a final walkthrough of the installation site. This chapter covers choosing proper enclosure mounting locations and mounting procedures as well as preparing the 4500R or 4500S enclosure for conduit access. The plant assigned project manager needs to pay particular attention to Chapter 2 “Pre-Installation Review” and Chapter 3 “System Documentation. preparing system layout diagrams.

703. This chapter covers routing. 702. tagging. proper wire terminations within the online system components is critical for a successful system startup. 745 junction boxes and 4500R or 4500S enclosures. and terminating cables within the V701. preparing.Chapter 7 Wire Terminations Often the cause of most system failures. 1-8 Introduction .

” final walk-through. and a system component review.” final walk-through. and system component review all in one day. • Confirms location of system components is appropriate It is not uncommon for plants to schedule the “Contractor Kickoff Meeting.Chapter 2 Pre-Installation Review Description The pre-installation review is a short but important phase in a successful online system implementation. The pre-installation review accomplishes the following: • Identify and Educate all parties involved in the online system installation • Makes sure that the contractor fully understands the scope of work • Sets the system installation schedule • Confirms that system components fit customer’s application • Confirms that all necessary system components are on site and available. 2-1 . it is the responsibility of the plant assigned project manager with the assistance of the CSI online project manager to ensure this phase of the system installation is completed successfully. Consisting of a “Contractor Kickoff Meeting. This is especially beneficial when the CSI online project manager is attending the “Contractor Kickoff Meeting” so that they may assist the plant assigned project manager during the final walk-through and system component review. For this reason it is also recommended that the online system has been shipped to the customer site before installation work begins.

Typically. Although many contractors will be educated on the system installation during the bid process by reviewing the installation manual and the system documentation (see Chapter 3).Contractor Kickoff Meeting Although referred to as the “Contractor Kickoff Meeting. this will involve: • Plant Assigned Project Manager • CSI Online Project Manager • End User(s) • Contractor Representative(s) • Information Systems Representative(s). It is important to confirm that they fully understand the scope of work by reviewing each part of the installation during this meeting. 2-2 Pre-Installation Review . this is the time to do so. If the system documentation has not been submitted to the contractors.” this meeting brings together all parties involved with the online system installation. The purpose of this meeting is to: • Assign Responsibilities • Review Scope of Work For Contractors • Answer Any Installation Related Questions • Review Customer Expectations of Installed System • Tentatively Set Schedules for Installation.

this is the opportunity to physically walk-through each part of the installation with the contractor’s representative(s) and the vendor’s representative (online project manager) to review: • Sensor Mounting Locations • Cable Pulls • Conduit/Cable Tray Use • Enclosure Mounting Locations • Environmental Concerns • Hazardous Locations. and the CSI online project manager. Using the system documentation (see chapter 3) as reference. Final Walk-Through 2-3 .Final Walk-Through The final walk-through is attended by the plant assigned project manager. contractor representative(s).

The review process simply consists of unpacking and inspecting system components to confirm all components are present. 2-4 Pre-Installation Review . and the CSI online project manager. quick-connects. It is the responsibility of the plant assigned project manager to gather shipped components into an accessible area for the review process. In particular. the following items should be confirmed during the review. contractor representative(s).) • Manuals • Junction box mounting tabs • 4500R or 4500S board configurations • 4500R or 4500S discrete input/output plug-in relays for correct configuration. The review should be attended by the plant assigned project manager.System Component Review The system component review confirms that the proper system components have been shipped and that nothing has been lost or damaged during shipment. etc. mounting pads. • Any non-standard system components • Sensor mounting accessories (studs. This is also the opportunity to familiarize the plant assigned project manager and the contractor with the different system components.

Proper documentation includes: system overview drawings showing the on-line system layout within the plant. and enclosures documented in cable administration charts. A successful installation requires that proper system documentation be created before a contractor begins working. and tags for all sensors. 3-1 . proper documentation of a system installation will not only avoid problems during installation but will also make system maintenance much more efficient. many system installations do not have documentation created until after an installation is completed. system layout drawings showing sensor and enclosure mounting locations. The 4500R or 4500S data collection unit and junction/switch box enclosures include see-through pouches for storing the on-line system documentation. This documentation must be given to a contractor before the installation begins and preferably as part of the bid package. it is important that the documentation which has been maintained by the plant assigned project manager is distributed to the proper plant personnel and readily available for system maintenance and troubleshooting. Unfortunately. cables.Chapter 3 System Documentation Description Often an overlooked part of the system installation. When an installation is finished.

it will be necessary for the plant assigned project manager to create or update the drawings. These drawings are normally prepared by a CSI applications engineer and included in the online system proposal during the sales process. The following system drawings were taken from an on-line system proposal. Example of System Overview Drawing (overall) 3-2 System Documentation .System Overview Drawings The system overview drawings illustrate how system components interconnect. If these drawings were not part of the proposal or if the system has changed significantly from the time the proposal was created.

Overall System Diagram: • 4500R or 4500Ss • Junction/Switch Boxes • Cables • 4500R or 4500S Network Segment Cables • Tags for each 4500R or 4500S. and Cables Machine Level Diagram: • Machine with Tag • Sensor Location with Tag System Overview Drawings 3-3 . Junction/Switch box. In general the following information should exist on each diagram.Example of System Overview Drawing (Machine Level) As illustrated. the system overview drawings should consist of an overall system diagram and then machine level diagrams showing sensor locations.

• Junction/Switch Boxes with Tag • Location on Plant Floor 3-4 System Documentation .

These are prepared by the plant assigned project manager utilizing facility blueprints. and sensor mounting. System Layout Marking Guidelines System Layout Drawings 3-5 . cable pulls. Use color-coded highlights and symbols to mark the different types of cable runs and enclosure mountings. The most common method for preparing these drawings is to copy blueprints of the plant floor/production line and mark the system installation locations.System Layout Drawings The system layout drawings illustrate exact locations for enclosure mounting. The following is a recommended method of marking system layout drawings. conduit installation.

3-6 System Documentation . There are two types of cable administration charts for the online system: junction box and 4500R. There is no recommended method for assigning tags but the names should be consistent and represent physical locations or machines. 23001. each enclosure will include a special clear plastic pouch on the inside cover of the enclosure to hold these cable administration charts for reference. For this reason. After tags are assigned. Before the system installation begins and preferably before bids are procured from contractors. For instance. a more meaningful name such as FAN1OV (fan number 1 outboard vertical) will make system maintenance and troubleshooting much easier. instead of naming a sensor. enclosure tags.Cable Administration Charts Cable administration charts are a convenient way to document wire terminations within system enclosures. which represents nothing. All enclosures for the CSI online system will need to have cable administration charts created. it is important to document these in cable administration charts. the project manager should work with the end user in the plant to determine sensor tags. and cable tags.

Junction Box The online system junction boxes each serve the same purpose: to provide a junction between the instrumentation cable and the multi-pair bundled cable which is pulled back to the 4500R. sensor type. and sensor location if the wire tag does not contain location information. These charts are shipped with the system and can be found inside the online system junction boxes. The following is an example of the junction box cable administration chart for a typical installation. Junction Box Cable Administration Chart Cable Administration Charts 3-7 . wire tag. The cable administration chart for a junction box simply documents the channel number.

tach. I/O. Each board has specific cable terminations which must be documented in the cable administration charts. The cable administration charts for the 4500R consist of two 8. The 4500R consists of removable boards to allow several different configurations. These boards include mux 1&2. Templates are included in the installation guide for the project manager to copy and fill out. 4500R Board Positions 3-8 System Documentation .4500R Enclosure The 4500R enclosure has several types of cable terminations with specific termination locations. and the DCM.5" x 11" pages.

Cable Administration Charts 3-9 .

3-10 System Documentation .

and 2 discrete I/O. 2 tachometers. A template for this chart has been included. 4500S Board Positions Cable Administration Charts 3-11 .4500S Enclosure The 4500S enclosure has one cable termination card for the 8 sensors. There is also a 10BaseT network termination and an AC power termination. These are to be documented on the 4500S cable administration chart.

3-12 System Documentation .

One copy should be sent to the CSI online project manager. misspelled wire tags. and make the necessary revisions in the system documentation. it is recommended that a copy of the system overview and layout drawings be placed in the pouch for quick reference. it is the project manager’s job to review the system documentation and make any revisions such as rerouted cables. etc. This is also the appropriate time to place the cable administration charts in the online enclosures.Documentation Storage After the system installation is complete. In each 4500R enclosure. Documentation Storage 3-13 . Each enclosure contains a clear plastic pouch to allow easy reference by contractors and service personnel. The last step is to create copies of the completed system documentation and distribute to the appropriate plant personnel.

3-14 System Documentation .

A0322DR Description and Handling Instructions A0322RI. A0322DR Image & Outline Drawing 4-1 .Chapter 4 Install Instrumentation A0322RI. A0322RA.

A0322RA Image & Outline Drawing 4-2 Install Instrumentation .

The A0322RI has a distinguishing bright yellow polyurethane jacket for easy identification while the A0322DR has a red polyurethane jacket.These sensors are stud mounted or epoxy mounted to machinery surfaces and transmit vibration data to the on-line monitoring system. or impact sensor housing before. hammer. The A0322RA is contained in a steel housing with an armored covered jacket. Do not drop. Although the integral cable has built in strain relief. Over-tightening of accelerometer will damage sensing element and void manufacturer’s warranty. Caution! Do not drop. during. force should be exerted directly on sensor connection during installation.Description The A0322RI and A0322RA are general purpose accelerometers with 90degree integral cable connections. When tightening down stud mounted accelerometers it is very important not to exceed specified torque. it is important that the cable not be strained with excessive pulling force during cable pulls. hammer. The A0322DR sensor is a general purpose accelerometer and temperature sensor with a 90-degree cable connection. Handling Instructions General purpose accelerometers are susceptible to mechanical shock and therefore it is very important for installers to take precaution when handling sensors. It is recommended that cable be secured to machine near the point of sensor installation if possible. Mechanical shock loads of over 5000 g’s will damage sensor and void manufacturer’s warranty. or impact the sensor housing before during or after installation. or after installation. The integral cable connection joins the sensor housing at a 90-degree angle to provide a low-profile installation. No more than 5-lbs. Caution! Do not exceed specified torque when tightening stud-mounted accelerometers. 4-3 .

Caution!

Do not exert more than 5-lbs. pull force directly on sensor/cable connection during wire pulls.
If sensor mounting occurs before cable is pulled in conduit or raceway to
junction box it is important to leave cable bundled and secured to machine.
Sensor cable cannot be stepped on or severely kinked or permanent signal
degradation will occur. Also, cable bundle should not be placed in such a
manner that it will cause undue strain at the sensor/cable connection.

Required Tools & Parts
Below is a listing of the require tools and parts in order to install the
A0322RI and A0322RA accelerometers.
Spot Face and End Mill Tool

Suggested Vendor:
Industrial Monitoring Instrumentation (a division of PCB, Inc.)
3425 Walden Avenue, Depew, New York 14043, 1-800-959-4464. Web
sites: www.IMI-sensors.com or www.PCB.com.
IMI Part # 080A127

4-4

Install Instrumentation

Description: the spot face tool attaches to a standard electric drill and provides a machined surface at least 1.1 times greater than the diameter of the
sensor. At the same time the tool drills a pilot hole which is then tapped for
the stud mounted sensor.

Spot Face and End Mill Tool

A901-1

A901-1 Mounting Pad

A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)
Note

Contractor should confirm Material Data Sheet conforms to
plant safety regulations and substitute epoxy if necessary.

4-5

40-200 inch-lbs. Torque Wrench with 1/8" hex bit

Suggested Vendor:
Grainger Part # 4JW57
Description:
3/8" drive inch-lbs. torque wrench. Any torque wrench with a range of
40 to 70 inch-lbs. and less than 5 inch-lbs. increments can be substituted.
1/4"-28 taps & tap handle
9/16" open end wrench

Surface Preparation
There are several ways to mount your accelerometers. This section discusses those ways and what you need to do to successfully mount your
accelerometers.
Stud Mounting
Note

Mounting location must provide a flat surface 1/2" in diameter.
If this is not possible, then an alternative mounting procedure
must be used. Do not proceed; contact project manager.

4-6

Install Instrumentation

then an alternative mounting procedure must be used.04" from the face.Note Mounting location must provide a case thickness exceeding . The surface should be smooth to touch with no noticeable irregularities. If this is not possible. contact project manager. 1 ···· Prepare the spot face and end milling tool by setting the drill bit depth to a minimum of .4". clean and degrease surface area. 4-7 . drill into mounting location until face has a minimum finish of 63 micro inches.325". The surface must be uniform on all sides. 3 ···· Keeping spot face and end milling tool perpendicular to machine surface. This will require the spot facing tool to remove approximately . 2 ···· Using wire brush and plant approved cleaner. Do not proceed. then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. If not.

tap pilot hole a minimum depth of .Note If the spot face is not uniform on all sides this is an indication that the spot face tool was not perpendicular to mounting surface and will not allow the sensor to be mounted properly.25". 4 ···· Using 1/4"–28 tap set. Spot Facing Tool 4-8 Install Instrumentation .

Proper (left) & Improper Spot Facing 4-9 .

1 ···· If necessary. contact project manager.-lbs. 6 ···· If adhesive does not setup within 1 minute. The surface should be smooth to touch with no noticeable irregularities. use spot facing tool to prepare flat surface. spray activator onto mounting surface. The surface must be uniform on all sides. this is an indication that too much epoxy was applied or that the mounting surface was not prepared properly. 4-10 Install Instrumentation . clean and degrease mounting area. 3 ···· Keeping spot face and end milling tool perpendicular to machine surface. 2 ···· Using wire brush and plant approved cleaner. 5 ···· Using A92016 2-part epoxy. of torque. Repeat installation steps 1-5.Epoxy Mounting Note Mounting Location must provide a flat surface 1/2" in diameter. Place a light coat of epoxy on surface of A0901-1 mounting pad and hold firmly against surface for 1 minute. then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. If this is not possible. If not.04" from the face. Do not proceed. then an alternative mounting procedure must be used. This will require the spot facing tool to remove approximately . 4 ···· Screw AO322 mounting stud into A901-1 mounting pad applying 78 ft. drill into mounting location until face has a minimum finish of 63 micro inches.

5 ···· If sensor is not to be mounted immediately. 2 ···· Using plant-approved epoxy. 3 ···· Using 1/4" allen wrench loosely screw A0322 into mounting location. Industrial tape is recommended. remove any lubricating fluid used during the tapping process. A0322 Quick Connect 4-11 . torque to 7-8 ft-lbs. rub a small amount of epoxy onto spot face. If after correct torquing. It will be necessary remove V205 and tap hole deeper. 4 ···· Using torque wrench with 1/4" hex bit.A0322 Mounting Stud Installation (Stud Mounting Only) 1 ···· Using plant-approved degreaser. it is necessary to cover exposed quick connect threads to prevent contamination. the A0322 mounting base is not seated against spot face this is an indication that the tap was not deep enough.

hand-tighten 9/16" captive nut and use a torque wrench with 9/16" open end to finish tightening to 50-60 in-lbs. 3 ···· Place sensor onto A0322 and hold in desired position to create the least amount of cable strain and cable exposure. Bundled cable must not be left hanging from sensor nor should bundled cable be exposed to damage such as on the plant floor. 4-12 Install Instrumentation . it is recommended that sensors not be mounted to machine. etc. If it is necessary to mount a sensor.Sensor Mounting Note If not ready to pull cables. it will be necessary to secure bundled sensor cable to machine in such a manner that no strain is placed on integral sensor/cable connector. maintenance access footholds. Holding sensor. 2 ···· Apply a thin coating of Loc-Tite semi-permanent thread locker to threads on sensor housing. 1 ···· If necessary. 5 ···· If not ready to perform cable pulls. then the bundled cable must be secured to the machine and protected from damage.8". clean A0322 mounting stud threads using plant approved degreaser/cleaner. Do not exceed bending radius of 2. 4 ···· Secure sensor cable to machine approximately 4 to 5" from mounting location using an appropriate size cable clamp.

Mounting Procedure 4-13 .

Proper Sensor Mounting with cable secured 4-14 Install Instrumentation .

A0322DS Description & Handling Instructions A0322LC. A0322DS 4-15 . A0322DS Image & Outline Drawing A0322LC.A0322LC.

Description The A0322LC is a general purpose accelerometer with a top exit integral connection. hammer. The integral cable connection enters the top of the sensor housing. Although the integral cable has built in strain relief. Caution! Do not exceed specified torque when tightening stud-mounted accelerometers. The A0322DS is a general purpose accelerometer and temperature sensor with a top exit integral connection. Mechanical shock loads of over 5000 g’s will damage sensor and void manufacturer’s warranty. 4-16 Install Instrumentation . Over tightening of accelerometer will damage sensing element and void manufacturer’s warranty. force should be exerted directly on sensor connection during installation. hammer. Caution! Do not drop. or after installation. during. A0322LC-NT can be purchased to allow the A0322LC or A0322DS to be easily removed from machine for maintenance. This sensors are stud mounted or epoxy mounted to machinery surfaces and transmit vibration data to the on-line monitoring system. or impact sensor housing before. Handling Instructions General purpose accelerometers are susceptible to mechanical shock and therefore it is very important for installers to take precaution when handling sensors. or impact the sensor housing before during or after installation. An optional quick release connection. When tightening down stud mounted accelerometers it is very important not to exceed specified torque. it is important that the cable not be strained with excessive pulling force during cable pulls. It is recommended that cable be secured to machine near the point of sensor installation if possible. Do not drop. No more than 5 lbs.

pull force directly on sensor/cable connection during wire pulls. A0322DS 4-17 .PCB. IMI Part # 080A127 A0322LC.Caution! Do not exert more than 5-lbs.) 3425 Walden Avenue. New York 14043.com. cable bundle should not be placed in such a manner that it will cause undue strain at the sensor/cable connection. Spot Face and End Mill Tool Suggested Vendor: Industrial Monitoring Instrumentation (a division of PCB. Required Tools & Parts Below is a listing of the require tools and parts in order to install the A0322LC and A0322DS accelerometers. Sensor cable cannot be stepped on or severely kinked or permanent signal degradation will occur.com or www. If sensor mounting occurs before cable is pulled in conduit or raceway to junction box it is important to leave cable bundled and secured to machine. Depew. Web sites: www.IMI-sensors. Inc. 1-800-959-4464. Also.

1 times greater than the diameter of the sensor.Description: the spot face tool attaches to a standard electric drill and provides a machined surface at least 1. Spot Face and End Mill Tool A212 Mounting Pad A212 Mounting Pad A92106 Loctite Depend mounting pad epoxy (epoxy mounting only) Note Contractor should confirm Material Data Sheet conforms to plant safety regulations and substitute epoxy if necessary. At the same time the tool drills a pilot hole which is then tapped for the stud mounted sensor. 4-18 Install Instrumentation .

Any torque wrench with a range of 40 to 70 inch-lbs. Torque Wrench with 1/4" hex bit Suggested Vendor: Grainger Part # 4JW57 Description: 3/8" drive inch-lbs. A0322LC. torque wrench. and less than 5 inch-lbs. increments can be substituted.A0322LC-NT Quick Release SS Nut & Threaded Base (Optional) A0322LC-NT Quick Release 40-200 inch-lbs. A0322DS 4-19 .

If this is not possible. then an alternative mounting procedure must be used.325". 4-20 Install Instrumentation .4". This section discusses those ways and what you need to do to successfully mount your accelerometers Stud Mounting Note Mounting location must provide a flat surface 1/2” in diameter. 1 ···· Prepare the spot face and end milling tool by setting the drill bit depth to a minimum of . contact project manager. The surface must be uniform on all sides. 3 ···· Keeping spot face and end milling tool perpendicular to machine surface. This will require the spot facing tool to remove approximately . then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. The surface should be smooth to touch with no noticeable irregularities.1/4"-28 taps & tap handle 9/16" open end wrench Surface Preparation There are several ways to mount your accelerometers. clean and degrease surface area. drill into mounting location until face has a minimum finish of 63 micro inches. If not. contact project manager. then an alternative mounting procedure must be used. Do not proceed.04" from the face. 2 ···· Using wire brush and plant approved cleaner. If this is not possible. Note Mounting location must provide a case thickness exceeding . Do not proceed.

25".Note If the spot face is not uniform on all sides this is an indication that the spot face tool was not perpendicular to mounting surface and will not allow the sensor to be mounted properly. Spot Facing Tool A0322LC. tap pilot hole a minimum depth of . 4 ···· Using 1/4"–28 tap set. A0322DS 4-21 .

Proper (left) & Improper Spot Facing 4-22 Install Instrumentation .

2 ···· Using wire brush and plant approved cleaner. A0322DS 4-23 . 1 ···· If necessary. Repeat installation steps 1-5. The surface must be uniform on all sides. If this is not possible. 6 ···· If adhesive does not setup within 1 minute. use spot facing tool to prepare flat surface.Epoxy Mounting Note Mounting location must provide a flat surface 1/2" in diameter. Place a light coat of epoxy on surface of A212 mounting pad and hold firmly against machine spot face surface for 1 minute. 3 ···· Keeping spot face and end milling tool perpendicular to machine surface. drill into mounting location until face has a minimum finish of 63 micro inches. This will require the spot facing tool to remove approximately . then an alternative mounting procedure must be used. this is an indication that too much epoxy was applied or that the mounting surface was not prepared properly. spray activator onto mounting surface. Do not proceed. If not. A0322LC. clean and degrease mounting area. then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. 4 ···· Screw mounting stud into A212 mounting pad until stud is flush with bottom of mounting pad. If using A0322LC-NT Quick-Connect then screw threaded base into mounting pad and torque to 5 ft-lbs. The surface should be smooth to touch with no noticeable irregularities. 5 ···· Using A92016 2-part epoxy.04" from the face. contact project manager.

2 ···· Apply a thin coating of Loc-Tite semi-permanent thread locker to threads on mounting stud. etc. Proper Sensor Mounting with cable secured 4-24 Install Instrumentation . Do not exceed bending radius of 2. 5 ···· If not ready to perform cable pulls.AO322LC Sensor Mounting (without Quick-Connect) 1 ···· If necessary. clean mounting location threads using plant approved degreaser/cleaner. Bundled cable must not be left hanging from sensor nor should bundled cable be exposed to damage such as on the plant floor.8". maintenance accesses. 4 ···· Secure sensor cable to machine approximately 4 to 5" from mounting location using an appropriate size cable clamp. 3 ···· Screw mounting stud into sensor housing and hand tighten. it will be necessary to secure bundled sensor cable to machine in such a manner that no strain is placed on integral sensor/cable connector. footholds. Screw sensor and mounting stud into mounting location and tighten with 9/ 16" torque wrench to 5 ft-lbs.

Caution! Do not terminate or secure cable to machine before mounting sensor. then bundled cable must be secured to machine and protected from damage.Caution! If not ready to pull cables. A0322LC. it is recommended that sensors not be mounted to machine. If necessary to mount sensor. A0322DS 4-25 .

torque to 7-8 ft-lbs. 2 ···· Using plant-approved epoxy. it is necessary to cover exposed quick connect threads to prevent contamination. Bundled cable must not be left hanging from sensor nor should bundled cable be exposed to damage such as on the plant floor. hand-tighten 7/8" captive nut and use a torque wrench with 7/8" open end to finish tightening to 50-60 in-lbs. rub a small amount of epoxy onto spot face. It will be necessary remove quick-connect base and tap hole deeper. 9 ···· Secure sensor cable to machine approximately 4 to 5" from mounting location using an appropriate size cable clamp.8".A0322LC with Quick-Connect Mounting Instructions 1 ···· Using plant-approved degreaser. Industrial tape is recommended. 6 ···· If necessary. clean A0322LC-NT Quick-Connect threads using plant approved degreaser/cleaner. etc. maintenance accesses. remove any lubricating fluid used during the tapping process. the A0322LC-NT Quick-Connect base is not seated against spot face this is an indication that the tap was not deep enough. 10 ·· If not ready to perform cable pulls. it will be necessary to secure bundled sensor cable to machine in such a manner that no strain is placed on integral sensor/cable connector. 5 ···· If sensor is not to be mounted immediately. Holding sensor. 4 ···· Using torque wrench with 1/4" hex bit. footholds. Do not exceed bending radius of 2. 4-26 Install Instrumentation . 8 ···· Place sensor onto A0322LC-NT and hold in desired position to create the least amount of cable strain and cable exposure. 7 ···· Apply a thin coating of Loc-Tite semi-permanent thread locker to threads on sensor housing. 3 ···· Using 1/4" allen wrench loosely screw AO322LC-NT into mounting location. If after correct torquing.

A0322DS 4-27 .Mounting Procedure A0322LC.

A0322RM Description & Handling Instructions A0322RM Image & Outline Drawing 4-28 Install Instrumentation .

pull force directly on sensor/cable connection during wire pulls. Caution! Do not exceed specified torque when tightening stud-mounted accelerometers. When tightening down stud mounted accelerometers it is very important not to exceed specified torque. it is important that the cable not be strained with excessive pulling force during cable pulls. or after installation. These sensors are stud mounted or epoxy mounted to machinery surfaces and transmit vibration data to the on-line monitoring system. or impact the sensor housing before during or after installation.Description The A0322RM is a general purpose accelerometer with 90-degree MIL-2 pin connection. hammer. Do not drop. It is recommended that cable be secured to machine near the point of sensor installation if possible. Over tightening of accelerometer will damage sensing element and void manufacturer’s warranty. Although the integral cable has built in strain relief. A0322RM 4-29 . Handling Instructions General purpose accelerometers are susceptible to mechanical shock and therefore it is very important for installers to take precaution when handling sensors. No more than 5-lbs. The MIL-2 pin connection joins the sensor housing at a 90-degree angle to provide a low-profile installation. Mechanical shock loads of over 5000 g’s will damage sensor and void manufacturer’s warranty. hammer. Caution! Do not drop. or impact sensor housing before. force should be exerted directly on sensor connection during installation. during. Caution! Do not exert more than 5-lbs.

New York 14043.com or www. Depew.) 3425 Walden Avenue. At the same time the tool drills a pilot hole which is then tapped for the stud mounted sensor. cable bundle should not be placed in such a manner that it will cause undo strain at the sensor/cable connection.If sensor mounting occurs before cable is pulled in conduit or raceway to junction box it is important to leave cable bundled and secured to machine. Spot Face and End Mill Tool 4-30 Install Instrumentation . Required Tools & Parts Spot Face & End Mill Tool Suggested Vendor: Industrial Monitoring Instrumentation (a division of PCB. 1-800-959-4464. Sensor cable cannot be stepped on or severely kinked or permanent signal degradation will occur. Also. IMI Part # 080A127 Description: the spot face tool attaches to a standard electric drill and provides a machined surface at least 1.com. Web sites: www. Inc.IMI-sensors.PCB.1 times greater than the diameter of the sensor.

increments can be substituted.A212 Mounting Pad (Epoxy Mounting Only) A212 Mounting Pad A92106 Loctite Depend Mounting Pad Epoxy (Epoxy Mounting Only) Note Contractor should confirm Material Data Sheet conforms to plant safety regulations and substitute epoxy if necessary. This section discusses those ways and what you need to do to successfully mount your accelerators A0322RM 4-31 . torque wrench. 40-200 inch-lbs Torque Wrench with 1/4" hex bit Suggested Vendor: Grainger Part # 4JW57 Description: 3/8" drive inch-lbs. Any torque wrench with a range of 40 to 70 inch-lbs. 1/4"-28 taps & tap handle 7/8" open end wrench Surface Preparation There are several ways to mount your accelerators. and less than 5 inch-lbs.

then an alternative mounting procedure must be used. The surface should be smooth to touch with no noticeable irregularities. 4-32 Install Instrumentation . 3 ···· Keeping spot face and end milling tool perpendicular to machine surface. If this is not possible.4". clean and degrease surface area. then an alternative mounting procedure must be used. If this is not possible. Note Mounting location must provide a case thickness exceeding . Do not proceed. The surface must be uniform on all sides.Stud Mounting Note Mounting location must provide a flat surface 1" in diameter. contact project manager. This will require the spot facing tool to remove approximately . then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. 2 ···· Using wire brush and plant approved cleaner. 1 ···· Prepare the spot face and end milling tool by setting the drill bit depth to a minimum of . Do not proceed. contact project manager.325". drill into mounting location until face has a minimum finish of 63 micro inches. If not.04" from the face.

Spot Facing Tool A0322RM 4-33 . 4 ···· Using 1/4"–28 tap set.25".Note If the spot face is not uniform on all sides this is an indication that the spot face tool was not perpendicular to mounting surface and will not allow the sensor to be mounted properly. tap pilot hole a minimum depth of .

Proper (left) & Improper Spot Facing 4-34 Install Instrumentation .

spray activator onto mounting surface. Repeat installation steps 1-5. use spot facing tool to prepare flat surface. The surface should be smooth to touch with no noticeable irregularities. This will require the spot facing tool to remove approximately . 6 ···· If adhesive does not setup within 1 minute. 2 ···· Using wire brush and plant approved cleaner. contact project manager. If not. 1 ···· If necessary.Epoxy Mounting Note Mounting Location must provide a flat surface 1" in diameter. A0322RM 4-35 . Place a light coat of epoxy on surface of A212-1 mounting pad and hold firmly against surface for 1 minute. 4 ···· Screw mounting stud into A212 mounting pad applying 7-8 ft-lbs. this is an indication that too much epoxy was applied or that the mounting surface was not prepared properly. then an alternative mounting procedure must be used. 5 ···· Using A92016 2-part epoxy. of torque. clean and degrease mounting area. The surface must be uniform on all sides.04" from the face. Do not proceed. then the tool was not engaged perpendicular to surface and the procedure must be repeated in a different location. If this is not possible. drill into mounting location until face has a minimum finish of 63 micro inches. 3 ···· Keeping spot face and end milling tool perpendicular to machine surface.

4-36 Install Instrumentation . rub a small amount of epoxy onto spot face. 5 ···· If sensor is not to be mounted immediately.A0322RM Mounting Stud Installation (Stud Mounting Only) 1 ···· Using plant-approved degreaser. remove any lubricating fluid used during the tapping process. Industrial tape is recommended. torque to 7-8 ft-lbs. If after correct torquing. 3 ···· Using 1/4" allen wrench loosely screw mounting stud into mounting location. the A0322 Quick-Connect base is not seated against spot face this is an indication that the tap was not deep enough. 2 ···· Using plant-approved epoxy. 4 ···· Using torque wrench with 1/4" hex bit. it is necessary to cover exposed quick connect threads to prevent contamination. It will be necessary remove mounting stud and tap hole deeper.

2 ···· Apply a thin coating of Loc-Tite semi-permanent thread locker to threads on sensor housing. Proper Sensor Mounting with cable secured A0322RM 4-37 . hand-tighten 7/8" captive nut and use a torque wrench with 7/8" open end to finish tightening to 50-60 in-lbs. clean A0322RM Quick-Connect threads using plant approved degreaser/cleaner. 4 ···· If not ready to pull cables.Sensor Mounting 1 ···· If necessary. cover exposed sensor connector threads with supplied connector cover. Holding sensor. 3 ···· Place sensor onto mounting base and hold in desired position to create the least amount of cable strain and cable exposure.

it is important to observe clearances between the sensor and the target as well as observe cable clearances. Caution! The V425 can be damaged if proper clearance is not maintained between sensor and actuator.V425 Description & Handling V425 Outline Drawing & Image Description The V425 Passive Magnetic Pickup is an industrial sensor used to measure the rotational speed of machinery. The sensor is commonly used to sense an actuator (target) on a rotating shaft giving a once per revolution trigger. Therefore. It is important follow installation procedures to set proper clearance. 4-38 Install Instrumentation . Handling The V425 is unique in that it is the only piece of system instrumentation which is installed near moving machinery (a rotating shaft typically).

If the included bracket will not work. then the contractor will have to fabricate a custom bracket. V425 Mounting Bracket V425 4-39 .Required Tools & Parts Mounting Bracket & Locking Nut (included) A universal mounting bracket is included with sensor which will fit a variety of applications.

5 inches F > .3 inches 4-40 Install Instrumentation .15 inches B > .Choosing Proper Actuator (Target) Actuator Dimensions The V425 is designed to be used with a key meeting the following minimum specifications: Key (Target) Dimensions A > .

Ideal actuators are soft iron. Modifying Large Actuators Actuator Material The actuator must be made of a metallic material with a high permeability.5 inches it is necessary to round the edges of the actuator to allow sensor to be as close as possible to actuator.If the chosen actuator has a dimension (A) which is must greater than . cold-rolled steel and #400 stainless steel. V425 4-41 .

5 ···· Secure bracket to mounting location and torque to bolt specifications V425 Mounting 4-42 Install Instrumentation . 3 ···· Place sensor/bracket assembly into mounting location and center sensor pole piece over actuator with pole piece touching actuator. 2 ···· Place sensor in mounting bracket and screw sensor into bracket exposing equal amount of threads on back and front of mounting bracket.Mounting Sensor Bracket 1 ···· Turn machinery shaft so that actuator is at mounting location.250 inch opening on mounting bracket. Mark hole locations on bracket. 4 ···· Drill and tap hole locations for appropriately sized bolt to fit .

Torque to 15 ft. V425 4-43 .-lbs. 7 ···· Cover exposed connector threads with included protective cap to prevent contamination. 4 ···· Slowly turn shaft and confirm that actuator is not contacting sensor. Let machine reach normal operating temperature and run through all operational speeds. If sensor is contacting shaft then repeat step (3) after loosening up lock nut.Mounting Sensor 1 ···· Screw locking nut onto sensor and thread completely onto sensor. 2 ···· Screw sensor into mounting bracket until sensor pole piece contacts actuator. 5 ···· Run machinery at full speed and confirm that sensor is not contacting actuator. 3 ···· Back sensor off 1 full turn and holding sensor in place thread locking nut against mounting bracket. 6 ···· Observe machinery during coastdown and confirm that sensor is not contacting actuator.

4-44 Install Instrumentation .

Box consist of individual 3 lug terminal blocks mounted on a DIN rail. The V745 is a 12 channel box (fiberglass or stainless steel) with 3 terminal phoenix connections for both the inputs and outputs.Chapter 5 Enclosure Mounting Mount V701.5" conduit connection. and 16 channel version in a fiberglass or stainless steel enclosure. V702. The V745 junction/switch box serves the dual purpose of providing a junction between the instrumentation and the 4500R or 4500S online system as well as allowing portable data collectors local data access. Sensor cables are individually pulled into box through standard PGME07 cord grips and exit the box through a 1. The V701 series consist of 8.5" conduit connection. Note Normal installation for the Model 4500R or 4500S unit is in an orientation such that the front panels are vertical. Sensor cables are individually pulled into box through standard PGME07 cord grips and exit the box through a 1. 12. and V745 Junction Boxes Description The V701 series junction boxes are NEMA 4X rated enclosures used to terminate the online instrumentation wiring. V703. 5-1 .

V701 Outline Drawing 5-2 Enclosure Mounting .

V745 Outline Drawing 5-3 .

Required Tools & Parts Mounting Feet (supplied with enclosure) Mounting Feet 5-4 Enclosure Mounting .

375 machine screws included with mounting feet. Mounting feet should aligned vertically to box to insure proper access for mounting. Torque screws to 31 inlbs. using bolts which will be provided by the contractor. 1 ···· Ensure chosen mounting location allows proper clearance for maintenance access. 4 ···· Attach enclosure to mounting bracket. Location should be well lit and should be at appropriate height off floor to allow service technician comfortable access. 2 ···· After choosing location. 3 ···· Attach mounting feet to back of enclosure using the 10-32x. prepare mounting bracket using outline drawing as a template for the mounting hole locations.Mounting Instructions Caution! Do not wire chassis to earth ground. Junction Box Access Requirements 5-5 .

5-6 Enclosure Mounting . Low-voltage instrumentation is terminated into the 4500R or the 4500S and is processed. The enclosure includes a power supply (if powered by 110VAC). and output via an Ethernet connection to a database server. The 4500R or 4500S is enclosed in a stainless steel enclosure which is intended to protect it from harsh industrial environments. analyzed. compressed.Mount 4500R and 4500S Data Collection Units Description The 4500R and the 4500S are online data acquisition systems used for predictive maintenance of plant machinery. a punch plate for pulling wire through. and cable management pathways along the sides and top of the enclosure. a duplex outlet receptacle for auxiliary power. a sub-panel for mounting accessories.

4500R Outline Drawing Mount 4500R and 4500S Data Collection Units 5-7 .

4500S Outline Drawing 5-8 Enclosure Mounting .

4500R or 4500S Enclsoure Access Drawing (Top View) Required Tools & Parts Mounting hardware not included. Mount 4500R and 4500S Data Collection Units 5-9 .

5-10 Enclosure Mounting . confirm that mounting location provides a path to earth ground. the door should be free to completely open to the side and there should be enough room to run conduit into the punch plate on the bottom of the box. 2 ···· If not using conduit into box. Attach all 4 mounting feet to rails and use hardened steel bolts with lock washer torqued to 50 ft.-lbs. In particular. Otherwise. a bonding wire must be used to connect enclosure to earth ground 1 ···· Ensure mounting location has proper access for installation and maintenance. It is acceptable to ground enclosure through conduit or mounting structure if grounded to earth. Location should be well lit and should be at appropriate height off floor to allow service technician comfortable access. 3 ···· The preferred method of mounting the 4500R or 4500S is to use mount the enclosure on two unistrut rails mounted on a vertical 24" center.Mounting Instructions Note 4500R or 4500S Enclosure must be grounded to earth.

Prepare 4500R or 4500S Cable Access Plate 5-11 .Prepare 4500R or 4500S Cable Access Plate Description The 4500R or 4500S enclosure is designed to have all cables enter from the bottom of the enclosure. Cable Access Plate Required Tools & Parts • Stainless steel hole punch or drill. The stainless steel plate is mounted to the box using 12 machine screws and a foam gasket to preserve a NEMA 4X rating. • Conduit fittings. a removable cable access plate was built into the bottom of the enclosure to allow contractors to remove the plate and prepare the access holes. For this reason.

2 V680 cable .5" conduit run. Two A680 cable pulls will require a 2" conduit run....5" conduit for 1 cable and . 1 V680 cable . The A680 cable is . 4500R or 4500S Ethernet Connection 1 ···· 4500R or 4500S Ethernet connection will be a 10BaseT Category 5 cable provided by the plant. 2 ···· The 4500R or 4500S Discrete input/output cable pulls will consist of either: a) A680 bundled cable pulls which will require 1. 4500R or 4500S Discrete Input/Outputs 1 ···· The 4500R or 4500S Discrete input/output cable pulls should enter the cable access plate on the right side (facing box) between the power pull and the Ethernet connection. 2 ···· Conduit fittings must be sized according to the number of A680 pulls coming from a junction box. An 8 channel junction box will use one A680 cable pull while 16 channel boxes will require two A680 pulls..5" conduit run.5" in diameter and will require a 1.. 2..0" conduit 4500R or 4500S Power 1 ···· Power line pull should be made to the far right corner of access plate (facing box) so that power cable is routed along right rear of enclosure.Determine Hole Size & Location A680 Bundled Cable Pulls 1 ···· A680 Cable pulls should be made on left side of access plate (facing box) so that cables can be easily routed along left side of enclosure. The cable pull should be to the right front of the cable access panel so that the CAT5 cable can be routed as far from the 4500R or 4500S power supply as possible along the right side of enclosure. 1..5" conduit 16-channel junction box . 2 ···· The conduit should be sized according to plant code and NEC for running power in the plant. 8-channel junction box . 2 ···· The Cat5 cable requires a minimum ..5" extra for each additional cable in pull. 5-12 Enclosure Mounting .

225 inches in diameter and either run in conduit. which will be .b) A672 single twisted pair cable. or pulled through cable access plate using 1/4" cord grips. Prepare 4500R or 4500S Cable Access Plate 5-13 .

5-14 Enclosure Mounting .

Wiring must conform to all applicable local codes and regulations. and any other standards must be followed. and pulling the online instrumentation cabling as well as the 680 bundled (multi-pair) cable from junction boxes to the 4500R and 4500S. wire size.Chapter 6 Cabling Requirements Introduction This chapter covers conduit installation guidelines. insulation voltage ratings. Warning! All wiring should be installed by a trained and qualified electrician. network cabling guidelines. power line specifications. color codes. Local codes and regulations regarding wire type. 6-1 .

24 AWG. PVC jacket. V745 12 pair. PVC jacket Table 2: Cable pulled in Tray or Aluminum Conduit Belden # Application Description 8168 V701 8-pair. Overall Braid Shield 8175 V702. Individual foil shield. Individual foil shield. Overall Braid Shield 8178 V703 18-pair. 6-2 Cabling Requirements . PVC jacket. V745 15-pair. 24 AWG. PVC jacket. Individual foil shield. Individual foil shield. 24 AWG. Overall Braid Shield Note For cables with overall braided shield. PVC jacket 9736 V703 17-pair.Jbox/4500R or 4500S Cable Recommendations Table 1: Cable pulled in Steel Conduit Belden # Application Description 9732 V701 9-pair. 24 AWG. the shield should be grounded to 4500R or 4500S enclosure via the grounding stud included on the 4500R or 4500S enclosure’s subpanel assembly. 24 AWG. PVC jacket 9734 V702. 24 AWG. Individual foil shield. Individual foil shield.

If plant codes will not allow the use of steel conduit then please contact project manager.. 4 ···· Effort should be made to route conduit away from power trays using the following guidelines: 6" .. 3 ···· Steel Conduit must be used. 440VAC 6-3 . c) Power cables for the 4500R or 4500S d) Any instrumentation cabling exceeding 50 feet. 220VAC 2’ .Conduit Installation Guidelines Note All conduit must be bonded to earth ground and adhere to IEEE 1100 specifications for grounding. 1 ···· The following cables must be pulled in Conduit: a) Between junction boxes and 4500R or 4500S b) Any 4500R or 4500S dedicated network segment cables not pulled in existing plant network infrastructure.. 110VAC 12" .. 2 ···· The conduit must be sized to not exceed a 40 percent fill...

5 ···· Conduit must enter 4500R or 4500S and junction boxes from bottom of enclosures. Conduit Access from Bottom 6-4 Cabling Requirements .

twisted pair. The instrumentation wire is pulled to the junction/switch boxes where it is joined to bundled. shielded. it is not normally enclosed in conduit although conduit will be required for specific applications. Care must be taken to ensure that exposed cabling is secured to machinery and plant infrastructure so as to not interfere with maintenance or cause safety hazards. multi-pair cabling ran back to the 4500R or 4500S.Pull Instrumentation Wiring Description The on-line instrumentation wiring is a polyurethane jacketed. instrumentation cable used to transmit millivolt level instrumentation signals to the online system. The cable is designed to provide noise shielding and protection within harsh industrial environments. Because the instrumentation to junction box pull is relatively short (<50 feet) and close to the machinery. Pull Instrumentation Wiring 6-5 .

Cable Variations There are four variations of instrumentation cable which are used in the online system: A.··· 2 Conductor. Instrumentation Cables 6-6 Cabling Requirements . ·· 2 Conductor. ·· 4 Conductor. Single Twisted-Pair Polyurethane Cable Integrated into V325 Sensor D. Single Twisted-Pair Polyurethane Cable With 2-Pin Mil Splash Proof Connector. ·· 2 Conductor. Single Twisted-Pair Polyurethane Cable Integrated into Sensor B. Single Twisted-Pair Armored Cable Integrated into Sensor C.

Required Tools & Parts • cable tie downs • wire labels • dielectric grease Installation Caution! If pulling in conduit cable pull force should not exceed 25 lbs. 3 ···· Choose a physical path for the sensor cable pull using the following guidelines: a) Remain 12" from 110VAC. Note Wire labels must be placed on each end of cable and have the same designation. 2 ···· Label cable on both ends using plant approved wire labels. Excessive force will deform twisted pair and degrade performance of cable. etc. Caution! Cables must be secured to plant infrastructure in such a manner that no safety hazards are created from plant personnel tripping on or catching slack cable on clothing or tool belt. 1 ···· If using the A612-I-30 cable. apply a thin coating of dielectric grease to connector and screw into sensor housing using hand force only. Wire label designations must be documented on “SENSOR LOCATION CARD” chart included on inside of junction/switch boxes. Pull Instrumentation Wiring 6-7 . 2’ from 220VAC and 440VAC power lines. Wire label designation must be the same on both ends of cable.

If using armored cable. d) Do not run any cable on floor. e) Do not run cable near pathways where it will be exposed to damage from moving machinery. shields. secure cable in 2-foot intervals to machinery and plant infrastructure using cable tie downs. 5 ···· At junction/switch box cable should be pulled through an existing PGME07 cord grip. Cut armor off with wire cutters and use heat shrink to seal end of armor. (Do not overtighten) Blunt cut cable leaving approximately 2 feet in box and relabel wire if necessary.b) Do not pull cable across machinery maintenance access areas: guards. Tighten cord grip with 9/16” wrench until cable is secure. access panels. 6-8 Cabling Requirements . 4 ···· Starting at sensor housing. remove armor before pulling through box by snipping the end of the armor with a pair of wire cutters and unraveling the length to be removed. c) Do not pull cable in machinery control/starting cable trays.

The twisted pair is 24 gauge and individually color-coded. At 4500R or 4500S enclosure. 3 ···· Blunt cut cable at junction box leaving 2 feet inside box for routing. 2 ···· Label wire according to project specifications and place label within 6 inches of cable access plate with label facing toward front of enclosure. A680 Required Tools & Parts • wire labels 4500R or 4500S Enclosure Installation 1 ···· Starting at junction box. The A680 is used to extend the on-line instrumentation wiring from the V701 and V745 junction boxes to the 4500R or 4500S data collection unit. pull cable through conduit run. Pull A680 Bundled Cable from Junction Box/4500R or 4500S 6-9 . blunt cut cable leaving 4 feet inside box for routing.Pull A680 Bundled Cable from Junction Box/4500R or 4500S Description The A680 bundled cable is a nine twisted pair instrumentation grade cable with individual foil shielding on each pair.

Although it is ultimately the responsibility of the plant to install and maintain the network. Note Although EIA/TIA 568/569 only requires CAT5 cabling. it is recommended that customers run at least CAT5e to be compatible with future upgrades. 2 ···· Pathways & Cable Trays per EIA/TIA 569. Note Network Cabling to 4500R or 4500S should be in steel conduit. the following guidelines are recommended: 1 ···· Handling & Care Guidelines per EIA/TIA 568/569.3 Ethernet protocol. 6-10 Cabling Requirements . It is recommended that customers run a dedicated physical network segment between the database server and 4500R or 4500S.Guidelines for Dedicated 4500R or 4500S Network Segment Description The 4500R or 4500S Data Collection Unit communicates with a database server via a 10BaseT-network connection adhering to the IEEE 802.

AC Power Specifications: • Nominal voltage:110VAC • Circuit Breaker:10 Amps (with duplex receptacle) 4500R or 4500S Power Circuit Guidelines 6-11 . Note Power circuit should contain an isolated ground.5 Amps • Nominal Current Draw1. An optional AC power supply can be purchased if 110 VAC is available. DC Power Specifications: • Nominal input voltage range:12v to 24v DC • Absolute input voltage range:10v to 36v DC • Maximum Current Draw3. Although the 4500R or 4500S contains input protection and some degree of line conditioning. the quality of the power provided to the 4500R or 4500S is very important. The 4500R or 4500S was designed to be powered by a DC supply to make use of existing plant process control power. it is important for the plant to follow specific guidelines when running power to the 4500R or 4500S enclosure.4500R or 4500S Power Circuit Guidelines Description The 4500R or 4500S Data Collection Unit is a laboratory grade instrument measuring millivolt level instrument signals. Therefore.5 Amps • Minimum wire gauge:16AWG • Cable:shielded twisted pair. Note Contractors should adhere to the IEEE 1100 specification for powering and grounding electronic equipment.

• Power ground:Isolated (from production equipment) 6-12 Cabling Requirements .

703.Chapter 7 Wire Terminations Terminate V701. Junction Box Routing 7-1 .5" conduit fitting on the right side of the box. The cables will be routed through the box leaving a service loop and terminated to 3-lug terminal blocks on the V701 series or industry standard Phoenix connectors on the V745. 702. and 745 Wiring Description The V701 and V745 series junction boxes will have single twisted pair instrumentation wire pulled through cable grips on the left side of box and one or more V680 bundled 9 twisted pair cable pulled through a 1.

Required Tools & Parts • wire labels • 24 AWG wire strippers • cable tie down 7-2 Wire Terminations .

5 ···· Terminate the wire into the proper terminal block as follows: a) Connect white wire (sensor positive input) to upper level of the terminal block. c) Connect braided shield to lower level of the terminal block. Note Shield connections pass through junction boxes and are not grounded at the box! 1 ···· Starting at cord grip pull wire to top of box on left side. Twisted Pair Prepared 4 ···· Strip 1/4" from each conductor and twist braided shield at end. 2 ···· Strip 1" of polyurethane jacket from cable. 7-3 . Pull service loop as shown in diagram. 3 ···· Carefully pull twisted pair conductors out of braided shield. b) Connect black wire (sensor negative input) to middle level of the terminal block. Do not overtighten connector. Do not remove braided shield. Turn terminal screw clockwise until contact with wire is made then 1/4 turn additional.Terminate Instrumentation Wire Caution! Use correct gauge strippers on individual conductors. Do not strip more than a 1/4" off conductor.

bundle cables and secure against side of junction box using only one cable tie down.Terminal Connections 6 ···· Relabel wire at phoenix connector 7 ···· After all cables are terminated. 7-4 Wire Terminations .

1 ···· Starting at cord grip. strip cable jacket and braided shield off cable. Do not strip more than a 1/4" off conductor. Turn terminal screw clockwise until contact with wire is made then 1/4 turn additional. Do not overtighten connector. 2 ···· Use the following pair sequence from top to bottom beginning at first terminal block: Positive Conductor Terminal Block Negative Conductor Foil Shield 1 Yellow Black Black 2 Blue Black Blue 3 Brown Black Blue 4 Orange Black Blue 5 White Black Red 6 Red Black Red 7 Green Black Green 8 Red White Blue 7-5 .Terminate V680 Bundled Cable Caution! Use 24 AWG gauge strippers on individual conductors.

Note For 16 channel box. V680 Cable Preparation 7-6 Wire Terminations . 4 ···· Pull to terminal block and blunt cut any extra wire. b) Negative Conductor on middle level of terminal block. Pull service loop as shown in diagram. start sequence over on terminal block #9. 6 ···· Strip 1/4" from each conductor and terminate to terminal block as follows: a) Positive Conductor on upper level of terminal block. 3 ···· Pull individual twisted pair (with foil shield in place) to top of box on right side. 5 ···· Remove 1" of foil shield from twisted pair and seal foil shield using heat shrink or electrical tape. c) Shield Drain on lower level of terminal block.

The 4500R enclosure also includes a 110V duplex receptacle for auxiliary power. control wiring (discrete input/outputs).Terminate 4500R Wiring Description The 4500R enclosure was designed to have cables enter from the bottom through a stainless steel removable access plate. and the network connection is routed along the right side of the enclosure. and a network connection. 4500R Cable Routing Terminate 4500R Wiring 7-7 . Instrumentation wiring is routed along the left side of the enclosure while control. power. power. The access plate will have conduit fittings/cord grips for instrumentation wiring.

. (left terminal)\ 4) Secure power cable to side of enclosure using only one cable tie down.. + (right-most terminal) b) – DC . Fan Tray Termination 7-8 Wire Terminations .... – (middle terminal) c) shield . 2) Pull wire to phoenix connector located next to the On/Off switch and blunt cut excess wire.Required Tools & Parts • Velcro cable tie downs • 5 AMP fuse block (required for auxiliary 110V AC power) • RJ45 CAT5 connector and tools Terminate Power DC (with Fan Tray) 1) Route Cable along right rear of box and up right side pulling service loop as shown in diagram.. 3) Remove 1" of cable jacket and strip conductors 1/4" and terminate to Phoenix connection as follows: a) + DC .

2 ···· Pull wire to Phoenix connector labeled input on the 4500R Power Supply card and blunt cut excess wire. 3 ···· Remove 1" of cable jacket and strip conductors 1/4" and terminate to Phoenix connection as follows: d) + DC .. + (left most terminal) e) – DC .. (right terminal) Terminate 4500R Wiring 7-9 ..DC (without Fan Tray) 1 ···· Route Cable along right rear of box and up right side pulling service loop as shown in diagram. – (middle terminal) f) shield ....

4500R Power Supply Termination 7-10 Wire Terminations .4 ···· Secure power cable to side of enclosure using only one cable tie down.

AC Power (with duplex receptacle) 1 ···· Route power cable from right rear of enclosure into the 4500R external power supply AC input connection. and ground according to AC input connector labels. 2 ···· Terminate power cable’s line. neutral. 3 ···· Splice 16 gauge wire from AC input connector to duplex receptacle. Phoenix Connection Terminate 4500R Wiring 7-11 . 4 ···· Install 5 amp in-line fuse on hot conductor running to duplex receptacle 5 ···· Terminate wire inside receptacle.

AC Power (without Duplex Receptacle) 1 ···· Route power cable from right rear of enclosure into the 4500R external power supply AC input connection... neutral. Turn terminal screw clockwise until contact with wire is made then 1/4 turn additional... Do not strip more than a 1/4" off conductor. 3 ···· Terminate in phoenix connector as follows: a) Relay Excitation Voltage . Strip 1" from cable jacket and 1/4" from each conductor. (–) c) Shield Drain . 2 ···· Blunt cut excess wire. Terminate Discrete Input/Outputs Caution! Use correct gauge strippers on individual conductors.. (+) b) Voltage Return . Do not overtighten connector. and ground according to phoenix connection labels. Pull cable down to discrete input/output channel. 1 ···· Pull cable up right side of enclosure (in front of AC power supply if present) and over the top of 4500R unit. 2 ···· Terminate power cord line. (GND) 7-12 Wire Terminations ..

5 ···· After all wires are pulled.4 ···· Relabel wire at connector. 6 ···· Document discrete input/output name. bundle wires with Velcro cable wrap on right side of enclosure and on top of 4500R. and 4500R channel number on cable administration chart. Discrete I/O Cable Routing Terminate 4500R Wiring 7-13 . Secure bundle to right side of enclosure in only one location. wire label name.

4 ···· Secure network connection to right side of enclosure using cable tie down. Network Connection Training 7-14 Wire Terminations . 3 ···· Blunt cut excess wire and attach RJ45 CAT5 connector using plant specified pintout for 10BaseT.Terminate Network Connection 1 ···· Pull network cable up right side of enclosure (in front of AC power supply if present) and along side of 4500R unit. 2 ···· Bring cable across 4500R power supply card and to 10BaseT RJ45 connection point.

3 ···· Remove cable jacket beginning where cable crosses over top of 4500R.Terminate A680 Bundled Cable Instrumentation Wiring Caution! Use 24 AWG gauge strippers on individual conductors. 5 ···· Blunt cut excess wire. 2 ···· Secure cable to left side of enclosure with cable tie down. Terminate 4500R Wiring 7-15 . Do not strip more than a 1/4" off conductor. 4 ···· Pull individual pairs down to proper channel on 4500R unit. Do not overtighten connector. Turn terminal screw clockwise until contact with wire is made then1/4 turn additional. Instrumentation Cable Routing 1 ···· Pull cable up left side of enclosure and over top of 4500R.

6 ···· Remove 1" of foil shield and place wire label around end of foil
shield. Wire label must match sensor wire label in junction box.
7 ···· Strip 1/4" from each conductor and terminate into phoenix connector
as follows:
a) Positive Conductor from Junction Box ... (+)
b) Negative Conductor from Junction Box ... (–)
c) Shield Drain ... GND
8 ···· Document sensor name, wire label name, and 4500R channel
number on 4500R cable administration chart.

7-16

Wire Terminations

Appendix

A

4500R or 4500S Default Network Addressing Schema
1

A-1

A-2

4500R or 4500S Default Network Addressing Schema

Appendix

B

Additional 4500R Connections

Introduction
On the following pages are additional connections that may help you in setting up the 4500R.

B-1

4500R Proximity Probe Interconnetion Diagram 1 B-2 Additional 4500R Connections .

4500R 4-20ma Current Loop Interconnection 2 3 4500R 4-20ma Current Loop Interconnection B-3 .

B-4 Additional 4500R Connections .

and any other standards must be followed. wire size. If it is not installed and maintained properly. Warning! All wiring should be installed by a trained and qualified electrician. The switch or circuit breaker must be in close proximity to the equipment and within easy reach of the operator. the 4500R unit may not function properly or in the manner desired. Caution! Installation and use of the Model 4500R or 4500S AC-DC Power Converter in a manner not specified by CSI may impair protection offered by the equipment. C-1 . color codes.Appendix C AC-DC Power Converter Introduction The AC-DC Converter is the power center of the 4500R or 4500S unit. insulation voltage ratings. Wiring must conform to all applicable local codes and regulations. Local codes and regulations regarding wire type. Warning! Power to the 4500R or 4500S AC-DC power converter PCB must include a remote disconnect switch or circuit breaker.

• All wiring should be installed by a trained and qualified electrician.Connecting and Maintaining the 4500R or 4500S unit General points to remember when installing the 4500R or 4500S unit and connecting power to it: • The Model 4500R or 4500S AC-DC Power converter PCB is connected to the mains supply through the AC Power Input terminal block located near the bottom of the panel. Wipe off with a clan damp cloth. • Fuses should be replaced by qualified personnel only.6A 250V Slo-Blow type (250V 1. • Normal installation of the Model 4500R or 4500S unit is in an orientation such that the front panels are vertical.6A T). • Replacement fuses should be 1. Required Tools and Parts • Velcro cable tie downs • Remote disconnect switch or circuit breaker • 5 AMP fuse block (required for auxiliary 110V AC power) • # 8 ring terminals • 16 GA wire strippers • Crimp tool for ring terminal • Flat tip screwdriver C-2 AC-DC Power Converter . • Wiring must conform to all applicable local codes and regulations. Abrasive cleaners or instruments should not be used. • Operators should use normal caution when cleaning surfaces of the Model 4500R or 4500S front panels.

60 hertz.4500R (with duplex receptacle) 1. ··· Terminate wire inside receptacle. Note No configuration setup of the unit is required to change operating voltage. Connecting and Maintaining the 4500R or 4500S unit C-3 . ··· Terminate power cable’s line. • Intended temperature ranges 5ºC (41ºF) to 50ºC (122ºF). 2. ··· Install 5 amp in-line fuse on hot conductor running to duplex receptacle. neutral. Pollution Degree 2 environments. 5. 4500R (without duplex receptacle) and 4500S 1. • Power input ranges of 100 .240 Volts. 50 . ··· Splice 16 gauge wire from AC input connector to duplex receptacle. • Altitude up to 2000m. 4. 3.···· Route power cable from right rear of enclosure into the 4500 AC-DC power converter AC input connection. 2. Safe Operation of the 4500R or 4500S AC-DC Power Converter The Model 4500R or 4500S AC-DC Power Converter PCB is suitable for safe operation in: • Intended for indoor use. • Relative humidity: 0 to 95% non-condensing. and ground according to AC input connector labels. ··· Terminate power cable’s line. 2 Amperes (maximum) and will dissipate approximately 35 Watts of power.···· Route power cable from right rear of enclosure into the 4500 AC-DC power converter AC input connection. • Overvoltage Category II (Installation Category II). neutral. and ground according to AC input connector labels.

Below is a brief description of the indicators. These include two power outputs and eleven LEDs. AC-DC Converter panel C-4 AC-DC Power Converter .Indicators There are several indicators on the AC-DC Converter panel.

···· Route cable along right rear of box and up the right side pulling a service loop. ··· Pull wire to the phoenix connector located just below the power status indicators and blunt cut excess wire. 3. 3. ··· Remove 1" of cable jacket and strip conductors 1/4" and terminate to Phoenix connector as follows: a) +DC … + ( top terminal) b) –DC … – (middle terminal) c) shield … Gnd (bottom terminal) The auxiliary sensor output connector is labeled: AUX+/–24V 25V. ··· Pull wire to the phoenix connector located just above the power switch and blunt cut excess wire.6A Fan output connections 1.···· Route cable along right rear of box and up the right side pulling a service loop. 2. Both are stenciled to indicate the maximum output voltage and current from the terminals. 0.Power Output Connectors Two power outputs provide optional power to auxiliary external sensors (such as proximity probes) and an external cooling fan. 2. Auxiliary sensor output connections 1. ··· Remove 1" of cable jacket and strip conductors 1/4" and terminate to Phoenix connector as follows: a) +DC … + ( top terminal) b) –DC … – (middle terminal) c) shield … Gnd (bottom terminal) Power Output Connectors C-5 .

The LEDs are listed in the following table: Front Panel Label C-6 Color Fail Red 3.3V Green 5V Green +12V Green –12V Green +24V Green AUI Green AUX24V Green Fan24 Green Power On Green AC Power Green AC-DC Power Converter . Ten are green and when “on” (illuminated) indicate that the corresponding voltage signal is at is “active” level. 0.The fan output connector is labeled: FAN24 25V.3A LED Indicators Eleven individual LEDs indicate the condition of internal and external voltage signals. One LED is red and when “on” (illuminated) indicates that power has failed.

Appendix D Connection Parameters Uses and Specifications Note This equipment is only suitable to use in Class I. Do not disconnect equipment unless you are in a non-hazardous area. Division 2. Groups C and D or non-hazardous locations. Warning! Explosion Hazard. Do not remove or replace lamps or fuses unless you have disconnected the power or you are in a non-hazardous area. D-1 . Warning! Explosion Hazard.

24VDC Imax = 100uA Ci = 1.24 VDC It = 5mA Imax = 50uA Ca = 1-uf Ci = 1.Specifications for equipment that supplies and receives energy: Mux Board: Vt = 24VDC Vmax = +/.5uf La = 100mH Li = 100mH Tach Board: Vmax = +/.5uf Li = 100mH I/O Board: D-2 Vt = 24VDC Vmax = 10VDC It = 500mA Imax = 500mA Ca = 10uf Ci = 1500uf La = 1mH Li = 1mH Connection Parameters .

4-23. 4-12. 4-26 A0322RA 4-1 A0322RI 4-1 A0322RM 4-28. 4-36 A0322DR 4-1 A0322DS 4-15 A0322LC 4-15 A0322LC with Quick-Connect 4-26 A0322LC-NT 4-16 A0322LC-NT Quick Release SS Nut & Threaded Base 4-19 A0322LC-NT Quick-Connect 4-23. 4-20. 4-31 10BaseT RJ45 7-14 110AC 6-3 220AC 6-3.Index Numerics 1/4"-28 taps & tap handle 4-6. 6-7 24 AWG gauge strippers 7-5 24 AWG wire strippers 7-2 440AC 6-3. 4-31 A212 mounting pad 4-23 A612-I-30 cable 6-7 A680 Bundled Cable 7-15 A680 Bundled Cable Pulls 5-12 A901-1 mounting pad 4-10 A92016 2-part epoxy 4-10. 6-7 4500 4-20ma Current Loop Interconnection B-3 4500 Enclosure 3-7. 4-35 A92106 4-5. 4-31 A A0322 4-11 A0322 Quick-Connect 4-11. 4-36 A0322RM Quick-Connect 4-37 A212 Mounting Pad 4-18. 4-20. 6-9 4500 Proximity Probe Interconnetion Diagram B-2 4500S Enclosure 3-11 5 AMP fuse block 7-8 9/16" open end wrench 4-6. 4-18 A92106 Loctite Depend Mounting Pad Epoxy (Epoxy Mounting Only) 4-31 AC Power (with duplex receptacle) 7-11 AC Power (without Duplex Receptacle 7-12 AC Power Specifications 6-11 AC-DC Power Converter C-1 safe operation C-3 Actuator Dimensions 4-40 Actuator Material 4-41 AO322 Quick-Connect 4-10 AO322LC Sensor Mounting 4-24 C cable tie down 7-2 cable tie downs 6-7 Cable Variations 6-6 Chapter 2 Pre-Installation Review 1-7 Chapter 3 System Documentation 1-7 Chapter 4 Instrumentation Installation 1-7 Chapter 5 Enclosure Mounting 1-7 Chapter 6 Cabling Requirements 1-7 Chapter 7 Wire Terminations 1-8 conduit steel 6-2 tray or aluminum 6-2 Connecting and Maintaining the 4500R or 4500S unit C-2 Connection Parameters D-1 Contractor Kickoff Meeting 2-2 I-1 .

D M DC (with Fan Tray) 7-8 DC (without Fan Tray) 7-9 DC Power Specifications 6-11 Dedicated V4500 Network Segment 6-10 Description 4-3. 4-29 dielectric grease 6-7 Documentation Storage 3-13 Machine Level Diagram 3-3 Mount V4500 and 4500S Data Collection Units 5-6 Mounting Bracket & Locking Nut 4-39 Mounting Sensor 4-43 Mounting Sensor Bracket 4-42 Mux Board D-2 E N EIA/TIA 568/569 6-10 Epoxy Mounting 4-10. uses and specifications D-1 Negative Conductor 7-5 O Final Walk-Through 2-3 Foil Shield 7-5 output connections auxiliary sensor C-5 fan C-5 Overall System Diagram 3-3 H P Handling Instructions 4-3. 7-12 Positive Conductor 7-5 Prepare V4500 Cable Access Plate 5-11 Project Manager 1-3 Pull Instrumentation Wiring 6-5 F I I/O Board D-2 Indicators C-4 LED C-6 Power Output Connectors C-5 auxillary sensor C-5 fan output C-6 Installation 6-7 J Jbox 6-2 Junction Box 7-16 I-2 R Required Tools & Parts 4-4 RJ45 CAT5 connector 7-8. 4-16. 4-29 PGME07 cord grip 6-8 phoenix connector 7-8. 4-35 Equipment warnings. 7-14 S SENSOR LOCATION CARD 6-7 Sensor Mounting 4-12. 4-37 Special 1-2 Spot Face & End Mill Tool 4-30 . 4-16. 4-23.

7-2 I-3 . 4-20. 4-17 Stud Mounting 4-6. 6-9. 4-32 Surface Preparation 4-6. 4-19. 4-31 V V425 4-38 V425 Passive Magnetic Pickup 4-38 V4500 and junction boxes 6-4 V4500 dedicated network segment cables 6-3 V4500 Discrete Input/Outputs 5-12 V4500 Ethernet Connection 5-12 V4500 Power 5-12 V4500 Power Circuit Guidelines 6-11 V4500 Power Supply 7-9 V4500 power supply card 7-14 V4500 Wiring 7-7 V680 Bundled Cable 7-5 V701 and V745 series junction 7-1 V701 series junction boxes 5-1 V745 junction/switch box 5-1 Velcro cable tie downs 7-8 W wire labels 6-7. 4-31 System Component Review 2-4 T Tach Board D-2 terminal block 7-3 7-5 Terminate Discrete Input/Outputs 7-12 Terminate Network Connection 7-14 Torque Wrench 4-6.Spot Face and End Mill Tool 4-4. 4-20.

I-4 .