Rockwell Dynarix

Dynamix 1444 Monitoring & Protection
John Raby
Commercial Engineer
PUBLIC INFORMATION
Rev 5058-CO900E
Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Introduction to Condition Monitoring
Applications
Machinery Protection
Introducing the Dynamix 1444 Series Monitors
Questions?
PUBLIC INFORMATION
What is Condition Monitoring?

1. Measurable phenomena (characteristics) are identified that collectively indicate
the condition of the machine.
The goal is to detect,

identify, and act on, changes
in the condition of a machine
that indicate some potential
failure.
2. Each of these characteristics is

measured, analyzed, and recorded so
that trends can be recognized.
3. As faults propagate trends of its
indicators typically amplify past alarm
set points, prompting action.
PUBLIC INFORMATION

Vibration: The Core Condition Monitoring Technology
Vibration is the preeminent CM technology for rotating equipment

because of these three principles:
All rotating equipment vibrates
Vibration increases/changes as equipment condition deteriorates
Vibration can be accurately measured and interpreted
Causes of vibration:
Forces that change in direction with time (e.g., Rotating Unbalance)

Forces that change in amplitude or intensity with time (e.g., Motor Problems)
Frictional Forces (e.g., Rotor Rub)
Forces that cause impacts (e.g., Bearing or Gear Tooth Defects)
Randomly generated forces (e.g., Turbulence)
PUBLIC INFORMATION

Vibration is a key parameter to monitor, but other
process parameters are also indicative of machine
condition
PUBLIC INFORMATION
Sustainable Condition Monitoring

What is it?
Self Sustaining Condition Monitoring

is a philosophy of how Condition
Monitoring Systems and Programs
should be applied
Sustainable Condition Monitoring Programs
Traditional Condition Monitoring Programs
to insure that they can be

sustained as personnel
change, program needs change,
and as organizations evolve.
PUBLIC INFORMATION

Considerations in applying Sustainable Condition Monitoring
Choose the right equipment to monitor

Do not fall into the trap of attempting to monitor everything.
Focus on Machines whose failure
Would have an immediate or significant impact on production, safety or quality

o Would require lengthy or expensive repairs
o
Determine the most common failure modes that cause down time in the
machine.
What causes 90% of the mechanical failures encountered?

Unbalance
o Misalignment / Looseness
o Defective Bearings
o
Design a closed loop solution that converts data to actionable information

Leverage existing plant automation and information architecture and existing skill sets.
Buy what you need and no more.
Automate as Much of the Solution as Possible.

PUBLIC INFORMATION

Apply Rules for Faults Common to the Monitored Machine
Unbalance (1 X RPM)
Bearing Wear (Vibration at frequencies

indicative of worn bearing elements)
Mechanical Looseness and

Misalignment (2x & 3x RPM)
Apply Standard, Well Defined Rules for Diagnostics

PUBLIC INFORMATION

Implement as Simple Logic
Most machinery problems can be

identified using one or more basic
if then statements that can be
easily modeled in Logic
Machinery Unbalance
If 1x rpm is > 5 mm/sec = WARNING
If 1x rpm is > 10 mm/sec = DANGER
Blade Pass (Flow Instability, Fouling)
PUBLIC INFORMATION
If 5x rpm is > 3.5 mm/sec = WARNING
If 5x rpm is > 7.0 mm/sec = DANGER


Present Actionable Information
Present Information in Meaningful Formats

PUBLIC INFORMATION
10
Quality
Production
Assurance
Predictive
Maintenance
Protection
Applications of Condition Monitoring
PUBLIC INFORMATION
Systems that sense, measure and monitor parameters and that act to mitigate
damage upon detection of an abnormal condition
The application of condition monitoring technologies for the purpose of optimizing

maintenance planning and costs.
When condition monitoring is applied to maintenance planning in a systematic
way, the process is called Condition Based Maintenance (CBM).
Systems that monitor and analyze machine condition so as to mitigate problems,

or allow their repair, before they impact production or the machines ability to
perform its function.
Systems that monitor and analyze machine or product condition so as to assure

promised quality.
Any Quality application will be an Engineered Solution
11
Protection versus Condition Monitoring

Protection
Monitoring
Protection systems are applied when failure of an asset

could cause:
Monitoring systems are applied for one of three reasons:
Predictive Maintenance: Systems are applied for the purpose of

optimizing maintenance planning and costs.
Production Assurance : Systems are applied or the purpose of

identifying developing faults in time to avoid unscheduled outages
on critical equipment that will impact production
Quality Control: Applied for the purpose of monitoring the quality

of a product or of machines that affect the quality of a product.
Physical harm
Unacceptable Environmental Damage
Exceptional financial loss due to:
Machine repair or replacement costs

Cost of lost production
Standards are often required to be satisfied. These may

include, among others:
API-670, Machinery Protection Systems

ISA-SP77.12, Turbine Supervisory Instrumentation
ISO 13849, Safety of Machinery
IEC 61508, Functional Safety
PUBLIC INFORMATION
12
Protection System Application
Protection systems are applied when

failure of an asset could cause:
Physical harm
Unacceptable Environmental Damage
Exceptional financial loss due to
o Machine repair or replacement costs
o Cost of lost production
Accidents Do Happen
December 25, 1993: Fermi 2 experienced a routine operational
history until Christmas Day in 1993, when a failure of one of the low
pressure turbines caused major damage to the turbine and the main
generator. After a 13-month outage to repair
The failure was caused by vibrations in the Low Pressure Turbine
which led to fatigue cracking of the low pressure turbine blades
PUBLIC INFORMATION
13
Introducing the Dynamix 1444 Series

Machine Protection
Machine Condition Monitoring
Intelligent, Distributed, Rugged, Safe

High Performance Dual Processors, Ethernet, Integrated, Rated to +70 C and Marine standards for Shock & Vibration, Hazardous Area Approved
PUBLIC INFORMATION
14

(just) 6
Catalog Numbers
A Single Main Module
+ a single main module terminal base
Three Optional Expansion Modules
+ one common terminal base for all expansion modules.

PUBLIC INFORMATION
15

in a new, innovative package
A Single Main Module
Ethernet connections located

for easy, uncluttered access
Connectors are angled for improved

access and visibility
+ a single main module terminal base

Removable
terminal
connectors
Both screw and

spring version
connectors available
Recessed frame
designed for
easy gripping
Integrated
BNC
connectors
Soldered together card

stack construction
Innovative DIN mount

design with tension
and leveling control
Three Optional Expansion Modules
+ one common terminal base for all expansion modules.

PUBLIC INFORMATION
16
Dynamix 1444 Series

1 Main Module
Dynamic Measurement Module
(requires the 1444-TB-A terminal base)
4 Dynamic Inputs
2 Speed Inputs (TTL)
4 Buffered Outputs (BNC & Terminal Pins)
2 Digital Inputs
Function is user programmable
2 Digital Outputs
2 Ethernet ports
Single or Device Level Ring (DLR)
1 SPDT Relay
Many, perhaps most, applications will require only

one or more Dynamic Measurement (Main) Modules
PUBLIC INFORMATION
17
Dynamix 1444 Series

1 Tachometer Expansion Module
4 Dynamic Inputs
2 Digital Inputs
2 Digital Outputs
2 Ethernet ports
1 SPDT Relay
Tachometer Signal Conditioner

Expansion Module
(requires the 1444-TB-B terminal base)
2 Speed Inputs
any common speed sensors
2 Speed Outputs (TTL)
to Local Bus & Terminal Pins
2 Buffered Outputs (BNC)
6 Dynamic Measurement Modules
served per
Tachometer
Expansion
Module
1 per Dynamic
Measurement
Module
When (non TTL) speed signals must be monitored, a single

Tachometer Signal Conditioner Expansion Module (TSCX)
must be added. The TSCX is hosted by one Main Module
but can serve its TTL output signals 6 Main Modules.
PUBLIC INFORMATION
18
Dynamix 1444 Series

1 Relay Expansion Module
4 Dynamic Inputs
2 Digital Inputs
2 Digital Outputs
2 Ethernet ports
1 SPDT Relay
When more than one relay

is needed, up to three
Relay Expansion
Modules may be added.
Relay function is specific to the host Main
Module.
Relay Expansion Module

Expansion Module
2 Speed Inputs
served per
Tachometer
Expansion
Module
1 per Dynamic
Measurement
Module
4 Singe Pole Double

Throw (SPDT) Relays
5A, 250VAC/30VDC
3 per Dynamic Measurement Module
PUBLIC INFORMATION
19
Dynamix 1444 Series

1 Analog Output Expansion Module
4 Dynamic Inputs
2 Digital Inputs
2 Digital Outputs
2 Ethernet ports
1 SPDT Relay
4-20mA Output Expansion Module
4 Channels
Proportional to any
measured value

Expansion Module
2 Speed Inputs
served per
Tachometer
Expansion
Module
When proportional analog outputs are required,

1 per Dynamic
one 4-20mA Output Expansion
Module may be
Measurement
Relay
Expansion Module
added.
Module
4 Singe Pole Double

Throw (SPDT) Relays
5A, 250VAC/30VDC
PUBLIC INFORMATION
20
Dynamix 1444 Series

2 Terminal Bases
1444-TB-A
Use with the 1444-DYN04-01RA

Dynamic
Measurement Module
4 Dynamic
Inputs
Includes last octets Ethernet
addressInputs
selection
2 Speed
(TTL)
Precision module / base alignment
guides
DIN mount tension / leveling
screwsInputs
2 Digital
Local Bus ribbon connectors Function is user programmable
2 Digital Outputs
1444-TB-B
2 Ethernet ports
Use with:
Single
Device Level Ring (DLR)
1444-TSCX02-02RB Tachometer
SignalorConditioner
Expansion Module
1 SPDT Relay
1444-RELX00-04RB Relay Expansion Module

1444-AOFX00-04RB
4-20mA
Output Expansion Module
4-20mA
Output Expansion
Module
Relay Modules
Relay) Expansion Module
(addressing for other expansion modules is automatic
(requires
the 1444-TB-B terminal base)
4 Channels
Precision module / base alignment guides
Proportional
to anytension / leveling screws
DIN mount
4 Singe Pole Double
measured
value
Local
Bus ribbon connectors
Throw (SPDT) Relays
5A, 250VAC/30VDC
(requires
the 1444-TB-B
base)
Includes
address terminal
selection
for

Expansion Module
2 Speed Inputs
served per
Tachometer
Expansion
Module
1 per Dynamic
Measurement
Module

PUBLIC INFORMATION
21
Dynamix 1444 Series

(just) 6
Catalog Numbers!
4 Dynamic Inputs
2 TTL Speed Inputs
4-20mA Output Expansion

Module
4 Channels
2 Speed Inputs
2 TTL Speed Outputs
Relay Expansion Module

Terminal Bases
4 SPDT Relays
PUBLIC INFORMATION

Expansion Module
1 Main Module Base

1 Expansion Module
Base
22
Dynamix 1444 Series

Ethernet
Ethernet
Protocol
Connectivity
IP Address
Concurrent Access
Time Synchronization
Connector (2): RJ45, shielded 1

Speed: 10MB / 100MB
Modes: Half/full duplex
Operation: Auto-switching
Auto negotiation
Auto mitigation
ODVA Conformance Tested
EtherNet/IP Industrial Protocol
Single Ethernet (IEEE 802.3)
Device Level Ring (ODVA)
Set by hardware switch on the terminal base,
Set in configuration 2
Controller (owner)
Up to 3 additional sessions
IEEE-1588 Standard Ver. 2
CIP Sync (ODVA)
1 Allen-Bradley
1585 Ethernet Media recommend

2 IP address retained in nonvolatile memory
PUBLIC INFORMATION
23
Dynamix 1444 Series

Power, Environment, Certifications & Approvals
Power
Redundant Supplies
Supply Voltage
Integral redundant power supply inputs with supply fault detection and status available on I/O
+24VDC (18V to 32V wide range input) designed to accommodate battery backed systems
Environment
Operating temperature
Conformal coating
-25C to +70C
All circuit cards are conformal coated
Electrical Safety
CE, CSA & UL
Hazardous Area
IECex-Zone 2 & ATEX Zone 2, cUL Class 1 Div 2 Groups A,B,C,D
Region & Country Marks

CE, C-Tick, Russia*, Brazil*, Korean*
Marine Certifications*
DNV, BV, ABS, Lloyds, RINA, GL, KRS
Functional Safety**
TUV certified to SIL 2***
* May not be available at initial release
** Will not be available at initial release
*** When used with local, expansion module, relays
PUBLIC INFORMATION
24
Dynamix 1444 Series

Architecture & Local Bus
TTL Signal
TTL
& TX
Signal
OK & TX OK
TTL Signal & TX OK
TTL Signal & TX OK
Power
Power
Host / Expansion Module Network
Host / Expansion Module Network
Architecture
Network Connections on Main Module
Insert / Remove Under Power
Interconnect via included ribbon cable between terminal bases
Local Bus
Host / Expansion Module Communications
Speed Signal Distribution
Power Distribution
PUBLIC INFORMATION
1444 Series & the Integrated Architecture

Fully Supported by Logix
Configuration from any Logix controller
Support included in
Studio 5000 V20+
Standard assemblies for
Configuration
Input
Output
PUBLIC INFORMATION
26
Dynamix 1444 Series

Designed to Serve Industry
The only architecture

capable of serving the
Machinery Protection &
Condition Monitoring
requirements of
any application in
any industry!
PUBLIC INFORMATION
27
General Protection Applications
Provide alarm indication / annunciation via local relays

and/or RA Visualization solutions
API-670 (5th Edition) Compliant Applications
Can satisfy all the requirements of the standard
While the controller is required for (initial) configuration, it

is not required for a 1444 Series system to perform its
function
1444 Series modules include nonvolatile memory.

At power up the system will load its saved configuration, if or
until its controller serves it another one
Safety (SIL-2) Applications
Requires use of local relays (expansion module)
All safety related attributes in the configuration assembly

are hidden
PUBLIC INFORMATION
28
Machinery Condition Monitoring

Logix Integrated Solutions
Apply simple rule based logic for Fault Diagnostic
Trend fault indicators in Process Historian
Implement advanced Monitoring Solutions for any

class of machine or for any complexity of
application
Implement least cost per channel multiplexed* solutions
Monitor machine tools and other cyclic applications with

Profiles to detect deviant behavior relative to position or time
Apply alarm limits based on process considerations (fluid

type, material, speed, etc.)
* Multiplexed systems are available as an SSB Solutions offering

PUBLIC INFORMATION
29
Dynamix 1444 Series

Capabilities
Machine Protection
Machine Condition Monitoring
Vibration
Acceleration
Velocity
Displacement
Absolute Shaft Vibration
Spike Energy (gSE)
Relays
4-20mA Outputs
Event Capture
Event Log
Trend / Alarm
Startup /
Coastdown
Speed
Pressure
Thrust
Case Expansion
Differential Expansion
Rod Drop
Real Time, Continuous, Surveillance

Real Time Processing of Critical Parameters, Continuous Processing of Diagnostic Data, Demand Processing of Infrequent Measures
PUBLIC INFORMATION
30
1444 Series Functional Specifications

Measurements Summary
Dynamic (AC) Measurements
Discrete Measurements
Per Channel Pair
SMAX Magnitude
Shaft Absolute Vibration
o Per Channel
Overall (2)
Order Magnitude & Phase (4)
FFT Band (8)
Not 1x (1)
Bias / Gap (1)
gSE Overall (1)
o
Demand Measurements
Synchronous, Asynchronous
TWF and FFT (to 12,800 lines)
Simultaneous Cross Module
Measurements
Static (DC) Measurements
Axial Position
Thrust
Valve Position
o Eccentricity
o Rod Drop
o Proportional Voltage
o
Complex Measurements
TWF and FFT (to 1600 lines)
o Asynchronous or Synchronous
o
Speed Measurements
Speed
Retains maximum speed measured
Single DC Channels
Paired DC Channels
o
Differential Expansion
Rate of change of speed
PUBLIC INFORMATION

Alarms & Relays Summary
Alarms & Relays
Measurement Alarms
Voted Alarms
Apply limits to measured parameter

24 measurement alarms may be defined
Apply voting logic to Measurement Alarms
13 voted alarms may be defined
Relays
Main modules include a single onboard physical relay. With
expansion modules this can be expanded to 5, 9 or 13 relays
PUBLIC INFORMATION
Associate with any voted alarm, or

Leave unassigned to actuate only on fault.

Event Capture
Startup / Coastdown buffers
o 4 buffers, each containing 640 discrete
data records & 64 dynamic data records
Allows for a potential single buffer of

up to 2560 discrete and 256
dynamic records
Alarm / Trend buffers
o Trigger on RPM and time
Include a post startup sample period
Coastdown
Running
high load
no load
Startup
PUBLIC INFORMATION
o Trend: 640 discrete data records & 64

dynamic data records
o Alarm: Trend buffer (copy) + 260 discrete
data records @ 100 ms sample rate
Trigger on:
Any alarm, or
Controller I/O
control bit
Event log
Records occurrences of:
Configuration Change
Alarm Set / Clear
Startup / Coastdown Begin /
End
more.
Dynamix 1444 Series

Controller I/O: The Usual 3 Assemblies
Configuration Assembly
Large Configuration Assembly
Requires Logix V20+
Basic application, channel input
types, I/O, and compliance
requirement defined in Module
Definition
allows Guided Configuration
of low level parameters
I/O is provided and managed

the same way as for any IA
product. Its just bigger!
PUBLIC INFORMATION
Controller Input
Input Assembly parameters selected
in Module Definition.
Assembly is fully exposed and

programmatically accessible
unless a SIL-2 application, in
which case all Safety related
assembly attributes are hidden
Controller Output
Control Bits
Data
Trip Inhibit
Set Point Multiply (2)
Gate Controls (2)
Alarm Reset
Alarm Buffer Trigger
Alarm Buffer Reset
Transient Buffer Resets (4)
Speeds (2)
Alarm Limits (16)
34
Rockwell Automations Network Strategy

With Dynamix Integrated into the Architecture
From the beginning the Dynamix
1444 Series was designed and
developed to execute this
CBM,
CBM Applications,
Asset Management
Applications
Dynamix
Protection
Dynamix
Condition
Monitoring
PUBLIC INFORMATION
core Rockwell Automation

strategy.
Native dual port Ethernet, the
EtherNet/IP protocol, Device
Level Ring, an integrated Logix
solution, and all of the products
and capabilities of Rockwell
Automations Integrated
Architecture
These are what makes the
Dynamix 1444 Series the
industries most open yet
secure, integrated and
capable solution for
machinery monitoring and

protection available today.
35
1444 Series System Architectures

Dedicated Condition Monitoring System
A single controller might manage

an entire condition monitoring
architecture for an entire plant...
PUBLIC INFORMATION
36
1444 Series System Architectures

Condition Monitoring within an Integrated Architecture
Or a plants monitoring
solutions might be split
based on criticality into sub
networks, each managed by
its own controller.
PUBLIC INFORMATION
37
The Dynamix 1444 Series

and the Integrated Architecture
An architecture with a
single core module that:
Can be applied to any
application
Can serve any Condition
Monitoring Application
Applies a native EtherNet/IP
backplane
Is a component of Rockwell
Automations Integrated
Architecture
PUBLIC INFORMATION
38
Questions?
Available:
Aug 2014
PUBLIC INFORMATION
Rev 5058-CO900E

Rockwell Dynarix

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rockwell Dynarix

Uploaded by

Copyright:

Available Formats

Dynamix 1444 Monitoring & Protection

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

What is Condition Monitoring?

The goal is to detect,

2. Each of these characteristics is

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

What is Condition Monitoring?

Vibration is the preeminent CM technology for rotating equipment

Forces that change in direction with time (e.g., Rotating Unbalance)

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

What is Condition Monitoring?

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Sustainable Condition Monitoring

Self Sustaining Condition Monitoring

Sustainable Condition Monitoring Programs

Traditional Condition Monitoring Programs

to insure that they can be

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Sustainable Condition Monitoring

Choose the right equipment to monitor

Would have an immediate or significant impact on production, safety or quality

What causes 90% of the mechanical failures encountered?

Design a closed loop solution that converts data to actionable information

Automate as Much of the Solution as Possible.

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Sustainable Condition Monitoring

Bearing Wear (Vibration at frequencies

Mechanical Looseness and

Apply Standard, Well Defined Rules for Diagnostics

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Sustainable Condition Monitoring

Most machinery problems can be

If 1x rpm is > 5 mm/sec = WARNING

If 1x rpm is > 10 mm/sec = DANGER

Blade Pass (Flow Instability, Fouling)

If 5x rpm is > 3.5 mm/sec = WARNING

If 5x rpm is > 7.0 mm/sec = DANGER

Sustainable Condition Monitoring

Present Information in Meaningful Formats

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Applications of Condition Monitoring

The application of condition monitoring technologies for the purpose of optimizing

Systems that monitor and analyze machine condition so as to mitigate problems,

Systems that monitor and analyze machine or product condition so as to assure

Protection versus Condition Monitoring

Protection systems are applied when failure of an asset

Monitoring systems are applied for one of three reasons:

Predictive Maintenance: Systems are applied for the purpose of

Production Assurance : Systems are applied or the purpose of

Quality Control: Applied for the purpose of monitoring the quality

Machine repair or replacement costs

Standards are often required to be satisfied. These may

API-670, Machinery Protection Systems

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Protection System Application

Protection systems are applied when

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Introducing the Dynamix 1444 Series

Intelligent, Distributed, Rugged, Safe

Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

Introducing the Dynamix 1444 Series

A Single Main Module

+ a single main module terminal base