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TURBINE SUPERVISORY INSTRUMENTATION

SELECTION GUIDE

MEASUREMENT MODULES
RELAY MODULES
POWER SUPPLY
COMMUNICATIONS
SOFTWARE
GRAPHIC TERMINALS
PROGRAMABLE CONTROLLERS
Introduction

In the past, the primary concern for companies that depend on turbo
machinery was simply protecting the asset from catastrophic failure. In today's
competitive environment, companies must not only protect their turbo
machinery but they must also protect the people that operate it while
maximizing production availability by detecting changes early and taking
corrective action.

Rockwell Automation - a global leader in industrial automation with more than


100 years of experience serving the changing needs of our customers in
industries such as power generation, oil and gas, and others - understands the
importance of turbo machinery as a primary mover for critical applications and
offers solutions specifically designed to meet the unique requirements of
steam, gas, and hydro turbines.

For a solution that includes both protection and monitoring of your critical
turbo machinery, Rockwell Automation's proven hardware, software and
services include everything you need to be successful.

XM Condition Monitoring and Protection modules

Our XM condition monitoring and protection system gives you the ability to
detect changes and faults as early as possible so that uptime and maintenance
planning are optimized. In addition to this capability, the modular design and
open industry network protocol of XM give you flexibility that results in the
most cost effective design, installation and information sharing available.

Emonitor and RSMACC Enterprise Online software

Emonitor and RSMACC Enterprise Online expert data analysis and CMMS
integration software makes storage and analysis of data easy, while making it
possible to integrate this information into CMMS systems so that the data
becomes actionable. Emonitor software also integrates data from portable
data collectors and online surveillance systems, giving you a complete picture
of plant asset health.

Services

Rockwell Automation is committed to your success. Therefore, you're


provided services that include every step - from initial planning and
assessment through to the final commissioning and documentation. Rockwell
Automation has the ability to perform complete turnkey turbine supervisory
instrumentation installation and retrofits or just the support you need to
complete your project. All services are designed to meet your specific needs.

1
2 Introduction

TSI System Integration Our integrated solution lowers your total cost by utilizing your existing plant
information and control platform as well as open industry standard protocols.

Integrated Architecture

Below is an illustration of a typical Rockwell Automation integrated TSI


system.

Emonitor RSMACC Reliability DCS


CMMS Enterprise Enterprise Online OnLine

Proprietary Serial,
OPC, Modbus, etc.

Ethernet

PanelView

Controller
Versa View
DeviceNet
TSI System Selection Guide 3

Retrofit Integration

The Rockwell Automation architecture can also be adapted to an existing


turbine system. Below is an illustration of a typical Rockwell Automation TSI
retrofit system.
4 Introduction

Turbine System Comparison


Monitoring System
Components Steam Turbine✞ Gas Turbine✞ Hydro Turbine✞
Measurements • Radial Vibration - Shaft • Radial Vibration • Radial Vibration
Relative • Thrust • Thrust
• Absolute Shaft • Speed • Speed
• Thrust/Expansion/Position • Temperature • Temperature
• Eccentricity • Phase • Phase
• Speed/Accel/Overspeed
• Temperature
• Phase
Measurement Modules
• XM-120 • XM-120 • XM-121
• XM-120E • XM-123 • XM-160/161/162
• XM-121 • XM-160/161/162 • XM-220
• XM-121A • XM-220 • XM-320
• XM-160/161/162 • XM-320 • XM-361/362
• XM-220 • XM-361/362
• XM-320
• XM-361/362
Sensors • 9000 Series • 9000 Series • 9000 Series
• 2100 Series • 2100 Series • 2100 Series
Power Supply 1606-XLP 1606-XLP 1606-XLP
HMI • VersaView • VersaView • VersaView
• PanelView Standard • PanelView Standard • PanelView Standard
• Strip Chart • Strip Chart • Strip Chart
• LED Indicator • LED Indicator • LED Indicator
• RSView • RSView • RSView
Control • PLC/DCS DeviceNet Interface • PLC/DCS DeviceNet Interface • PLC/DCS DeviceNet Interface
• ControlLogix • ControlLogix • ControlLogix
• OPC Gateway • OPC Gateway • OPC Gateway
• Gateways and Bridges • Gateways and Bridges • Gateways and Bridges
• Relay Logic (XM-440) • Relay Logic (XM-440) • Relay Logic (XM-440)
• 4-20mA I/O • 4-20mA I/O • 4-20mA I/O
• Overspeed Relay (XM-442)
Reliability • Emonitor • Emonitor • Emonitor
• RSMACC EOL • RSMACC EOL • RSMACC EOL
• ROL • ROL • ROL
✞ Recommendation is in bold text.
TSI System Selection Guide 5

System Selection Checklist Use the following Checklist as a guide to specify your turbine system.

✓ Step See
1 Select the measurements

Choose the measurements that you want to Steam turbine system page 7
monitor on your turbine system. Gas turbine system page 19
Hydro turbine system page 25
2 Select modules based on measurement

Match the measurements and the XM modules. Steam turbine system page 11
Gas turbine system page 21
Hydro turbine system page 27
3 Select integration strategy

Choose the HMI and control hardware for your HMI products page 31
system. Control systems page 33
4 Select software

Choose the software product you need to XM Serial Configuration Utility page 37
configure and manage your system. RSLinx software page 38
RSNetworx for DeviceNet software page 38
Emonitor Enterprise software page 39
RSMACC EOL software page 40
5 Select project services
Determine the expertise needed to install a new Engineering design services page 41
system, or retrofit an existing one. Turnkey projects page 41
Reliability Online Service programs page 42
Available product services page 42
Training page 43
Repair, Exchange & Renewal parts page 43
6 Select optional accessories

Choose sensors, power supply, enclosure, cables, Sensors page 45


junction boxes, etc. if necessary. Power Supplies page 46
Cables page 46
Junction Box page 46
Enclosures page 46
Sensor Adhesives / Mounting Tools page 47
Portable Data Collectors page 47
Surveillance Monitoring page 48
6 Introduction
Steam Turbine System

Typical Radial System Overview

CASE
EXPANSION RADIAL MEASUREMENTS
LEFT BRG #1 BRG #2 BRG #3 BRG #4 BRG #5 BRG #6 BRG #7

TEMP TEMP TEMP TEMP TEMP TEMP TEMP

ECCENTRICITY

PHASE

"B" "A"

HIGH PRESSURE LOW PRESSURE


GENERATOR EXCITER
TURBINE TURBINE
(OR OTHER DRIVEN COMPONENT)

"B" "A"
ROTOR/THRUST
POSITION
"A" & "B"
SPEED/OVERSPEED
VALVE
POSITION ROTOR ACCELERATION

DIFF. EXPANSION
1 SET TO MONITOR
1 SET SPARE

CASE
EXPANSION
RIGHT

Measurements This section describes the recommended vibration monitoring for a steam
turbine. Use this information to help you select the measurements that you
want to monitor.

Radial Vibration Measurement - Shaft Relative

Radial vibration measures the radial motion of the rotating shaft relative to the
case. This measurement gives the first indication of a fault, such as unbalance,
misalignment, cracked shaft, oil whirl or other dynamic instabilities. Vibration
measurements can be made in a single plane or a two plane (X-Y) arrangement
where the sensors are 90 degrees apart and perpendicular to the shaft. Eddy
current probes are usually installed in a hole drilled through the bearing cap
and are held in place by either a bracket or a probe holder.

7
8 Steam Turbine System

Absolute Shaft Measurement

Absolute Shaft Vibration is a measure of the shaft’s motion relative to free


space. The measurement is typically applied when the rotating assembly is five
or more times heavier than the case of the machine. Absolute shaft motion is
proportional to the vector addition of the casing absolute motion and the shaft
relative motion.

Phase Measurement
D GAP
APPROX. D GAP
.060

PREFERRED
W D=1/4
W=3/8 OR LARGER
ALTERNATE
W
Phase is defined as the angle between a reference mark (usually a keyway on
(PROTRUSION) (DEPRESSION)
the shaft) and the heavy spot on the rotor. Phase measurement is required for
accurate balancing of any rotor. It also provides an indication of shaft cracks,
misalignment, mass loss (such as throwing a blade), and other faults.
AXIAL DRILLED HOLE EPOXIED STEEL
3/8"DIA.x 1/4" DEEP SHIM STOCK

Speed/Acceleration Measurement

Speed is a measurement of shaft rotation in revolutions per minute. During


start-up, speed is a critical measurement as it allows the operator to: increase
speed quickly through shaft critical frequencies; hold the speed stable during
“heat soak” plateaus; and, for electric generators, to accurately match the
synchronous frequency before connecting the generator to the power grid.

Acceleration measures how fast speed is increasing or decreasing. It is


monitored by the operator during turbine roll up, so that a steady increase in
machine speed is achieved. Once the turbine is in normal operation,
acceleration is not monitored.

Eccentricity Measurement

Eccentricity is a measurement of the amount of sag or bow in a rotor. It may


also provide indication of a bent shaft. This measurement is used by the
operator to indicate when the machine can safely be brought up to speed
without causing rubs or damage to the seals.
TSI System Selection Guide 9

Differential Expansion (DE) Measurement


SHAFT

d b
a
Differential expansion is the difference between the thermal growth of the
c

d = BEVEL ANGLE
rotor compared to the thermal growth of the case. Differential expansion
monitoring is most critical during a turbine "cold" start-up. A common steam
a = DETECTED RANGE
c = INDICATED RANGE

Ramp turbine has a thick, heavy case, and a lighter, hollow rotor. Due to the mass of
ROTOR LONG
the case it will grow slower than the rotor, so the operator must make sure the
case has expanded enough to keep it from making contact with the rotor. To
monitor, transducers can be placed on a collar or ramp that have been
2"MIN.
550mils NOMINAL GAP machined onto the turbine.
2"MIN.

Collar

Rotor/Thrust Position Measurement


Dual Thrust
The primary purpose of the thrust position measurement is to monitor thrust
bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion
detection should be used when the machine is required to shutdown. This
method requires two transducers mounted on each bearing. When both
independent set points cross the shutdown limit the machine will be turned
off. Single thrust motion detection should be used when the machine does not
have to be shutdown and there is another means of verifying thrust bearing
failure. Thrust position measurements are taken within 12 inches of the thrust
bearing, monitoring the thrust collars movement between the active and
inactive thrust shoes and their subsequent wear. Measurements taken outside
Single Thrust
of the thrust bearing area (greater than 12 inches) are generally effected by the
rotors thermal expansion and an increase in the required dynamic
measurement range. This measurement is typically referred to as rotor (axial)
position.

Valve Position Measurement

Valve position is a measurement of how much a valve is open or closed, usually


a throttle valve. It provides the operator with an idea of the current load on a
machine in the form of a percentage; 0% correlates to a valve closed and 100%
correlates to a valve open.
10 Steam Turbine System

Overspeed - Triple Redundant Protection Measurement

Overspeed is one of the most dangerous conditions that can occur in a


turbine, and is defined when a machine accelerates beyond its maximum
permissible rotational speed. It is monitored by an Electronic Overspeed
Detection System (EODS).

Shell (Case) Expansion Measurement


10-3/16

3 9-1/2

Steam temperature varies greatly between startup, operation, and shutdown.


3-1/4 4-1/2
Shell expansion is a measurement of how much the turbine's case expands
3/4
from its fixed point outward as it is heated. Continuous indication of shell
thermal growth allows the operator to manage the amount of shell distortion
as the load is increased or decreased.
3/8
15/16
3-1/2
2-5/8

Figure 9-1

Temperature Measurement

Temperature measurements are taken to determine how hot a bearing is


operating. These measurements may provide a secondary validation of
operation or maintenance problems. An increase in a temperature reading may
be due to excessive bearing loading, insufficient clearances, or misalignment.
TSI System Selection Guide 11

XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.

Your selection of measurements determines which XM module you need for


your steam turbine system.

If you want to measure select description


Radial Vibration - Shaft XM-120 Standard Dynamic The XM-120 Standard Dynamic Measurement Module is an intelligent,
Relative Measurement Module 2-channel, general-purpose monitor. The module supports monitoring of
shaft, casing or pedestal vibration in rotating equipment by accepting
Phase input from any eddy current probe, standard accelerometer, or any voltage
output measurement device such as a velocity or pressure transducer. In
addition to dynamic inputs, the module accepts one tachometer input to
provide speed, phase and order analysis functions making it capable of
calculating over 14 critical parameters per channel simultaneously.

For more information on the XM-120 module, see publication


ENMON-TD120.
Absolute Shaft XM-121 Low Frequency The XM-121 Low Frequency Dynamic Module with alternative XM-121A
Dynamic Module firmware loaded is an intelligent 2-channel monitor capable of supporting
a single absolute shaft measurement. The XM-121A firmware is included
on the distribution CD with every standard XM-121.

Many of the specifications are similar to the XM-121 Low Frequency


Module. The HPF’s available in the XM-121 allow for measurements to be
as low as .2 Hz (12 CPM).

For more information on the XM-121 module with XM-121A firmware, see
publication GMSI10-TD047.
Speed XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurement
module that accepts input from two tachometers of any standard type
Acceleration including eddy current probes, magnetic pickups, optical tachometers and
TTL output devices. The module measures speed, rotor acceleration and
peak speed and is capable of detecting zero speed, locked rotor and
reverse rotation. The module may also serve as a component of an
Electronic Overspeed Detection System (EODS).

For more information on the XM-220 module, see publication


ENMON-TD220.
Eccentricity XM-120 Standard Dynamic The XM-120 Standard Dynamic Measurement Module with alternative
Measurement Module XM-120E firmware, enables eccentricity monitoring, critical for steam
turbine operation. The XM-120E firmware is included on the distribution
CD with every standard XM-120.

For more information on the XM-120 module with XM-120E firmware, see
publication ENMON-TD002.
12 Steam Turbine System

If you want to measure select description


Differential Expansion XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The
module can be configured to measure any of: Axial Position, Valve
Rotor/Thrust Position Position, Case Expansion or Differential Expansion. The XM-320 supports
multiple single and dual-probe methods of measuring differential
Valve Position expansion. The appropriate method is machine specific and requires
review of the installation.
Shell (Case) Expansion
For more information on the XM-320 module, see publication
ENMON-TD320.
Temperature XM-361 Universal Temperature The XM-361 Universal Temperature Module is a 6-channel general
Module purpose temperature monitor. Each channel can be configured to measure
either an RTD or an isolated thermocouple.
or
XM-362 Isolated Temperature The XM-362 Isolated Temperature Module is a 6-channel temperature
Module monitor designed specifically for use with thermocouples.

For more information on the temperature modules, see publication


ENMON-TD361.
Triple Redundant XM-220 Dual Speed Module The XM-442 Voted EODS Relay Module provides high performance voted
Overspeed relays as a component of an Electronic Overspeed Detection System.
XM-442 Voted EODS Relay When coupled with three XM-220 Dual Speed Modules, an XM-442
Module provides a single 2-out-of-3 overspeed trip relay plus separate relays for
alarm (1 of 3 voting), system fault and transducer fault. A single XM-442
paired with three XM-220 modules meets the requirements with regards
to the measurement, detection and relay actuation component of API-670
section 5.4.8 Electronic Overspeed Detection.

For more information on the XM-220 module, see publication


ENMON-TD220. For more information on the XM-442 module, see
publication GMSI10-TD048. For more information on the Electronic
Overspeed Detection System, see publication GMSI10-UM015.
TSI System Selection Guide 13

Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.

TIP Additional requirements may include power supply,


enclosure, cables, junction box, sensor adhesives/mounting
tools, etc. See Optional Accessories on page 45.

Radial Vibration - Shaft Relative Configuration


Radial Vibration Configuration Parts

Cat. No. Description Qty


1440-VST02-01RA XM-120 Standard Dynamic Measurement Module 1
1440-TB-A Terminal Base for XM-120 / XM-121 / XM-122 1
Option 1✞
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 2
EK-2170-0-80 8mm extension cable, 8m 2
EK-2108-9-001 8mm probe driver, 9m system 2
Option 2 (for replacement of existing shaft riders only)
EK-17253 Shaft Rider 18.5 to 20 in 1
EK-09712 Model 544M Velocity Transducer 1

✞ For probe holder options, see publication ENACC-PP210.

Absolute Shaft Configuration

Absolute Shaft Configuration Parts

Cat. No. Description Qty


1440-VLF02-01RA XM-121 Low Frequency Dynamic Measurement Module 1
with XM-121A firmware
1440-TB-A Terminal Base for XM-120 / XM-121 / XM-122 1
EK-43808I Model 9100VO Velocity Output Accelerometer 1
EK-46801I 32' Accelerometer Cable (splash proof) 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1
EK-2170-0-80 8mm extension cable, 8m 1
EK-2108-9-001 8mm probe driver, 9m system 1
EK-29000-DPH-01 Dual Probe Holder 1
14 Steam Turbine System

Speed/Phase Configuration

Only one option is necessary for a speed/phase measurement.

Phase Configuration Parts

Cat. No. Description Qty


Included with XM-120/121/122/123 Modules
Option 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1
EK-2170-0-80 8mm extension cable, 8m 1
EK-2108-9-001 8mm probe driver, 9m system 1
Option 2
EK-44395 Hall Effect speed sensor, magnetic, zero velocity 1
EK-47774 Cable, Hall Effect speed sensor, 16ft, blunt cut 1

Speed/Acceleration Configuration

Only one option is necessary for a speed/acceleration measurement.

Speed/Acceleration Configuration Parts

Cat. No. Description Qty


1440-SPD02-01RB XM-220 Dual Speed Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
Option 1
EK-2111-40-00-1-10 11mm dia NCPU probe, 1m cable 2
EK-2171-0-80 11mm extension cable, 8m 2
EK-2111-9-001 11mm probe driver, 9m system 2
Option 2
EK-44395 Hall Effect speed sensor, magnetic, zero velocity 1
EK-47774 Cable, Hall Effect speed sensor, 16ft, blunt cut 1
TSI System Selection Guide 15

Eccentricity Configuration

Eccentricity Configuration Parts

Cat. No. Description Qty


1440-VST02-01RA XM-120 Standard Dynamic Measurement Module with 1
XM-120E firmware
1440-TB-A Terminal Base for XM-120 / XM-121 / XM-122 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1
EK-2170-0-80 8mm extension cable, 8m 1
EK-2108-9-001 8mm probe driver, 9m system 1

Differential Expansion (DE) Configuration

Differential Expansion Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
EK-48486 Calibrated System, 500 Mil 1
Includes:
• (1) 25mm dia tip right angle mounting plate & 1
meter armored cable
• (1) 8.0 meter armored extension cable
• (1) Drive calibrated for 25mm probe 9 meter
electrical length
16 Steam Turbine System

Rotor/Thrust Position Configuration


Rotor/Thrust Position Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
Option 1: Rotor/Thrust
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1 or 2
EK-2170-0-80 8mm extension cable, 8m 1 or 2
EK-2108-9-001 8mm probe driver, 9m system 1 or 2
Option 2: Position
EK-2111-40-00-1-10 11mm dia NCPU probe, 1m cable 1
EK-2171-0-80 11mm extension cable, 8m 1
EK-2111-9-001 11mm probe driver, 9m system 1

Valve Position Configuration


Valve Position Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
Select one of the following part numbers
EK-15383 LVDT - 0-2 in range 1
EK-15629 Cam (Valve) position detector rotary potentiometer 1400 1
Ohm
EK-16282 Cam (Valve) position detector rotary potentiometer 2000 1
Ohm
TSI System Selection Guide 17

Triple Redundant Overspeed Configuration

Triple Redundant Overspeed Configuration Parts

Cat. No. Description Qty


1440-SPD02-01RB XM-220 Dual Speed Module 3
1440-TB-B Terminal Base B for XM-320 / XM-220 3
1440-REX03-04RG XM-442 Voted EODS Relay Module 1
1440-TB-G Terminal Base G for XM-442 1
EK-2111-40-00-1-10 11mm dia NCPU probe, 1m cable 3
EK-2171-0-80 11mm extension cable, 8m 3
EK-2111-9-001 11mm probe driver, 9m system 3

Shell (Case) Expansion Configuration

Shell (Case) Expansion Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
EK-15383 Linear Variable Displacement Transducers (LVDT) 1

Temperature Configuration

Temperature Configuration Parts

Cat. No. Description Qty


Option 1:Thermocouple or 2 or 3 Wire RTD
1440-TUN06-00RE XM-361 Universal Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
Option 2: Isolated Thermocouple
1440-TTC06-00RE XM-362 Isolated TC Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
18 Steam Turbine System
Gas Turbine System

Typical Gas System Overview

RADIAL MEASUREMENTS
BRG #1 BRG #2

TEMP TEMP
SPEED

PHASE
SPEED

GENERATOR
Compressor Shaft Turbine Shaft (OR OTHER DRIVEN
COMPONENT)

THRUST
POSITION
"A" & "B"

Measurements This section describes the recommended vibration monitoring for a gas
turbine. Use this information to help you select the measurements that you
want to monitor.

IMPORTANT The turbine OEM should be referenced before choosing


type and placement of measurements.

Radial Vibration Measurement

Radial Vibration gives the first indication of a fault, such as unbalance,


misalignment, cracked shaft, oil whirl, or other dynamic instabilities.

Shaft Relative - Fluid Film (Sleeve/Babbit) Bearing


Two Plane
Arrangement
This measures the radial motion of the rotating shaft relative to the case.
Vibration measurements can be made in a single plane or a two plane (X-Y)
arrangement where the sensors are 90 degrees apart and perpendicular to the
shaft. Eddy current probes are usually installed in a hole drilled through the
bearing cap and are held in place by either a bracket or a probe holder.

19
20 Gas Turbine System

Case Absolute - Anti-friction (Ball or Rolling Element) Bearings

Case Mounted Vibration measurements can be made by a transducer mounted on the


Arrangement
machine’s casing. Mounting locations are generally determined by the OEM.

Phase Measurement
D GAP
APPROX. D GAP
.060

Phase is defined as the angle between a reference mark (usually a keyway on


W D=1/4 W
W=3/8 OR LARGER
PREFERRED ALTERNATE

the shaft) and the heavy spot on the rotor. Phase measurement is required for
(PROTRUSION) (DEPRESSION)

accurate balancing of any rotor. It also provides an indication of shaft cracks,


AXIAL DRILLED HOLE EPOXIED STEEL
misalignment, mass loss (such as throwing a blade), and other faults.
3/8"DIA.x 1/4" DEEP SHIM STOCK

Speed Measurement

Speed is a measurement of shaft rotation in revolutions per minute. Speed is a


critical measurement during start-up and operation.

Thrust Position Measurement


Dual Thrust
The primary purpose of the thrust position measurement is to monitor thrust
bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion
detection should be used when the machine is required to shutdown. This
method requires two transducers mounted on each bearing. When both
independent set points cross the shutdown limit the machine will be turned
off. Single thrust motion detection should be used when the machine does not
have to be shutdown and there is another means of verifying thrust bearing
Single Thrust failure.

Temperature Measurement

Temperature measurements are taken to determine how hot a bearing is


operating. These measurements may provide a secondary validation of
operation or maintenance problems. An increase in a temperature reading may
be due to excessive bearing loading, insufficient clearances, or misalignment.
TSI System Selection Guide 21

XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.

Your selection of measurements determines which XM module you need for


your gas turbine system.

If you want to measure select description


Radial Vibration XM-123 Aeroderivative Module The XM-123 Aeroderivative Module is an intelligent 2-channel
special-purpose monitor that is uniquely suited for monitoring
Phase Aeroderivative Gas Turbines. The XM-123 can be configured, per channel,
to perform either tracking filter or band pass style measurements while it
Note: For FFT, TWF and also continuously measures each channel’s broad band overall level.
additional calculated These capabilities, along with its extraordinary configurability, enable the
parameters, the XM-120 XM-123 to meet the demanding monitoring requirements of almost any
module (1440-VST02-01RA) engine in service today.
should be used in conjunction
with the XM-123 module. For more information on the XM-123 module, see publication
ENMON-TD123. For more information on the XM-120 module, see
publication ENMON-TD120.
Speed XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurement
module that accepts input from two tachometers of any standard type
including eddy current probes, magnetic pickups, optical tachometers and
TTL output devices. The module measures speed, rotor acceleration and
peak speed and is capable of detecting zero speed, locked rotor and
reverse rotation. The module may also serve as a component of an
Electronic Overspeed Detection System (EODS).

For more information on the XM-220 module, see publication


ENMON-TD220.
Thrust Position XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The
module can be configured to measure any of: Axial Position, Valve
Position, Case Expansion and Differential Expansion.

For more information on the XM-320 module, see publication


ENMON-TD320.
Temperature XM-361 Universal Temperature The XM-361 Universal Temperature Module is a 6-channel general
Module purpose temperature monitor. Each channel can be configured to measure
either an RTD or an isolated thermocouple.
or
XM-362 Isolated Temperature The XM-362 Isolated Temperature Module is a 6-channel temperature
Module monitor designed specifically for use with thermocouples.

For more information on the temperature modules, see publication


ENMON-TD361.
22 Gas Turbine System

Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.

TIP Additional requirements may include power supply,


enclosure, cables, junction box, sensor adhesives/mounting
tools, etc. See Optional Accessories on page 45.

Radial Vibration Configuration


Radial Vibration Configuration Parts

Probe Operating
Cat. No. Description Temperature Range Qty
1440-VAD02-01RA XM-123 Aeroderivative Module 1
1440-TB-A Terminal Base for XM-123 / XM-120 1
Option 1: Shaft Relative
EK-2105-70-00-1-10✞ 8mm dia NCPU probe, 1m cable -40 to +350°F (-40 to 2
+177°C)
EK-2170-0-80 8mm extension cable, 8m Connector: max. 257°F 2
(+125°C)
EK-2108-9-001 8mm probe driver, 9m system -36 to +176°F (-38 to 2
+80°C)
Option 2: Case Absolute
EK-43807I✞ 9100HT High Temperature Accelerometer -65 to +500°F (-54 to 1
+260°C)
EK-46801I 32’ Accelerometer Cable (splash proof) 1
✞ Sensors must meet operating temperature requirements. Specialty, high temperature probes and case mounted
sensors are available. Special care should be taken when specifying sensor for aeroderivative gas turbine
applications.

TIP For FFT, TWF and additional calculated parameters, the


XM-120 module (1440-VST02-01RA) should be used in
conjunction with the XM-123 module.
TSI System Selection Guide 23

Phase/Speed Configuration

Only one option is necessary for a phase/speed measurement.

Phase Configuration Parts

Cat. No. Description Qty


Phase/Speed
Included with XM-123/120/121/122 Modules
Speed
1440-SPD02-01RB XM-220 Dual Speed Module 1
1440-TB-B Terminal Base B for XM-220 / XM-320 1
Option 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1
EK-2170-0-80 8mm extension cable, 8m 1
EK-2108-9-001 8mm probe driver, 9m system 1
Option 2
EK-44395 Hall Effect speed sensor, magnetic, zero velocity 1
EK-47774 Cable, Hall Effect speed sensor, 16ft, blunt cut 1

Thrust Position Configuration


Thrust Position Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Dual Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1 or 2
EK-2170-0-80 8mm extension cable, 8m 1 or 2
EK-2108-9-001 8mm probe driver, 9m system 1 or 2
24 Gas Turbine System

Temperature Configuration

Temperature Configuration Parts

Cat. No. Description Qty


Option 1: Thermocouple or 2 or 3 Wire RTD
1440-TUN06-00RE XM-361 Universal Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
Option 2: Isolated Thermocouple
1440-TTC06-00RE XM-362 Isolated TC Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
Hydro Turbine System

Typical Hydro Turbine System Overview

Generator
R
A
D
I
A
THRUST
TEMP L
POSITION
"A" & "B" M
E
A
S
U
Shaft R
SPEED/PHASE E
M
TEMP E
N
T
S

Turbine
CAVITATION

Measurements This section describes the recommended vibration monitoring for a hydro
turbine. Use this information to help you select the measurements that you
want to monitor.

Radial Vibration Measurement

Radial Vibration gives the first indication of a fault, such as unbalance,


misalignment, cracked shaft, oil whirl, or other dynamic instabilities.

Shaft Relative - Fluid Film (Sleeve/Babbit) Bearing

This measures the radial motion of the rotating shaft relative to the case.
Vibration measurements can be made in a single plane or a two plane (X-Y)
arrangement where the sensors are 90 degrees apart and perpendicular to the
shaft. Eddy current probes are usually installed in a hole drilled through the
bearing cap and are held in place by either a bracket or a probe holder.

25
26 Hydro Turbine System

Case Absolute - Anti-friction (Ball or Rolling Element) Bearings


Cavitation

Vibration measurements can be made by a transducer mounted on the


machine’s casing. Mounting locations are generally determined by the OEM.

Cavitation is defined as the formation of vapor pockets in a liquid. In hydro


turbines, cavitation can cause a large amount of noise, damage to the machine,
and a loss of efficiency. It is measured by a case mounted accelerometer on
either the draft tube or turbine head cover.

Phase/Speed Measurement
D GAP
APPROX. D GAP
.060

PREFERRED
W D=1/4
W=3/8
OR LARGER

ALTERNATE
W
Phase is defined as the angle between a reference mark (usually a keyway on
(PROTRUSION) (DEPRESSION)
the shaft) and the heavy spot on the rotor. Phase measurement is required for
accurate balancing of any rotor. It also provides an indication of shaft cracks,
misalignment, mass loss (such as throwing a blade), and other faults.
AXIAL DRILLED HOLE EPOXIED STEEL
3/8"DIA.x 1/4" DEEP SHIM STOCK

Speed is a measurement of shaft rotation in revolutions per minute. Speed is a


critical measurement during start-up and operation.

Thrust Position Measurement


Dual Thrust

The primary purpose of the thrust position measurement is to monitor thrust


bearing wear and to ensure against axial rubs. Dual (redundant) thrust motion
detection should be used when the machine is required to shutdown. This
method requires two transducers mounted on each bearing. When both
independent set points cross the shutdown limit the machine will be turned
off. Single thrust motion detection should be used when the machine does not
have to be shutdown and there is another means of verifying thrust bearing
failure.

Single Thrust

Temperature Measurement

Temperature measurements are taken to determine how hot a bearing is


operating. These measurements may provide a secondary validation of
operation or maintenance problems. An increase in a temperature reading may
be due to excessive bearing loading, insufficient clearances, or misalignment.
TSI System Selection Guide 27

XM Modules The XM series is a group of intelligent, specialty I/O modules designed for
machinery protection and condition monitoring. The XM modules monitor
critical machinery parameters such as vibration, temperature, position, and
speed. The XM modules may be applied as a standalone system, or they can be
integrated with existing automation and control systems, including PLCs and
displays, to provide maintenance and operations with intelligent information
to aid in protecting machinery from catastrophic failures and planning
production and maintenance activities.

Your selection of measurements determines which XM module you need for


your hydro turbine system.

If you want to measure select description


Radial Vibration XM-121 Low Frequency The XM-121 Low Frequency Vibration Module is identical to the XM-120
Dynamic Module Standard Vibration Module except for the available high pass filter (HPF)
Phase selections. The HPF’s available in the XM-121 allow for measurements to
be as low as .2 Hz (12 CPM) making it ideal for monitoring low speed
machinery such as hydroturbines and many fans, gearboxes, paper rolls,
extruder presses and other low speed equipment.

For more information on the XM-121 module, see publication


ENMON-TD120.
Speed XM-220 Dual Speed Module The XM-220 Speed Module is an intelligent 2-channel measurement
module that accepts input from two tachometers of any standard type
including eddy current probes, magnetic pickups, optical tachometers and
TTL output devices. The module measures speed, rotor acceleration and
peak speed and is capable of detecting zero speed, locked rotor and
reverse rotation. The module may also serve as a component of an
Electronic Overspeed Detection System (EODS).

For more information on the XM-220 module, see publication


ENMON-TD220.
Thrust Position XM-320 Position Module The XM-320 Position Module is a 2-channel multi-purpose monitor. The
module can be configured to measure any of: Axial Position, Valve
Position, Case Expansion and Differential Expansion.

For more information on the XM-320 module, see publication


ENMON-TD320.
Temperature XM-361 Universal Temperature The XM-361 Universal Temperature Module is a 6-channel general
Module purpose temperature monitor. Each channel can be configured to measure
either an RTD or an isolated thermocouple.
or
XM-362 Isolated Temperature The XM-362 Isolated Temperature Module is a 6-channel temperature
Module monitor designed specifically for use with thermocouples.

For more information on the temperature modules, see publication


ENMON-TD361.
28 Hydro Turbine System

Typical Configurations The following configurations are examples of a typical system. Reference
OEM specifications and existing sensor dimensions before selecting
replacement sensors.

TIP Additional requirements may include power supply,


enclosure, cables, junction box, sensor adhesives/mounting
tools, etc. See Optional Accessories on page 45.

Radial Vibration Configuration

Radial Vibration Configuration Parts

Cat. No. Description Qty


1440-VLF02-01RA XM-121 Low Frequency Dynamic Measurement Module 1
1440-TB-A Terminal Base A for XM-120 / XM-121 / XM-122 1
Option 1: Shaft Relative
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 2
EK-2170-0-80 8mm extension cable, 8m 2
EK-2108-9-001 8mm probe driver, 9m system 2
Option 2: Case Absolute and Cavitation
EK-43784I 9100 General Purpose Accelerometer 1
EK-46801I 32’ Accelerometer Cable (splash proof) 1
TSI System Selection Guide 29

Phase/Speed Configuration

Only one option is necessary for a phase/speed measurement.

Phase/Speed Configuration Parts

Cat. No. Description Qty


Phase/Speed
Included with XM-121/120 Modules
Speed
1440-SPD02-01RB XM-220 Dual Speed Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
Option 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1
EK-2170-0-80 8mm extension cable, 8m 1
EK-2108-9-001 8mm probe driver, 9m system 1
Option 2
EK-44395 Hall Effect speed sensor, magnetic, zero velocity 1
EK-47774 Cable, Hall Effect speed sensor, 16ft, blunt cut 1

Thrust Position Configuration


Thrust Position Configuration Parts

Cat. No. Description Qty


1440-TPS02-01RB XM-320 Position Module 1
1440-TB-B Terminal Base B for XM-320 / XM-220 1
EK-2105-70-00-1-10 8mm dia NCPU probe, 1m cable 1 or 2
EK-2170-0-80 8mm extension cable, 8m 1 or 2
EK-2108-9-001 8mm probe driver, 9m system 1 or 2
30 Hydro Turbine System

Temperature Configuration

Temperature Configuration Parts

Cat. No. Description Qty


Option 1: Thermocouple or 2 or 3 Wire RTD
1440-TUN06-00RE XM-361 Universal Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
Option 2: Isolated Thermocouple
1440-TTC06-00RE XM-362 Isolated TC Temperature Module 1
1440-TB-E Terminal Base E for XM-36x 1
Integration Products

This section describes the integration strategy. Select the human machine
interface (HMI), control system, and reliability products that best fit your
needs.

XM systems use the DeviceNet™ open standard for all communications.


DeviceNet is an open, low-level network that provides connections between
simple industrial devices (such as sensors and actuators) and higher-level
devices (such as HMIs, PLCs, and computers). The DeviceNet network uses
the proven Common Industrial Protocol (CIP) to provide the control,
configure, and data collection capabilities for industrial devices.

HMI Products Rockwell Automation offers the following HMI products for your system.

VersaView Industrial Computers and Monitors

VersaView® products are a family of industrial computer and monitor


solutions, comprised of integrated display computers, workstations,
non-display computers, and flat panel monitors. VersaView products offer
effortless management of changing technology, a rugged but cost-effective
design, and easier product configuration. All VersaView products provide the
latest industrial solution available, optimized for visualization, control,
information processing, and maintenance application.

VersaView CE Industrial Computers

VersaView CE products offer open Windows CE terminals in Windows®


desktop environments - bringing together features of operator interfaces and
industrial computers. It is a high performance computer with a compact flash
drive and integrated RSView® Machine Edition runtime (no activation
required). There’s no hard disk, no fan, and no moving parts, which means
maximum reliability on the plant floor. Easy to set up and maintain, VersaView
CE means an open system that’s rugged and economical, offering high
functionality in an easy to use package.

31
32 Integration Products

RSView Enterprise Series Software

RSView Enterprise Series software from Rockwell Software is a line of HMI


software products designed with a common look, feel, and navigation to help
speed HMI application development and training time. With RSView
Enterprise Series 3.0, you can reference existing Logix data tags. Any changes
made to these referenced tags are automatically inherited by RSView software.
RSView Enterprise Series software includes:

• RSView Studio lets you create applications in a single design


environment. It configures RSView Supervisory Edition, RSView
Machine Edition, VersaView CE, and PanelView Plus applications. It
supports editing and reusing projects for improved portability between
embedded machine and supervisory HMI systems.

• RSView Machine Edition (ME) is a machine-level HMI product that


supports both open and dedicated operator interface solutions. It
provides a consistent operator interface across multiple platforms
(including Microsoft Windows CE, Windows 2000/XP, and PanelView
Plus solutions), and is ideal for monitoring and controlling individual
machines or small processes.

• RSView Supervisory Edition (SE) is an HMI software for


supervisory-level monitoring and control applications. It has a
distributed and scalable architecture that supports
distributed-server/multi-user applications. This highly scalable
architecture can be applied to a stand-alone, one-server/one-user
application or to multiple users interfacing with multiple servers.

PanelView Standard Operator Terminals

PanelView™ Standard operator terminals are engineered for maximum


performance in space saving flat panel designs. These electronic operator
interfaces feature pixel graphics capabilities and high-performance
functionality in color, grayscale, and monochrome displays. The PanelView
Standard family offers a complete line of rugged electronic operator interface
solutions in a variety of sizes and configurations to meet specific application
requirements, all with a rich collection of hardware and software features
designed to simplify programming and improve operator productivity. The
high performance functionality of the PanelView Standard line includes
advanced alarm handling, screen security, analog gauges, ATA PC memory
card, universal language support, and online printing for more intuitive
operator control.
TSI System Selection Guide 33

Control Systems Rockwell Automation offers the following control system solutions for your
system.

PLC/DCS DeviceNet Interface

The XM module may be linked directly to a PLC or other control system via
industry standard DeviceNet scanner cards. Host controllers can then scan
XM modules for data, alarm and relay status information in real-time.
Prioritizing messaging insures that changes to any alarm or relay status is
immediately communicated to network controllers.

ControlLogix

The ControlLogix system provides sequential, process, motion, and drive


control together with communications and state-of-the-art I/O in a small,
cost-competitive package. The system is modular, so you can design, build, and
modify it efficiently - with significant savings in training and engineering. A
simple ControlLogix system consists of a standalone controller and I/O
modules in a single chassis.

You can also use the ControlLogix system as a gateway. Include the
communication modules you need for connectivity to other networks. For this
use, a controller is not required. The ControlLogix Gateway integrates into
existing PLC-based systems so that users with existing networks can send or
receive messages to or from other networks.

For more information on the ControlLogix products, see publication


1759-SG001.

OPC Gateway

OPC (OLE for Process Control) is a set of industry-standard specifications


that allow plant floor devices such as DCSs and PLCs to communicate and
exchange data with software applications such as HMIs and Process
Historians. The OPC standards allow different automation and control
applications, field systems and devices, and business and office applications
supplied by different vendors to work with one another.

RSLinx Classic software is an OPC-compliant server exposing the required


interfaces for an OPC client application to access data consistent with other
OPC-compliant servers.
34 Integration Products

Gateways and Bridges

XM-500 Ethernet Gateway

The XM-500 Ethernet Gateway provides a powerful bridge between an XM


DeviceNet network and Ethernet. The Gateway provides complete DeviceNet
Master functionality and support for a fully populated DeviceNet network
with up to 63 devices. On the Ethernet side, the XM-500 offers a standard
TCP/IP interface and support for the Ethernet protocol. Recommended for
systems designed primarily to communicate with RSMACC EOL and
Emonitor.

For more information, see publication ENMON-TD500.

1788 EN2DN Ethernet/IP to DeviceNet Linking Device

The 1788 EN2DN Ethernet/IP to DeviceNet Linking Device has the


capability to bridge explicit messages from an Ethernet/IP network to a
DeviceNet network, or scan the DeviceNet network via Ethernet/IP. Can be
used with any Logix controller or third party controller with Ethernet/IP
support. Recommended for systems requiring integration with automation
environments, e.g. PLCs, and visualizations.

1788 CN2DN ControlNet to DeviceNet Linking Device

One side of the Linking Device is a DeviceNet scanner with the capacity for
handling 500 bytes of data in and out from DeviceNet compliant devices. The
other side is a ControlNet scheduled adapter with redundant media
communications and a Network Access Port.

IMPORTANT Rockwell Automation's Encompass Partners provide


additional gateways for almost any network; see
http://www.rockwellautomation.com/encompass/ for
further details.

XM-440 Master Relay Module

The XM-440 Master Relay Module combines four relay outputs with XM bus
master capabilities to provide remote, shared and voted relay operation for
distributed XM measurement modules. The XM-440 module offers high
power relays suitable for use in most protection applications.
TSI System Selection Guide 35

XM-442 Voted EODS Relay Module

The XM-442 module is designed to mate with three XM-220 Dual Speed
Modules to provide an API compliant triple redundant Electronic Overspeed
Detection System (EODS). The XM-442 provides four high power relays that
serve as the EODS alarm and shutdown relays.

4-20mA Outputs

The XM modules offer a 4-20mA isolated analog output per channel


proportional to the selected measurement. Each output is independently
programmed to represent any measured parameter, from either channel with a
maximum load of 300 ohms. The 4-20mA outputs can interface directly with
existing strip chart recorders and LED indicators to monitor and control the
health of your turbine system.
36 Integration Products
Software Products

Your network configuration determines what software packages you need to


configure and manage your system.

XM Serial Configuration The XM Serial Configuration Utility software is an easy to use Windows
application for installing and configuring the XM Series modules. The tool can
Utility Software read, write, and modify configurations stored on disk, upload configuration
from a module; download configurations and firmware updates to a module;
and view data from a module.

The Utility software is provided on the XM Documentation and Configuration


Utility CD that is packaged with the XM modules.

IMPORTANT To use the XM Serial Configuration Utility, connect the PC


to a module’s serial port using the following serial cable.

Cat. No. Description


1440-SCDB9-FXM2 XM Serial Communications Cable

37
38 Software Products

RSLinx Software RSLinx™ software is a complete communication server providing plant-floor


device connectivity for a wide variety of Rockwell Software applications such
as RSLogix™ 5/500/5000, RSView32, RSView Enterprise Series, and
RSMACC™ Enterprise Online Condition Monitor (RSMACC EOL). In
addition, several open interfaces are provided for third-party HMI, data
collection and analysis packages, and custom client-application software.
RSLinx software can support multiple software applications simultaneously,
communicating to a variety of devices on many different networks.

RSLinx 2.x software is now joined by RSLinx Enterprise software, a new


product within the RSLinx family that provide unparalleled connectivity to
Logix processors. RSLinx Enterprise software currently can support working
as a data server for widely distributed RSView Supervisory Edition products,
RSSql™, RSBizWare Historian™, and RSBizWare PlantMetrics™
applications, RSView Machine Edition including PanelView Plus and
VersaView hardware platforms, and RSView Supervisory Edition Station.

You can communicate from anywhere to anywhere using RSLinx software.


RSLinx v2.43 or later is required for compatibility with the entire line of XM
modules.

RSNetWorx for DeviceNet RSNetWorx™ software configures and manages the communication between
the devices on your control network. RSNetWorx for DeviceNet provides an
Software instant, selectable view of any DeviceNet network. With this software, you can
TSI System Selection Guide 39

configure DeviceNet I/O devices and create a scan list. The DeviceNet
scanner stores the configuration information and scan list.

Emonitor Enterprise The Emonitor® suite is a complete machinery information software system
for Condition Based Maintenance programs. By incorporating multiple data
Software sources, such as online systems, portable data collectors and OPC servers,
Emonitor can easily present a complete picture of the state of your machinery.
A collection of analysis tools, statistical based alarms and rule-based logic
allows you to quickly and easily identify problem areas among large amounts of
data.
40 Software Products

Emonitor historical data can be accessed via any application utilizing the
following data access standards:

• Open Database Connectivity (ODBC) - ODBC provides access to data


from any application regardless of which database management system
(DBMS) is handling the data. It is independent of programming
language, database system, and operating system.

• MIMOSA - MIMOSA is an open standard in which equipment asset


software components are able to communicate and exchange data
automatically without propriety or supplier-specific interface protocols.

• Extensible Markup Language (XML) - XML is a simple, flexible text


format designed to facilitate the sharing of data across different systems.
Programs are able to modify and validate documents in languages based
on XML without prior knowledge of their form.

RSMACC Enterprise Online RSMACC Enterprise Online Condition Monitor is an information


presentation and analysis tool that provides you the ability to quickly and
Software intuitively evaluate plant, machinery, and system status at a glance. Using the
Enterprise Online Configuration Utility from within RSMACC Enterprise
Online Condition Monitor, you can remotely configure data collection
parameters, alarms, and relays on the XM modules.

Third Party Software Rockwell Automation offers connectivity solutions allowing our products to
integrate with a variety of third party data sources directly via OPC, DeviceNet
Products Standard and Scanner Bridges.
Project Services

A TSI system retrofit begins with a walk down of the machine and the creation
of a project scope document. From this, a bill of material and quotation
document will be generated.

Rockwell Automation Project Services provides the expertise needed to scope


and install a new TSI system, or the retrofit of an existing one.

Engineering Design Rockwell Automation has the engineering resources and specific TSI
knowledge to effectively design a new system or plan a retrofit. The design
Services services include:

• Functional Design Specification


• Installation Drawings
• Custom Product Design
• Application Review
• Network Evaluation
• Customized Operational and Troubleshooting Guides

Turn Key Rockwell Automation’s performance history and depth of knowledge help to
deliver successful turnkey projects.

• Project Management
• Plan, design, build and install the solution
• Integrate TSI solution with other plant systems
• Factory Acceptance Testing with Documentation Package suitable for
most ISO 9000 Requirements
• Mechanical and Electrical services
• On-Site Acceptance Testing with Documentation Package
• System Commissioning
• Software Configuration
• As-Built Drawing Package
• Factory or On-Site Training of plant personnel on operation and
maintenance of the system
• Final Report Documentation Package

41
42 Project Services

Reliability Online (ROL) Rockwell Automation ROL Services turns TSI data into actionable
Condition-based Maintenance information.
Service Programs
• The TSI system can be designed to be accessed over a phone line or
through a secure internet connection
• Regular or on demand analysis expertise is provided remotely
• Asset health information is accessed through the internet with an easy
to use web portal (see illustration below)

Select the Product Services Services Menu

Cat. No. Description


1443-S-OLTK Turnkey Installations and Services for on-line systems
1443-S-DOC Documentation Service - Reports, Drawings and System
Specifications
1443-S-MON On-line Systems Commissioning, Inspection, Application and Training
1443-S-CAL Standard Annual Calibration or Troubleshooting Service for on-line
systems
1443-ROL-CAS Reliability Online (ROL) analysis service
TSI System Selection Guide 43

Training Utilizing the Rockwell Automation training offerings can significantly improve
the productivity and efficiency of the plant floor staff by giving them the
knowledge, skills and learning aids to maintain both legacy automation systems
and today’s advanced automation technologies.

Training Menu

Course No. Description


CCP422 DeviceNet Maintenance and Troubleshooting
CCP163 DeviceNet/RSNetWorx Design and Configuration
EK-ICM101 Introduction to Vibration Technology
EK-ICM121 Dynamic Balancing
EK-ICM141 Emonitor Odyssey/Enshare Basic
EK-ICM162 Using Your Enpac with Emonitor
EK-ICM165 XM System Fundamentals
EK-ICM201 Vibration Analysis I
EK-ICM221 Emonitor Odyssey/Enshare Advanced
EK-ICM261 Vibration Analysis II
EK-ICM281 Time Waveform Analysis
EK-ICM301 Vibration Analysis III
RS-RSMACC RSMACC Installation and Configuration

Repair, Exchange & Rockwell Automation provides comprehensive repair services including
remanufacturing services for a wide variety Rockwell Automation products,
Renewal Parts repair services for non-Rockwell Automation products, exchange services for
over 12,000 Allen-Bradley catalog products, and renewal parts for many legacy
Allen-Bradley products.
44 Project Services
Optional Accessories

Sensors Rockwell Automation offers a comprehensive range of Sensors for use with
both condition monitoring and protection systems.

Accelerometers bare the workload in vibration monitoring and data collection


processing. Designed for use in a broad range of applications, various types of
accelerometers including high frequency, low frequency, high temperature, and
specialty sensors offer a variety of frequency ranges and reference sensitivities
to provide the best selection for each measurement concern.

9000 Series Accelerometers

9000 series Accelerometers are designed for use in a broad range of


applications including high frequency, low frequency and high temperature and
offer a variety of frequency ranges and reference sensitivities to provide the
best selection for each measurement application.

For more information on 9000 series accelerometers, see publication


GMSI10-SG001, which is available on the Rockwell Automation web site
(http://www.rockwellautomation.com/services/conditionmonitoring/
sensors.html).

2100 Series

The 2100 Series of non-contact pick-ups are designed to meet the stringent
requirements of the American Petroleum Institute (API) Standard 670. The
sensors are non-contacting eddy-current type transducers that measure the
dynamic and/or static displacement of the target relative to the mounting
fixture. The system consists of a non-contact pickup probe,
oscillator/demodulator (probe driver) and interconnecting cable. These
systems are typically used to measure shaft radial and axial vibration, shaft
eccentricity, shaft axial position, case expansion, differential expansion and
other instances where non-contacting, relative measurements must be made.

We also provide a variety of probe holder options. For more information on


2100 series non-contact pickups and probe holder options, see publication
ENACC-PP210, which is available of the Rockwell Automation web site
(http://www.rockwellautomation.com/services/conditionmonitoring/
sensors.html).

45
46 Optional Accessories

Power Supplies The XM series is designed to operate with 24V DC power supplies. The
following Allen-Bradley 1606-XLP power supplies are recommended for use
with all XM applications. The 1606-XLP series is a general purpose,
DIN-rail-mount power supply.

Cat. No. Full Rated Load


1606-XLP-30E 1.3A
1606-XLP-50E 2.1A
1606-XLP-100E 4.2A

Capacity of the power supply must meet or exceed the total maximum load
required by the XM system. If the total system power requirement exceeds the
1606-XLP-100E power supply, use multiple powers supplies and connections.
Note that the total current draw through the side connector cannot exceed 3A.
Maximum loads for each module can be found in the data sheet and User
Manual for the specific module.

It may be necessary to provide a redundant power source to the XM system


for critical applications. All XM modules provide redundant power supply
input terminals so if the primary 24V power supply fails, the secondary power
supply will automatically be used in its place.

For assistance in calculating the power requirements for your XM system,


contact your local Rockwell Automation Customer Service.

Cables Rockwell Automation offers a variety of cables for interfacing industrial


vibration sensors to termination and switch boxes, portable data collectors,
readout devices, and recording and analysis instruments. For individual
product offerings, see publication GSMG10-PL001.

Junction Box Rockwell Automation offers a 20 terminal junction box to house electrical
components and facilitate wiring. For individual product offerings, see
publication GMSG10-PL001.

Enclosures Rockwell Automation offers a broad line of UL approved NEMA enclosures


to house and protect your XM system. NEMA enclosures are rated by the
National Electrical Manufacturers Association (NEMA) and designed for
hazardous or non-hazardous locations and indoor or outdoor use.
TSI System Selection Guide 47

Rockwell Automation offers the following enclosure types.

Enclosure Type Intended Use and Description


NEMA 4 Indoor or outdoor use primarily to provide a
degree of protection against windblown
dust and rain, splashing water, and hose
directed water; undamaged by the
formation of ice on the enclosure.
NEMA 4X✞ Indoor or outdoor use primarily to provide a
degree of protection against corrosion,
windblown dust and rain, splashing water,
and hose-directed water; undamaged by the
formation of ice on the enclosure.
NEMA 12✞ Indoor use primarily to provide a degree of
protection against dust, falling dirt, and
dripping noncorrosive liquids.

✞ NEMA Type 4X and 12 rated enclosures are available with solid door or polycarbonate window.

For individual product offerings, see publication GMSG10-PL001.

Sensor Adhesives / Rockwell Automation offers sensor adhesives and mounting tools to prepare
the machinery surfaces for installation of the sensors. For individual product
Mounting Tools offerings, see publication GMSG10-PL001.

Portable Data Collectors A portable data collector is capable of performing condition monitoring data
collection, analysis, and root cause correction. The Enpac portable data
collectors are Windows CE based, high performance, data collectors and signal
analyzers. Their comprehensive measurement capability, analysis functions and
ease of use make them the perfect tool for a portable predictive maintenance
strategy.

The Enpac 2500 is an easy to use, cost effective, scalable solution that meets
the needs of the novice as well as advanced user. Key attributes include size,
easy to read color display, and speed of data collection. The Enpac 2500 is a
rugged and reliable instrument with a built in laser tachometer and advanced
analysis capabilities such as optional 2-channel functions, 2-plane balancing,
and more.

For more information on the Enpac 2500, see publication GMSI10-PP03.


48 Optional Accessories

Surveillance Monitoring The Enwatch is a cost-effective solution for monitoring the condition of the
important machines in a plant. It bridges the gap between portable data
collectors with manual periodic update capabilities and more expensive
continuous monitoring systems.

For more information on the Enwatch, see publication GMSI10-PP014.


TSI System Selection Guide 49
Listen. Think. Solve, Allen-Bradley, Emonitor, PanelView, RSBizware Historian, RSBizware PlantMetrics, RSLinx, RSLogix, RSMACC, RSSQL, VersaView and XM are trademarks ofRockwell Automation, Inc.

DeviceNet is a trademark of the Open DeviceNet Vendor Association (ODVA).

Windows is a registered trademarks of the Microsoft Corporation.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

GMSI10-SG002A-EN-P - June 2006 Copyright ©2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.