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Machinery Condition Monitoring

MCM800

Product Description

MCM800 Product Guide

NOTICE The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license.

Copyright © 2007 ABB All rights reserved.

Release: September 2007 Document number: 9A63010 Rev D (Preliminary) This product is protected by the following patents: Patent No. 6,414,495 Patent No. 6,546,361 Patent No. 6,668,234 Disclosure number: US-0700515 (patent pending)

TRADEMARKS Registrations and trademarks used in this document include:

Windows Registered trademark of Microsoft Corporation.

PROFIBUS-DP Trademark of Profibus International (P.I.).


TABLE OF CONTENTS About This Book

0.1 Overview......................................................................................................................................4 0.2 Use of Warnings, Caution, Information, and Tip Icons................................................................5 0.3 Terminology .................................................................................................................................5 0.4 Related Documentation ...............................................................................................................6

1 Introduction 1.1 Product Overview ........................................................................................................................7

1.1.1 MPM810 Overview ..................................................................................................................7 1.1.2 TBU850 Overview ...................................................................................................................7

1.2 MCM800 Details ..........................................................................................................................8 1.2.1 Termination Base Unit (TBU850) ............................................................................................8 1.2.2 MPM810 Module .....................................................................................................................8

1.3 Prerequisites and Requirements .................................................................................................8 1.4 Product Features .........................................................................................................................9

1.4.1 Field I/O Capabilities ...............................................................................................................9 1.4.2 Communication........................................................................................................................9

2 Installation 2.1 Installing Termination Base Unit (TBU850) ...............................................................................10 2.2 Termination Base Unit Connections ..........................................................................................10 2.3 Installing Module (MPM810) ......................................................................................................11 2.4 Module Interconnection .............................................................................................................11

3 Configuration 3.1 Before You Start ........................................................................................................................12 3.2 Termination Base Units .............................................................................................................12

3.2.1 Signal Input Configuration .....................................................................................................15 3.2.2 Relay Output Configuration ...................................................................................................16 3.2.3 Event Marker Input Configuration..........................................................................................17

3.3 DIP Switch Configuration...........................................................................................................18 3.3.1 Profibus/Modbus Dipswitch ...................................................................................................18

3.3.1.1 Profibus/Modbus Address.............................................................................................18 3.3.2 Profibus/Modbus Address .....................................................................................................19 3.3.3 Option Dipswitch....................................................................................................................19

3.3.3.1 Operating Mode ............................................................................................................19 3.3.3.2 Configuration Retention................................................................................................19 3.3.3.3 Module Output Mode ....................................................................................................20

3.3.4 MPM810 ................................................................................................................................20 3.4 MCM800 Configuration via Profibus & Ethernet........................................................................20

3.4.1 Module Specific Parameters sent to MCM800......................................................................20 3.4.2 Channel Specific Parameters sent to MCM800 ....................................................................21 3.4.3 Active Data Sent To the MCM800.........................................................................................22 3.4.4 Active Data Reported By the MCM800 .................................................................................24

4 Operation 4.1 General Description ...................................................................................................................27 4.2 I/O Conditioning Functions ........................................................................................................27

4.2.1 Signal Inputs..........................................................................................................................27 4.2.2 Event Marker Inputs ..............................................................................................................28 4.2.3 Relay Outputs........................................................................................................................28

4.3 Functions ...................................................................................................................................29

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4.3.1 Vibration ................................................................................................................................29 4.3.2 Eccentricity ............................................................................................................................30 4.3.3 Thrust (Rotor) Position ..........................................................................................................31 4.3.4 Differential Expansion ...........................................................................................................31 4.3.5 Case Expansion ....................................................................................................................32 4.3.6 Dual Probe.............................................................................................................................32 4.3.7 SMAX ....................................................................................................................................33 4.3.8 Complementary Position .......................................................................................................34 4.3.9 Waveform Capture Settings ..................................................................................................35

5 Maintenance 5.1 Preventive Maintenance ............................................................................................................36 5.2 Hardware Indicators...................................................................................................................36

5.2.1 MPM810 I/O Module LEDs....................................................................................................36 5.3 Troubleshooting .........................................................................................................................37 5.4 Module Replacement.................................................................................................................39

5.4.1 General..................................................................................................................................39 5.4.2 Replacement .........................................................................................................................39 5.4.3 Returning a Module ...............................................................................................................39

5.5 Firmware Upgrade .....................................................................................................................39 6 Specifications

6.1 MCM800 Product Specifications ...............................................................................................40

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About This Book

0.1 Overview This book provides a description of the MCM800 I/O modules and termination units. It provides instructions for installation, start-up, and information regarding capacity and performance. This book is not intended to be the sole source of instruction for the MCM800 I/O system.

This section provides introductory and background information including guidelines about how to find information in the manual related documentation.

The Introduction section provides a product and functional overview.

The Installation section provides installation guidance.

The Configuration section provides details for customizing the units to meet the requirements of individual applications. The main information is structured as follows:

• Design considerations and guidelines.

• Capacity and performance.

The Operation section describes the various start modes and operating modes available for each installation.

The Maintenance section focuses on detecting faults using built-in diagnostics. It explains system status displays in operator stations and LEDs on I/O modules.

In the Specifications section you will find a data sheet that lists the capacities of all of the components of the MCM800 module.

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0.2 Use of Warnings, Caution, Information, and Tip Icons This publication includes Warning, Caution, and Information statements where appropriate to point out safety related or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols should be interpreted as follows:

0.3 Te

An electrical warning icon indicates the presence of a hazard, which could result in electrical shock.

A warning icon indicates the presence of a hazard, which could result in personal injury.

A caution icon indicates important information or a warning related to the concept discussed in the text. It might indicate the presence of a hazard, which could result in corruption of software or damage to equipment/property.

An information icon alerts the reader to pertinent facts and conditions.

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

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

Term Description

I/O device A complete I/O device consists of one TBU and one I/O module.

I/O module An I/O module is an active, electronic and signal conditioning unit. It can be a part of an I/O device.

MCM Machinery Condition Monitoring

TBU The Termination Base Unit is a passive base unit containing process terminals.

DTM Device Type Manager

EU Engineering Unit

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

Title Description

MCMDSS MCM800 Data Source Service

MCM Client MCM800 Client

MCM Configuration Tool MCM800 Ethernet Configuration Tool

Analyst User’s Guide AnalystTM User’s Guide

Release Notes Release Notes for latest product version

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1 Introduction The Machinery Condition Monitoring Module MCM800 provides a complete set of functions for comprehensive Turbine Supervisory Instrumentation. These functions include:

• Vibration Monitoring

• Eccentricity

• Thrust (Rotor) Position

• Differential Expansion

• Case Expansion

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

1.1 Product Overview The MCM800 is comprised of a Termination Mounting Unit (TBU850) and a Processing Module (MPM810).

Its main function is to provide rotating machinery monitoring and protection capability independent from any master DCS or PLC. This independence results in higher reliability and faster response time.

The MCM800 system implements widely used monitoring and protection algorithms available in the industry. Each function also has a set of software configuration parameters.

The MCM800 system has a built-in Profibus-DP Communication Interface to facilitate integration with external control systems or other Profibus compatible devices.

1.1.1 MPM810 Overview

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

The MPM810 performs these functions:

• Executes the selected functions of the MCM800 system.

• Communicates to the control system via Profibus DP.

1.1.2 TBU850 Overview

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

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1.2 MCM800 Details

1.2.1 Termination Base Unit (TBU850)

The Termination Base Unit (TBU850) is an active base unit that receives and conditions the analog signals, and then digitizes the signal for use by the MPM810. It contains the power and field I/O terminals, Profibus communication connectors, serial interface ports, and relay output terminals.

The TBU850 can be mounted on a standard DIN rail. It has a mechanical latch to lock the TBU850 to the DIN rail. The latch can be released with a screwdriver.

1.2.2 MPM810 Module

The MPM810 resides in an open ventilated plastic enclosure. On the front of the MPM810 module there are eleven LEDs indicating the module and I/O status. Refer to Section 5.2.1 for the status indication of the LEDs.

MPM810 module can be easily replaced in a fully operational I/O station. The design of the module and TBUs protect the module from being damaged by excessive voltage or current.

1.3 Prerequisites and Requirements Before operation a complete set of parameters must be downloaded using Profibus DP and the MCM800 DTM or the MCMDSS and the Ethernet Configuration tool. The Profibus master must configure the module before operation can occur.

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1.4 Product Features

1.4.1 Field I/O Capabilities

Power Input +24VDC, -24VDC, Common Parallel terminals for use in daisy-chaining modules

Analog Inputs

Channels 1-4 System Power: +24VDC, -24VDC, or +15VDC current limited to 30mA. Constant current 4.7mA available for +24VDC

Event Marker Input

System Power: -24 VDC current limited to 30mA

Relay Outputs

Alert Dry Contact (Form C) 2A @ 24 VDC / VAC (resistive load) Normally deenergized/energized selectable

Danger Dry Contact (Form C) 2A @ 24 VDC / VAC (resistive load) Normally deenergized/energized selectable

DIP Switches

Profibus Address Seven switches for address selection; one for mode selection

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

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

1.4.2 Communication

RS-485

Profibus DP V1 Configuration, Control, and Reporting Values

Modbus Reporting Values

Ethernet

10/100 BaseT TCP/IP Configuration, Control, and Reporting Values. Firmware Upgrades.

RS-232

Debug Debugging and Firmware Upgrades.

Note: a special cable is required.

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2 Installation

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

Figure 2-1 TBU850 Locking Mechanism

Then insert the edge of the DIN rail into the angled tabs located on the metal base. Once inserted, apply pressure on the TBU850 so the metal cover lies flat against the DIN rail. While holding in place, use the flat head screwdriver to set the locking mechanism to the sliding position by turning the device clockwise 90 degrees. Position the TBU850 to the desired location and set the locking mechanism to the locked position by turning another 90 degrees.

Although the locking mechanism is in the “locked” position, it is possible

2.2 Te

that the unit may slide given enough force, especially if mounted on a vertical DIN rail. To further secure the modules, it is recommended to install a DIN rail end-bracket, or place machine screws through the secure tabs on the TBU850.

rmination Base Unit Connections A TBU850 provides a slot for the MPM810 module.

Two DSUB9 connectors are located on the right and left side of the TBU for Profibus and Modbus communication.

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

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

The serial communication port can be used to:

• Download new firmware.

• An interface port for debugging

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2.3 Installing Module (MPM810) Install module by aligning the connectors of the TBU and module, and then pushing the units together.

Ensure that the module is fully engaged into the TBU. Partial engagement

2.4 M
may produce unexpected results
After connection to the TBU, lock the I/O module in place using the I/O Module Locking device.

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

Figure 2-2 MCM800 Module Interconnection

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3 Configuration

3.1 Before You Start

Read this manual thoroughly before landing wires to the Termination Unit

and applying power to the modules.

3.2 Termination Base Units The terminals of the TBU850 provide the connections for power and all of the field I/O signals of the MCM800. Table 3-1 through Table 3-5 lists the terminals used by the MCM800 and the signals for connection.

Terminal Description

1 +24VDC Power (in)

2 Power Common (in)

3 -24VDC Power (in)

4 +24VDC Power (out)

5 Power Common (out)

6 -24VDC Power (out)

Table 3-1 TBU850 Power Terminals

Figure 3-1 Typical Power Connection

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1 Transducer Power (+) (out)

2 Constant Current (4.7mA)

3 Transducer Common

4 Transducer Signal

5 Transducer Power (-) (out)

6 Earth Ground (Shield)

Table 3-2 TBU850 Signal Terminals Channels 1-4


1 EM Out (+) – TTL

2 EM Out (-) – TTL

3 Transducer Common

4 EM Common (out)

5 EM Signal (out)

6 EM Common (in)

7 EM Signal (in)

8 Transducer Power (-) (out)

9 Earth Ground (Shield)

Table 3-3 TBU850 Event Marker Terminals

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1 Alert Normally Closed

2 Alert Common

3 Alert Normally Open

4 Danger Normally Closed

5 Danger Common

6 Danger Normally Open

Table 3-4 TBU850 Relay Contacts

Terminal PA1 PB1 PA2 PB2

1 RS-232 Com NC NC NC

2 RS-232 TXD NC NC NC

3 Profi A+ (in) Profi B+ (out) Profi A+ (out) Profi B+ (in)

4 RS-232 RXD NC NC NC

5 NC NC NC NC

6 NC NC NC NC

7 NC NC NC NC

8 Profi A– (in) Profi B– (out) Profi A– (out) Profi B– (in)

9 NC NC NC NC

Case Earth Ground

(Shield)

Earth Ground

(Shield)

Earth Ground

(Shield)

Earth Ground

(Shield)

Table 3-5 TBU850 D-SUB9 (Profibus) Connector

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3.2.1 Signal Input Configuration

The MCM800 signal input channels terminals are designed to interface to a variety of transducers. Figures 3-2 through 3-5 show the differentTBU850 wiring configurations associated with the different type of transducers.

Figure 3-2 Eddy Current Probe Configuration

Figure 3-3 Piezoelectric velocity probes and accelerometers

Figure 3-4 Moving Element Velocity Probes

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Figure 3-5 DC LVDT’s

3.2.2 Relay Output Configuration

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

Figure 3-6 Relay Terminal Connections

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3.2.3 Event Marker Input Configuration

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

Figure 3-7 Event Marker with single TBU850

Figure 3-8 Event Marker with multiple TBU850‘s

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3.3 DIP Switch Configuration The TBU850 requires proper Dipswitch setting prior to operation.

3.3.1 Profibus/Modbus Dipswitch

3.3.1.1 Profibus/Modbus Address

Determine the Profibus/Modbus address of the module and set Dipswitch S1 to the proper address. Valid Profibus addresses range from 0 to 125; however addresses 0 & 1 are reserved for the Profibus Master. Therefore, valid MCM800 addresses range from 2 to 125.

Note: System Redundancy requires a slave backup address to be n+64; therefore the highest possible primary address with System Redundancy enabled is 61 for a backup address of 125.

Table 3-6 shows the switch settings for addresses 0–63. The switch settings for addresses 64–127 correspond to the first 63 settings in the table, with switch 2 (S1) set to the “1” position.

Switch 2345678

Profibus Address

Switch 2345678

Profibus Address

Switch 2345678

Profibus Address

Switch 2345678

Profibus Address

0000000 0 0010000 16 0100000 32 0110000 48 0000001 1 0010001 17 0100001 33 0110001 49 0000010 2 0010010 18 0100010 34 0110010 50 0000011 3 0010011 19 0100011 35 0110011 51 0000100 4 0010100 20 0100100 36 0110100 52 0000101 5 0010101 21 0100101 37 0110101 53 0000110 6 0010110 22 0100110 38 0110110 54 0000111 7 0010111 23 0100111 39 0110111 55 0001000 8 0011000 24 0101000 40 0111000 56 0001001 9 0011001 25 0101001 41 0111001 57 0001010 10 0011010 26 0101010 42 0111010 58 0001011 11 0011011 27 0101011 43 0111011 59 0001100 12 0011000 28 0101100 44 0111100 60 0001101 13 0011001 29 0101101 45 0111101 61 0001110 14 0011010 30 0101110 46 0111110 62 0001111 15 0011111 31 0101111 47 0111111 63

A “1” corresponds to the switch position labeled “ON” or “CLOSED”

Table 3-6 Profibus/Modbus Address Selection

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Figure 3-9 Address and Option Dipswitch

3.3.2 Profibus/Modbus Address

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

Setting Description

0 System Redundancy Disabled

1 System Redundancy Enabled

3.3.3 Option Dipswitch

3.3.3.1 Operating Mode

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

Switch 1 Switch 2 Description

0 0 Normal Mode

0 1 Diagnostic Mode

1 0 Low Speed Mode

1 1 Calibration Mode

3.3.3.2 Configuration Retention

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

Switch 3 Description

0 Use and store Default settings at start-up.

1 Store configuration and use at start-up.

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3.3.3.3 Module Output Mode

Switch 4 determines the output protocol for ports PA1&2 and PB1&2.

Switch 4 Description

0 Modbus RTU protocol.

1 Profibus DP-V1 protocol.

3.3.4 MPM810

There are no configurable settings on this board.

3.4 MCM800 Configuration via Profibus & Ethernet The MCM800 system uses Profibus DP for communication with the control system. For an 800 xA system a CI854A (or similar) Profibus master is used to communicate to the module.

• Refer to the Profibus Users Guide for more information.

3.4.1 Module Specific Parameters sent to MCM800

Description Range Units Type IP Address NNN.xxx.xxx.xxx 0 to 255 None I IP Address xxx.NNN.xxx.xxx 0 to 255 None I IP Address xxx.xxx.NNN.xxx 0 to 255 None I IP Address xxx.xxx. xxx.NNN 0 to 255 None I Subnet Mask NNN.xxx.xxx.xxx 0 to 255 None I Subnet Mask xxx.NNN.xxx.xxx 0 to 255 None I Subnet Mask xxx.xxx.NNN.xxx 0 to 255 None I Subnet Mask xxx.xxx. xxx.NNN 0 to 255 None I English/Metric EU 0, 1 None B Angular Position of Event Marker probe -360 to 360 Degrees I

Event Marker Detect Voltage 0 to 15 Volts I Normal Alert relay state 0,1 None B Normal Danger relay state 0,1 None B

IP Address and Subnet Mask – The IP Address and Subnet Mask is required for the module to communicate over Ethernet. It is a unique address for a specific network. The default values are 192.168.222.111 and 255.255.0.0. The configuration tools will allow a new address to be set. Once set the user must switch to the new address for proper communication.

English/Metric – Set this value to a “0” if the engineering units are English and a “1” if they are in metric.

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

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

Normal Alert/Danger relay state – Set to “0” for Normally Deenergized (energize to activate relay), and “1” for Energized (deenergize to activate relay).

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3.4.2 Channel Specific Parameters sent to MCM800

Description Range Units Type Channel type 0 to 10 None I Block output select 0 to 5 None I Probe type 0 to 8 None I Probe Sensitivity Full mv/EU R Integration 0 to 2 None I Angular Position of Probe -360 to 360 Degrees I Ramp Angle 0 to 90 Degrees R Probe DC Voltage High Failure Threshold -24 to +24 Volts R

Probe DC Voltage Low Failure Threshold -24 to +24 Volts R

N for Nth Order 3 to 10 None I Dual Vote Enable 0,1 None B Non-linear Correction: X1 Full EU R For Future Use Non-linear Correction: Y1 Full EU R For Future Use Non-linear Correction: X2 Full EU R For Future Use Non-linear Correction: Y2 Full EU R For Future Use Non-linear Correction: X3 Full EU R For Future Use Non-linear Correction: Y3 Full EU R For Future Use Non-linear Correction: X4 Full EU R For Future Use Non-linear Correction: Y4 Full EU R For Future Use Non-linear Correction: X5 Full EU R For Future Use Non-linear Correction: Y5 Full EU R For Future Use

Channel type – This value specifies the operation of the channel. 0 = None (Valid for all channels) 1 = Vibration (Channels 1-4 only) 2 = Eccentricity (Channels 1-4 only) 3 = Thrust (Rotor) Position (Channels 1-4 only) 4 = Differential Expansion (Channels 1-4 only) 5 = Case Expansion (Channels 1-4 only) 6 = Dual Probe - Relative (Channels 1 & 3 only) 7 = Dual Probe – Seismic (Channels 2 & 4 only) 8 = Dual Probe – Absolute (Channels 5 & 6 only)

For channel 5, channel 1 must be set to Relative (6), and channel 2 must be set to Seismic (7). For channel 6, channel 3 must be set to Relative (6), and channel 4 must be set to Seismic (7).

9 = SMAX (Channels 5-7only) For channel 5, channel 1 & 2 must be set to Vibration (1) and Probe Type must be Eddy Current (1) for channels 1 & 2. For channel 6, channel 3 & 4 must be set to Vibration (1) and Probe Type must be Eddy Current (1) for channels 1 & 2. For channel 7, channels 5 & 6 must be set to Dual Probe – Absolute.

10 = Complementary Position (Channels 5 & 6 only) For channel 5, channel 1 & 2 must be set to Thrust (3) or Differential Expansion (4). For channel 6, channel 3 & 4 must be set to Thrust (3) or Differential Expansion (4).

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Output Select – This value specifies value of the output (valid for all channels). 0 = Peak-to-peak 1 = Peak 2 = RMS 3 = Average 4 = Calculated peak-to-peak 5 = Calculated peak

Probe Type – This value specifies type of probe (valid for channels 1-4 only). 0 = None 1 = Proximity Probe 2 = DC LVDT 3 = Accelerometer 4 = Moving Element velocity probe 5 = Piezoelectric velocity probe 6 = Complementary proximity probe 7 = Ramped proximity probe 8 = Ramped complementary proximity probe

Probe Sensitivity – This value specifies sensitivity of the probe in “mv/EU” (valid for channels 1-4 only).

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

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

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

Probe DC Voltage High/Low Failure Thresholds – This value is the voltage beyond which the module will report bad quality for that channel.

N for Nth Order – This value is specifies a user defined order calculation from 3 to 10.

Non-linear Correction – These are (x,y) pairs of values used to correct for non-linearity effects of probes. (Note: For Future Use Only)

3.4.3 Active Data Sent To the MCM800

Description Range Units Type Shaft Rotational Direction 0,1 None B Set Alert Relay 0,1 None B Set Danger Relay 0,1 None B Reset Diagnostic Function 0,1 None B High Danger Threshold Full EU R High Alert Threshold Full EU R Low Alert Threshold Full EU R Low Danger Threshold Full EU R Alert Delay 0.1 to 300 Seconds R Danger Delay 0.1 to 300 Seconds R Alert Enable 0,1 None B Danger Enable 0,1 None B Filter Low Cutoff Frequency 1 to 1,000 Hz I Filter High Cutoff Frequency 30 to 15,000 Hz I Null Position in Engineering Units Full EU R Null Position Voltage -24 to +24 Volts R

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Description Range Units Type Set Null Position Voltage 0,1 None B Waveform Capture 0,1 None B Run-up Capture 0,1 None B Rundown Capture 0,1 None B Event Capture 0,1 None B

Shaft Rotational Direction – The value indicates the rotation of the shaft. 0 = Clockwise 1 = Counter-clockwise

Set Alert / Danger Relay – These values will force the relay to the “active” state. 0 = Normal operation 1 = Force relay active.

Reset Diagnostic Function – A transition from ‘0’ to ‘1’ forces a reset of the Ethernet communication interface.

0 = Normal Operation 1 = Forces Ethernet Network close and restart.

High Alert / Danger Threshold – These values determine the point above which the corresponding action will occur. (Valid for all channels).

Low Alert / Danger Threshold – These values determine the point below which the corresponding action will occur. (Valid for all channels).

Alert / Danger Delay – These values determine the delay in seconds the condition must exist before activating Alert or Danger status. Note: If the value exceeds the Danger setpoint before the Alert delay expires, the module will immediately set the Alert status. (Valid for all channels).

Alert / Danger Enable – These values enable the alert and danger action. (Valid for all channels).

0 = Action disabled 1 = Action enabled

Filter Low / High Cutoff Frequency – These values set the cutoff frequency above or below which the signal is attenuated. The value specified is the -3dB point of a 4-pole Butterworth filter. (Valid for channels 1-4, Vibration, Relative, or Seismic channel types).

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

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

Set Null Position Voltage – This value forces the MCM to set the internal NVRAM to correspond to the Null Position EU and Voltage. (The MCM uses the locally stored values to determine position.)

0 = Normal operation 1 = Set Null Position

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

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3.4.4 Active Data Reported By the MCM800

Description Range Units Type Module Alert 0,1 None B Module Danger 0,1 None B Dual Vote Alert Ch 1&2 0,1 None B Dual Vote Danger Ch 1&2 0,1 None B Dual Vote Alert Ch 3&4 0,1 None B Dual Vote Danger Ch 3&4 0,1 None B Dual Vote Alert Ch 5&6 0,1 None B Dual Vote Danger Ch5&6 0,1 None B MCM Mode 0,1 None B Calibration Active 0,1 None B Diagnostic Error 0,1 None B Orders Active 0,1 None B Event Marker Status 0,1 None B Zero Speed Indicator 0,1 None B Invalid IP Address 0,1 None B Profibus Active 0,1 None B Software Version Major 0 to 255 None I Software Version Minor 0 to 255 None I Software Version Revision 0 to 255 None I Software Version Pre-Release 0 to 255 None I Speed 0 to 30,000 RPM R Overall Output Full EU R DC Voltage -24 to +24 Volts R DC Relative Gap Full EU R Ethernet OnlyOrder 0.5x Amplitude Full EU R Order 0.5x Phase 0 to 359 Degrees R Order 1x Amplitude Full EU R Order 1x Phase 0 to 359 Degrees R Order 2x Amplitude Full EU R Order 2x Phase 0 to 359 Degrees R Order Nx Amplitude Full EU R Order Nx Phase 0 to 359 Degrees R Order Not1x Amplitude Full EU R N for Nth Order 0 to 359 Degrees R Critical Error 0,1 None B Configuration Error 0,1 None B Probe Voltage Error 0,1 None B Bad Data 0,1 None B Suspect Data 0,1 None B Alert Active 0,1 None B Alert Low Active 0,1 None B Alert High Active 0,1 None B Danger Active 0,1 None B Danger Low Active 0,1 None B Danger High Active 0,1 None B Time Waveform Buffer Full 0,1 None B Time Waveform Capture Complete 0,1 None B Time Waveform Runup Active 0,1 None B Time Waveform Rundown Active 0,1 None B Time Waveform Event Log Active 0,1 None B

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Module Alert / Danger – These values indicate the Alert / Danger alarm status. 0 = Normal 1 = Alert / Danger Active

Dual Vote Alert / Danger – These values indicate if both channels are active when Dual Voting is enabled.

0 = Normal 1 = Alert / Danger Active (Both channels)

MCM Mode – These values reflect the operational mode of the MCM800 based on Dipswitch S2. 0 = Normal 1 = Low Speed

Calibration Active – This value indicates the calibration status. 0 = Not calibrating (Normal) 1 = Module is calibrating

Diagnostic Error – This value indicates the diagnostic status. 0 = Diagnostics successfully passed 1 = Diagnostics failed

Orders Active – This value indicates orders are being calculated. 0 = Orders are not being calculated 1 = Orders are being calculated

Event Marker Status – This value indicates Event Marker Status. 0 = Event Marker Failed 1 = Event Marker OK

Zero Speed Indicator – This value indicates if shaft has stopped. 0 = Speed is >= 1 RPM or bad quality (Event Marker Status = 0) 1 = Speed is < 1 RPM and good quality (Event Marker Status = 1)

Invalid IP Address – This value indicates if the IP address or subnet mask is invalid. 0 = IP Address and Subnet mask is valid 1 = IP Address or Subnet mask is invalid

Profibus Active – This value indicates a Profibus Master is communicating 0 = Profibus not communicating 1 = Profibus is communicating

Software Version – These values indicate the software Version major.minor / revision.pre-release.

Speed – This value indicates the current speed in RPM.

Overall Output – This value indicates the overall movement or position in Engineering Units according to channel type. (Valid for all channels)

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

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

Order 0.5x Amplitude – This value indicates the Half Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only)

Order 0.5x Phase – This value indicates the Half Order phase angle in degrees. (Valid for channels 1-6, Vibration only)

Order 1x Amplitude – This value indicates the First Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only)

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Order 1x Phase – This value indicates the First Order phase angle in degrees. (Valid for channels 1-6, Vibration only)

Order 2x Amplitude – This value indicates the Second Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only)

Order 2x Phase – This value indicates the Second Order phase angle in degrees. (Valid for channels 1-6, Vibration only)

Order Nx Amplitude – This value indicates the Nth Order Vibration component in Engineering Units. (Valid for channels 1-6, Vibration only)

Order Nx Phase – This value indicates the Nth Order phase angle in degrees. (Valid for channels 1-6, Vibration only)

Order Not1x Amplitude – This value indicates the Not First Order Vibration components in Engineering Units. (Valid for channels 1-6, Vibration only)

N for Nth Order – This value indicates the Nth Order phase angle in degrees. (Valid for channels 1-6, Vibration only)

Critical Error – This value indicates any module error detected by the system. 0 = Normal 1 = Error

Configuration Error – This value indicates a channel is configured improperly. 0 = Normal 1 = Error

Probe Voltage Error – This value indicates the channels DC voltage is out of limits. 0 = Normal 1 = Error

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

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

Alert, Alert Low, Alert High Active – These values indicate the Overall value has exceeded the specified range.

0 = Normal 1 = Alert

Danger, Danger Low, Danger High Active – These values indicate the Overall value has exceeded the specified range.

0 = Normal 1 = Danger

Time Waveform Buffer Full – This value indicates Capture buffer is full. 0 = Normal 1 = Buffer Full

Time Waveform Capture Complete – This value indicates a single capture has completed. 0 = Normal 1 = Complete

Time Waveform Runup, Rundown, & Event Active – These values indicate the MCM800 is actively capturing respective waveform data.

0 = Normal 1 = Active

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4 Operation

4.1 General Description The MCM800 system is part of ABB’s 800 xA technology platform. The modules that comprise this system operate independently from the main DCS controller, providing dedicated monitoring and protective features, including:

• Vibration Monitoring

• Eccentricity

• Thrust (Rotor) Position

• Differential Expansion

• Case Expansion

The TBU850 conditions these field signals and passes the digitized results to the MPM810 controller. The MPM810 uses the field data in the execution of its functions.

In the next sections of this manual, the MCM800 system is broken down into three main functional areas for analysis purposes:

• I/O Functions

• Protective Functions

• Testing Functions.

These functions include both hardware and software components.

4.2 I/O Conditioning Functions I/O Conditioning functions convert the field electrical signals into digital data, which is then transferred to the micro-controller in the MPM810.

4.2.1 Signal Inputs

The MCM800 can accept up to four signal inputs. These can range from approximately +20 volts to –20volts. They pass through over-voltage protection devices then into a differential input to reduce common mode noise. The signal passes through a four-pole low-pass anti-aliasing filter with a corner frequency of about 20 kHz. This filter reduces high frequencies that may be falsely interpreted. Finally, the signal is digitized by an Analog-to-Digital converter sampling at 50 kHz. The digitized signal is passed to the MPM810 where it is processed.

Internally the signal is separated into an AC and a DC component. The AC component is used for vibration and eccentricity measurements. The DC component is used for Thrust, Differential Expansion, Case Expansion, and for signal quality.

The AC signal is filtered using the frequency parameters set by the user to reduce unwanted frequencies. The filters used are digital 2-pole Butterworth high-pass and low-pass filters. The output of the filter may be integrated from velocity to displacement or acceleration to velocity. The signal is finally analyzed and output as a peak, peak-to-peak, RMS or average value.

The DC signal is filtered to remove the AC component providing a steady output value. For all type of configurations the DC voltage provides ranging from about +24 volts to –24 volts. This signal is used to determine signal quality as specified by the user. It is

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also used for all position measurements. The position is determined from a “null” position previously set.

4.2.2 Event Marker Inputs

The MCM800 accepts a once-per-revolution pulse with a minimum pulse height of 1.7 v and a minimum pulse width of 100 µsec (larger signals are preferred). The Event Marker has two functions:

• Shaft speed (in RPM’s)

• Orders calculations

Speed is measured between 1 RPM and over 20,000 RPM’s. When the speed goes below 1 RPM, the module interprets this as zero speed. If the speed is suddenly lost above 20 RPM’s the speed output is set bad quality.

For orders calculations, the event marker is used to determine the running speed of the shaft. These calculations produce an amplitude of 1 times running speed (1X), 2 times running speed (2X), one-half times running speed (half-X), and N times running speed (NX). N is a number between 3 and 10 specified by the user. In addition, a Not 1X value is calculated. A phase angle is produced for half-X, 1X, 2X, and NX.

4.2.3 Relay Outputs

For each signal channel there are up to four alarm levels available.

High Danger

High Alert

Low Alert

Low Danger

If enabled, the MCM800 will activate on-board relays indicating a problem exists. There is one relay for Alert and one relay for Danger. Time delays of 0.1 to 300 seconds are available to avoid false alarms.

The relays are Form-C providing a normally open and normally closed contact. In addition, parameters enable the user to specify normally energized and normally deenergized relays.

The user must be careful when using these features to ensure expected results.

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

4.3.1 Vibration

This function measures shaft vibration.

Typical Vibration Configuration (valid for channels 1-4)

Channel Type 1 = Vibration Output Select 0 = Peak-to-peak

1 = Peak 2 = RMS 3 = Average 4 = Calculated peak-to-peak 5 = Calculated peak

Probe Type 1 = Proximity Probe 3 = Accelerometer 4 = Moving Element velocity probe 5 = Piezoelectric velocity probe

Probe Sensitivity Millivolts / EU Integration 0 = None

1 = Velocity to displacement (velocity probes only) 2 = Acceleration to velocity (accelerometers only)

Angular Position of Probe

High Failure Threshold

Typical settings Proximity Probe = -0.5 Accelerometer = 20.0 Moving Element velocity probe = 20.0 Piezoelectric velocity probe = 20.0

Low Failure Threshold

Typical settings Proximity Probe = -20.0 Accelerometer = 0.5 Moving Element velocity probe = -20.0 Piezoelectric velocity probe =0.5

N for Nth Order 3 – 10 (User specified)

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Filter Low Cutoff Frequency

User defined (recommendations listed below) Proximity Probe = 1 Accelerometer = 10 Moving Element velocity probe = 10 Piezoelectric velocity probe = 10 Integrated signals with low frequency noise = 40

Filter High Cutoff Frequency

User defined (recommendations listed below) Low Speed (< 1000 RPM) = 200 Medium Speed (1000-5000 RPM) = 600 to 2000 High Speed (> 5000 RPM) = up to 2000 Highest speed of interest in Hertz times 10

Shaft Rotation Direction

Shaft rotation is determined looking axially from the driver to driven direction. 0 = Clockwise 1 = Counter-clockwise

4.3.2 Eccentricity

This function measures shaft eccentricity.

Typical Eccentricity Configuration (valid for channels 1-4)

Channel Type 2 = Eccentricity Output Select 0 = Peak-to-peak Probe Type 1 = Proximity Probe Probe Sensitivity Millivolts / EU Angular Position of Probe

High Failure Threshold Proximity Probe = -0.5

Low Failure Threshold Proximity Probe = -20.0

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4.3.3 Thrust (Rotor) Position

This function measures Thrust or Rotor Position.

Typical Thrust Configuration (valid for channels 1-4)

Channel Type 3 = Thrust Probe Type 1 = Proximity Probe

6 = Complementary proximity probe Probe Sensitivity Millivolts / EU High Failure Threshold Proximity Probe = -0.5

Low Failure Threshold Proximity Probe = -20.0

Null Position in Engineering Units User defined.

Null Position voltage Set by user.

4.3.4 Differential Expansion

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

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

Channel Type 4 = Differential Expansion Probe Type 1 = Proximity Probe

2 = DC LVDT 6 = Complementary proximity probe 7 = Ramped Complementary proximity probe

Probe Sensitivity Millivolts / EU Ramp Angle (for probe type 7 only)


Proximity Probe = -0.5 DC LVDT = probe dependent





Non-linear Correction

User defined. This is intended to extend the usable range of a probe. (For Future Use Only)

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0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20

4.3.5 Case Expansion

This function measures Case Expansion.

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

Channel Type 5 = Case Expansion Probe Type 1 = Proximity Probe

2 = DC LVDT Probe Sensitivity Millivolts / EU High Failure Threshold






4.3.6 Dual Probe

This function measures shaft vibration using a Dual Probe.

The Dual Probe application combines a Relative Probe (channel 1) with a Seismic Probe (channel 2) producing an Absolute signal (channel 5). Likewise, channel 3 (Relative) and channel 4 (Seismic) produces channel 6 (Absolute).

Typical Dual Probe Configuration

Parameter Relative (1/3) Seismic (2/4) Absolute (5/6) Channel Type 6 = Relative 7 = Seismic 8 = Absolute Output Select 0 = Peak-to-peak 0 = Peak-to-peak 0 = Peak-to-peak Probe Type 1 = Proximity Probe

4 = Moving Element velocity probe 5 = Piezoelectric velocity probe

N/A

Probe Sensitivity

Millivolts / EU Millivolts / EU N/A

Integration 0 = None

1 = Velocity to displacement

N/A

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Parameter Relative (1/3) Seismic (2/4) Absolute (5/6) Angular Position of Probe

45

-45 N/A


Proximity Probe = -0.5 velocity probe = 20.0 N/A


Proximity Probe = -20.0 Moving Element velocity probe = -20.0 Piezoelectric velocity probe =0.5

N for Nth Order

3 – 10 (User specified) Same as relative Same as relative

Filter Low Cutoff Frequency

User defined (recommendations listed below) 1 to 10 Hz

User defined (recommendations listed below) 5 to 10 Hz

N/A

Filter High Cutoff Frequency

User defined (recommendations listed below) Low Speed (< 1000 RPM) = 200 Medium Speed (1000-5000 RPM) = 600 to 2000 High Speed (> 5000 RPM) = up to 2000 Highest speed of interest in Hertz times 10

Same as relative N/A

4.3.7 SMAX

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

The SMAX application combines an X (channel 1) with a Y (channel 2) producing an SMAX signal (channel 5). Likewise, channel 3 (X) and channel 4 (Y) produces channel 6 (SMAX). In addition, if two Dual Probes are placed in an X/Y configuration SMAX is calculated using channel 7.

The X and Y designators are arbitrary. What is more important is the probe angles and direction of rotation.

Typical SMAX Configuration (valid channels 5-7)

Configure the X and Y channels as vibration channels or dual probes.

Channel Type 9 = SMAX Output Select 0 = Peak-to-peak

1 = Peak

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4.3.8 Complementary Position

This function measures Thrust or Differential Expansion in a complementary position.

The Complementary Position application compares the signals from channels 1 and 2 to output channel 5, or channels 3 and 4 for channel 6.

Typical Complementary Position Configuration (valid channels 5&6)

Channel Type 10 = Complementary Position Set Sensitivity for channel 1 or 3 to mV / EU and 2 or 4 to (-) mV /EU

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

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

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

The value of the Complementary output depends on the quality of each of the two hardware inputs. The quality is based on the High and Low failure voltages. Refer to the section that explains the Probe Failure Voltage setting.

The two probes can be mounted in such a way that the probes are either overlapping or non-overlapping as shown below.

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4.3.9 Waveform Capture Settings

The MCM800 has 4 logic signals that control when time waveform data is captured. Controller logic can be written to capture a single time waveform or capture a series of time waveforms during a runup, a rundown or during an event such as a plant trip.

Capture Waveform

On a transition from false to true the current waveform will be captured and transmitted to the Data Server. Once captured, the Capture Time Waveform flag becomes true. At least 5 waveforms can be retained in a buffer to await transfer. If the buffer fills, the Buffer Full flag becomes true and the MCM800 will not capture additional waveforms until buffer space is available. If Capture Waveform remains true, no additional waveforms will be captured. While it is not normally necessary, DCS logic can check the Capture Time Waveform and Buffer Full flags.

Runup Capture

When Runup Capture is true, the current waveform will be stored every time speed increases by Delta RPM or more. Runup Capture continues while the flag is true and there is enough storage on the MCM800. There is enough memory to store up to 40 files, but files can be off-loaded to the Data Server while the data is being captured. Delta RPM is specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the Runup Data flag.

Rundown Capture

Same as Runup Capture except speed must decrease by Delta RPM or more.

Event Active

The Event Waveform file contains up to 40 waveforms. The MCM800 will retain a configurable amount of waveforms from the Current Data Buffer at a configurable Skip-over Factor prior to Event Active. The purpose is to store data from before and after an event such as a Danger alarm or a machinery trip. Construction of the Event Waveform file starts when Event Active becomes true. Construction continues until 40 waveforms, including pre-event captures, are stored or Event Active becomes false, constituting a file. When a file is complete, the Event Data flag becomes true until the waveforms are uploaded to the Data Server. If Event Active remains true, no additional Event Waveform files will be constructed. The Skip-over Factor and Number of Pre-trigger Waveforms are specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the Event Data flag.

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5 Maintenance

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

5.2 Hardware Indicators

5.2.1 MPM810 I/O Module LEDs

LED Description

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

RxTxA Profibus Bus A communication. The LED is AMBER if the module is communicating over Bus A

RxTxB Profibus Bus B communication. The LED is AMBER if the module is communicating over Bus B

STATUS The LED is GREEN when running normally, completed diagnostics, or completed calibration. It is AMBER during startup, running diagnostics or calibration. It is RED if the module failed startup, diagnostics or calibration

CH1 Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration error. OFF means channel is not configured.







Table 5-1 MPM810 LEDs

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5.3 Troubleshooting

Symptom Possible Causes Corrective Action Module is not plugged in correctly.

Re-adjust the module to fit properly.

Operating mode not set up correctly.

Check Profibus Address DIPswitch. Check Ethernet IP address. Check option DIPswitch.

Module does not initialize.

Hardware failure. Replace the module.

No power to module Check +24 & -24 volt power supplies and connector.

Module is not plugged in correctly.

Re-adjust the module to fit properly.

R/F LED is OFF.

Hardware failure. Replace the module. Module is not plugged in correctly.

Re-adjust the module to fit properly. R/F LED is RED.


Profibus not communicating Check Profibus master and configuration

Loose or disconnected Check the cable for proper fitting. RxTxA & RxTxB LED’s are OFF

Profibus not properly terminated Check Profibus termination DIPswitch S3.

STATUS LED is AMBER. The module is on startup, calibration or diagnostic mode.

If LED does not turn green after several minutes the module may be faulty. Replace module.

Module failed startup Replace MPM810 Module failed diagnostic Replace MPM810 STATUS LED is RED. Module failed calibration Replace TBU850.

CHn LED is OFF. Channel not configured Check configuration

CHn LED is AMBER Channel is in Alert condition.

This is usually a normal condition. However, it could be caused by a noisy signal or an improper configuration.

CHn LED is REDChannel is in Danger condition.

This is usually a normal condition. However, it could be caused by a noisy signal or an improper configuration.

CHn LED is blinking AMBER There is a configuration error. Check configuration. No configuration defined for channel.

Configure channel using configuration tool. Channel status indicates a

Critical error, but no Configuration error. Configuration not saved. Re-configuration channel and set

dipswitch to save parameters.

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Symptom Possible Causes Corrective Action

MCM800 reporting incorrect values.

There are numerous possible causes for incorrect values, some are listed below.

• Signal noise • Poor connection • Improper power and

ground • Improper shielding • Incorrect sensitivity • Incorrect filter values • Improper calibration • Malfunctioning hardware.

The possible corrective actions are just as numerous, some are listed below.

• Check signal path • Check cable connections • Check cable shielding • Check sensitivity value • Check or adjust filter

settings • Recalibrate TBU850. • Verify module with known

input signal • Replace MPM810 or

TBU850.

Incorrect speed or phase Noise on Event Marker input signal

Check cables for any faults. This may be an infrequent occurrence that can not be easily identified and corrected.


Improper actuation of termination unit relays. Noise on input signal

Check cables for any faults. This may be an infrequent occurrence that can not be easily identified and corrected.


38


5.4 Module Replacement

5.4.1 General

All I/O modules are designed for long, trouble-free service. If it is determined that the module is faulty, replace it with a new one. DO NOT try to repair the module as replacing components may adversely affect the module's performance and void the warranty. If it becomes necessary to replace any parts, contact the ABB Customer Service Department.

All I/O modules can be exchanged on-line with the process power supply connected. However, it is important to understand the consequences of a module exchange on-line and how it affects the process. Replacement of an I/O module affects all channels on the module. It also sometimes indirectly affects the outputs, via some application function, on another module.

5.4.2 Replacement

Replace faulty or suspect I/O modules in the following way:

• Provide access to the module by loosening the module locking device.

• Grip the module firmly and extract the module.

• Store extracted modules in envelopes.

• Insert the new module carefully and completely.

• Ensure that the module contacts mate properly with the contacts in the TBU and activate the locking mechanism in place.

Modules initialize automatically and will begin to execute in a few seconds.

5.4.3 Returning a Module

When returning a module, first obtain a Return Material Authorization (RMA) number. Be sure to show this number prominently on the outside of the shipping container, on the shipping label, and on the packing list.

Include the part description, the part number, the serial number, and the symptoms of the problem. Please provide as much information as possible.

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

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6 Specifications

6.1 MCM800 Product Specifications GENERAL

Microprocessors MCF5282 @ 64 MHz PLL MC56321 DSP @ 250 MHz PLL

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

I/O Module Mounting One slot in Modular Termination Unit (TBU850)

I/O Termination Termination Base Unit (TBU850)

TBU Cabinet Mounting Standard 35mm DIN Rail

TU Terminal Blocks 24A/250V Compression: 0.14-1.5 / 0.14-1.5 / 28-16 solid[mm2] / stranded[mm2] / AWG

OPERATING

Positive Power +24 VDC current limited 30 mA each

Negative Power -24 VDC current limited 30 mA each

Constant Current 4.7 mA (for piezoelectric devices)

Digital Output (Alert / Danger) Dry Relay Contact (Form C) 2A @ 24 VDC

ELECTRICAL

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

Module Consumption 7.5 W each supply (typical)

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

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ENVIRONMENTAL

CE Mark (pending) EMC96 Directive (89/336/EEC) Low Voltage Directive (73/23/EEC)

This product, when installed in a cabinet, was designed to comply with the following Directives/Standards for CE Marking. EN50082-2 Generic Immunity Standard - Part 2: Industrial EnvironmentEN61010-1 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use - Part 1: General Requirements

Certifications (pending) Canadian Standards Association (CSA)

This card was designed for use as process control equipment in an ordinary (non-hazardous) location.

Ambient Temperature 0° to 55° C (32° to 131° F)

Humidity 5% to 90% RH (±5%) up to 55°C (non-condensing) 5% to 40% RH (±5%) up to 70°C (non-condensing)

Atmospheric Pressure Sea level to 3 km (1.86 miles)

Air Quality Non-corrosive

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

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