Rack Configuration and Utilities Guide 129777-01

8/20/2019 Rack Configuration and Utilities Guide 129777-01

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Part Number 129777-01

Revision A, January 1996

3500 Monitoring System

Rack Configuration and Utilities Guide


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Copyright © 1995 Bently Nevada Corporation

All Rights Reserved.

No part of this publication may be reproduced, transmitted, stored in a retrieval system or

translated into any human or computer language, in any form or by any means, electronic,mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written

permission of the copyright owner,

Bently Nevada Corporation

Post Office Box 157

Minden, Nevada 89423

Copyright infringement is a serious matter under the United States of America and foreign

copyright laws.


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iii

Contents

IntroductionSetting Up a New Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installing the SoftwareComputer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Running the Configuration SoftwareWays to Use Rack Configuration Software . . . . . . . . . . . . . . . . . . . . . . 6

Configuring a New Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Building a Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Modifying a Rack Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Using the Main Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Connecting a Computer to a 3500 Rack . . . . . . . . . . . . . . . . . . . . . . . . 10

Direct Connection S RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Direct ConnectionS RS422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Remote Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Initiating Communication with a 3500 Rack . . . . . . . . . . . . . . . . . . . . . 15

Discontinuing Communication with a 3500 Rack . . . . . . . . . . . . . . . . . 16

Uploading and Downloading Configurations . . . . . . . . . . . . . . . . . . . . 17

Opening and Saving Configuration Files . . . . . . . . . . . . . . . . . . . . . . . 19

Printing Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Copying Configuration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Copying Monitor Channel Configurations . . . . . . . . . . . . . . . . . . . 20

Copying Channel Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Copying Module Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Configuring the Modules in a Rack Configuring the Rack Interface Module . . . . . . . . . . . . . . . . . . . . . . . . 24

Configuring Keyphasor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Configuring Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Setting Monitor and Channel Options . . . . . . . . . . . . . . . . . . . . . . 27

Setting Alarm Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Configuring Relay Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Configuring Communication Gateway Modules . . . . . . . . . . . . . . . . . . 33


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Defining the Contents of Registers . . . . . . . . . . . . . . . . . . . . . . . . . 33

Setting Communication Gateway Communication Parameters . . . . . 35

Configuring a Triple Modular Redundant Rack . . . . . . . . . . . . . . . . . . . 37

Software Operation for TMR Systems . . . . . . . . . . . . . . . . . . . . . . 37

Configuring TMR Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Using the Rack Configuration UtilitiesSetting Module and Channel Switches . . . . . . . . . . . . . . . . . . . . . . . . . . 40Setting the 3500 Rack Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Disabling Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Enabling Trip Multiply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Rack Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Viewing the System Event List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Viewing the Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Verifying the Operation of a 3500 Rack . . . . . . . . . . . . . . . . . . . . . . . . 44

Running the Test UtilitiesStarting the Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

RIM Host Port Test Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Setting Up Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Displaying Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Communication Gateway Port Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Setting up Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Displaying Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Files Used by Configuration SoftwareDescription by File Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

List of Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Cable Part Numbers and DiagramsCable Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cable Pin Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Modem File Programming Information


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Introduction

1

IntroductionThis manual shows how to use the following software that comes with the 3500

Monitoring system.

Software Name Function

Rack Configuration Set operating parameters so that all the

modules in a 3500 monitoring rack work

together.

RIM Host Port Test Test the output of the CONFIGURATION

PORT on the Rack Interface Module (front

of the rack) and the Host Connector on the

Rack Interface I/O Module (rear of the rack).

Comm Gateway Port Test Test the HOST and RACK ports on the

Comm Gateway I/O module.

Setting Up a New RackUse the following procedure to set up, configure, and verify a new rack. If your

rack has a custom configuration from the factory, skip step 5.

1. Set the hardware switches and jumpers on the Rack Interface Module

(RIM), the backplane, the 3500/42 Monitors, and the relay modules. The

3500 Monitoring System Rack and Installation Manual shows how to set

the jumper on the backplane. The other jumper settings are described in the

operation and maintenance manuals for the RIM, the 3500/42 Monitor, andthe relay modules.

2. Connect the field wiring to the rack as described in the operation and

maintenance manuals for all the modules installed in the rack and in the

3500 Field Wiring Diagram Package (part number 130432-01).


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3. Test all of the communication ports on the rack by using the test utilities

listed in the following table:

Port to be Location of Utility to use... Refer to page...

tested... port...

CONFIGUR- Rack Interface RIM Host Port 47

ATION PORT Module Test Utility

HOST Rack Interface RIM Host Port 47

I/O Module Test Utility

HOST and Comm Gateway Comm Gateway 50

RACK I/O Module Port Test Utility

4. Configure the rack using the 3500 Rack Configuration Software.

5. Adjust the zero position voltage and scale factor for all monitors in the rack

by using the Adjust Button on the channel options screens.

6. Use the verification procedures in the operation and maintenance manualsfor the modules in the rack and the Verify option in the Rack Configuration

Software to verify that the rack is configured and operating correctly.


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Installing the Software

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Installing the SoftwareThe 3500 Rack Configuration Software, the test utilities, and the configuration

tutorial are shipped on a set of diskettes labeled 3500 Monitoring System Rack

Configuration Software. One installation program installs all of these

programs.

Computer RequirementsThe Configuration and test utilities require a 386/20 - 80387 computer or better,

4 megabytes of RAM, 25 megabytes of unused hard disk space, a VGA

monitor, and an RS232 serial port. The computer must also have one of the

following versions of Microsoft Windows installed and running: Windows 3.1,

Windows for Workgroups 3.11, or Windows NT 3.5.

Installation InstructionsTo install the configuration, test utilities, and configuration tutorial on your computer:

1. Start Windows and choose the Run command from the File menu.

2. Insert the disk labeled "3500 Monitoring System Rack Configuration

Software", (disk 1) into drive A or B.

3. In the Command Line box, type a:setup if you put the disk into drive A or

b:setup if you put the disk into drive B.

4. When the installation program starts, follow the instructions on your screen.

If you do a complete installation, the installation program will create a new

group called 3500 Software in the Program Manager and add the followingicons to the group:


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Running the Configuration SoftwareA 3500 rack can contain a variety of modules that can be set up to operate

different ways. The process of setting system, module, and channel options so

that all the modules in a 3500 rack work together is called configuration.

Configuring a 3500 rack consists of using the Rack Configuration Software toset options and then downloading the settings to the rack. You can use the

program two ways: You can run the program at any convenient place, save the

settings in configuration files, and then later download the configuration to the

rack. Or you can connect the computer to the rack first and then upload and

download the configuration as required.

In this Section...

topic page topic page

Ways to Use Rack Configuration Uploading and Downloading

Software 6 Configurations 17

Using the Main Configuration Opening and Saving Configuration

Display 8 Files 19

Connecting a Computer to a 3500 Copying Configuration

Rack 10 Information 20

Initiating Communication with a

3500 Rack 15


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Running the Configuration Program

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Ways to Use Rack Configuration SoftwareThe following lists illustrate the typical uses of the Rack Configuration

Software.

Configuring a New RackA 3500 Monitoring Rack cannot operate without a valid configuration. Use this

process after you have installed the rack, set all switches and jumpers, andconnected transducers. If your rack came with a custom configuration from the

factory, you can skip this procedure.

Process step... Refer to page...

Connect the computer to the rack 10

Initiate communication 15

Upload the default configuration from the rack 17

Modify the default Configuration

Download the configuration to the rack 17

Discontinue communication 17Disconnect the computer from the rack

Building a Rack ConfigurationUse this process if you choose to prepare a series of configuration files at your

desk and then download the files to the racks at a later time.


Identify the modules in slots 1 through 15 8

Set Rack Interface Module options 24Set Keyphasor options 26

Set Monitor options 27

Set channel options for monitor modules 27

Set Comm Gateway options 33

Set alarm setpoints for monitor modules 29

Set alarm drive logic for relay channels 31

Save the configuration file 19


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Modifying a Rack ConfigurationUse this process to change the configuration of a 3500 rack that is installed and

operating.


Connect the computer to the rack 10

Initiate communication 15

Upload the configuration from the rack 17

Modify the Configuration

Download the configuration to the rack 17

Discontinue communication 17

Disconnect the computer from the rack


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Running the Configuration Software

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Reference Information

S helps you keep track

of which rack and rack

file you are configuring.

Mode Buttons and Indicator S control how the Rack

Configuration Software operates.

Menu Bar S access commands to connect to a rack, manipulate configuration files, copy

configuration settings from one module to another, and control the operation of the rack.

Rack Diagram S shows

the modules that are

installed in the rack.

Use this diagram and

the Options and

Setpoints mode buttons

to move to

configuration screens.

Using the Main Configuration ScreenThe following figure lists the parts of the Main Configuration Screen and

summarizes how to use them.


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Set module and channel options.

Enter the Module Option screen by clicking the Options

button and then clicking on the module to be configured.

Set alarm setpoints for channels in monitor modules

Enter the Alarm Setpoint screen by clicking on the

Setpoints push button and then clicking on the monitor

module to be configured.

Build a rack.

Place modules in slots 1 through 15 by clicking on a slot

and then selecting a module from the drop down list.

Although you can enter most configuration settings in any order you choose, we

recommend that you create a rack configuration by using the mode buttons on

the Main Configuration display from top to bottom as suggested in the

following figure. Because these buttons control how the Configuration Software

operates, be sure that the correct button is depressed before you proceed with an

operation.


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Connecting a Computer to a 3500 RackYou can connect a computer to a 3500 Monitoring rack the following three

ways:

Method for Use this method...

Connecting

Direct to temporarily connect your computer when the computer is

near the 3500 rack. Direct connection can use RS232 or

RS422 protocol.

Remote to connect a 3500 rack to a computer that is located off site.

The computer must have a modem and the 3500 rack must

have access to a dedicated phone line.

Network if your computer is connected to a network that has a station

that is connected to the HOST connector on the Rack

Interface I/O module of a 3500 rack and is running the Data

Acquisition DDE Server Software.


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Direct Connection to the Rack Interface Module

Direct Connection S RS232Connect the computer directly to the rack by using an RS232 cable (Bently

Nevada part number 130118-XXXX-XX) as shown in the following figure. If

the Rack Interface I/O Module does not have an internal modem, you can also

connect the RS232 cable to the Rack Interface I/O Module by using the port

labeled HOST. Set the switch below the port to the RS232 position.

Using the CONFIGURATION PORT lets you configure only the rack that your computer is connected to. Using the HOST port on the Rack Interface I/O

Module lets you use the rack address to configure all of the racks connected in

the daisy chain.


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Direct Connection Using RS422 Protocol

Direct Connection S RS422If the Rack Interface I/O Module does not have an internal modem, you can

connect the computer directly to the rack using RS422 communication. Install

an RS232-to-RS422 converter between the computer and the rack. The cable

from the converter should be connected to the port on the rear of the Rack

Interface I/O Module labeled HOST. Set the switch below the port to the

RS422 position.

An alternate method of direct connection to RS422 is to install an RS422/485

Data Aquisition Card (Bently Nevada part number 02230415) in your PC, and

using the Host to 3500 Rack RS422 Interface Cable (Bently Nevada part

number 132632-XXXX-XX for PVC insulation or 132633-XXXX-XX for Teflon insulation). Connect the cable from the RS422 Card to the port on the

rear of the Rack Interface I/O Module labeled HOST. Set the switch below the

port to the RS422 position.


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With Internal

ModemWith RS232/422

connector.

Connecting the Computer to a Rack using a Modem

Remote CommunicationThe 3500 Monitoring Rack has two versions of the Rack Interface I/O Module:

one with a RS232/422 terminal and one with an internal modem. The internal

modem will operate at speeds up to 14.4 kbaud.

Many laptop computers and some desktop models also contain internal modems.

Baud rates on these modems can vary from 4800 to 28.8 kbaud. The modem-to-

modem communication speed is determined by the quality of the phoneconnection and the protocol of the information being transmitted. The speed at

which the computer communicates with the modem does not have to be identical

to the modem-to-modem communication rate.

To use modems to connect the computer and the rack:

1. Verify that you have dedicated telephone communications available at the

computer and rack locations.


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Running the Configuration Program

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3500 Rack with Internal Modem

Standard modem cable

3500 Rack with External Modem

Standard

modem cable

2. At the computer: Connect the phone line to the internal or external modem

phone port. If you use an external modem, connect a standard modem cable

between the computer serial COM port and the modem.

3. At the rack: Connect the phone line to the internal modem on the Rack

Interface I/O Module. If you use an external modem, connect the standard

modem cable to the port labeled CONFIGURATION PORT on the front of

the RIM or to the port labeled HOST on the Rack Interface I/O Module.

Verify that the RS232/RS422 switch on the I/O module is set to the RS232

position.

The following figures show some of the ways for using modems to connect the

computer to the rack.

Note: The Rack Interface Module (RIM) configuration must be set to indicate

a modem is present on the front or rear 3500 RIM port.


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ConfiguringComputer

Data Acquisition

DDE server

Ethernet cable

Daisy-chained3500 racks


14

Network ConnectionIf the configuring computer has network access to a Data Acquisition DDE

Server as shown in the following figure, you can configure all racks that are

daisy chained to the server by using the Network connection.

Dynamic Data Exchange (DDE) is a method of exchanging or providing data to

and from Windows applications. This method lets multiple devices access the

data simultaneously.

Initiating Communication with a

3500 RackAfter you have connected the computer to the rack and started the Rack

Configuration Software, use the following procedure to initiate communication between the rack and the computer:

1. Select the Connect option in the File menu. A list of connection methods

will appear (Direct, Remote, and Network).

2. Select the connection method that corresponds to how your computer is

connected to the rack(s) that you will configure. Refer to the previous

section for information about these methods.

3. Enter the appropriate communication parameters into the connect dialog box

using the following table for reference:


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Communication Description

Parameter

Connect Password The password on the 3500 rack to be configured.

This password is set when the RIM options are

configured.

Rack Address The setting on the RACK ADDRESS switch on the

Rack Interface Module in the 3500 rack to be

configured.

Com Port The connector on the configuring computer used to

communicate with the 3500 rack.

Baud The rate of the computer-to-modem or Computer-to-

rack communication.

Phone Number The phone number of the modem for the 3500 rack to

be configured

Data Acquisition (DDE) The network name of the computer that is running

Server Computer Name 3500 Data Acquisition software and that is connected

to the daisy-chained 3500 racks to be configured.

4. Initiate communication by clicking on Connect. A successful connect to the

rack is indicated by the message "Connection established".

Discontinuing Communication with a 3500

Rack

Before you disconnect the cable between the configuring computer and the rack,discontinue communication by clicking on the Disconnect command in the File

menu. This command initiates the following actions:

C return any module that is still in configuration mode to run mode (under

user control)

C release the configuration token if the configuring computer has the token

C hang up the modem if the computer was using remote communication


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Although disconnecting the cables without invoking the Disconnect command

causes no harm, we recommend using the command when you're finished

communicating with a rack.

Uploading and Downloading ConfigurationsYou transfer configuration settings between the configuring computer and therack to be configured by using a process called uploading (rack to computer) or

downloading (computer to rack). The Upload and Download commands are in

the File menu.

To upload a configuration:

1. Connect the configuring computer to the rack to be configured. (Refer to

page 10 of this manual.)

2. Establish communication with the rack by using the procedure in the

"Initiating Communication with a 3500 Rack" section.

3. Click on the Upload command in the File menu. A prompt will appear that

indicates the progress of the upload and indicates if the upload wassuccessful.

4. Terminate communication with the rack by clicking on the Disconnect

command in the File menu.

5. Disconnect the configuring computer from the rack.

If an error occurs while uploading a configuration from the rack, the upload will

continue and the default configuration will be loaded for the module where the

error occurred.

To download a configuration:

1. Connect the configuring computer to the rack to be configured. (Refer to

page 10 of this manual.)

2. Establish communication with the rack by using the procedure in the

"Initiating Communication with a 3500 Rack" section.

3. Move the configuration keylock on the front panel of the Rack Interface

Module from Run to Program. (All functions of the rack will continue

operating with the keylock set to Program.)


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4. Click on the Download command in the File menu. The Download

Configuration screen will appear.

5. Choose which module configurations to download by marking the check box

next to the module name.

6. Initiate the download by clicking OK.

7. Set the keylock on the front panel of the Rack Interface Module fromProgram to Run.

8. Terminate communication with the rack by clicking on the Disconnect

command in the File menu.

9. Disconnect the configuring computer from the rack.

If an error occurs while downloading a configuration to the rack, the

downloading will stop and you can choose whether to download the portion of

the configuration that is correct or to abort the download.


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Opening and Saving Configuration FilesUse the Open command in the File menu to load a configuration file that has

been stored on disk into the Rack Configuration Software.

Use the Save command to store the current configuration in the Rack

Configuration Software to a file on disk. We recommend that you save the

configuration of all 3500 Monitoring Racks to files on disk.

All rack configuration files contain a maximum of 8 characters and end with a

file name extension of .RAK. The default directory for configuration files is

\3500\trains\primcfg. Although you can place the files in any directory, keep the

following special considerations in mind:

C If multiple 3500 racks are daisy chained together, place the rack

configuration files for these racks in the same directory.

C If the 3500 Data Acquisition Software is to provide historical trend data,

place all rack configuration files for the racks daisy chained to the Data

Acquisition computer in the \3500\trains\primcfg directory.

Printing Catalog NumbersThe Print menu lets you print a list of the catalog numbers of all the modules

that are displayed on the Main Configuration screen. This option makes it easy

to order a new 3500 rack or to order replacement modules for an existing rack.


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The arrow buttons let you

copy channel settings

between channels in a

channel pair...

... or from one channel pair

to another.

Copying Configuration InformationThe 3500 Rack Configuration Software makes it easy to copy the configuration

settings of channels and modules.

Copying Monitor Channel Configurations

An equal sign between the arrow buttons indicates that the configuration of the

channels or channel pairs are the same. "Copy" indicates that the configuration

of the channels or channel pairs are not the same. The arrow buttons copy the

monitor options but not the alarm setpoints.


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The Copy button

on the Setpoint

Configuration

screens lets you

copy the alarm

setpoints from onechannel in a

monitor to another

channel of the

same type.

Copying Channel Setpoints

Copying Module ConfigurationsThe Copy menu lets you copy the configuration parameters from one module to

another module of the same type. This command copies both the module

options and the alarm setpoints.


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Use the upper row of

buttons to choose the

slot of the module with

the configuration that

you want to copy.

Use the lower row of

buttons to choose the slot

or slots that you will

copy the configuration

to.

If the slot or slots chosen in the lower row of buttons do not contain the same

type of module as in the slot chosen in the upper row, the program will replace

the module before it copies the configuration parameters.


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Configuring the Modules in a RackConfigure a 3500 rack by setting the operating parameters for all modules in the

rack and for all channels in each module. You set these parameters by using

dialog boxes that appear when you click on the Options button and then on a

module. The dialog boxes use conventional Windows selection tools like check

boxes, radial buttons, and drop down lists. If you are not familiar with thesetools, refer to your Windows documentation. The online help system for the

Rack Configuration Software contains definitions of all the configuration

options.

In this section...

topic page topic page

Configuring the Rack Interface Configuring Relay Modules 31

Module 24

Configuring Keyphasor Modules 33Modules 26

Configuring Monitors 27 Redundant Rack 37

Configuring Comm Gateway

Configuring a Triple Modular


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Configuring the Modules in a Rack

23

Configuring the Rack Interface ModuleThe option display for the Rack Interface Module (RIM) lets you set options for

the power supply and the RIM. The screen looks like this:

The following table defines the configuration parameters for the RIM:

Configuration Description

Parameter

Rear Port / Front The Rack Configuration Module has two ports for accessing

Port the information in the 3500 rack. These ports can operate

simultaneously and can transmit and receive messages using a

Bently Nevada proprietary protocol. Use these fields to

identify how devices are connected to these ports.

I/O Option Identifies the type of Rack Interface I/O Module that is

installed in the rack: RS232/RS422 I/O Module or Internal

Modem I/O Module.

External Modem When the rack is equipped with an RS232/RS422 module,

this field lets you identify the type of external modem

connected to 3500 rack.


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Parameter

24

Byte Timeout The number of bytes of communication line "dead time"

needed to signal an end of message. Each port on the Rack

Interface Module may have a different Byte Timeout setting.

Connect A password that "gates" all access to the 3500 rack. WithoutPassword this password, the Rack Interface Module will not accept

commands or requests from an external personal computer.

Configuration A password that "gates" configuration information to be

Password downloaded to a 3500 rack. Without this password, the Rack

Interface Module will not accept any configuration commands

from an external personal computer.

Dynamic Signal The monitors that will provide data to the External Dynamic

Option Data Interface (DDIX) or the External Transient Data

Interface (TDIX). The DDIX and TDIX are Bently Nevada

communication processors.Agency ApprovalThe agency approval for the 3500 rack. The option selected

in this field must match the approval rating of the rack.

Mounting Option The mounting configuration of the rack being configured. The

option selected in this field must match the mounting option of

the rack.

Power Supply The power supplies that are installed in the rack.

Top / Bottom


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Configuring Keyphasor ModulesConfigure Keyphasor modules by completing the configuration parameters on

the Keyphasor screen.

The following table defines the configuration parameters for the Keyphasor

Module:


Parameter

Signal Polarity The type of mark observed by the Keyphasor transducer S

notch or projection.

Type The type of Keyphasor transducer connected to the Keyphasor

I/O Module

Hysteresis The voltage level above and below the threshold value which

is required to trigger the conditioned Keyphasor signal.

Threshold The voltage level of the input signal from the Keyphasor

transducer where the conditioned Keyphasor signal is

triggered.


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Parameter

26

Events Per The number of pulses in a Keyphasor signal for each shaft

Revolution rotation.

Orientation The location of the Keyphasor transducer on the machine.

Upper RPM The upper limit of the full scale range for the Keyphasor rpm.

Limit The Keyphasor Module will scale the rpm value between 0

and this value.

RPM Clamp The value that the data provided through the Communication

Value Gateway will be clamped to when a Keyphasor transducer

goes invalid.

I/O Module The type of I/O module connected to the Keyphasor Module.

Configuring MonitorsThe two steps for configuring monitors are setting monitor and channel options

and setting alarm setpoints.

Setting Monitor and Channel OptionsMonitors have two dialog boxes for setting options. The first box is for setting

monitor options and looks similar to the following screen.


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The second box is for setting options for each channel in the monitor module

and looks like this:


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28

...or by entering the

setpoint value in the

number boxes. The

alarm will occur if

the value moves

outside of the

colored area in the

bar graph.

Adjust all alarm

setpoints except

phase by either

clicking anddragging the

bargraph...

Choose up to two

proportional values

that will have

setpoints for danger

alarms.

Setting Alarm SetpointsAn alarm setpoint is the level of the proportional value at which an alarm will

occur if the value moves above or below the level. To set alarm setpoints, use

the monitor option displays to enable alarms and use this approach:


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If the red or yellow area is outside of the

intended acceptance region, reverse the

angle values in the number boxes.

Adjust the phase angle for 1X or 2X

acceptance regions by entering the angles

into the number boxes above or below the

angle diagrams. The acceptance region is

indicated by the yellow or red area in the

circle.


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S02C03A2

Alarm level (2) / Danger

Channel number (3)

Slot number (2)

S02C##A2

Code applies to

all channels in

in the monitor slot


30

Click on a module...

Choose the relay

channel to configure in

this group box.

...the list of alarms for the

module will be displayed

here. The number of

alarms depends on what

channels are active and

which alarms are

configured.

Configuring Relay ModulesUse the Relay Association screen to enter the alarm logic that controls what

alarms cause the relays to activate. Enter the Relay Association screen by

clicking on the Options pushbutton and then clicking on the relay module to be

configured. To enter the alarm logic:

The alarm logic in the Relay Association window contains the logic that controls

when a relay channel is activated. The logic consists of alarm codes, AND (*)

and OR (+) symbols, and parentheses. The AND operator has precedence over

the OR operator and parentheses are used to control the order of the operatorsfor complex logic. When the logic is true, the relay for that channel will

activate.

This figure shows

the meaning of the

digits in alarm

codes:


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31

Add an alarm code by

clicking on the code and then

clicking Enter or by double

clicking on the code. The

alarm code will appear inthe Alarm Drive Logic box.

Add AND, OR, and

parentheses to the alarm

logic by clicking on these

buttons.

Use the left arrow button to

backspace one character in

the string. Use the CLR

button to clear the alarm

logic box and start over.

To enter alarm logic for the channel:


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Enter the number of channels whose

primary values will be included inthe message

The number in parenthesis indicates

number of channels in the module

that have proportional values.

Configuring Communication Gateway

ModulesThe Communication Gateway screen lets you enable a Distributed Control

System (DCS) computer to scan 3500 racks more efficiently and set the

communication parameters of the HOST and RACK ports on the Comm

Gateway I/O Module.

Defining the Contents of RegistersRegisters 30001 to 30448 Modbus (0 to 447 decimal) in the Communication

Gateway Module are reserved for the primary proportional values from

monitors and Keyphasor Modules. The Communication Gateway screen lets

you place these primary proportional values into contiguous registers so that a

DCS can scan 3500 racks efficiently. You can reduce the scan time by

including only those values required by the DCS and excluding the contents of

unnecessary or empty registers.

All the other data that is available from the monitors and Keyphasor Modules is

stored in fixed registers on the Communication Gateway Module. All fixed and programmable registers of the Communication Gateway Modules are described

in the Communication Gateway Operation and Maintenance Manual (part

number 129769-01).

To define the contents of the reserved registers, enter integers from 0 to 32 into

the number boxes in the columns labeled "Positions Reserved". The integer

indicates the number of channels in the modules whose primary proportional

value will be included in the message.

Enter 0 to include no values from the module. Enter 4 to include the primary

proportional value from all 4 channels in a module. Enter a number that is


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33

greater than the number shown in parenthesis to insert zeros into the successive

registers of the message. Press Use Module Defaults to include the primary

proportional value from all channels in all modules in the rack that have

proportional values available.

For example, the above display would include the following values in the

Communication Gateway registers:

Register Address The register contains the primary

proportional value from...

Decimal Modbus Slot # Channel #

0 30001 2 11 30002 5 1

2 30003 5 2

3 30004 5 3

4 30005 5 4

5 30006 none zero

6 30007 none zero

7 30008 9 1

8 to 447 30009 to 30448 none 439 zeros


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To determine which values are the primary proportional value for each module,

refer to the operation and maintenance manual for that module.

Setting Communication Gateway Communication

ParametersThe Port 1 and Port 2 buttons on the Communications Gateway screen let you

set communication parameters for the HOST and RACK connectors on the

Communication Gateway I/O Module. When you click on Port 1 or Port 2, the

following window will appear.

The following table describes the fields in this window:


Parameter

Active Turn a port on (: ) or off (9 ). When a port is turned off, no

machinery data is available.

Address The address of the modbus port on the Communication

Gateway I/O Module.

Connection The type of connection between the 3500 rack and the

Distributed Control System (DCS) computer.


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Parameter

35

Config Allowed Specify if the 3500 rack can be configured from the DCS

computer. Check (:)the box for yes; clear (9) the box for

no. Refer to the Communication Gateway Operation and

Maintenance Manual for a list of items which can be

configured through the Communication Gateway ports.

Parity The type of communication verification contained in each

message byte. The parity setting in a Communication

Gateway Module must agree with the setting at the external

device connected to the module. Each Communication

Gateway port may be set up with a different parity setting.

Stop Bits The number of bits which will be added to each 3500

Communication Gateway message. Each byte within a

message will contain 1 start bit, 8 data bits, and either 1 or 2

stop bits. The Stop Bits setting in the Communication

Gateway Module must agree with the setting at the externaldevice connected to the module. Each Communication

Gateway port can have a different Stop Bits setting.

Baud Rate The rate at which messages are transmitted and received from

the 3500 Communication Gateway. Specifically, it represents

the number of bits which can be transmitted and received from

the Communication Gateway in 1 second. The Baud Rate

setting in the Communication Gateway Module must agree

with the setting at the external device connected to the module

Each Communication Gateway port can have a different Baud

Rate setting.

Byte Timeout The amount of time that the Communication Gateway module

will wait to determine that a command has been received on

the DCS link. This value is expressed as the time required to

send x bytes at the current baud rate.

Full Scale Data The value used to scale the proportional data.

Range


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Parameter

36

Numeric Format The number system that the communication protocol uses to

send and receive data. For the Modbus protocol, the system is

Hex.


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Configuring a Triple Modular Redundant

RackA triple modular redundant (TMR) rack contains a TMR Rack Interface

Module and redundant power supplies, monitors, and TMR relay modules.

To identify the rack as TMR: 1. Click on the Slot button.

2. Click on the Rack Interface Module. A drop down list will appear.

3. Choose "TMR" from the list.

Software Operation for TMR SystemsThe Configuration Software operates differently to help you configure TMR

racks more easily. Take note of the following items when you configure a TMR

rack:

C Since the program automatically inserts groups of three monitors into a

TMR rack, be sure that the two slots to the right of the monitor to be

inserted are empty.

C For groups of TMR monitors that use the TMR I/O (Bussed) option: set

the monitor options, channel options, and alarm setpoints for all monitors in

the group by configuring the left-most monitor only. The Rack

Configuration Software automatically copies these configuration settings to

the other monitors in the group.

C Enter alarm drive logic for just one of the two TMR Relay Modules. The

Rack Configuration Software automatically copies the alarm drive logic

from one TMR Relay Module to the other. You can enter or edit the alarm

drive logic in either the upper or lower relay.

C The alarm logic for channels in relay modules uses alarm codes from theleft-most monitor in a TMR group. Although the alarm code includes the

slot number for the left-most monitor in the group, the alarm logic applies to

all the monitors in the group.


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TMR I/O: Discrete TMR I/O: Bussed

Configuring TMR FunctionsTMR racks have the following additional functions that must be configured:

I/O module and Voting.

TMR I/O Options

Monitors in a TMR group can have input from redundant transducers (TMR I/O: Discrete) or from a single transducer (TMR I/O: Bussed). The following

figures show the channel 1 input for the TMR I/O options: Discrete and Bussed.

Voting Options

The TMR Rack Interface Module continuously checks the output of monitors in

a rack by using 2 out of 3 voting. The configuration settings used to control this

voting are Comparison and % Comparison.

Comparison: The enabled proportional value used in the 2 out of 3 voting.


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% Comparison: The highest allowed percent difference between the middle

value of the three monitors in a TMR group and the individual values of each

monitor.


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40

Using the Rack Configuration UtilitiesThis section describes the options in the

Utilities menu. You must be connected to a

3500 rack to use these options.

Setting Module and Channel SwitchesModule and channel switches let you temporarily bypass or inhibit module and

channel functions. A checked box (:) indicates that the switch is enabled. A

cleared box (9) indicates that the switch is disabled. The functions of these

switches are defined in the individual module manuals and in the help system of

the Rack Configuration Software.


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Using the Rack Configuration Utilities

41

Setting the 3500 Rack Date and TimeUse this dialog box to read or reset the date and time on the clock in a 3500

Monitoring rack. The date and time are used to time stamp data collected from

monitor channels and items entered into the Alarm and System Event lists.

Clicking on the Send button will set the rack date and time as follows:

If the Send Host Data and ...the Send Time command will ..

Time to Rack box is...

selected send the current data and time of the computer

to the rack

not selected send the date and time that is shown in the Date

and Time box to the rack

Clicking on the Read button will cause the configuration software to read and

display the date and time from the 3500 rack.

When this dialog box is initially displayed, it will contain the computer's date

and time.

Disabling AlarmsAlarm Inhibit lets you disable alarms (both

alert and danger) and relay activation in the

rack. This feature is useful when you

service and verify your 3500 rack. The

current status of Rack Alarm Inhibit


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(hardware contact and software) are displayed at the top of this screen.

Enabling Trip MultiplyTrip Multiply lets you extend monitor alarm

setpoints by the trip multiply value specified

in the monitor option. This feature is useful

during machine ramp-up or ramp-down.The current status of Trip Multiply

(hardware contact and software) are

displayed at the top of this screen.

Rack ResetRack Reset lets you reset latched alarms, latched not OK's and timed OK defeat

This feature is useful when you service and verify your 3500 rack.

Viewing the System Event ListSystem events are actions or occurrences such as configuration changes, moduleerrors, and status messages. The System Event List is filled in a round robin

fashion and may contain up to 500 entries. The help system in the Rack

Configuration Software defines all the system events.


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Using the Rack Configuration Utilities

43

You can run a self-test on any module in a 3500 rack by using the Module Self-

test button on the System Events screen. The results of the self-test are posted

in the list. The help system in the Rack Configuration Software explains how to

run a self-test.

The configuration software uploads 20 events at a time from the 3500 rack.

You can scroll through these 20 events by dragging the vertical scroll bar upand down or by clicking the up and down arrows. Display additional 20-event

pages by pressing the Page Up, Page Down, or Latest Events buttons.

Viewing the Alarm ListThe Alarm List is a chronological list of alarms, not OK events, and tripped

relays. The list is filled in a round robin fashion and contains up to 1000

entries.

The configuration software uploads 20 events at a time from the 3500 rack.

You can scroll through these 20 events by dragging the vertical scroll bar up


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and down or by clicking the up and down arrows. Display additional 20-event

pages by pressing the Page Up, Page Down, or Latest Events buttons.

Verifying the Operation of a 3500 RackThe Verification screens display information about the status and output of the

modules in a 3500 rack. Use the output of these screens and the procedures in

the operation and maintenance manuals that come with the 3500 modules toverify the operation of a 3500 rack.


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Running the Test Utilities

45

Running the Test UtilitiesThe two test utilities that come with the Rack Configuration Software are the

RIM Host Port Test Utility and the Comm Gateway Port Test Utility. This

section shows how to run the utilities and explains how each utility displays

data.

Starting the UtilitiesIf you installed the 3500 Rack Configuration Software and test utilities by using

a normal installation, icons for the configuration software and test utilities will

be placed in a group called 3500 Software.

Start a test utility by double clicking on the icon for that utility. The opening

displays of the utilities show how to connect the computer running the utility to

a 3500 rack.


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RIM Host Port Test UtilityThe Host ports on the Rack Interface Module and the Rack Interface I/O

Module are used for communication between a computer that runs the Rack

Configuration Software or the Data Acquisition/DDE Server Software and a

3500 rack. The ports are also used to daisy chain up to twelve 3500 racks. The

RIM Host Port Test Utility lets you verify that the HOST ports are operating properly.

The options in the menu bar operate as described in the following table:

Option Name Description

File

Start Display Program Open the screen that displays the output of the

Exit End the utility.

communication port being tested.

Com Set Up Set options that control the communication

between the test computer and the rack.

Help

Program Information Display a screen that explains what the utility

About

does.

Display a screen that contains copyright

information and the version number of the utility.


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Setting Up CommunicationsThe Program Set Up display of the RIM Host Port Test Utility contains the

following options:

Option Name Use this option to...

Run Mode Identify the type of connection between the computer and the

rack. Direct: RS232 cable. Modem: modem and telephone

line.

Com Port Identify the computer port that is connected to the rack.

Baud Rate Choose the rate of communication between the computer and

the rack.

Modem Identify the type of modem connected to the test computer and

the telephone number of the rack to be tested. Use this field

only if you are using a modem to connect the test computer to

the rack.

Displaying Test DataTo display the output of the RIM Host Port, click on Start Display Program in

the File menu. The RIM Host Port Test Utility will continue to scan the

selected 3500 racks until you click on Stop Scan. The utility displays the

information as shown in this display.


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The following table describes the fields in the Test Data Display:

Field Description

Name

Address The address of the rack being tested.

Family # The name of the device being tested.

RIM # The model number of the Rack Interface Module in the

rack being tested.

Firmware The version number of the firmware that is running in the

Rack Interface Module being tested.

Rack An 8-bit word that contains information about the

Status operating condition of the communication port being

Bytes tested.

When you click on a byte number button, the utility displays additional

information about the meaning of the bits:


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Communication Gateway Port TestThe HOST and RACK ports on the Communications Gateway I/O Module let

you connect 3500 Monitor Racks to a process control system that uses Modbus

communication protocol. The Comm Gateway Port Test Utility lets you verify

that these ports are operating properly.

The options in the menu bar operate as described in the following table:

Option Name Description

File

Scan Program Display the communication parameters of any

Data Display Display all proportional values for a monitor.

Manual Program Send messages to the Comm Gateway and display

Exit End the utility.

Comm Gateway Module in a Modbus daisy chain.

the response in hex values.

Com Set Up Set options that control the communication between

the test computer and the rack.

Help

Program Information Display a screen that explains what the utility does.

About Display a screen that contains copyright

information and the version number of the utility.


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Setting up CommunicationsThe Com Set Up display of the Comm Gateway Port Test Utility contains the

following options:

Option Name Use this option to...

CGM Port Identify the port address of the Communication Gateway

Address Module.

Comm Port Identify the computer port used to communicate between the

test computer and Comm Gateway Module.

Baud Rate Choose the rate of communication between the computer and

the Comm Gateway Module.

Parity Choose the type of communication verification contained in

each message byte. The parity setting within the

Communication Gateway Module must agree with the setting

at the external device connected to the module. Each

Communication Gateway port can have a different parity

setting.

Stop Bits Set the number of bits which will be added to each 3500

Communication Gateway message. Each byte within a

message will contain 1 start bit, 8 data bits, and either 1 or 2

stop bits. The Stop Bits setting must agree with the setting at

the external device connected to the Communication Gateway.

Each Communication Gateway port may be set up with a

different Stop Bits setting.

If you don't know the communication settings for a Comm Gateway Module, you

can have the Scan Program under the File menu automatically detect these

settings.

Displaying Test ResultsThe Comm Gateway Port Test Utility lets you display test results three ways:

Scan Program, Data Display, and Manual Program.


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The proportional

value as a percent of

full scale.

The number label

for the proportional

value.

Scan Program lets you display the communication parameters of any Comm

Gateway Module in the Modbus daisy chain. Enter the address of the rack at the

prompt.

Data Display lets you display all proportional values for a monitor as a percent

of full scale.

Use the tables in the Appendix A of the Communication Gateway Module

Operation and Maintenance manual (part number 129769-01) and the operation

and maintenance manuals of the 3500 monitors to determine what proportional

value corresponds to the numbers on the Data Display.

Manual Program is for advanced communication diagnostics. This test lets you

compose messages to send to the Comm Gateway Module and then displays the

response to the message in decimal values.


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Use this portion of the

display to compose the

message to send to the

Comm Gateway Module.

The response to themessage appears here in

decimal value.

Appendix A of the Communication Gateway Operation and Maintenance manua

(part number 129769-01) describes the structure of the messages that are

composed and received on the Manual Program display.


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Files Used by Configuration Software

53

Files Used by Configuration SoftwareThe installation program adds files to your hard disk that are used by the Rack

Configuration Software. Do not modify or move any of the files listed in this

section except for the rack configuration files (.RAK).

Description by File Extension

Extension File Type Use

.DEF Default Default configuration settings.

.DAT Modem data files Modem and modem initialization strings.

.TBL DSP Table files Tables of DSP coefficients that the software uses

to configure corner frequencies.

.DLL Windows Dynamic Assist the Rack Configuration Software in a

Link Libraries number of ways.

.INI Initialization Stores startup information such as customer name,

customer location, and ship date.

.VBX Microsoft Visual Basic The Rack Configuration Software uses these files

application to create the user interface.

development files

.RAK Rack Configuration Store user-defined rack configurations.

Files

.EXE Executable software The main configuration program and product

and utilities service utilities.

.HLP Help files The 3500 Rack Configuration help file.


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List of FilesThe 3500 installation program adds the following files to your hard drive:

** This file comes with MS Windows. The installation program adds this file

only if it is not found or if the version on the hard disk is older than the one on

the installation disks.


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Files Used by Configuration Software

55

The following diagram is a continuation of the diagram from the previous page

and shows the additional subdirectories and files that are under dsptbls.


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Cable Part Numbers and DiagramsThis section contains information about the cables used to connect the

configuring computer to 3500 Monitoring racks.

Cable Part NumbersCable Part Number Description

130118-XXXX-XX Host to 3500 Rack RS232 Interface Cable



(PVC Insulation)

(Teflon Insulation)

02290860 Host to External Modem Cable -- RS232

130119-01 Host Computer to RS232/422 Converter

Cable

130120-XXXX-XX RS232/422 Converter to 3500 Rack Cable --

131106-XXXX-XX RS232/422 Converter to 3500 Rack Cable --

RS422 (PVC Insulation)

RS422 (Teflon Insulation)

130121-XX-XX RS422 Extension Cable

Cable Pin Out DiagramsThe following diagrams show the wiring for cables that are manufactured byBently Nevada:


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Cable Part Numbers and Diagrams

57

Part Number 130118-XXXX-XX

Host to 3500 Rack RS232 Interface Cable

Part Number 132632-XXXX-XX / 132633-XXXX-XX

Host to 3500 Rack RS422 Interface Cable


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Part Number 02290860

Host to External Modem Cable -- RS232

Part Number 130119-01

Host Computer to RS232/422 Convert Cable


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Cable Part Numbers and Diagrams

59

Part Number 130120-XXXX-XX / 131106-XXXX-XX

RS232/422 Converter to 3500 Rack Cable -- RS422

Part Number 130121-XX-XX

RS422 Extension Cable


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Modem File Programming InformationThe Rack Configuration Software supports a number of popular modems. To

customize your configuration software to work with these and other modems a

modem setup file has been provided in the \3500 directory called

HOSTMDM.DAT. The modem setup file contains programming information

for all supported modems and allows one additional custom configuration. Thisfile is a simple ASCII text file that can be inspected or modified with any DOS

or Windows text editor. The following entries are provided in the modem setup

file:

Setup Entry Use...

Hayes Ultra 9600 For Hayes Ultra 9600 modem using the V.32

protocol.

Hayes Optima 9600 For Hayes Optima 9600 modem using the V.32

protocol.

Motorola FasTalkII

Custom

For Motorola FasTalkII modem using the V.32

protocol

For support of other types of modems. The entry

supplied is a copy of the Hayes Ultra 9600 modem

setup.

To support other modems, use the Custom modem type. To do this, you should

edit the Custom entry as required and select the Custom modem type from the

Remote Connect screen. Be aware that modems are highly nonstandard; getting

a new modem to work will require an intimate understanding of how to operate

and program that modem.

The modem setup file consists of a "entry" name followed by 6 modem command

fields. The fields contains modem setup and control information along with

modem initialization strings. Use these guidelines when editing the fields:

C The maximum length of a line is 80 ASCII characters. Consult your modem

manual to determine the maximum initialization string length.

C The commands must be in the same order as listed in the following table.


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C Fields that are not needed should be left blank but not deleted.

C Lines cannot be added or swapped.

Custom Modem Line Definitions

Modem File Entry Line Definition

1 Reset to factory default string

2 Initialization string 1

3 Initialization string 2 *

4 Dial Method (Touch Tone or Pulse)

5 Connect string (the text returned when a connection is made)

6

Seconds to wait for answer *

* Null if not needed

Some experimenting may be required to obtain the modem settings that give the

best results. Since the modem to modem connection baud rate is determined bythe modem, it is usually necessary to enable hardware flow control (RTS/CTS).

Many modems will automatically default to data compression. This feature can

cause large "dead times" in commands and responses from the Personal

Computer and the 3500 rack. The 3500 rack looks for a specific amount of

dead time in a command to signify the end of a message. To ensure that the rack

correctly services commands sent from the personal computer, you should either

set the "Byte Time Out" field in the Rack Interface Module's configuration to a

large value OR setup the modem to not utilize these features.


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Rack Configuration and Utilities Guide 129777-01

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