Advancements in Transmitter-Based Monitoring Systems AM2005 San Diego, California Wednesday, May 11 from 3:00 - 4:00 PM Frank Howard President

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Advancements in Transmitter-Based Monitoring
SystemsAM2005San Diego, CaliforniaWednesday,
May 11 from 300 - 400 PM Frank
HowardPresident
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Transmitter Strategy

• Enable users to make use of their existing PLC
  and DCS Systems for Machinery Condition
  Monitoring.
• Offer Wonderware HMI systems where the users DCS
  or PLC is inadequate or will be upgraded in the
  future.

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Transmitter Based Systems

• Advantages
• Low Cost (1/2 Legacy Systems)
• Simple to Install.
• Can make use of existing sensors.
• Distributive Architecture.
• 4-20 mA noise free.
• Digital to save wiring costs
• Choice of Protocol
• Easy repair and replacement.
• Local Dynamic Signal w/BNC.
• Disadvantages
• No Remote Dynamic or Transient Data.

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Legacy Systems

• Large centralized Rack based systems.
• Control Room mounted.
• Originally Capital Projects.
• OEM supplied sensors.
• All sensors wired to Rack
• Requires lots of instrument wire and conduit
  (2x cost).
• Large Racks do nothing that a PLC or DCS system
  cannot do.
• Overall Values.
• Time Delay.
• Power up inhibit.
• OK Circuit.
• 99 not wired to Shutdown.
• Many are Obsolete.

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Whats Changed ?

• Hardware
• PLC and DCS Systems are faster, cheaper and more
  common.
• Many Plants are upgrading to New DCS and PLC
  Systems.
• HMI Systems like Wonderware are available.
• People
• Vibration and machinery specialists are retiring,
  or spread out.
• A lot of specialty work is contracted.
• Engineers and Technicians are forced to be Jack
  of All Trades.
• Operators are being assigned more tasks OCM.
• Users want smarter, simpler and easier to
  maintain systems.
• Users are more budget conscious.
• Engineers and Technicians are more computer
  oriented.
• Major machine flaws have been fixed.

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Distributive Systems

• Hard or Soft Alarms (Hardware or Software)
• Transmitters or Monitors are local to machine.
• Analog to Digital Converters (ADC) new or
  existing.
• Communications in users preferred protocol.
• Modbus RS-485
• Modbus TCP/IP
• Hundreds of others
• Make use of existing networks.
• Make use of existing Historians.
• Keeps overhead and bandwidth requirement low.
• Make use of Operators existing CRTs !
• Instrumentation people understand 4-20 mA !
• No proprietary protocols.
• Use all available hardware like Industrial
  Radio Modems.
• Easy repair or replacement.

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Types of Transmitter Based Systems

• Transmitters
• OK Circuit.
• BNC Output.
• 4-20 mA Output.
• Transmitters with Analog to Digital Converter
• Same as above .
• Digital Output (Choice of Protocol).
• Choice of Protocol.
• Transmitters w/ADC and Wonderware HMI
• Same as above .
• Wonderware license.
• Custom Wonderware runtime.

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Why 4-20 mA

• Extremely accurate.
• Low voltages (typically 24 VDC).
• Long distances can be handled.
• Voltage has resistance losses.
• 4-20 mA Current constant anywhere on loop.
• Noise immunity.
• Very common in process measurements.
• Instrument Technicians understand.

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3-Wire Transmitter
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25 Channel System 24 VDC
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25 Channel System 4-20 mA
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4-20 mA Compliance

• Compliance The total amount of resistance in
  the circuit that the 4-20 mA Transmitter is able
  to power.
• Calculate by adding together
• Shunt Resistor
• 100 O (.4 TO 2.00 Volts DC)
• 250 O (1 to 5 Volts DC)
• Wire Resistance (at 68 F)
• 18 AWG 6.385 O per 1,000
• 20 AWG 10.15 O per 1,000
• 22 AWG 16.14 O per 1,000
• Power Protection Resistor (If used)

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Protocols
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Ethernet TCP/IP

• TCP - Transmission Control Protocol, provides a
  reliable stream delivery and virtual connection
  service to applications through the use of
  sequenced acknowledgement with retransmission of
  packets when necessary (TCP/IP).
• Ethernet - is a widely used data communications
  network standard developed by DEC, Intel, and
  Xerox. It uses a bus topology and CMSA/CD access
  method. The terms Ethernet and the IEEE 802.3
  standard are often used interchangeably.

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CMCP500 Series Transmitters

• CMCP525 Acceleration (Accelerometer)
• CMCP530 Velocity (Accelerometer)
• CMCP535 Displacement (Velocity)
• CMCP540 Radial Vibration (Eddy Probe)
• CMCP545 Thrust Position (Eddy Probe)
• CMCP547 Differential Expansion
• CMCP548 Case/Shell Expansion
• CMCP549 Valve Position

• CMCP560 RTD Temperature
• CMCP565 Thermocouple
• CMCP570 Solid State Temperature
• CMCP575 Speed
• CMCP580 Process Variable
• CMCP585 Eccentricity

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CMCP500 and CMSS500 Transmitter Features

• Compact Size.
• Din Rail Mountable.
• OK Circuit (lt2 mA).
• Optional Filters.
• ISO Standards.
• CE Approved.
• BNC Buffered Output.
• Terminal Buffered Output (CMU).
• 24 VDC Powered (NEC Low Voltage).
• Selectable Range.

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CMCP500 and CMSS 500 Monitor Features

• OK, Alert and Danger Relays.
• Selectable as Latching or Non-Latching.
• Trip Multiply.
• Reset terminal.
• Bypass terminal.
• Selectable Time Delay.
• Connector for optional display.
• BNC w/switch to set alarm levels
• Can be added later.

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Case History 1
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Case History 1

• Problem.
• Coal Crushers with embedded accelerometers needed
  monitoring.
• User wanted to use existing DCS system.
• Existing system was not working properly.
• User unwilling to pay for conduit and instrument
  wire.
• Low Speed Bearings needed Enveloping.
• Solution.
• Velocity and Enveloping Transmitters Used (some
  slow speed).
• 16 Channel ADC using Modbus TCP/IP Ethernet used.
• Industrial Ethernet Radio Modem used.
• No lost packets. Very robust.
• Both Modbus RS-485 and TCP used.

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Case History 1
Master Radio
Slave Radio
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Case History 2
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Case History 2

• Problem
• TSI System for GE Turbine Generator Set.
• Customer wanted to use existing New DCS System.
• Wanted local display for operators.
• Intermediate terminals to save installation time.
• Solution
• CMCP500 Series Transmitters.
• Pre-wired Integrated Custom Panel.
• 4-20 mA Loop to DCS.
• Custom Mimic Panel w/Displays.

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Case History 2
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Case History 2
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Case History 3
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Case History 3

• Problem
• 6 IRD/Entek 5815 Monitors mounted in outdoor
  cabinets.
• Critical service on high temperature furnace
  fans.
• IRD/Entek no longer supported.
• Primary competition BNC
• 1 Vibration Channel.
• 8 Temperature Channels.
• Solution
• CMCP530 Transmitter.
• ADC with direct RTD input.
• 15 Industrial Touch Screen Rack Mount Computers.
• Custom Wonderware HMI w/Bargraphs.

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Case History 3
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Case History 3
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Case History 3
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Case History 3
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Case History 3
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Case History 3
Main Screen
Alarm List
Historical Trend
Real Time Trend
Real Time Trend
Setup
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Case History 4
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Case History 4

• Problem
• Large Kinetic UPS System Monitoring.
• Vibration, Enveloping, Temperatures, Speed,
  Pressures.
• Flywheel Diameter Calculation.
• Solution
• CMSS530, CMSS590, CMCP540 and CMCP545
  Transmitters.
• Process Variables direct to ADC.
• 12.1 Touch Screen Rack Mount Industrial
  Computer.
• Custom Wonderware HMI.

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Case History 4
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Case History 4
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Case History 4
Main Screen
Alarm List
Historical Trend
Real Time Trend
Real Time Trend
Setup
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Other Transmitter Based Systems
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Transmitter Tips

• Be sure to program in Time Delays. (3 second
  standard).
• OK Circuits should be designed into transmitter
  (lt2 mA).
• BNC Buffered Output.
• Peak or RMS.
• True RMS (is it really, pseudo, quasi, ?).
• Optional Filters (Low Pass, High Pass).
• 24 VDC (NEC low voltage).
• Optional Displays.
• ISO Standards are available.

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Go Wireless !
Industrial Radios

• Features Include
• Class I, Div II, Groups A,B,C,D.
• Superior noise immunity - advanced frequency
• hopping spread spectrum technology.
• Worldwide Unlicensed 2.4 GHz.
• Ethernet (TCP/IP, Ethernet/IP, Modbus/TCP,
  etc.)
• MODBUS RTU RS-485, RS-422, RS-232.
• 32 Frequency Channels.
• Up to 16 mile range w/ Hi Gain Antennas.
• Can be extended with Repeaters.
• 250 Kbps RF Data Rate.
• Configurable to Master/Repeater/Remote with
• Windows setup / diagnostics software.

Ethernet Model
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Thank You

• Questions ?