Rev.9 CSI 4500 System Installation

Reference Manual
CSI 4500
Machinery Health Monitor
Online System Installation and Configuration
Part # 97101 Rev. 9
Copyright
2010 by Emerson Process Management.
All rights reserved.
No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into
any language in any form by any means without the written
permission of Emerson Process Management.
Disclaimer
This manual is provided for informational purposes.
EMERSON PROCESS MANAGEMENT MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. Emerson Process Management
shall not be liable for errors, omissions, or inconsistencies
that may be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Information in this document
is subject to change without notice and does not represent a
commitment on the part of Emerson Process Management.
The information in this manual is not all-inclusive and
cannot cover all unique situations.
Product Support
Should you have any comments on this documentation or
questions concerning the Agreement on the following
pages, please contact Emerson Process Managements
Product Support Department.
Addresses:
The Americas and Canada
Emerson Process Management
835 Innovation Drive
Knoxville, TN 37932 USA
Phone: 865-675-4274
FAX: 865-218-1416
mhm.custserv@emersonprocess.com
Europe and Middle East
Emerson Process Management
Research Park Inerleuvenlaan 50 Leuven 3001 Belgium
Phone: 32/16/74/.14.71
UK 441516779418
FAX: 32/16/74.14.19
ii
emacust@emersonprocess.com
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Emerson Process Management Asia Pacific Pte Ltd
1 Pandan Crescent
Singapore 128461
Phone: 65.67708706
FAX: 65.67708006
MHM-TechSupport@AP.EmersonProcess.com
Worldwide Web:
http://www.MHM.AssetWeb.com
CSI 4500 Machinery Health Monitor Reference Manual
This document was written, illustrated, and produced by
Emerson Process Managements Engineering Publications
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Emerson Process Management logo; Infranalysis; InfraRoute; MachineView; MotorView; Nspectr; OilView
(Japan); AMS Machinery Manager; Reliability-Based
Maintenance, and logo; are registered trademarks of
Emerson Process Management.
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are pending trademarks of Emerson Process Management.
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License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMS
AND CONDITIONS OF THIS AGREEMENT BEFORE
OPENING THE PACKAGE OR PROCEEDING WITH
INSTALLATION. OPENING THE PACKAGE OR COMPLETING THE INSTALLATION INDICATES YOUR
ACCEPTANCE OF THE TERMS AND CONDITIONS
CONTAINED IN THIS AGREEMENT.
IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS CONTAINED IN THIS AGREEMENT,
CANCEL ANY INSTALLATION AND PROMPTLY
RETURN THIS PRODUCT AND THE ASSOCIATED
DOCUMENTATION TO CSI, AND YOUR MONEY
WILL BE REFUNDED. NO REFUNDS WILL BE GIVEN
FOR PRODUCTS WITH DAMAGED OR MISSING
COMPONENTS.
Definition of Software
As used herein, software refers to any computer program
contained on any medium. Software includes downloadable
firmware for use in devices such as analyzers or MotorStatus units and it includes computer programs executable on
computers or computer networks.
Software License
You have the non-exclusive right to use this software on
only one device at a time. You may back-up the software for
archival purposes. For network systems, you have the nonexclusive right to install this software on only one server.
Read/write access is limited to the number of concurrent use
licenses purchased. The number of guest-only accesses is up
to a maximum of 250.
CSI grants you a non-exclusive right to use the Software
solely for your own internal data processing operations on
the CSI designated supported operating platform for up to
any applicable maximum number of licensed users. You
may not relicense the Software or use the Software for third
party training, commercial time sharing, rental, or service
bureau use. Client may not use the Software in, as, or with
an ASP (Application Service Provider).
Software Updates
CSI agrees to provide you, at no charge except for media,
preparation and shipping charges, for one (1) year from the
date of purchase, all updates to the software made at the sole
discretion of CSI. Should you purchase a software support
agreement for the next succeeding year following the first
year from the date of purchase, and thereafter on an annual

basis, and if CSI is still providing support, you may purchase the same, annually, at the then existing rate.
Updates/Upgrades
Upon receipt of new CSI software replacing older CSI software, you have 30 days to install and test the new CSI software on the same or a different device. At the end of the 30day test period, you must both remove and return the new
CSI software or remove the older CSI software.
Ownership
The licensed software and all derivatives are the sole property of Computational Systems, Inc. You may not disassemble, decompile, reverse engineer or otherwise translate the
licensed program. You may not distribute copies of the program or documentation, in whole or in part, to another party.
You may not in any way distort, or otherwise modify the
program or any part of the documentation without prior
written consent from CSI.
Transfer
You may transfer the software and license to another party
only with the written consent of CSI and only if the other
party agrees to accept the terms and conditions of this
Agreement. If you transfer the program, you must transfer
the documentation and any backup copies or transfer only
the documentation and destroy any backup copies.
Copyright
The software and documentation are copyrighted. All rights
are reserved.
Termination
If you commit a material breach of this Agreement, CSI
may terminate the Agreement by written notice.
Virus Disclaimer
CSI uses the latest virus checking technologies to test all its
software. However, since no antivirus system is 100% reliable, we strongly advise that you use an anti-virus system in
which you have confidence to verify the software is virusfree. CSI makes no representations or warranties to the
effect that the licensed software is virus-free.
NO WARRANTY
THE PROGRAM IS PROVIDED "AS-IS" WITHOUT
ANY WARRANTIES, EXPRESS OR
iii
IMPLIED, INCLUDING BUT NOT LIMITED TO ANY

WARRANTIES OR MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY AND REMEDIES
IN NO EVENT WILL CSI BE LIABLE TO YOU OR ANY
THIRD PARTY FOR ANY DAMAGES,
INCLUDING ANY LOST PROFITS, LOST SAVINGS,
OR OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES ARISING OUT OF THE USE OR THE
INABILITY TO USE THIS PROGRAM.
THE LICENSEE'S SOLE AND EXCLUSIVE REMEDY
IN THE EVENT OF A DEFECT
IN WORKMANSHIP OR MATERIAL IS
EXPRESSLY LIMITED TO THE REPLACEMENT
OF THE DISKETTES OR OTHER MEDIA. IN NO
EVENT WILL CSI'S LIABILITY EXCEED THE
PURCHASE PRICE OF THE PRODUCT.
Export Restrictions
You agree to comply fully with all laws, regulations, decrees
and orders of the Unites States of America that restrict or
prohibit the exportation (or re-exportation) of technical data
and/or the direct product of it to other countries, including,
without limitation, the U.S. Export Administration Regulations.
U.S. Government Rights
When provided to the U.S. government, the computer software and related materials and documentation are provided
subject to the same license rights as those enumerated
above.
Hardware Technical Help
1. Please have the number of the current version of your
firmware ready when you call. The version of the
firmware in Emerson Process Managements CSI 2100
series, CSI 2400, and other analyzers appears on the
power-up screen that is displayed when the analyzer is
turned on.
2. If you have a problem, explain the exact nature of your
problem. For example, what are the error messages?
When do they occur? Know what you were doing
when the problem occurred. For example, what mode
were you in? What steps did you go through? Try to
determine before you call whether the problem is
repeatable.
iv
Hardware Repair
Emerson Process Management repairs and updates its hardware products free for one year from the date of purchase.
This service warranty includes hardware improvement,
modification, correction, recalibration, update, and maintenance for normal wear. This service warranty excludes
repair of damage from misuse, abuse, neglect, carelessness,
or modification performed by anyone other than Emerson
Process Management.
After the one year service warranty expires, each return of
a Emerson Process Management hardware product is subject to a minimum service fee. If the cost of repair exceeds
this minimum fee, we will call you with an estimate before
performing any work. Contact Emerson Process Managements Product Support Department for information concerning the current rates.
Obsolete Hardware
Although Emerson Process Management will honor all
contractual agreements and will make every effort to ensure
that its software packages are backward compatible, to
take advantage of advances in newer hardware platforms
and to keep our programs reasonably small, Emerson Process Management reserves the right to discontinue support
for old or out-of-date hardware items.
Software Technical Help
1. Please have the number of the current version of your
software ready when you call. The version number for
software operating under Windows is displayed by
selecting About under the Help menu bar item.
2. If you have a problem, explain the exact nature of your
problem. For example, what are the error messages?
(If possible, make a printout of the error message.)
When do they occur? Know what you were doing
when the problem occurred. For example, what mode
were you in? What steps did you go through? Try to
determine before you call whether the problem is
repeatable.
3. Please be at your computer when you call. We can
serve you better when we can work through the
problem together.
Software Technical Support
Emerson Process Management provides technical support
through the following for those under support agreement:
Telephone assistance and communication via the

Internet.
Mass updates that are released during that time.
Interim updates upon request. Please contact Emerson
Process Management Product Support for more
information.
Returning Items
1. Call Product Support (see page 2) to obtain a return
authorization number. Please write it clearly and
prominently on the outside of the shipping container.
2. If returning for credit, return all accessories originally
shipped with the item(s). Include cables, software
diskettes, manuals, etc.
3. Enclose a note that describes the reason(s) you are
returning the item(s).
4. Insure your package for return shipment. Shipping
costs and any losses during shipment are your
responsibility. COD packages cannot be accepted and
will be returned unopened.
vi
Contents
Chapter 1 Introduction
Special Emphasis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Plant Appointed Project Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Where to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2 Pre-Installation Review

Contractor Kickoff Meeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Final Walk-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
System Component Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 2 System Documentation

System Overview Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
System Layout Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cable Administration Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CSI 4500 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
CSI 4500S and CSI 4500MS Enclosures . . . . . . . . . . . . . . . . . . . . . 2-11
Documentation Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Chapter 3 Install Instrumentation

Description and Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Required Tools & Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
A911 Mounting Stud Installation (Stud Mounting Only) . . . . . . . . . 3-10
Sensor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
vii
A0322LC, A0322DS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . .
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AO322LC Sensor Mounting (without Quick-Connect) . . . . . . . . . .
A0322LC with Quick-Connect Mounting Instructions . . . . . . . . . .
3-14
3-14
3-16
3-18
3-23
3-25
A0322RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description & Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . .
Surface Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A0322RM Mounting Stud Installation (Stud Mounting Only) . . . .
Sensor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-27
3-27
3-29
3-30
3-35
3-36
V425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Description & Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Choosing Proper Actuator (Target) . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Mounting Sensor Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Mounting Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Chapter 4 Enclosure Mounting

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Required Tools & Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Mounting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Mount the CSI 4500 Data Collection Units . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Mounting Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Prepare the CSI 4500 Cable Access Plate . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determine Hole Size & Location . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11
4-11
4-11
4-12
Chapter 5 Cabling Requirements

Pull Instrumentation Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
viii
Pull V680 Bundled Cable from Junction Box/CSI 4500 . . . . . . . . . . . . . . 5-9

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CSI 4500 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Guidelines for Dedicated CSI 4500 Network Segment . . . . . . . . . . . . . . 5-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Power Circuit Guidelines for the CSI 4500 enclosure . . . . . . . . . . . . . . . 5-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Chapter 6 Wire Terminations

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Terminate Instrumentation Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Terminate V680 Bundled Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Terminate CSI 4500 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Terminate Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Chapter 7 System Hardware Configuration

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Monitoring Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
CSI 4500 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Signal Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
CSI 4500 SYSTEM ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . 7-8
CSI 4500M G2 Processor Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
CSI 4500 Signal Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
CSI 4500 Tachometer Input Module. . . . . . . . . . . . . . . . . . . . . . . . . 7-23
CSI 4500 Relay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
CSI 4500 MSIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
CSI 4500 G1 Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
CSI 4500 DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
CSI 4500 AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
CSI 4500 AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
CSI 4500 Transient Daughterboard . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
ix
Replacing the CSI 4500 Transient Daughterboard Hard Drive . . . . 7-60

CSI 4500 Transient Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
General Wiring Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Configuring a 4500 with Hyperterminal . . . . . . . . . . . . . . . . . . . . . 7-72
4500 G2 Processor Card LCD navigation screens . . . . . . . . . . . . . . 7-78
Data Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Overall Level Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Spectral Scan Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Calibrating the CSI 4500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
Test Signal Generator (TSG) Calibration. . . . . . . . . . . . . . . . . . . . . 7-96
Gross Scan (GS) Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98
DSP Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Transient Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99
Appendix A CSI 4500 Default Network Addressing Schema

Appendix B Additional CSI 4500 Connections
CSI 4500 Proximity Probe Interconnetion Diagram . . . . . . . . . . . . . . . . . B-2
CSI 4500 4-20ma Current Loop Interconnection. . . . . . . . . . . . . . . . . . . . B-3
Appendix C AC-DC Power Converter

Connecting and Maintaining the CSI 4500 . . . . . . . . . . . . . . . . . . . . . . . . C-2
Required Tools and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
CSI 4500 (with duplex receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
CSI 4500 (without duplex receptacle) . . . . . . . . . . . . . . . . . . . . . . . . C-3
Safe Operation of the CSI 4500 AC-DC Power Converter . . . . . . . . C-3
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Power Output Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Auxiliary sensor output connections . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Fan output connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Appendix D Connection Parameters

Specifications for equipment that supplies and receives energy: . . . .D-2
Index
xi
xii
Chapter
Introduction
Preface
Congratulations on your purchase of the CSI 4500 Machinery Health Monitor
online system. Along with your system hardware and software, you have been
provided several manuals to assist in installing, learning, and maintaining your
system. This particular document is the AMS Suite: Machinery Health Manager
Online Installation and Configuration. The purpose of this manual is to provide
system installers specific requirements and instructions for the correct installation and configuration of the CSI 4500 Machinery Health Monitor online
system and accessories.
This manual does not attempt to explain the operation or application of the CSI
4500 Machinery Health Monitor online system nor does it cover hardware or
software specifications.
Note
Normal installation for the Model CSI 4500 Machinery Health

Monitor unit is in an orientation such that the front panels are vertical.
1-1
Read This First

Special Emphasis
These conventions are used throughout this manual to call attention to the adjacent text:
Note
A note indicates special comments or instructions.
Caution!
A caution indicates actions that may have a major impact on the

system integrity.
Warning!
The Warning paragraph warns you of actions that could cause

serious injury or death.
1-2
Introduction
How to Use
There are two intended audiences for this manual: the plant appointed project
manager, and the contractor. As such, it is important that each understand how
to make use of this document.
Warning!
All wiring should be installed by a trained and qualified electrician. Wiring must conform to all applicable local codes and regulations. Local codes and regulations regarding wire type, wire size,
color codes, insulation voltage ratings, and any other standards
must be followed.
Warning!
Power to the CSI 4500 Machinery Health Monitor power converter

PCB must include a remote disconnect switch or circuit breaker.
The switch or circuit breaker must be in close proximity to the
equipment and within easy reach of the operator.
Caution!
Use of the CSI 4500 Machinery Health Monitor AC-DC Power

converter in a manner not specified by Emerson may impair protection offered by the equipment.
Plant Appointed Project Manager

The project manager will be involved in budgeting money for the installation
work, setting schedules, procuring bids from contractors, and supervising the
system install. Therefore, it is important that the project manager understand the
scope of work which is involved with an on-line system installation which can
be properly estimated by reviewing each section of this manual. Furthermore,
this manual is divided into sections:
Pre-Installation Review
How to Use
1-3
System Documentation
Install Instrumentation
Enclosure Mounting
Cabling Requirements
Wire Terminations.
These sections follow the natural progression of a system installation which
should make it easier for the project manager to estimate schedules and budgets
for the installation. Another important function of the project manager is to procure bids from contractors. Each contractor should receive a copy of this manual
and use that as a basis for their scope of work. Apart from the installation
manual, all the contractor should need is a copy of the system proposal and any
supplemental information for special purchases. When reviewing bids from
contractors it is very important that each contractors scope of work is based on
this installation manual and all exceptions are noted.
Before the contractor begins work, the project manager will have the important
duty of performing an installation review and creating proper system documentation. The installation review, which may include a Contractor Kickoff
Meeting attended by a CSI 4500 online project manager, is intended to educate
everyone involved with the installation on requirements, deadlines, procedures,
etc. The installation review also requires the project manager to perform a final
walk-through of the installation site and determine if the purchased hardware is
adequate and if any additional hardware will be required.
System documentation is often neglected until an installation is completed. The
project manager must be in charge of creating proper system documentation for
the contractor before the installation begins. This includes assigning labels, creating system diagrams, and filling out cable administration charts. Having the
proper system documentation will make the contractors job easier and reduce
the number of mistakes made.
Finally the project manager should use this installation manual to validate the
work being performed by the contractor. Particular attention should be paid to
any Notes or Cautions within the document, which are the most common
causes of a poor installation.
1-4
Introduction
Contractor
The contractor will use this manual for two purposes: preparing a bid for the
system installation, and as a guide during the system installation. When preparing a bid for the system installation, it is imperative that the contractor
reviews all parts of the manual that are specific to the installation and list any
exceptions to the manual within the bid. If the contractor takes no exceptions,
then it will be assumed that the bid covers the scope of work as defined in the
installation manual.
As an installation guide, it is not necessary that the installer be familiar with the
entire manual. The manual is written so a contractor when performing a certain
action, such as installing an AO322LC sensor, can turn to that particular section
and have a complete instruction set without referencing any other part of the
manual. This should make it easier when many people are involved with the
installation, each performing a specific function.
How to Use
1-5
Supplemental Information
This installation and configuration manual covers the standard online system
components. For specific customer installations, there will be non-standard
components purchased with the online system. For each of these components,
an installation guide supplement will be prepared by Emerson and included with
the installation guide. If a purchased component cannot be found in the installation guide, please contact your CSI 4500 Monitor project manager and request
an installation guide supplement.
1-6
Introduction
Where to Start
The chapters in this manual are intended to follow the natural progression of a
system installation. The plant assigned project manager needs to pay particular
attention to Chapter 2 Pre-Installation Review and Chapter 3 System Documentation. Contractors need to review Chapters 4-8 to fully understand the
scope of work involved in the online system installation. The following is a brief
summary of each chapter.
Chapter 2 Pre-Installation Review
The pre-installation review could also be called installation preparation. This

involves a contractor kickoff meeting, a final walkthrough of the installation
site, and examination of the delivered system components.
Chapter 3 System Documentation
System documentation is prepared before the system installation begins. This

involves assigning sensor names, wire tag designations, enclosure names, preparing system layout diagrams, and filling out the cable administration charts.
Chapter 4 Install Instrumentation
The online system instrumentation includes the 322 family of accelerometers

and the 425 tachometer. This chapter covers the handling requirements, required
tools, and the installation procedures for each piece of instrumentation.
Chapter 5 Enclosure Mounting
The online system will have two types of enclosures: junction boxes (707 family
and the 745) and the CSI 4500. This chapter covers choosing proper enclosure
mounting locations and mounting procedures as well as preparing the CSI 4500
for conduit access.
Chapter 6 Cabling Requirements
This chapter covers conduit installation guidelines, network cabling guidelines,

power line specifications, and pulling the online instrumentation cabling as well
as the bundled (multi-pair) cable from junction boxes to the CSI 4500.
Where to Start
1-7
Chapter 7 Wire Terminations
Often the cause of most system failures, proper wire terminations within the
online system components is critical for a successful system startup. This
chapter covers routing, tagging, preparing, and terminating cables within the
V707, 727, 745 junction boxes and the CSI 4500.
The CSI 4500 may be configured into a variety of configurations based on two
system racks. This chapter covers the hardware configuration for the CSI 4500.
1-8
Introduction
Chapter
Description
The pre-installation review is a short but important phase in a successful online
system implementation. Consisting of a Contractor Kickoff Meeting, final
walk-through, and a system component review, it is the responsibility of the
plant assigned project manager with the assistance of the CSI 4500 Monitor
online project manager or online system engineer to ensure this phase of the
system installation is completed successfully. The pre-installation review
accomplishes the following:
Identify and Educate all parties involved in the online system installation
Makes sure that all parties fully understands the scope of work
Sets the system installation schedule
Confirms that system components fit customers application
Confirms that all necessary system components are on site and available.
Confirms location of system components is appropriate
It is not uncommon for plants to schedule the Contractor Kickoff Meeting,
final walk-through, and system component review all in one day. This is especially beneficial when the CSI 4500 online project manager is attending the
Contractor Kickoff Meeting so that they may assist the plant assigned project
manager during the final walk-through and system component review. For this
reason it is also recommended that the online system has been shipped to the
customer site before installation work begins.
2-1
Contractor Kickoff Meeting

Although referred to as the Contractor Kickoff Meeting, this meeting brings
together all parties involved with the online system installation. Typically, this
will involve:
Plant Assigned Project Manager
CSI Online Project Manager or CSI Online Systems Engineer
End User(s)
Contractor Representative(s)
Information Systems Representative(s).
The purpose of this meeting is to:
Assign Responsibilities
Review Scope of Work For Contractors
Answer Any Installation Related Questions
Review Customer Expectations of Installed System
Tentatively Set Schedules for Installation.
Although many contractors will be educated on the system installation during
the bid process by reviewing the installation manual and the system documentation (see Chapter 3). It is important to confirm that they fully understand the
scope of work by reviewing each part of the installation during this meeting. If
the system documentation has not been submitted to the contractors, this is the
time to do so.
2-2
Final Walk-Through
The final walk-through is attended by the plant assigned project manager, contractor representative(s), and the CSI 4500 online project manager or online systems engineer. Using the system documentation (see chapter 3) as reference, this
is the opportunity to physically walk-through each part of the installation with
the contractors representative(s) and the vendors representative (online project
manager or online systems engineer) to review:
Sensor Mounting Locations
Cable Pulls
Conduit/Cable Tray Use
Enclosure Mounting Locations
Environmental Concerns
Hazardous Locations.
Final Walk-Through
2-3
System Component Review

The system component review confirms that the proper system components
have been shipped and that nothing has been lost or damaged during shipment.
The review should be attended by the plant assigned project manager, contractor
representative(s), and the CSI 4500 online project manager or online systems
engineer. It is the responsibility of the plant assigned project manager to gather
shipped components into an accessible area for the review process. The review
process simply consists of unpacking and inspecting system components to confirm all components are present. This is also the opportunity to familiarize the
plant assigned project manager and the contractor with the different system
components. In particular, the following items should be confirmed during the
review.
Any non-standard system components
Sensor mounting accessories (studs, mounting pads, quick-connects,
etc.)
Manuals
Junction box mounting tabs
CSI 4500 board configurations
CSI 4500 discrete input/output plug-in relays for correct configuration.
2-4
Chapter
Description
Often an overlooked part of the system installation, proper documentation of a
system installation will not only avoid problems during installation but will also
make system maintenance much more efficient. Unfortunately, many system
installations do not have documentation created until after an installation is
completed. A successful installation requires that proper system documentation
be created before a contractor begins working. Proper documentation includes:
system overview drawings showing the on-line system layout within the plant;
system layout drawings showing sensor and enclosure mounting locations; and
tags for all sensors, cables, and enclosures documented in cable administration
charts. This documentation must be given to a contractor before the installation
begins and preferably as part of the bid package. When an installation is finished, it is important that the documentation which has been maintained by the
plant assigned project manager is distributed to the proper plant personnel and
readily available for system maintenance and troubleshooting. The CSI 4500
data collection unit and junction/switch box enclosures include see-through
pouches for storing the on-line system documentation.
2-1
System Overview Drawings

The system overview drawings illustrate how system components interconnect.
These drawings are normally prepared by a CSI 4500 Online Business Development Manager and included in the online system proposal during the sales
process. If these drawings were not part of the proposal or if the system has
changed significantly from the time the proposal was created, it will be necessary for the plant assigned online systems engineer to create or update the drawings. The following system drawings were taken from an on-line system
proposal.
Example of System Overview Drawing (overall)
2-2
Example of System Overview Drawing (Machine Level)
As illustrated, the system overview drawings should consist of an overall system

diagram and then machine level diagrams showing sensor locations. In general
the following information should exist on each diagram.
Overall System Diagram:
CSI 4500
Junction/Switch Boxes
Cables
CSI 4500 Network Segment Cables
Tags for each CSI 4500, Junction/Switch box, and Cables
Machine Level Diagram:
Machine with Tag
Sensor Location with Tag
2-3
Junction/Switch Boxes with Tag

Location on Plant Floor
Additional Information to Keep:
IP address of online server
IP addresses of CSI 4500s
Note
Each IP address should be linked to the corresponding CSI 4500.
2-4
System Layout Drawings

The system layout drawings illustrate exact locations for enclosure mounting,
conduit installation, cable pulls, and sensor mounting. These are prepared by the
plant assigned project manager utilizing facility blueprints. The most common
method for preparing these drawings is to copy blueprints of the plant floor/production line and mark the system installation locations. Use color-coded highlights and symbols to mark the different types of cable runs and enclosure
mountings. The following is a recommended method of marking system layout
drawings.
System Layout Marking Guidelines
System Layout Drawings
2-5
Cable Administration Charts

Cable administration charts are a convenient way to document wire terminations
within system enclosures. Before the system installation begins and preferably
before bids are procured from contractors, the project manager should work
with the end user in the plant to determine sensor tags, enclosure tags, and cable
tags. There is no recommended method for assigning tags but the names should
be consistent and represent physical locations or machines. For instance, instead
of naming a sensor, 23001, which represents nothing, a more meaningful name
such as FAN1OV (fan number 1 outboard vertical) will make system maintenance and troubleshooting much easier. After tags are assigned, it is important
to document these in cable administration charts. All enclosures for the CSI
online system will need to have cable administration charts created. For this
reason, each enclosure will include a special clear plastic pouch on the inside
cover of the enclosure to hold these cable administration charts for reference.
There are two types of cable administration charts for the online system: junction box and CSI 4500.
2-6
Junction Box
The online system junction boxes each serve the same purpose: to provide a
junction between the instrumentation cable and the multi-pair bundled cable
which is pulled back to the CSI 4500. The cable administration chart for a junction box simply documents the channel number, wire tag, sensor type, and
sensor location if the wire tag does not contain location information. The following is an example of the junction box cable administration chart for a typical
installation. These charts are shipped with the system and can be found inside
the online system junction boxes.
Junction Box Cable Administration Chart
2-7
CSI 4500 Enclosure

The CSI 4500 enclosure has several types of cable terminations with specific
termination locations. (See illustrations of CSI 4500 enclosures on page 7 - 4.)
The CSI 4500 consists of removable boards to allow several different configurations. The CSI 4500 can include up to two SIG(nal) boards, a tach board, an
I/O board, and the DCM board. Each board has specific cable terminations
which must be documented in the cable administration charts. The cable administration charts for the CSI 4500 consist of two 8.5" x 11" pages and may be used
the for the CSI 4500M, CSI 4500T, and CSI 4500Q models. Templates are
included in the installation guide for the online system enginer to copy and fill
out.
CSI 4500M with full compliment of boards.

Starting from left: two SIG boards, one tach board,
one I/O board, and DCM board.
2-8
2-9
2-10
CSI 4500S and CSI 4500MS Enclosures

The CSI 4500S and CSI 4500MS enclosures have one cable termination card for
the 8 sensors, 2 tachometers, and 2 discrete I/O. There is also a 10BaseT network termination and an AC power termination. These are to be documented on
the CSI 4500S cable administration chart. A template for this chart has been
included. This template may also be used for the CSI 4500MS.
CSI 4500MS or CSI 4500S Board Positions
2-11
2-12
Documentation Storage
After the system installation is complete, it is the project managers job to
review the system documentation and make any revisions such as rerouted
cables, misspelled wire tags, etc. and make the necessary revisions in the system
documentation. The last step is to create copies of the completed system documentation and distribute to the appropriate plant personnel. One copy should be
sent to the CSI 4500 online project manager. This is also the appropriate time to
place the cable administration charts in the online enclosures. Each enclosure
contains a clear plastic pouch to allow easy reference by contractors and service
personnel. In each CSI 4500 enclosure, it is recommended that a copy of the
system overview and layout drawings be placed in the pouch for quick reference.
Documentation Storage
2-13
2-14
Chapter
A0322RI, A0322RA, A0322DR

Description and Handling Instructions
A0322RI, A0322DR Image & Outline Drawing
3-1
A0322RA Image & Outline Drawing
3-2
Description
The A0322RI and A0322RA are general purpose accelerometers with 90degree integral cable connections. The A0322DR sensor is a general purpose
accelerometer and temperature sensor with a 90-degree cable connection.These
sensors are stud mounted or epoxy mounted to machinery surfaces and transmit
vibration data to the on-line monitoring system. The integral cable connection
joins the sensor housing at a 90-degree angle to provide a low-profile installation. The A0322RI has a distinguishing bright yellow polyurethane jacket for
easy identification. The A0322DR has a red polyurethane jacket, three wires
(signal/power, temperature, return) instead of two (signal/power and return),
and requires two channel connections to the CSI 4500. The A0322RA is contained in a steel housing with an armored covered jacket.
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and therefore it is very important for installers to take precaution when handling sensors.
Do not drop, hammer, or impact the sensor housing before during or after installation. Mechanical shock loads of over 5000 gs will damage sensor and void
manufacturers warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or

after installation.
When tightening down stud mounted accelerometers it is very important not to
exceed specified torque. Over-tightening of accelerometer will damage sensing
element and void manufacturers warranty.
Caution!
Do not exceed specified torque when tightening stud-mounted

accelerometers.
Although the integral cable has built in strain relief, it is important that the cable
not be strained with excessive pulling force during cable pulls. No more than 5lbs. force should be exerted directly on sensor connection during installation. It
is recommended that cable be secured to machine near the point of sensor installation if possible.
3-3
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable

connection during wire pulls.
If sensor mounting occurs before cable is pulled in conduit or raceway to junction box it is important to leave cable bundled and secured to machine. Sensor
cable cannot be stepped on or severely kinked or permanent signal degradation
will occur. Also, cable bundle should not be placed in such a manner that it will
cause undue strain at the sensor/cable connection.
Required Tools & Parts

Below is a listing of the required tools and parts in order to install the A0322RI
and A0322RA accelerometers.
Spot Face and End Mill Tool, part number 88001.
Description: the spot face tool attaches to a standard electric drill and provides
a machined surface at least 1.1 times greater than the diameter of the sensor. At
the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
Spot Face and End Mill Tool
3-4
A901-1
A901-1 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Note
Contractor should confirm Material Data Sheet conforms to plant

safety regulations and substitute epoxy if necessary.
40-200 inch-lbs. Torque Wrench with 1/8" hex bit
Suggested Vendor:
Grainger Part # 4JW57
Description:
3/8" drive inch-lbs. torque wrench. Any torque wrench with a range of 40
to 70 inch-lbs. and less than 5 inch-lbs. increments can be substituted.
1/4"-28 taps & tap handle
9/16" open end wrench
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers.
3-5
Stud Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter. If

this is not possible, then an alternative mounting procedure must
be used. Do not proceed; contact project manager.
Note
Mounting location must provide a case thickness exceeding .4". If

1 . . Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2 . . Using wire brush and plant approved cleaner, clean and degrease surface
area.
3 . . Keeping spot face and end milling tool perpendicular to machine surface,
drill into mounting location until face has a minimum finish of 63 micro
inches. This will require the spot facing tool to remove approximately
.04" from the face. The surface should be smooth to touch with no
noticeable irregularities. The surface must be uniform on all sides. If not,
then the tool was not engaged perpendicular to surface and the procedure
must be repeated in a different location.
3-6
Note
If the spot face is not uniform on all sides this is an indication that
the spot face tool was not perpendicular to mounting surface and
will not allow the sensor to be mounted properly.
4. . .Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
3-7
Proper (left) & Improper Spot Facing
3-8
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1/2" in diameter. If

1. . . If necessary, use spot facing tool to prepare flat surface.
2. . . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
3. . . Keeping spot face and end milling tool perpendicular to machine surface,
4. . . Screw AO322 mounting stud into A901-1 mounting pad applying 7-8 ft.lbs. of torque.
5. . . Using A92016 2-part epoxy, spray activator onto mounting surface.
Place a light coat of epoxy on surface of A0901-1 mounting pad and hold
firmly against surface for 1 minute.
6. . . If adhesive does not setup within 1 minute, this is an indication that too
much epoxy was applied or that the mounting surface was not prepared
properly. Repeat installation steps 1-5.
3-9
A911 Mounting Stud Installation (Stud Mounting Only)

1 . . Using plant-approved degreaser, remove any lubricating fluid used
during the tapping process.
2 . . Using plant-approved epoxy, rub a small amount of epoxy onto spot face.
3 . . Using 1/4" allen wrench loosely screw A911 into mounting location.
4 . . Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A911 mounting base is not seated against spot face this is an
indication that the tap was not deep enough.
5 . . If sensor is not to be mounted immediately, it is necessary to cover
exposed quick connect threads to prevent contamination. Industrial tape
is recommended.
A911 Quick Connect
3-10
Sensor Mounting
Note
If not ready to pull cables, it is recommended that sensors not be

mounted to machine. If it is necessary to mount a sensor, then the
bundled cable must be secured to the machine and protected from
damage.
1. . . If necessary, clean A0322 mounting stud threads using plant approved
degreaser/cleaner.
2. . . Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
3. . . Place sensor onto A0322 and hold in desired position to create the least
amount of cable strain and cable exposure. Holding sensor, hand-tighten
9/16" captive nut and use a torque wrench with 9/16" open end to finish
tightening to 50-60 in-lbs.
4. . . Secure sensor cable to machine approximately 4" to 5" from mounting
location using an appropriate size cable clamp. Do not exceed bending
radius of 2.8".
5. . . If not ready to perform cable pulls, it will be necessary to secure bundled
sensor cable to machine in such a manner that no strain is placed on
integral sensor/cable connector. Bundled cable must not be left hanging
from sensor nor should bundled cable be exposed to damage such as on
the plant floor, maintenance access footholds, etc.
3-11
Mounting Procedure
3-12
Proper Sensor Mounting with cable secured
3-13
A0322LC, A0322DS
Description & Handling Instructions
A0322LC, A0322DS Image & Outline Drawing
3-14
Description
The A0322LC is a general purpose accelerometer with a top exit integral connection. The A0322DS is a general purpose accelerometer and temperature
sensor with a top exit integral connection. The sensors are stud mounted or
epoxy mounted to machinery surfaces and transmit vibration data to the on-line
monitoring system. The integral cable connection enters the top of the sensor
housing. An optional quick release connection, A0322LC-NT can be purchased
to allow the A0322LC or A0322DS to be easily removed from machine for
maintenance.
Caution!

after installation.
exceed specified torque. Over tightening of accelerometer will damage sensing
Caution!

accelerometers.
not be strained with excessive pulling force during cable pulls. No more than 5
lbs. force should be exerted directly on sensor connection during installation. It
A0322LC, A0322DS
3-15
Caution!

cause undue strain at the sensor/cable connection.

Below is a listing of the required tools and parts in order to install the A0322LC
and A0322DS accelerometers.
Spot Face and End Mill Tool, part number 88001.
The spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the sensor.
At the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
3-16
A212 Mounting Pad
A212 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Note

A0322LC-NT Quick Release SS Nut & Threaded Base (Optional)
A0322LC-NT Quick Release
A0322LC, A0322DS
3-17
40-200 inch-lbs. Torque Wrench with 1/4" hex bit

Suggested Vendor:
Description:
Surface Preparation
There are several ways to mount your accelerometers. This section discusses
those ways and what you need to do to successfully mount your accelerometers
Stud Mounting
Note
Mounting location must provide a flat surface 1/2 in diameter. If

3-18
Note

1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
A0322LC, A0322DS
3-19
Note
4 . . Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
3-20
A0322LC, A0322DS
3-21
Epoxy Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter. If

1 . . If necessary, use spot facing tool to prepare flat surface.
2 . . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
4 . . Screw mounting stud into A212 mounting pad until stud is flush with
bottom of mounting pad. If using A0322LC-NT Quick-Connect then
screw threaded base into mounting pad and torque to 5 ft-lbs.
5 . . Using A92016 2-part epoxy, spray activator onto mounting surface. Place
a light coat of epoxy on surface of A212 mounting pad and hold firmly
against machine spot face surface for 1 minute.
6 . . If adhesive does not setup within 1 minute, this is an indication that too
3-22
AO322LC Sensor Mounting (without Quick-Connect)

1. . .If necessary, clean mounting location threads using plant approved
degreaser/cleaner.
2. . .Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on mounting stud.
3. . .Screw mounting stud into sensor housing and hand tighten. Screw sensor
and mounting stud into mounting location and tighten with 9/16" torque
wrench to 5 ft-lbs.
4. . .Secure sensor cable to machine approximately 4 to 5" from mounting
radius of 2.8".
5. . .If not ready to perform cable pulls, it will be necessary to secure bundled
the plant floor, maintenance accesses, footholds, etc.
A0322LC, A0322DS
3-23
Caution!
If not ready to pull cables, it is recommended that sensors not be

mounted to machine. If necessary to mount sensor, then bundled
cable must be secured to machine and protected from damage.
Caution!
Do not terminate or secure cable to machine before mounting

sensor.
3-24
A0322LC with Quick-Connect Mounting Instructions

1. . .Using plant-approved degreaser, remove any lubricating fluid used during
the tapping process.
2. . .Using plant-approved epoxy, rub a small amount of epoxy onto spot face.
3. . .Using 1/4" allen wrench loosely screw AO322LC-NT into mounting
location.
4. . .Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A0322LC-NT Quick-Connect base is not seated against spot
face this is an indication that the tap was not deep enough. It will be
necessary remove quick-connect base and tap hole deeper.
5. . .If sensor is not to be mounted immediately, it is necessary to cover
is recommended.
6. . .If necessary, clean A0322LC-NT Quick-Connect threads using plant
approved degreaser/cleaner.
7. . .Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
8. . .Place sensor onto A0322LC-NT and hold in desired position to create the
least amount of cable strain and cable exposure. Holding sensor, handtighten 7/8" captive nut and use a torque wrench with 7/8" open end to
finish tightening to 50-60 in-lbs.
9. . .Secure sensor cable to machine approximately 4 to 5" from mounting
radius of 2.8".
10. .If not ready to perform cable pulls, it will be necessary to secure bundled
the plant floor, maintenance accesses, footholds, etc.
A0322LC, A0322DS
3-25
Mounting Procedure
3-26
A0322RM
Description & Handling Instructions
A0322RM Image & Outline Drawing
A0322RM
3-27
Description
The A0322RM is a general purpose accelerometer with 90-degree MIL-2 pin
connection. These sensors are stud mounted or epoxy mounted to machinery
surfaces and transmit vibration data to the on-line monitoring system. The MIL2 pin connection joins the sensor housing at a 90-degree angle to provide a lowprofile installation.
Caution!

after installation.
exceed specified torque. Over tightening of accelerometer will damage sensing
Caution!

accelerometers.
not be strained with excessive pulling force during cable pulls. No more than 5lbs. force should be exerted directly on sensor connection during installation. It
Caution!

3-28
cause undo strain at the sensor/cable connection.

Spot Face & End Mill Tool, part number 88001.
The spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the sensor.
At the same time the tool drills a pilot hole which is then tapped for the stud
mounted sensor.
A0322RM
3-29
A212 Mounting Pad (Epoxy Mounting Only)
A212 Mounting Pad
A92106 Loctite Depend Mounting Pad Epoxy (Epoxy Mounting Only)

Note

40-200 inch-lbs Torque Wrench with 1/4" hex bit
Suggested Vendor:
Description:
Surface Preparation
There are several ways to mount your accelerators. This section discusses those
ways and what you need to do to successfully mount your accelerators
3-30
Stud Mounting
Note
Mounting location must provide a flat surface 1" in diameter. If

Note

1. . .Prepare the spot face and end milling tool by setting the drill bit depth to
a minimum of .325".
2. . .Using wire brush and plant approved cleaner, clean and degrease surface
area.
3. . .Keeping spot face and end milling tool perpendicular to machine surface,
A0322RM
3-31
Note
4 . . Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
3-32
A0322RM
3-33
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1" in diameter. If

1 . . If necessary, use spot facing tool to prepare flat surface.
2 . . Using wire brush and plant approved cleaner, clean and degrease
mounting area.
4 . . Screw mounting stud into A212 mounting pad applying 7-8 ft-lbs. of
torque.
5 . . Using A92016 2-part epoxy, spray activator onto mounting surface. Place
a light coat of epoxy on surface of the A212 mounting pad and hold firmly
against surface for 1 minute.
6 . . If adhesive does not setup within 1 minute, this is an indication that too
3-34
A0322RM Mounting Stud Installation (Stud Mounting Only)

1. . .Using plant-approved degreaser, remove any lubricating fluid used during
the tapping process.
2. . .Using plant-approved epoxy, rub a small amount of epoxy onto spot face.
3. . .Using 1/4" allen wrench loosely screw mounting stud into mounting
location.
4. . .Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after correct
torquing, the A0322 Quick-Connect base is not seated against spot face
this is an indication that the tap was not deep enough. It will be necessary
remove mounting stud and tap hole deeper.
5. . .If sensor is not to be mounted immediately, it is necessary to cover
is recommended.
A0322RM
3-35
Sensor Mounting
1 . . If necessary, clean A0322RM Quick-Connect threads using plant
approved degreaser/cleaner.
2 . . Apply a thin coating of Loc-Tite semi-permanent thread locker to threads
on sensor housing.
3 . . Place sensor onto mounting base and hold in desired position to create the
least amount of cable strain and cable exposure. Holding sensor, handtighten 7/8" captive nut and use a torque wrench with 7/8" open end to
finish tightening to 50-60 in-lbs.
4 . . If not ready to pull cables, cover exposed sensor connector threads with
supplied connector cover.
3-36
V425
Description & Handling
V425 Outline Drawing & Image
Description
The V425 Passive Magnetic Pickup is an industrial sensor used to measure the
rotational speed of machinery. The sensor is commonly used to sense an actuator (target) on a rotating shaft giving a once per revolution trigger.
Handling
The V425 is unique in that it is the only piece of system instrumentation which
is installed near moving machinery (a rotating shaft typically). Therefore, it is
important to observe clearances between the sensor and the target as well as
observe cable clearances.
Caution!
The V425 can be damaged if proper clearance is not maintained

between sensor and actuator. It is important to follow installation
procedures to set proper clearance.
V425
3-37

Mounting Bracket & Locking Nut (included)
A universal mounting bracket is included with sensor which will fit a variety of
applications. If the included bracket will not work, then the contractor will have
to fabricate a custom bracket.
V425 Mounting Bracket
3-38
Choosing Proper Actuator (Target)

Actuator Dimensions
The V425 is designed to be used with a key meeting the following minimum
specifications:
Key (Target) Dimensions
A > .15 inches

B > .5 inches
F > .3 inches
V425
3-39
If the chosen actuator has a dimension (A) which must be greater than .5 inches
it is necessary to round the edges of the actuator to allow sensor to be as close
as possible to actuator.
Modifying Large Actuators
Actuator Material
The actuator must be made of a metallic material with a high permeability. Ideal
actuators are soft iron, cold-rolled steel and #400 stainless steel.
3-40
Mounting Sensor Bracket

1. . .Turn machinery shaft so that actuator is at mounting location.
2. . .Place sensor in mounting bracket and screw sensor into bracket exposing
equal amount of threads on back and front of mounting bracket.
3. . .Place sensor/bracket assembly into mounting location and center sensor
pole piece over actuator with pole piece touching actuator. Mark hole
locations on bracket.
4. . .Drill and tap hole locations for appropriately sized bolt to fit .250 inch
opening on mounting bracket.
5. . .Secure bracket to mounting location and torque to bolt specifications
V425 Mounting
V425
3-41
Mounting Sensor
1 . . Screw locking nut onto sensor and thread completely onto sensor.
2 . . Screw sensor into mounting bracket until sensor pole piece contacts
actuator.
3 . . Back sensor off 1 full turn and holding sensor in place thread locking nut
against mounting bracket. Torque to 15 ft.-lbs.
4 . . Slowly turn shaft and confirm that actuator is not contacting sensor. If
sensor is contacting shaft then repeat step (3) after loosening up lock nut.
5 . . Run machinery at full speed and confirm that sensor is not contacting
actuator. Let machine reach normal operating temperature and run
through all operational speeds.
6 . . Observe machinery during coastdown and confirm that sensor is not
contacting actuator.
7 . . Cover exposed connector threads with included protective cap to prevent
contamination.
3-42
Chapter
Enclosure Mounting
Mount V707, V727, and V745 Junction Boxes

Description
The junction boxes are NEMA 4X rated enclosures used to terminate the online
instrumentation wiring. The junction boxes consist of a 12- channel version in
a fiberglass or stainless steel enclosure. Box consist of individual 3 lug terminal
blocks mounted on a DIN rail.
The V745 junction/switch box serves the dual purpose of providing a junction
between the instrumentation and the CSI 4500 online system as well as allowing
portable data collectors local data access. The V745 is a 6 or 12 channel box
(fiberglass or stainless steel) with 3 terminal phoenix connections for both the
inputs and outputs.
Note
Normal installation for the CSI 4500 Monitor unit is in an orientation such that the front panels are vertical.
4-1
Junction box outline drawing
4-2
Enclosure Mounting
V745 outline drawing
4-3

Mounting Feet (supplied with enclosure)
Mounting Feet
4-4
Enclosure Mounting
Mounting Instructions
1. . .Ensure chosen mounting location allows proper clearance for
maintenance access. Location should be well lit and should be at
appropriate height off floor to allow service technician comfortable
access.
2. . .After choosing location, prepare mounting bracket using outline drawing
as a template for the mounting hole locations.
3. . .Attach mounting feet to back of enclosure using the 10-32x.375 machine
screws included with mounting feet. Torque screws to 31 in-lbs.
Mounting feet should aligned vertically to box to insure proper access for
mounting.
4. . .Attach enclosure to mounting bracket, using bolts which will be provided
by the contractor.
Junction Box Access Requirements
4-5
Mount the CSI 4500 Data Collection Units

Description
The CSI 4500 is an online data acquisition system used for predictive maintenance of plant machinery. Low-voltage instrumentation is terminated into the
CSI 4500 and is processed, analyzed, compressed, and output via an Ethernet
connection to a database server. The CSI 4500 is enclosed in a stainless steel
enclosure which is intended to protect it from harsh industrial environments.
The enclosure includes a power supply (if powered by 110VAC), a duplex outlet
receptacle for auxiliary power, a sub-panel for mounting accessories, a punch
plate for pulling wire through, and cable management pathways along the sides
and top of the enclosure.
4-6
Enclosure Mounting
CSI 4500 Outline Drawing
4-7
CSI 4500S Outline Drawing
4-8
Enclosure Mounting
CSI 4500 Enclsoure Access Drawing (Top View)

Mounting hardware not included.
4-9
Mounting Instructions
Note
All CSI 4500 enclosures must be grounded to earth. It is acceptable

to ground enclosure through conduit or mounting structure if
grounded to earth. Otherwise, a bonding wire must be used to connect enclosure to earth ground
1 . . Ensure mounting location has proper access for installation and
maintenance. In particular, the door should be free to completely open to
the side and there should be enough room to run conduit into the punch
plate on the bottom of the box. Location should be well lit and should be
at appropriate height off floor to allow service technician comfortable
access.
2 . . If not using conduit into box, confirm that mounting location provides a
path to earth ground.
3 . . The preferred method of mounting the CSI 4500 is to mount the enclosure
on two unistrut rails mounted on a vertical 24" center. Attach all 4
mounting feet to rails and use hardened steel bolts with lock washer
torqued to 50 ft.-lbs.
4-10
Enclosure Mounting
Prepare the CSI 4500 Cable Access Plate

Description
The CSI 4500 enclosure is designed to have all cables enter from the bottom of
the enclosure. For this reason, a removable cable access plate was built into the
bottom of the enclosure to allow contractors to remove the plate and prepare the
access holes. The stainless steel plate is mounted to the box using 12 machine
screws and a foam gasket to preserve a NEMA 4X rating.
Cable Access Plate

Stainless steel hole punch or drill.
Conduit fittings.
4-11
Determine Hole Size & Location

Multi-pair Bundled Cable Pulls
1 . . Multi-pair cable pulls should be made on left side of access plate (facing
box) so that cables can be easily routed along left side of enclosure.
2 . . If used, optional conduit fittings must be sized according to the number of
multi-pair cable pulls coming from a junction box. For example, a
standard 12-channel box will require two pulls. An optional 6- channel
junction box will use one cable pull. The multi-pair cable is normally .5"
in diameter and will require a 1.5" conduit run. Two multi-pair cable pulls
will require a 2" conduit run.
CSI 4500 Power
1 . . Power line pull should be made to the far right corner of access plate
(facing box) so that power cable is routed along right rear of enclosure.
2 . . The conduit should be sized according to plant code and NEC for running
power in the plant.
CSI 4500 Ethernet Connection
1 . . The CSI 4500 Ethernet connection will be a 10BaseT (for CSI 4500R and
CSI 4500S) or 100BaseT (for CSI 4500M, CSI 4500T and CSI 4500Q).
Category 5 cable provided by the plant. The cable pull should be to the
right front of the cable access panel so that the CAT5 cable can be routed
as far from the the CSI 4500 power supply as possible along the right side
of enclosure.
2 . . The Cat5 cable requires a minimum .5" conduit run.
CSI 4500 Discrete Input/Outputs
1 . . The CSI 4500 Discrete input/output cable pulls should enter the cable
access plate on the right side (facing box) between the power pull and the
Ethernet connection.
2 . . The CSI 4500 Discrete input/output cable pulls will consist of either:
a) Multi-pair bundled cable pulls which will require 1.5" conduit for 1
cable and .5" extra for each additional cable in pull.
4-12
Enclosure Mounting
b) A672 single twisted pair cable, which will be .225 inches in diameter
and either run in conduit, or pulled through cable access plate using 1/
4" cord grips.
4-13
4-14
Enclosure Mounting
Chapter
Introduction
This chapter covers conduit installation guidelines, network cabling guidelines,
power line specifications, and pulling the online instrumentation cabling as well
as the multipair bundled cable from junction boxes to the CSI 4500
Warning!
must be followed.
5-1
Jbox/CSI 4500 Cable Recommendations

Table 1: Cable pulled in Steel Conduit
Belden #
Application
Description
9732
V707/V727
9-pair, 24 AWG, Individual foil shield, PVC jacket
9734
V727/ V745
12 pair, 24 AWG, Individual foil shield, PVC jacket
Table 2: Cable pulled in Tray or Aluminum Conduit

Belden #
Application
Description
8168
V707
8-pair, 24 AWG, Individual foil shield, PVC jacket, Overall

Braid Shield
8175
V727/V745
15-pair, 24 AWG, Individual foil shield, PVC jacket, Overall

Braid Shield
Note
For cables with overall braided shield, the shield should be

grounded to the CSI 4500 enclosure via the grounding stud
included on the CSI 4500 enclosures subpanel assembly.
5-2
Conduit Installation Guidelines

Note
All conduit must be bonded to earth ground and adhere to IEEE

1100 specifications for grounding.
1The following cables must be pulled in Conduit:
a) Between junction boxes and the CSI 4500
b) Any CSI 4500 dedicated network segment cables not pulled in
existing plant network infrastructure.
c) Power cables for the CSI 4500
d) Any instrumentation cabling exceeding 50 feet.
2The conduit must be sized to not exceed a 40 percent fill.
3Steel Conduit must be used. If plant codes will not allow the use of steel
conduit then please contact project manager.
4Effort should be made to route conduit away from power trays using the
following guidelines:
6" ... 110VAC
12" ... 220VAC
2 ... 440VAC
5-3
5 Conduit must enter the CSI 4500 and junction boxes from bottom of
enclosures.
Conduit Access from Bottom
5-4
Pull Instrumentation Wiring

Description
The on-line instrumentation wiring is a polyurethane jacketed, twisted pair,

shielded, instrumentation cable used to transmit millivolt level instrumentation
signals to the online system. The cable is designed to provide noise shielding
and protection within harsh industrial environments. The instrumentation wire
is pulled to the junction/switch boxes where it is joined to bundled, multi-pair
cabling ran back to the CSI 4500. Because the instrumentation to junction box
pull is relatively short (<50 feet) and close to the machinery, it is not normally
enclosed in conduit although conduit will be required for specific applications.
Care must be taken to ensure that exposed cabling is secured to machinery and
plant infrastructure so as to not interfere with maintenance or cause safety hazards.
5-5
Cable Variations
There are four variations of instrumentation cable which are used in the on-line
system:
A. 2 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
Sensor
B. 2 Conductor, Single Twisted-Pair Armored Cable Integrated into Sensor
C. 4 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
A0322 Series Sensor
D. 2 Conductor, Single Twisted-Pair Polyurethane Cable With 2-Pin Mil
Splash Proof Connector.
Instrumentation Cables
5-6

cable tie downs
wire labels
dielectric grease
Installation
Caution!
If pulling in conduit cable pull force should not exceed 25 lbs.

Excessive force will deform twisted pair and degrade performance
of cable.
Note
Wire labels must be placed on each end of cable and have the same
designation. Wire label designations must be documented on
SENSOR LOCATION CARD chart included on inside of junction/switch boxes.
Caution!
Cables must be secured to plant infrastructure in such a manner

that no safety hazards are created from plant personnel tripping on
or catching slack cable on clothing or tool belt, etc.
1If using the A612-I-30 cable, apply a thin coating of dielectric grease to
connector and screw into sensor housing using hand force only.
2Label cable on both ends using plant approved wire labels. Wire label
designation must be the same on both ends of cable.
3Choose a physical path for the sensor cable pull using the following
guidelines:
a) Remain 12" from 110VAC, 2 from 220VAC and 440VAC power
lines.
5-7
b) Do not pull cable across machinery maintenance access areas:

guards, shields, access panels.
c) Do not pull cable in machinery control/starting cable trays.
d) Do not run any cable on floor.
e) Do not run cable near pathways where it will be exposed to damage
from moving machinery.
4 Starting at sensor housing, secure cable in 2-foot intervals to machinery
and plant infrastructure using cable tie downs.
5 At junction/switch box cable should be pulled through an existing
PGME07 cord grip. Tighten cord grip with 9/16 wrench until cable is
secure. (Do not overtighten) Blunt cut cable leaving approximately 2 feet
in box and relabel wire if necessary. If using armored cable, remove armor
before pulling through box by snipping the end of the armor with a pair
of wire cutters and unraveling the length to be removed. Cut armor off
with wire cutters and use heat shrink to seal end of armor.
5-8
Pull V680 Bundled Cable from Junction Box/CSI 4500

Description
The V680 bundled cable is a nine twisted pair instrumentation grade cable with
individual foil shielding on each pair. The twisted pair is 24 gauge and individually color-coded. The V680 is used to extend the on-line instrumentation
wiring from the V707 and V745 junction boxes to the CSI 4500 data collection
unit.
V680

wire labels
CSI 4500 Enclosure

Installation
1Starting at junction box, pull cable through conduit run. At the CSI 4500
enclosure, blunt cut cable leaving 4 feet inside box for routing.
2Label wire according to project specifications and place label within 6
inches of cable access plate with label facing toward front of enclosure.
3Blunt cut cable at junction box leaving 2 feet inside box for routing.
Pull V680 Bundled Cable from Junction Box/CSI 4500
5-9
Guidelines for Dedicated CSI 4500 Network Segment

Description
The CSI 4500 Data Collection Unit communicates with a database server via a
10BaseT-network (for CSI 4500R and CSI 4500S) or 100BaseT (for CSI
4500M, CSI 4500T and CSI 4500Q) connection adhering to the IEEE 802.3
Ethernet protocol. It is recommended that customers run a dedicated physical
network segment between the database server and the CSI 4500. Although it is
ultimately the responsibility of the plant to install and maintain the network, the
following guidelines are recommended:
1 Handling & Care Guidelines per EIA/TIA 568/569.
Note
Although EIA/TIA 568/569 only requires CAT5 cabling, it is recommended that customers run at least CAT5e to be compatible
with future upgrades.
2 Pathways & Cable Trays per EIA/TIA 569.
Note
Network Cabling to the CSI 4500 should be in steel conduit.
5-10
Power Circuit Guidelines for the CSI 4500 enclosure

Description
The CSI 4500 Data Collection Unit is a laboratory grade instrument measuring
millivolt level instrument signals. Therefore, the quality of the power provided
to the CSI 4500 is very important. Although the CSI 4500 contains input protection and some degree of line conditioning, it is important for the plant to follow
specific guidelines when running power to the CSI 4500 enclosure.
Note
Contractors should adhere to the IEEE 1100 specification for powering and grounding electronic equipment.
DC Power Specifications:
Nominal input voltage range:12v to 24v DC

Absolute input voltage range:10v to 36v DC
Maximum Current Draw3.5 Amps
Nominal Current Draw1.5 Amps
Minimum wire gauge:16AWG
Cable:shielded twisted pair.
AC Power Specifications:
Nominal voltage:110VAC
Circuit Breaker:10 Amps (with duplex receptacle)
Power ground:Isolated (from production equipment)
Power Circuit Guidelines for the CSI 4500 enclosure
5-11
5-12
Chapter
Wire Terminations
Terminate V707, 727, and 745 Wiring

Description
The V707 and V745 series junction boxes will have single twisted pair instrumentation wire pulled through cable grips on the left side of box and one or more
V680 bundled 9 twisted pair cable pulled through a 1.5" conduit fitting on the
right side of the box. The cables will be routed through the box leaving a service
loop and terminated to 3-lug terminal blocks on the V701 series or industry standard Phoenix connectors on the V745.
Junction Box routing
6-1

wire labels
24 AWG wire strippers
cable tie down
6-2
Wire Terminations
Terminate Instrumentation Wire

Caution!
Use correct gauge strippers on individual conductors. Do not strip

more than a 1/4" off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
Note
Shield connections pass through junction boxes and are not

grounded at the box!
1. . .Starting at cord grip pull wire to top of box on left side. Pull service loop
as shown in diagram.
2. . .Strip 1" of polyurethane jacket from cable.
3. . .Carefully pull twisted pair conductors out of braided shield. Do not
remove braided shield.
Twisted Pair Prepared
4. . .Strip 1/4" from each conductor and twist braided shield at end.
5. . .Terminate the wire into the proper terminal block as follows:
a) Connect white wire (sensor positive input) to upper level of the terminal block.
b) Connect black wire (sensor negative input) to middle level of the terminal block.
c) Connect braided shield to lower level of the terminal block.
6-3
Terminal Connections
6 . . Relabel wire at phoenix connector

7 . . After all cables are terminated, bundle cables and secure against side of
junction box using only one cable tie down.
6-4
Wire Terminations
Terminate V680 Bundled Cable

Caution!
Use 24 AWG gauge strippers on individual conductors. Do not

strip more than a 1/4" off conductor. Do not overtighten connector.
Turn terminal screw clockwise until contact with wire is made then
1/4 turn additional.
1. . .Starting at cord grip, strip cable jacket and braided shield off cable.
2. . .Use the following pair sequence from top to bottom beginning at first
terminal block:
Terminal Block
Positive Conductor
Negative
Conductor
Foil Shield
Yellow
Black
Black
Blue
Black
Blue
Brown
Black
Blue
Orange
Black
Blue
White
Black
Red
Red
Black
Red
Green
Black
Green
Red
White
Blue
6-5
Note
For 16 channel box, start sequence over on terminal block #9.

3 . . Pull individual twisted pair (with foil shield in place) to top of box on
right side. Pull service loop as shown in diagram.
4 . . Pull to terminal block and blunt cut any extra wire.
5 . . Remove 1" of foil shield from twisted pair and seal foil shield using heat
shrink or electrical tape.
6 . . Strip 1/4" from each conductor and terminate to terminal block as
follows:
a) Positive Conductor on upper level of terminal block
b) Negative Conductor on middle level of terminal block
c) Shield Drain on lower level of terminal block.
V680 Cable Preparation
6-6
Wire Terminations
Terminate CSI 4500 Wiring

Description
The CSI 4500 enclosure was designed to have cables enter from the bottom
through a stainless steel removable access plate. The access plate will have conduit fittings/cord grips for instrumentation wiring, control wiring (discrete
input/outputs), power, and a network connection. Instrumentation wiring is
routed along the left side of the enclosure while control, power, and the network
connection is routed along the right side of the enclosure. The CSI 4500 enclosure also includes a 110V duplex receptacle for auxiliary power.
Example above: CSI 4500R cable routing.

Other CSI 4500s that can be placed inside an enclosure include
the CSI 4500M, CSI 4500Q, and CSI 4500T.
6-7

Velcro cable tie downs
5 AMP fuse block (required for auxiliary 110V AC power)
RJ45 CAT5 connector and tools
Terminate Power
DC (with Fan Tray)
1) Route Cable along right rear of box and up right side pulling service loop
2) Pull wire to phoenix connector located next to the On/Off switch and blunt
cut excess wire.
3) Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connection as follows:
a) + DC ... + (right-most terminal)
b) DC ... (middle terminal)
c) shield ... (left terminal)\
4) Secure power cable to side of enclosure using only one cable tie down.
Fan Tray termination
6-8
Wire Terminations
DC (without Fan Tray)
1. . . Route Cable along right rear of box and up right side pulling service loop
2. . . Pull wire to Phoenix connector labeled input on the CSI 4500 Power
Supply card and blunt cut excess wire.
3. . . Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connection as follows:
d) + DC ... + (left most terminal)
e) DC ... (middle terminal)
f) shield ... (right terminal)
6-9
4 . . Secure power cable to side of enclosure using only one cable tie down.
CSI 4500 Power Supply termination
6-10
Wire Terminations
AC Power (with duplex receptacle)
1. . .Route power cable from right rear of enclosure into the CSI 4500 external
power supply AC input connection.
2. . .Terminate power cables line, neutral, and ground according to AC input
connector labels.
3. . .Splice 16 gauge wire from AC input connector to duplex receptacle.
4. . .Install 5 amp in-line fuse on hot conductor running to duplex receptacle
5. . .Terminate wire inside receptacle.
Phoenix Connection
6-11
AC Power (without Duplex Receptacle)
1 . . Route power cable from right rear of enclosure into the CSI 4500 external
power supply AC input connection.
2 . . Terminate power cord line, neutral, and ground according to phoenix
connection labels.
Terminate Discrete Input/Outputs
Caution!
Use correct gauge strippers on individual conductors. Do not strip

more than a 1/4" off conductor. Do not overtighten connector. Turn
terminal screw clockwise until contact with wire is made then 1/4
turn additional.
1 . . Pull cable up right side of enclosure (in front of AC power supply if
present) and over the top of the CSI 4500 unit. Pull cable down to discrete
input/output channel.
2 . . Blunt cut excess wire. Strip 1" from cable jacket and 1/4" from each
conductor.
3 . . Terminate in phoenix connector as follows:
a) Relay Excitation Voltage ... (+)
b) Voltage Return ... ()
c) Shield Drain ... (GND)
6-12
Wire Terminations
4. . .Relabel wire at connector.

5. . .After all wires are pulled, bundle wires with Velcro cable wrap on right
side of enclosure and on top of the CSI 4500. Secure bundle to right side
of enclosure in only one location.
6. . .Document discrete input/output name, wire label name, and CSI 4500
channel number on cable administration chart.
Discrete I/O cable routing
6-13
Terminate Network Connection
1 . . Pull network cable up right side of enclosure (in front of AC power supply
if present) and along side of CSI 4500 unit.
2 . . Bring cable across CSI 4500 power supply card and to 10/100BaseT RJ45
connection point.
3 . . Blunt cut excess wire and attach RJ45 CAT5 connector using plant
specified pinout for 10/100BaseT.
Note
Eight-position jack pinout should conform to plant standards for

10/100Base-T connections.
4 . . Secure network connection to right side of enclosure using cable tie
down.
Network Connection training
6-14
Wire Terminations
Note
Daisy Chaining of multiple CSI 4500s using the NIC/HUB is not

recommended. This introduces single point failures into a network.
6-15
Terminate A680 Bundled Cable Instrumentation Wiring

Caution!
Use 24 AWG gauge strippers on individual conductors. Do not

strip more than a 1/4" off conductor. Do not overtighten connector.
Turn terminal screw clockwise until contact with wire is made
then1/4 turn additional.
Instrumentation cable routing
1 . . Pull cable up left side of enclosure and over top of CSI 4500.
2 . . Secure cable to left side of enclosure with cable tie down.
3 . . Remove cable jacket beginning where cable crosses over top of CSI 4500.
4 . . Pull individual pairs down to proper channel on CSI 4500 unit.
5 . . Blunt cut excess wire.
6 . . Remove 1" of foil shield and place wire label around end of foil shield.
6-16
Wire Terminations
Wire label must match sensor wire label in junction box.

7. . .Strip 1/4" from each conductor and terminate into phoenix connector as
follows:
a) Positive Conductor from Junction Box ... (+)
b) Negative Conductor from Junction Box ... ()
c) Shield Drain ... GND
8. . .Document sensor name, wire label name, and CSI 4500 channel number
on CSI 4500 cable administration chart.
6-17
6-18
Wire Terminations
Chapter
System Hardware Configuration
Introduction
Description
The CSI 4500 Machinery Health Monitor is a multi-channel, multi-tasking,
multi-processor data acquisition system primarily intended for monitoring
heavy industrial rotating machinery. Typical signal inputs are dynamic AC
machine vibration signatures from accelerometers, velocity probes, or proximity probes. These signals include two components: the dynamic AC component, which represents machine vibration, and a DC component, which
represents the sensor bias level. In the case of a proximity probe, the DC component represents the gap, or average distance between the probe tip and the
machine shaft. Other signal inputs include process signals; these are DC parameters such as temperature or pressure.
Tachometer inputs are used to determine machine speed. These tachometer signals are typically generated from a proximity probe or passive magnetic sensor
positioned at a machine shaft keyway or gear, producing a pulse train (not necessarily 1x machine speed) representing the machine phase and running speed.
A final class of inputs are digital inputs which represent machine states, such as
running, off, starting, etc. These inputs are used to control or modify the data
acquisition state. Common state control inputs are relay closures or machine
RPM. AC or DC signal levels can also be used for state control.
Monitoring Methods
The CSI 4500 uses three basic data monitoring methods.
8-1
Overall Level Monitoring
Overall Level Monitoring is defined as (1) the acquisition of the overall level of
the dynamic AC vibration signal, typically the RMS value of the signal, and/or
(2) the DC sensor bias level, or (3) measurement of a DC process signal. Note
that all these signal inputs are DC values (The RMS value is a DC value proportional to the overall energy content of the AC signal). The Overall Level inputs
are multiplexed into a fast successive approximation ADC controlled by the CSI
4500 DCM. Overall Level Monitoring is a continuous process, with all input
channels AC+DC measured twice every second. When the Transient option is
included, true waveform Peak-to-Peak may be included in Overall Level Monitoring.
Spectral Scan
Spectral Scan is defined as the acquisition and analysis of dynamic AC signals

only. The signals are acquired, two channels at a time (referred to as CHX and
CHY), with a dual channel delta-sigma ADC controlled by the system DSP. The
DSP performs analysis of the acquired time waveforms and transmits the results
to the CPU host processor. Preprogrammed groups of Spectral Scan measurement parameters (AP Sets) may be assigned to specific machine state conditions
to tailor data acquisition to specific machine operational states.
Transient Data Capture
Transient data capture is the acquisition of continuous time waveforms of

dynamic AC signals. Transient data is captured in parallel for all channels.
Other data stored as Transient data include 1/sec Overall Level data, tach pulse
records, and acquisition timestamps. The Transient data is stored on hard disk,
and is available for real time analysis via Ethernet.
8-2
CSI 4500 System Configuration

The CSI 4500 system may be configured into a variety of configurations based
on two system racks.
The CSI 4500R Monitor supports one or two signal input modules, one tachometer input module, one relay module, a G1 CPU module, and an AC or DC
power supply.
The CSI 4500M Monitor supports one or two signal input modules, one tachometer input module, one relay module, a G2 CPU module, and an AC or DC
power supply.
The CSI 4500T Monitor supports two signal input modules, one tachometer
input module, one relay module, a G2 CPU module, a CSI 4500 Transient
Daughterboard, one or two Transient Filter Boards, and an AC power supply.
The CSI 4500S Monitor supports one multi-signal input module, a G1 CPU
module, and an AC or DC power supply.
The CSI 4500MS Monitor supports one multi-signal input module, a G2 CPU
module, and an AC or DC power supply. The CSI 4500MS Monitor is not
upgradeable to transient capability.
The CSI 4500Q Monitor supports one or two signal input modules, one tachometer input module, one relay module, a G2 CPU module, and an AC or DC
power supply.
CSI 4500 System Configuration
8-3
CSI 4500 System Basic Configurations

CSI 4500M monitor (left) and CSI 4500MS monitor (right)
SI 4500 Syste
CSI 4500 System Basic Configurations

CSI 4500R monitor (left) and CSI 4500S monitor (right)
8-4
Installation Considerations
Signal Quality
The data collected by the CSI 4500 system can only be as good as the signals
presented at the CSI 4500 inputs. Typically, signals from sensors such as accelerometers are of millivolt levels. Signals of this magnitude can easily be overwhelmed by interference from any number of sources in an industrial
environment.
Sensor Cable Type
Shielded-twisted-pair cable is recommended for all CSI 4500 System sensor

inputs. Conductor size can vary from 22 to 16 AWG. This type of cable provides
protection from both low frequency interference such as 50Hz-60Hz sources
due to the twisting, and protection due to RF and static discharge sources due to
the overall shielding.
Coaxial cable is not recommended. This type of cable has lower immunity to
50Hz-60Hz interference.
If multiple twisted-pair is used, it must be of the type that maintains an isolated
100% shield for each cable pair.
Sensor Cable Routing
Sensor cables should be routed in grounded conduit or in cable trays reserved

for low voltage control type signals. Sensor cables must not be routed through
conduit or cable trays containing AC power lines. If low voltage sensor cables
are routed in cable trays containing AC power cables, it is likely that line frequency components will be induced into the sensor signals. These induced components can be larger than the actual signal from the sensors.
Accelerometer, velometer, and passive magnetic tachometer cable distance is
limited to 500ft, 150m. Displacement sensor cable distance from amplifier is
limited to 1000ft, 300m.
Note
Distances are reduced if non-standard cable is used.
8-5
Note
Displacement probe power signals should be individually fused, so

that a single probe failure (short), does not disable other probes.
Ethernet Cable Routing
Ethernet cables should be routed in grounded conduit or in cable trays reserved

for low voltage control type signals. Ethernet cables must not be routed through
conduit or cable trays containing AC power lines. If ethernet cables are routed
in cable trays containing AC power cables, it is likely that line frequency components will be induced into the ethernet cable.
Ethernet cable distance is limited to 300ft,100m.
Grounding and Shielding
The shield termination of each shielded twisted pair cable must be terminated as
required by the particular installation. If the cable shield is connected to the
sensor case or the sensor cable - conductor at the sensor side, the cable shield
should not be connected at the CSI 4500 input side. The shield connection at the
CSI 4500 inputs is connected directly to the CSI 4500 chassis ground. Therefore, if a shield connection has also been made at the sensor side, a noise current,
typically at line frequency, can flow in the shield conductor. Voltage produced
by this noise current will then be coupled into the sensor signal lines. This condition is referred to as a ground loop.
In general, the shield should be connected at either the sensor end or the CSI
4500 end of the cable, but not both. However, this is just a guideline. If the primary noise pickup problem in a sensor line is due to static or RF frequency
sources, the shield connection should be tied at both ends to provide a better
shield for this condition. If this causes a ground loop condition, the shield connection can be made at the CSI 4500 end via a resistor or capacitor, which will
break the ground loop current flow while still providing some measure of
overall shielding.
It is important to realize that there is no best way to terminate cable shields.
Shield termination sometimes must be determined on a sensor by sensor basis
to correct noise problems of the particular installation.
8-6
Cable Terminations
Cables should be terminated neatly at the CSI 4500 system inputs. The outer
cable coverings should not be stripped back farther than necessary, and the
exposed cable shields should not be allowed to touch from cable to cable. The
shields should be cut back as little as possible so that the minimum of unshielded
signal conductors are exposed.
Cables should be clearly marked at the CSI 4500 inputs with labels indicating
the sensor location.
Sufficient cable slack should be left in the bottom of the CSI 4500 enclosure so
that CSI 4500 modules can be removed without having to remove the cable
input plugs from the CSI 4500 module. Extra cable can also prevent having to
pull new cables if wiring mistakes are made when terminating the sensor lines.
Junction Boxes
In many installations, sensor cables are connected via junction boxes. In this
case, the cable +, -, and shield connections must be maintained from input
to output. Shield connections must not be allowed to touch from cable to cable,
and shields must not be connected to the local junction box ground.
Cables should be terminated in the junction boxes following the recommendations of the previous section.
System Grounding
For personnel safety and correct system operation, the CSI 4500 system must be
grounded properly. The CSI 4500 enclosure should be bolted to a grounded
beam or wall. A grounding wire must also be connected from the CSI 4500
enclosure to a nearby earth ground. Use a minimum 14 AWG stranded cable for
grounding.
Inside the CSI 4500 enclosure, verify grounding wires from the CSI 4500
chassis to the enclosure frame, and from the enclosure door to the enclosure
frame have been installed.
8-7
CSI 4500 SYSTEM ENVIRONMENT

The CSI 4500 system has been designed to withstand moderate industrial conditions. The maximum allowable ambient temperature for the CSI 4500R,
4500M, 4500S, or 4500MS system enclosure is 120(degrees)F, 48(degrees)C.
The CSI 4500 system enclosure should never be mounted in direct sunlight. The
CSI 4500 system enclosure should be kept sealed so that water leakage and condensation does not occur.
CSI 4500 system enclosures installed in 100F to 120F ambient environments
should have the CSI 4500 Fan Tray installed to eliminate hot spots in the CSI
4500 enclosure. CSI 4500 system enclosures installed in locations exceeding
120F must be actively cooled. CSI 4500 system enclosures mounted in locations
that are colder than 32F should be actively heated. Thermostats should be used
inside the CSI 4500 enclosure to keep the temperatures between 50F and 100F
for maximum system reliability.
Note
Temperatures inside the CSI 4500 enclosures can exceed 140F

when ambient temperatures reach 120F. While the CSI 4500
system has been tested to operate reliably in temperatures this
high, it should be realized that the CSI 4500 electronics would age
at much higher rates than electronics maintained below 100F. It is
therefore recommended that active cooling be employed to keep
the CSI 4500 system electronics below 100F at all times for maximum system reliability and longevity.
Note
The use of a hard drive on the CSI 4500 Transient Daughterboard

places strict temperature limits on the CSI 4500 system. The CSI
4500 Fan Tray (PN B4500FT) must be used. Ambient temperature
must be limited to 30C, 86F.
8-8
Note
The use of an enclosure with the CSI 4500MS places strict temperature limits on its use. The CSI 4500 Fan Tray (PN B4500FT) must
be used. Ambient temperature must be mlimited to 30C, 86F.
8-9
CSI 4500M G2 Processor Card

PN B4532MB
The CSI 4500 G2 Processor Module is a redesigned version of the original CSI
4500 DCM (Data Collection Module). Improvements include: greater Spectral
resolution, bandwidth, and overall data collection speed, dual port 100BaseT
Ethernet, larger on board memory, improved calibration generator, ability to
monitor power supply voltages, integral data display, front panel Sysfail Relay
and calibration port, and support for the Transient Daughterboard.
The CSI 4500 G2 Processor Module provides all data acquisition, data storage,
and data communications functions for the CSI 4500 system. The CSI 4500 G2
Processor Module is capable of simultaneous, continuous measurement of two
channels for detailed Spectral analysis, thirty-two RMS and DC values for
Gross Scan measurements, up to sixteen tachometers for machine speed measurement, and up to sixteen digital state inputs.
Gross Scan values, tachometer values, and digital input states may be combined
logically to determine machine operating state, which may be used to define
specific data acquisition states. The system can be configured to transmit and
store data on either time interval or based on the amount of change of the data
values.
Two 10/100Base-T Ethernet ports and one RS-232 serial port are provided for
system communications and diagnostics. Additional front panel ports provide
access to calibration and signal diagnostic connections, and a dry contact SPDT
Sysfail relay. (See diagram on page 7 - 16.) This relay is energized when the
CSI 4500 CSI 4500 G2 Processor CPU successfully boots. On a CPU failure or
power loss, the relay will de-energize.
Note
Sysfail relay may not be used for other, e.g., vibration monitoring,
purposes.
The CSI 4500 G2 Processor Module may be configured to download its operational firmware via Ethernet upon every boot, or operate on firmware which has
been stored in FLASH memory.
8-10
The CSI 4500 G2 Processor Module has an on-board signal generator capable
of producing sinusoidal and DC signals which are routed to the input modules
during system calibration and on Power On Self Test (POST). The function generator should be recalibrated at least once a year with a NIST traceable volt
meter. Consult the Appendix for specific procedures to calibrate the CSI 4500
system.
The CSI 4500 G2 Processor Module automatically detects input module type
and configuration, and only permits database configurations based on the
existing card set.
The CSI 4500 G2 Processor Module supports the CSI 4500 Transient Daughterboard, which add 32 channel parallel time waveform acquisition capabilities to
the CSI 4500 system.
8-11
CSI 4500 G2 Processor Module Specifications
1. . ADC resolution
24 bits, 2 channel simultaneous
2. . Dynamic range
100dB
3. . Spectral resolution
100 to 6400 lines
4. . Analysis bandwidths
10Hz to 40KHz in 1,2,4,8 sequence
5. . Spectral scan rate
Depends on analysis bandwidth,

resolution, and number of averages
6. . Amplitude accuracy
< 1% , software corrected
7. . Frequency accuracy
< .01%, crystal based
8. . Total harmonic distortion
< -90dB, all ranges
9. . Phase accuracy
< 2%, software corrected
10. Signal to Noise + Distortion

(SINAD)
< -85dB, all ranges
11. Spectral gain amplifiers
Av = 1 - 4095, THD < -80dB,
12. Delta sigma ADC filter
> 90dB stopband FIR
13. Dynamic analysis types:
Total Energy, Energy in a range,

Non-synchronous energy in a range,
Synchronous energy in a range,
Synchronous peak, Synchronous phase,
True peak, Waveform peak to peak,
RPM
14. Averaging
Normal, Order Tracking, Synchronous
15. Units
English / Metric, Hz / CPM / order
16. Windows
Hanning / Uniform
17. Gross Scan rate

spectral scan
64ch RMS + DC / sec independent of
18. Gross Scan accuracy
< 1% full scale, software corrected
19. Gross Scan resolution
16 bits
20. Data acquisition state

control
21. Memory capacity
8-12
Relay input, RPM based, Gross Scan

amplitude
Up to 32Mbytes SDRAM, 32Mbytes
FLASH
22. .Local data storage interval
User definable
23. .Network communications
10/100base-T Ethernet
24. .Local communications
Up to 38.4Kbs RS232
25. .On board test generator
0v - 3v pk, 0.25Hz - 50KHz sine +/-7.2

DC, GND +/- 1mv
26. .Test generator amplitude
< 0.5%
27. .Test generator frequency
< 0.01% crystal based
CSI 4500 G2 Front Panel Features
8-13
Caution!
The NIC / HUB connections cannot be used to create a daisy chain

connection. In other words, you can connect to the NIC or the
HUB, but not to both at the same time.
CSI 4500 G2 PCB
8-14
CSI 4500 G2 Jumper Settings
8-15
CSI 4500 G2 front panel system Sysfail Status Relay connections.

Relay is shown de-energized.
Relay limit 24VDC 1A
8-16
CSI 4500 G2 front panel Calibration / Diagnostic Test Port connections.

These connections are only valid when under the control
of the DHM Diagnostic Software application.
CSI 4500 Signal Input Module

The CSI 4500 Signal Input module allows acquisition of data from up to sixteen
sensors. The sensor types include accelerometer, passive velocity, active
velocity, and displacement. The CSI 4500 Signal Input Module will also accept
non-specific AC or DC inputs from any source that conforms to the CSI 4500
input range limits.
The CSI 4500 Signal Input Module provides the following programmable functions for each channel: Input Attenuator /1, /2, Gain x1, x10, integrator on, off.
The combination of input attenuator and gain setting provide four input range
combinations as shown in Table 1.
8-17
Table 1: CSI 4500 Signal Input Module Input Ranges

Attenuator
Gain
Input Range +/-
/2
x1
10.0v, 100g, 100ips, 50mil
/1
x1
5.0v, 50g, 50ips, 25mil
/2
x10
1.0v, 10g, 10ips, 5mil
/1
x10
0.5v, 5g, 5ips, 2.5mil
The integrator allows acceleration signals to be converted to velocity.

The CSI 4500 Signal Input Module selects two of the sixteen channels at a time
and routes them to the CSI 4500 G1 or G2 Module for Spectral analysis. RMSto-DC conversion DC filtering is performed on all sixteen channels. The RMS
and DC signals are routed to the CSI 4500 G1 or G2 module for Overall Level
collection.
The CSI 4500 Signal Input Module accepts the CSI 4500 Transient Filter Board.
The CSI 4500 Transient Filter Board is required for Transient data acquisition.
4-20mA signals may be measured provided a resistor is added across the
channel input. A typical value is 250 ohms, which converts 4-20mA to 1-5 volts.
A typical value is 250 ohms which converts 4-20mA to 1-5 Volts. Maximum
series resistor value is 1000 ohms.
To make DC measurements with a input range greater than +/-10VDC (such as
thrust), input scaling resistors must be added to the sensor input (when using
Machiner Health Manager software versions 4.9x and earlier.) See Modifying
the CSI 4500 Input Ratio to Accept DC Process Signals Greater Than +/- 10
VDC on page 7 - 91.
8-18
CSI 4500 Signal Input Module Specifications
B4532MX
1. . .Number of AC channels
16
2. . .Channel bandwidth
DC to 40 KHz
3. . .AC coupling corner frequency
< 0.5 Hz
4. . .AC channel accuracy
5. . .Analog integration
61.45/f
6. . .Analog integrator accuracy
< 2% (frequency + amplitude)
7. . .Input ranges
+/-0.5v, +/- 1.0v, +/-5v, +/- 10v AC or

DC, +/- 24v DC, +/- 24v CM
8. . .Powered sensor types
Accelerometer, Velocity
9. . .Sensor power
>4mA CC w/ 22v compliance
10. .Powered sensor channel

input impedance
500 K Ohm ( single ended )
11. .Non-powered sensor types
Displacement, DC or AC Process
12. .Non-powered channel

input impedance
1Meg ohm ( differential )
13. .RMS to DC converter
1 per channel, 1Hz - 40KHz
14. .Mux card analog outputs
CHX, CHY, RMS, DC / PROCESS,

TRANSIENT (from daughterboard)
8-19
CSI 4500 Signal Input Module card face

Typical wiring connection
8-20
CSI 4500 Signal Input Module PCB
8-21
CSI 4500 Signal Input Module Details
8-22
CSI 4500 Tachometer Input Module

The CSI 4500 Tachometer Input Module allows measurement of up to sixteen
pulse tachometer sources. Tachometer sensor types may include, but are not
limited to: Active displacement sensor, passive magnetic, or TTL pulse type
from various sources.
The CSI 4500 Tachometer Input Module features either fixed voltage trigger or
adaptive automatic triggering. Triggering parameters may be set independently for each tachometer sensor input.
An input gain selection of x1 or x5 may be selected for each channel. A gain of
x5 is recommended for tachometer inputs smaller than 1V pk-pk. If the x5 input
gain is used, care should be taken to make sure that the input signal remains
within +/-24V, including any sensor bias or gap voltage.
A hardware frequency divider is provided for the AUX0, AUX1, and SPECTRAL channels which may be configured from divide-by-2 to divide-by-65536.
A hardware divider is provided for the TRAN0 - TRAN3 channels may be configured from divide-by-2 to divide-by-256.
An edge select is provided for the AUX0, AUX1, and SPECTRAL channels
which inverts the post trigger pulse waveform.
The CSI 4500 Tachometer Input Module produces seven triggered outputs
which are routed to the CSI 4500 G1 or G2 Module: AUX0 and AUX1, which
are routed to the G1 or G2 Module for Overall Level acquisition, SPECTRAL,
which is used for Spectral analysis, and TRAN0 - TRAN3 which are used by the
Transient Daughterboard (when present).
TRAN0 - TRAN3 are hard wired to Tach channel inputs 13-16.
Note
Tachometers used for 4500 transient signal operation must be

(physically) connected to tachometer card inputs 13, 14, 15, or 16.
Tachometers at these connections may be used (simultaneously)
for normal and transient operation.
8-23
CSI 4500 Tachometer Input Module Specifications
PN B4532TA
1. . Number of tach channels
16
2. . Frequency input range

(CSI 4500 G1)
0.3Hz to 1Khz (18RPM - 60kRPM)
3. . Frequency input range

(CSI 4500 G2)
0.1Hz to 2Khz (6RPM - 120kRPM)
4. . Tach frequency accuracy
0.1 %
5. . Tach resolution
0.002 Hz @ 60 Hz ( 0.1RPM )
6. . Tachometer types
Displacement, TTL, Magnetic
7. . Tachometer input and

trigger range
+/- 0.5v to +/- 24v, +/- 24v CM
8. . Tachometer pulse
characteristics
9. . Tachometer modes
1 pulse / rev, 500uS min. pulse

width
Volt compare, Automatic Adaptive,
Divide by N
10. Tachometer input impedance1Meg ohm differential
8-24
CSI 4500 Tachometer Input Module card face

8-25
CSI 4500 Tachometer Input Module PCB
8-26
CSI 4500 Tachometer Input Module Details
8-27
CSI 4500 Relay Module

PN B4532IO
The CSI 4500 Relay Module accepts industry standard OPTO22 style relays
to provide up to sixteen optically isolated digital inputs or digital outputs.
OPTO22 relay module types include, but are not limited to: DC Input, AC
Input, DC Output, AC Output, or Dry Contact.
Configuration switches on the CSI 4500 Relay Module must be set to match the
relay type installed. Refer to the CSI 4500 Relay Module Configuration Switch
Settings illustration for information on how to set the configuration switches.
Specifications
1. . Number of channels
outputs
16, can be any combination of inputs and/or
2. . Relay channel types
Standard DC transistor Opto-22 style
3. . Response time
50uS to 50mS, depending on module
4. . System interface
Interrupt driven
Note
CSI does not provide AC-relay product versions. If a customer

chooses to replace relays with AC-type, local electrical and
product safety regulations must be observed for the AC voltage
connections.
8-28
CSI 4500 Relay Module card face

Typical wiring conection
8-29
CSI 4500 Relay Module PCB
8-30
CSI 4500 Relay Module configuration switch settings
8-31
CSI 4500 MSIG Module

PN B4532MM
The CSI 4500 MSIG Module combines the features of the CSI 4500 Signal
Input, Tachometer Input, and Relay Modules to allow a combination of sensor
and relay types in one module.
The CSI 4500 MSIG Module provides twelve channels of vibration or process
signal sensor inputs, two channels or tachometer sensor inputs, and two optically isolated relay channels. The CSI 4500 MSIG Module is used only in CSI
4500 "S" unit configurations. The CSI 4500 MSIG Module may not be used in
CSI 4500 "R" or "M" configurations, and may not be used for Transient applications.
The specifications for the CSI 4500 MSIG channels are the same as the specifications of the individual module types.
8-32
CSI 4500 MSIG Module Specifications
1. . .Number of AC channels12 per MSIG card

2. . .Channel bandwidthDC to 40 KHz
3. . .AC coupling corner frequency< 0.5 Hz
4. . .AC channel accuracy< 1%, software corrected
5. . .Analog integration61.45/f
6. . .Analog integrator accuracy< 2% (frequency + amplitude)
7. . .Input ranges
+/-0.5v, +/- 1.0v, +/-5v, +/- 10v AC or DC,

+/- 24v DC, +/- 24v CM
8. . .Powered sensor typesAccelerometer, Velocity

9. . .Sensor power
>4mA CC w/ 22v compliance
10. .Powered sensor channel

input impedance 500 K Ohm ( single ended )
11. .Non-powered sensor typesDisplacement, DC or AC Process
12. .Non-powered channel input
impedance
1Meg ohm ( differential )
13. .RMS to DC converter1 per channel, 1Hz - 40KHz
14. .Number of tach channels2
15. .Frequency input range
(CSI 4500 G1) 0.3Hz to 1Khz (18RPM - 60kRPM)
16. .Frequency input range
(CSI 4500 G2) 0.1Hz to 2Khz (6RPM - 120kRPM)
17. .Tach frequency accuracy0.1 %
18. .Tach resolution 0.002 Hz @ 60 Hz ( 0.1RPM )
19. .Tachometer typesDisplacement, TTL, Magnetic
20. .Tachometer input and
trigger range
+/- 0.5v to +/- 24v, +/- 24v CM
21. .Tachometer pulse
characteristics 1 pulse / rev, 500uS min. pulse width
22. .Tachometer modesVolt compare, Automatic Adaptive,
Divide by N
23. .Tachometer input impedance1Meg ohm differential
8-33
24. Number of channels16, can be any combination of inputs

and/or outputs
25. I/O channel typesStandard DC Opto-22 style
26. Response time 50uS to 50mS, depending on module
27. System interfaceInterrupt driven
CSI 4500 MSIG Module card face

8-34
CSI 4500 MSIG PCB
8-35
CSI 4500 MSIG Module Jumper Settings
8-36
CSI 4500 G1 Processor Module

PN B4500MB
The CSI 4500 G1 Processor Module provides all data acquisition, data storage,
and data communications functions for the CSI 4500R and CSI 4500S system.
The CSI 4500 G1 Processor Module is capable of simultaneous, continuous
measurement of two channels for detailed Spectral analysis, thirty-two RMS
and DC values for Overall Level measurements, up to sixteen tachometers for
machine speed measurement, and up to sixteen digital state inputs.
Overall Level values, tachometer values, and digital input states may be combined logically to determine machine operating state, which may be used to
define specific data acquisition states. The system can be configured to transmit
and store data on either time interval or based on the amount of change of the
data values.
A 10Base-T Ethernet port and two RS-232 serial port are provided for system
communications and diagnostics
The CSI 4500 G1 Processor Module downloads operational firmware via
Ethernet upon every boot.
The CSI 4500 G1 Processor Module has an on board signal generator capable
of producing sinusoidal and DC signals which are routed to the input modules
during system calibration and on Power On Self Test (POST). The function generator should be recalibrated at least once a year with a NIST traceable volt
meter. Consult the Appendix for specific procedures to calibrate the CSI 4500R
system.
The CSI 4500 G1 Processor Module automatically detects input module type
and configuration, and only permits database configurations based on the
existing card set.
8-37
G1 Processor Module Specifications
1. . ADC resolution
16 bits, 2 channel simultaneous
2. . Dynamic range
> 80dB, all ranges
3. . Spectral resolution
100 to 6400 lines,
4. . Analysis bandwidths
10Hz to 20KHz
5. . Spectral scan rate:
Depends on analysis bandwidth,

resolution, and number of averages
6. . Amplitude accuracy
< 1% , software corrected
7. . Frequency accuracy
< .01%, crystal based
8. . THD
< -80dB, all ranges
9. . Phase accuracy
10. Noise floor
< -90dB, all ranges
11. Spectral gain amplifiers
Av = 1 - 4095, THD < -80dB,
12. Spectral AA filter
20KHz, 4th order elliptic, < -80dB THD
13. Delta sigma ADC filter
> 90dB stopband FIR
14. Dynamic analysis types:
Total Energy, Energy in a range,

Non-synchronous energy in a range,
Synchronous energy in a range,
Synchronous peak, Synchronous phase,
True peak, Waveform peak to peak, RPM
15. Averaging
Normal, Order Tracking, Synchronous
16. Units
English / Metric, Hz / CPM / order
17. Windows
Hanning / Uniform
18. Gross Scan rate
64ch RMS + DC / sec independent of

spectral scan
19. Gross Scan accuracy
< 1% full scale, software corrected
20. Gross Scan resolution
16 bits
21. Data acquisition state

control
8-38
Relay input, RPM based,

Gross Scan amplitude
22. Memory capacity
Up to 16Mbytes SRAM
23. Data storage interval
User definable
24. .Network communications
10Mbps Ethernet, 10base-T, AUI
25. .Local communications
Up to 38.4Kbs RS232, 2 ports
26. .On board test generator
.05v - 3v pk, 10Hz - 20kHz

sine 0.1v - 3v DC, GND +/- 1mv
27. .Test generator amplitude
< 0.5% manually adjustable
28. .Test generator frequency
< 0.01% crystal based
CSI 4500 G1 Processor Module front panel features
8-39
CSI 4500 G1 Processor Module PCB
8-40
CSI 4500 G1 Processor Module jumper settings
8-41
CSI 4500 DC Power Supply

PN B4500PS
The CSI 4500 DC PS Module is only intended for use with CSI 4500R and
4500S units. This module operates on DC input voltages and produces all
system power for the CSI 4500 system. An internal power monitoring circuit
measures all power levels and indicated failures on a front panel LED and alerts
the CSI 4500 G1 Processor Module.
In addition to the CSI 4500 system voltages, the CSI 4500 DC PS Module produces an additional +12 voltage to provide power for the Ethernet AUI port on
the CSI 4500 G1 Processor Module, and a non-specific 24VDC output that may
be configured as either +24VDC or -24VDC. Configuration of this power
supply is by means of jumpers on the PC board.
Caution!
Remove input power from the CSI 4500 DC PS Module before

removing the module from the CSI 4500 rack. Failure to do so may
result in damage to the unit. Make sure the input power switch in
the OFF position before connecting input power to avoid
arcing.
The CSI 4500PS must be installed in the rightmost slot in the CSI 4500 System
Chassis.
CSI 4500 DC Power Supply Specifications
8-42
1. DC Input:
+12vDC, +24vDC nominal

+10vDC, +36vDC absolute
2. DC Outputs:
+3.3v
+5v
+/-12v
+24v
+12AUI
24AUX
@ 1.9A
@ 1.5A
@ .31A
@ .42A
@ .83A
@ .6A
Startup Current Characteristics
1. Input Current Startup

Surge Duration
2. +12v Input Current
Startup Surge
3. +24v Input Current
Startup Surge
Total start up time = 35mS.

3A pk, no +12AUI or AUX24 load
3.5A pk, +12AUI and AUX24 loaded
1.75A pk, no +12AUI or AUX24 load
8-43
CSI 4500 DC Power Supply

Front panel features
8-44
CSI 4500 DC Power Supply PCB
8-45
CSI 4500 DC Power Supply Jumper Settings
8-46
CSI 4500 AC Power Supply

PN B4500AC
The CSI 4500 AC PS Module (PN B4500AC) is only intended for use with CSI
4500R, 4500S, and 4500T units. This module operates on AC input voltages and
produces all system power for the CSI 4500 system. An internal power monitoring circuit measures all power levels and indicated failures on a front panel
LED and alerts the CSI 4500 G1 Processor Module.
In addition to the CSI 4500 system voltages, the CSI 4500 AC PS Module (PN
B4500AC) produces an additional +24VDC voltage to provide power for the
optional 4500 Fan Tray, and a non-specific 24VDC output that may be configured as either +24VDC or -24VDC. Configuration of this power supply is by
means of jumpers on the PC board.
Warning!
Remove input power from the CSI 4500 AC PS (PN B4500AC)

Module before removing the module from the CSI 4500 rack. Hazardous voltages are present on the PC board.
Failure to remove input power before removing the CSI 4500 AC PS Module
(PN B4500AC) may result in damage to the unit. Make sure the input power
switch in the OFF position before connecting input power to avoid arcing.
The CSI 4500PS (PN B4500AC) must be installed in the rightmost slot in the
CSI 4500 System Chassis.
8-47
CSI 4500 AC Power Supply (PN B4500AC) Specifications
1. AC Input 110/220 VAC 50/60Hz

105/230 VAC absolute
2. DC Outputs+3.3v
@ 1.9A
. . . +5v
@ 1.5A
. . . +/-12v
@ .31A
. . . +24v
@ .42A
. . . +24Fan
@ .3A
. . . 24AUX
@ .6A
Power dissipation:~50 Watts fully loaded
8-48
CSI 4500 AC Power Supply (PN B4500AC)

Front Panel Features
8-49
CSI 4500 AC Power Supply (PN B4500AC) PCB
8-50
CSI 4500 AC Power Supply (PN B4500AC) Jumper Settings
8-51
CSI 4500 AC Power Supply

PN A4532AC
The CSI 4500 AC PS (PN A4532AC) Module is only intended for use with CSI
4500M and 4500MS units. This module operates on AC input voltages and produces all system power for the CSI 4500 system. An internal power monitoring
circuit measures all power levels and indicated failures on a front panel LED
and alerts the CSI 4500 G2 Processor Module.
In addition to the CSI 4500 system voltages, the CSI 4500 AC PS Module (PN
A4532AC) produces an additional +24VDC voltage to provide power for the
optional DC Fan Tray, and a non-specific 24VDC output that may be configured as either +24VDC or -24VDC. Configuration of this power supply is by
means of jumpers on the PC board.
The CSI 4500 AC PS (PN A4532AC) is designed to provide the extra power
required by the Transient Daughterboard and Transient Filter Boards.
WARNING: Remove input power from the CSI 4500 AC PS Module (PN
A4532AC) before removing the module from the CSI 4500 rack. Hazardous
voltages are present on the PC board.
Failure to remove input power before removing the CSI 4500 AC PS Module
(PN A4532AC) may result in damage to the unit. Make sure the input power
switch in the "OFF" position before connecting input power to avoid arcing.
The CSI 4500PS must be installed in the rightmost slot in the CSI 4500 System
Chassis.
CSI 4500 AC Power Supply (PN A4532AC) SPECIFICATIONS
8-52
1. AC Input
110/220 VAC 50/60Hz
...
105/230 VAC absolute
2. DC Outputs
+3.3v
@ 1.9A
...
+5v
@ 1.5A
...
+/-12v
@ .31A
...
+24v
@ .42A
...
+24Fan
@ .3A
...
24AUX
@ .6A
Power dissipation: CSI 4500M System ~55 Watts fully loaded

Power dissipation: CSI 4500T System with full Transient: ~80 Watts
CSI 4500 AC Power Supply (PN A4532AC)

Front panel features
8-53
CSI 4500 AC Power Supply (PN A4532AC) PCB
8-54

Jumper settings
8-55
CSI 4500 Transient Daughterboard

PN B4532DB
The CSI 4500 Transient Daughterboard adds the capability for 32 channel parallel, continuous time waveform acquisition. All collected time waveform data,
along with 32 channel Overall Level data and up to four tachometer pulse
records is stored on an internal hard drive, which provides approximately 45
minutes per Gbyte of storage.
The CSI 4500 Transient Daughterboard can also stream data via Ethernet to
analysis applications in near real time, without affecting data collection or onboard data storage.
While collecting time waveforms and tachometer pulses, the CSI 4500 Transient daughterboard continuously calculates the peak-to-peak value of each
channel's waveform. When configured, this value may be sent to the CSI 4500
G2 Processor Module for use as the overall level instead of the RMS value produced by the CSI 4500 Signal Input Module.
The hard drive used on the CSI 4500 Transient Daughterboard is specially rated
for 24-7 operation. It is recommended that this drive be replaced on a yearly
basis. In emergencies, any 2-1/2 in parallel IDE drive may be used temporarily,
but these drives are not generally rated for continuous operation.
Note
The use of a hard drive on the CSI 4500 Transient Daughterboard

places strict temperature limits on the CSI 4500 system. The CSI
4500 Fan Tray must be used. Ambient temperature must be limited
to 30C, 86F.
When installing the CSI 4500 Transient Daughterboard on the CSI 4500 G2
Processor Module, make sure all five mating connectors are fully engaged, and
then install all six mounting screws.
8-56
CSI 4500 Transient Daughterboard Specifications
1. Number of channels
32 channels
2. AC channel accuracy
< 1%, software corrected, 3% Mag/Phase
3. Frequency range
2 KHz/ch
4. ADC resolution
16 bits
5. Spectral resolution
200 lines - 6400 lines
6. Dynamic range
>80 dB
7. Number of tach channels
4 fixed channels from the CSI 4500 tach

card
8. Minimum / maximum
tach frequency input
0.1Hz to 2KHz
9. Tach accuracy (%)
0.1 %
10. Data memory
Up to 64Mbytes SDRAM, 60G+ hard drive
11. Communication
10\100base-T Ethernet
8-57
CSI 4500 Transient Daughterboard PCB

(mounted on CSI 4500 G2 processor)
8-58

jumper settings
8-59
Replacing the CSI 4500 Transient Daughterboard Hard Drive

To change the CSI 4500 Transient Daughterboard hard drive, remove the four
hard drive mounting screws as shown below. Gently remove the hard drive
ribbon cable from the hard drive and remove the old hard drive. Install the new
hard drive in the bracket. Do not over tighten the screws. Replace the ribbon
cable, taking care that it is correctly lined up.
Before the new hard drive can be used, it must first be formatted by the Transient
Daughterboard. Apply power to the CSI 4500 system. Ignore any hard drive
error messages produced by the Transient Daughterboard on the HyperTerminal
monitor. When the 4500 System has booted, use the DHM program to format
the hard drive.
When the drive has been formatted, reboot the CSI 4500. Again, ignore any hard
drive error messages produced by the Transient Daughterboard on the HyperTerminal monitor. When the POST process is complete, the firmware will automatically prepare the hard drive with the Transient File System. This process
may take up to an hour. When this process is complete, reboot the CSI 4500. The
boot process should now complete normally, with no hard drive error messages,
and, if configured, Transient data collection should begin (indicated by a
flashing hard drive indicator on the CSI 4500 G2 front panel).
Note
CSI provides an industrial rated HDD, capable of 100% duty cycle.

CSI recommends that an equivalent HDD be utilized.
8-60
Replacing the CSI 4500 Transient Daughterboard Hard Drive
8-61
CSI 4500 Transient Filter Board

PNB4532FB
The CSI 4500 Transient Filter Board provides parallel anti-aliasing filters for
the signal channels on the CSI 4500 Signal Input Module. Either one or two CSI
4500 Transient Filter Boards may be used to configure either a 16 or 32 channel
Transient System. Configuration jumpers on the CSI 4500 Transient Filter
Boards must be properly set to configure the board as Channel 1-16 or Channel
17-32. See Fig .
When installing the CSI 4500 Transient Filter Board on the CSI 4500 Signal
Input Module, make sure both mating connectors are fully engaged, then install
all three mounting screws.
CSI 4500 Transient Filter Board Specifications
8-62
Number of channels
16
Filter type
8th order elliptic low pass
Filter passband frequency
DC to 2kHz
Attenuation
80dB
Passband ripple
<1dB
Stop band frequency
3.12kHz
CSI 4500 Transient Filter Board PCB

(mounted on CSI 4500 Signal Input Module)
8-63

jumper settings
8-64
General Wiring Notes
CSI 4500 SIG, TACH, and IO Module wiring notes
8-65
Junction box wiring notes
8-66
CSI 4500 System Power and Ground Wiring notes
8-67
CSI 4500 rack dimensions
8-68
CSI 4500 wall mount enclosure dimensions
8-69
CSI 4500 MS and S rack dimensions
8-70
CSI 4500 MS and S wall mount enclosure dimensions
8-71
Configuring a 4500 with Hyperterminal

Connecting
Using a Null_Modem Cable make a connection from the serial port on your PC
typically to the COM 2 on the CSI 4500 G1.
Configure Hyperterminal on your PC to use the serial port (typically COM 1)
with the following settings:
9600 baud
8 data bits
stop bit
no parity
no flow control
Turn power on to 4500 Unit. From here, you should be able to watch the boot
process. You may interrupt boot by pressing the Space bar after the VxWorks
copyright is displayed as shown below. By the time Press any key to stop autoboot is displayed, most of the time alloted for pressing a key has passed.
Interrupting the boot process will allow the configuration of boot specific
parameters.
VxWorks System Boot
Copyright 1984-1997 Wind River Systems, Inc.
CPU: CSI DCM-4500
Version: 5.3.1
BSP version: 2.09a
Creation date: Nov 7 2001, 09:13:16
Press any key to stop auto-boot...
8-72
If allowed to complete without interruption, the boot process should finish with
a screen similar to this:
Component
Last Calibrated
----------------
-------------------------------------
TSG
2001-02-28 15:08:39
GS
2001-04-02 12:13:16
TACH
Uncalibrated
DSP
2002-01-17 17:52:18
Cfg Table
Last 'Put' (GUID: 0x00000000-0000-00000000000000000000)

(GUID time: None)
---------
------------------------------------
DIO
Default Table
GS
Default Table
TACH
Default Table
SCHED
Default Table
PRED
Default Table
LIMIT
Default Table
This unit will begin annnouncing it's availability in 78 seconds

ppp0: ppp 2.1.2 started by anonymous
ppp0: Connected...
ppp0: Connect: ppp0 <--> /tyCo/0
0x93c0eac (t_startup): startup: All modules initialized correctly.
Navigation
The following list is printed to the screen by interrupting boot and typing "?" or
help.
?
- print this list
- boot (load and go)
- print boot params
- change boot params
- load boot file
g adrs
- go to adrs
d adrs[,n]
- display memory
8-73
z adrs
- modify memory
f adrs, nbytes, value
- fill memory
t adrs, adrs, nbytes
- copy memory
- print fatal exception
n netif
- network interface device address and other

important information
Using the above commands, you should be able to navigate through the boot
configuration console. Typically the only commands that will be used here are
the "?", the "@", the "p", and the "c". Note: When modifying an entry simply
type new setting in, do not attempt to backspace over existing entry.
Transient console redirect
If the Transient system has the 0x0400 boot flag set, the console I/O is redirected
to COM1 on the front of the CPU and
No output will be seen when connected to the internal COM2 port
Pressing CTRL-B will switch between the CSI 4500 G2 Processor and
Transient output in the COM1 terminal session
Pressing CTRL-T will display which current console output is being
shown in the COM1 terminal session.
Changing configuration
Once the boot process has been interrupted, you should get the prompt
[VxWorks Boot] : At this prompt, type c and press enter to configure the unit.
Each parameter in the configuration will be brought up and you can type a new
value and press enter to replace the old value, press enter to accept the old value,
type . and press enter to clear the value or type - and press enter to go back
to the previous parameter.
Note
DCMI is another term for CSI 4500 G1 Processor. DCMII is

another term for CSI 4500 G2 Processor.
8-74
Standard CPU Configurations
CSI 4500 G1 Processor Configuration

boot device
: cs
processor number
: 0
host name
file name
: bin/csi4500
inet on ethernet (e)
: 192.168.0.10:ffffff00
inet on backplane (b)
host inet (h)
: 192.168.0.1
gateway inet (g)*
user (u)
: anonymous
ftp password (pw) (blank = use rsh)
: anonymous
flags (f)
: 0x9008
target name (tn)
startup script (s)
other (o)
CSI 4500 G2 Processor Configuration

boot device
: shend0
processor number
: 0
host name
file name
: bin/4500dcmII
: 192.168.0.10:ffffff00
host inet (h)
: 192.168.0.1
gateway inet (g)*
user (u)
: anonymous
: anonymous
flags (f)
: 0x1409
target name (tn)
startup script (s)
other (o)
* If a gateway is used, the address must be specified as a boot parameter.
8-75
Transient Configuration
boot device
: shend0
processor number
: 0
host name
file name
: bin/4500t
: 192.168.0.11ffffff00
host inet (h)
: 192.168.0.1
gateway inet (g)
user (u)
: anonymous
: anonymous
flags (f)
: 0x1409
target name (tn)
startup script (s)
other (o)
: (IP Address of WINS server, if configured)
Explanation of CSI 4500 G1 Processor boot flags

0x0002 - load local system symbols
0x0004 - don't autoboot
0x0008 - quick autoboot (no countdown)
0x0020 - disable login security
0x0040 - use bootp to get boot parameters
0x0080 - use tftp to get boot image
0x0100 - use proxy arp
0x0800 - shadow files on RAM disk. Boot from it directly if possible
0x1000 - shadow files on RAM disk. Boot from it if net-boot fails
0x2000 - skip RAM testing on cold boot
0x4000 - disable input from shell
0x8000 - turn OFF MUX CC diodes on cold boot
Typical CSI 4500 G1 Processor Boot Flags in the field
8-76
With Bootp
0x9048
Without Bootp
0x9008
Explanation of 4500 CSI 4500 G2 Processor and Transient boot flags

0x0001 - skip SDRAM testing on cold boot (for testing)
0x0002 - load local system symbols (for debug)
0x0004 - don't autoboot (for testing)
0x0008 - quick autoboot (no countdown)
0x0010 - disable input from shell
0x0020 - disable login security
0x0040 - use bootp to get boot parameters (network boot only)
0x0080 - use tftp to get boot image (network boot only)
0x0100 - use proxy arp (network boot only)
0x0200 - ignore BOOTROM update image in FLASH (for testing)
0x0400 - turn OFF MUX CC diodes on cold boot (DCMII only)
0x0400 - redirect the console I/O to the DCMII (Transient only)
0x0800 - disable boot file update in FLASH (for development)
0x0800 - boot over a WAN, requiring extended FTP timeouts
The 0x0800 flag applies only if one of the three flags below is set:
0x1000 - attempt network, fallback on FLASH boot (legacy 4500 mode)
0x2000 - boot ALWAYS from network, never fallback on FLASH
0x4000 - boot ONCE from network. This flag clears itself after one boot
The system will normally try to get boot params, boot image, and startup script first from
FLASH. If the FLASH boot fails, the system will revert to a network boot as a backup. The
0x1000, 0x2000, and 0x8000 flags modify this default behavior (listed with highest precedence first).
Typical CSI 4500 G2 Processor Boot Flags in the field:

CPU
With Bootp
Without Bootp
DCMII
0x1449
0x1409
Transient 0x1449
0x1409
General Boot Flag Notes
For CSI 4500 G1 Processor, CSI 4500 G2 Processor, and Transient systems,
boot flags can be listed by typing a question mark (?) into the HyperTerminal at
the vxWorks boot prompt.
8-77
Warning!
For CSI 4500 G2 Processor and Transient systems, the SDRAM

testing (0x001) flag causes FLASH boot to fail. Dont use 0x0001
flag on 4500dcmII and 4500T bootROMs prior to v3.01b.
For CSI 4500 G2 Processor and Transient systems, the BootROM update feature is not implemented yet (0x0200 ignored).
For Transient systems, if redirect is used, do not connect internal transient board
com port to PC since all output will be directed to the external com port.
Subnet Masks
The subnet mask on a 4500 defaults to 255.255.255.0 (ffffff00) and should be

specified when configuring the 4500. The subnet mask should also match the
subnet mask used on the server. If they do not match, network communication
failure is possible. To specify a subnet maks, enter it on the configuration labled
inet on ethernet. The IP address of the unit should be entered first, followed
by a colon and then the subnet mask in hexadecimal.
The subnet mask is presented in Windows as a set of four decimal numbers, each
of which can have a value from 0 to 255, seperated by periods (i.e.
255.255.248.0). In the 4500, the subnet mask is represented as a series of four
hexadecimal pairs with no seperation (i.e. fffff800). A hexadecimal conversion
table can be used to convert the numbers. The calculator in Windows' Accessories can also be used for conversion when set to scientific mode.
4500 G2 Processor Card LCD navigation screens

The 4500 CPU has an LCD screen on the front along with several navigation
buttons below. You can view various settings and data on this screen while at the
unit. Not all settings and data for the unit can be viewed from the screen, as it is
not meant to be used as a replacement for the Online Watch program.
The first screen presented is the main menu. The menu choices on this screen
are View System Status, Adjust Contrast Settings, and view Gross Scan Data.
The IP address of the host server for the 4500T is also displayed.
8-78
The menus are navigated by use of the six buttons below the LCD screen. Four
arrows, enter (the lower right arrow that goes down and then left) and escape
(the upper right arrow that goes up and then left). While navigating the screens
of the LCD display, pressing escape will return you to the previous menu.
In the LCD screen, below the menu options, there are four boxes that may or
may not contain icons.
The first or left most icon shows three boxes connected by lines to show that the
4500 has established a connection to the online server. A two box connection
will appear when the 4500 has a connection to DHM (a troubleshooting and
diagnostic tool used primarily for support purposes).
The second icon (a set of wavy lines) will appear next to the unit connection
during a Live data connection with a transient unit.
The fourth or right most icon is a heart shape which indicates that the
unit has booted without any errors. This icon should flash or fade on and
off at a regular pace once the unit has fully booted.
If the heartbeat is displayed as being broken, it indicates that one or more POST
(Power On Self Test) failures occurred during the unit bootup.
8-79
Adjusting Contrast
From the main menu, selecting Adjust Contrast displays the adjust contrast
screen. On this screen, you can adjust the contrast of the LCD display for maximum readability. The left and right arrow keys change the contrast quickly in
large steps and the up and down arrow keys allow you to make finer adjustments.
Gross Scan Data
Selecting Gross Scan Data from the menu will display a screen with gross scan
AC values for the first four signal channels on the 4500. The up and down
arrows may be used to scroll through the channels four at a time. Only the AC
gross scan values are available and they are displayed in Volts RMS (4500M,
4500MS, 4500T) or Peak-to-Peak (4500T), depending upon how the channel
was configured in O_config.
System Status Menu
Selecting System Status on the menu takes you to the System Status menu where
there are choices for showing online POST status, online boot parameters, transient POST status and transient boot parameters.
8-80
Online POST Information
Selecting Online POST from the System Status menu will display the Firmware
version, EPROM version, PLD 0 version and the unit onboard temperature. The
temperature is the temperature inside of the 4500 itself, not of any monitored
equipment.
Pressing the up and down arrows from this screen will allow you to page
through several screens of information about the 4500.
The next screen displays versions for some of the internal components of the
4500. This information is used for troubleshooting purposes only.
The next screen displays the total amount of onboard system memory as well as
the IP address and Subnet Mask that the CSI 4500 G2 Processor board is currently using.
8-81
The final screen displays POST results for: Gross Scan, Digital Signal Processor, Tachometer and Power tests. These should always say passed.
Online Boot Parameters
Selecting Online BootParams from the main menu allows access to the boot
parameters used by the online side of the 4500. The first screen shows the
Device, UnitID, Processor and Unit settings for the CSI 4500 G2 Processor
board. These are used for troubleshooting purposes. Using the up and down
arrows allows you to page through several more screens of information
The next screen displays the 4500 IP address, Subnet Mask and Host IP address
used by the CSI 4500 G2 Processor . The Subnet Mask and Host IP address settings should be identical to the settings for the Transient board. The IP address,
however, will always be different.
8-82
The next screen displays the bootfile name that the CSI 4500 G2 Processor will
use to load its firmware.
The next screen displays the name of the startup script used by the CSI 4500 G2
Processor board if one is in use or a blank (as shown) if not. Startup scripts
allow some changes to the behavior of the 4500 and will generally be set up
during system commissioning.
The final screen displays the FTP User name and FTP User Password used to
connect to the server to download firmware for the CSI 4500 G2 Processor
board. The Bootflags setting is shown as well. These are set during commissioning and generally will not need to be changed.
8-83
Transient POST
Selecting Trans POST from the System Status menu will allow you to access the
POST results and other information related to the Transient board. The first
screen shows Transient Firmware revision, BootProm revision, PLD0 revision,
and PLD1 revision for the Transient board. As with the CSI 4500 G2 Processor
board, these are only used for troubleshooting.
The next screen displays the DSP PLD version, Transient Main revision, Transient Diagnostic revision and Hard Drive Size of the Transient board. The hard
drive size is the total size in megabytes. With the initial release of the 4500T,
60GB is the standard drive size installed in the system.
The next screen shows the IP address and MAC address of the Transient board.
8-84
The final screen displays the Transient POST status, Digital Signal Processor
POST Status, and Power POST Status for the Transient board. All three of these
should display passed.
Transient Boot Parameters
Finally, on the System Status menu, Transient Boot Parameters may be selected.
This will give you access to the boot parameters used by the Transient board.
The first screen displays the Device, Processor number and Unit number of the
Transient board. This information is used for troubleshooting purposes only.
The second screen displays the IP address, Subnet Mask and Host IP address
used by the Transient board. The Subnet Mask and Host IP address settings
should be identical to the settings for the CSI 4500 G2 Processor board. The IP
address, however, will always be different.
8-85
The next screen displays the Firmware bootfile name loaded via FTP from
online server. The actual location of this file on the server is typically
C:\Inetpub\FTProot\bin and the file should be named 4500T
The next screen displays the name of the startup script used by the Transient
board if one is in use or a blank (as shown) if not. Startup scripts allow some
changes to the behavior of the 4500 and will generally be set up during system
commissioning.
The final screen displays the FTP User name and FTP User Password used to
connect to the server to download firmware for the Transient board. Also displayed is the Bootflags setting which is set during commissioning and should
not need changed thereafter. The Oth field should contain the IP address of the
WINS server on the network.
8-86
Data Types
Overall Level Parameters
All Overall Level inputs must be DC in nature. Any Overall Level input of a
dynamic nature must be fed through the RMS / DC converter path. It is not technically valid to convert RMS values from an RMS/DC converter to Pk or Pk-Pk
Measurement Units unless the input is sinusoidal in nature. However, the CSI
4500 allows this. RMS values are multiplied by 1.414 or 2.828 to convert from
RMS to Pk and Pk-Pk respectively.
Spectral Scan Parameters

All Spectral Scan Parameters must be AC in nature. It is possible to convert
some analysis type results between Measurement Unit types and Display Unit
types. In general, Measurement Unit Conversions are only possible with spectral analysis types. Time waveforms analysis types cannot be converted.
Analysis Type: Overall Level
Iincludes Overall RMS Level, Sensor DC Bias, Gap, DC or AC Process signals

Note
Some DC Process inputs could provide Pk, Pk-Pk, or other Measurement Units
Data Types
8-87
Input Type
Input Unit
HW Int.
RMS/DC
Meas. Unit
Disp. Unit
DC
V / E.U.
no
no
DC
E.U.
AC
V / E.U.
no
yes
RMS
E.U.
ACCEL
V / 32.2 ft/sec
V / 32.2 ft/sec
no
yes
yes
yes
RMS
RMS
gs
in/s
V / 9.81 m/s
V / 9.81 m/s
no
yes
yes
yes
RMS
RMS
gs
mm/s
V / i/s
V / i/s
no
yes
yes
yes
RMS
RMS
i/s
mils
V / mm/s
V / mm/s
no
yes
yes
yes
RMS
RMS
mm/s
microns
V / mil
no
yes
RMS
mils
V / micron
no
yes
RMS
microns
VEL
DISP
Analysis Type: Spectral
Includes: Total Energy, Energy within a Frequency Range, Synchronous Energy

within a Frequency Range, Non-Synchronous Energy within a Frequency
Range, HFD, Relative Synchronous Harmonics, Average, Synchronous Peak
Note
RMS, PK, PK-PK Measurement Units are valid and can be freely
converted.
8-88
Input Type
Input Unit
HW Int.
SW Int.
SW Diff.
Disp. Unit
AC
V / E.U.
no
no
no
E.U.
ACCEL
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
V / 32.2 ft/sec
no
no
no
yes
yes
yes
no
single
double
no
single
no
no
no
no
no
no
single
gs
in/s
mils
i/s
mils
gs
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
V / 9.81 m/s
no
no
no
yes
yes
yes
no
single
double
no
single
no
no
no
no
no
no
single
gs
mm/s
micons
mms
micons
gs
V / i/s
V / i/s
V / i/s
V / i/s
V / i/s
no
no
yes
no
yes
yes
yes
yes
yes
no
no
no
single
single
i/s
mils
mils
gs
i/s
V / mm/s
V / mm/s
V / mm/s
V / mm/s
V / mm/s
no
no
yes
no
yes
no
single
no
no
no
no
no
no
single
single
mm/s
microns
microns
gs
mm/s
V / mil
V / mil
V / mil
no
no
no
no
no
no
no
single
double
mils
i/s
gs
V / micron
V / micron
V / micron
no
no
no
no
no
no
no
single
double
microns
mm/s
gs
VEL
DISP
Data Types
8-89
Analysis Type: Time Waveform
Includes Variance, True Peak, Waveform Pk-Pk

Note
Measurement Unit Type is specific to Analysis Type. No Software

Integration or Differentiation can be performed.
Input Type
Input Unit
HW Int.
Disp. Unit
AC
V / E.U.
no
E.U.
ACCEL
V / 32.2 ft/sec
V / 32.2 ft/sec
no
yes
gs
in/s
V / 9.81 m/s
V / 9.81 m/s
no
yes
gs
mm/s
V / i/s
V / i/s
no
yes
i/s
mils
V / mm/s
V / mm/s
no
yes
mm/s
microns
V / mil
no
mils
V / micron
no
microns
VEL
DISP
8-90
Non Vibration Unit Analysis Types
Includes Peak to Average Ratio, Average to Minimum Ratio, Kurtosis, Skewness, Synchronous Phase
These analysis types produce non unit ratios or specific unit types such as
degrees of phase. Measurement Unit Type will not apply to these parameters.
Modifying the CSI 4500 Input Ratio to Accept DC Process Signals Greater Than
+/- 10 VDC
Note
This is only necessary for AMS: Machinery Manager version 4.9x

and earlier. For version 5.x this wont be necessary.
The CSI 4500 is capable of monitoring signals with +/- 10V peak AC or DC
signal ranges and +/- 24V DC bias ranges. In certain cases, such as a proximity
probe thrust measurement, the signal range is greater than +/- 10V. In this case
the input must be rescaled to allow the signal to be correctly measured.
Two equal value resistors are added in series, one with the positive signal wire,
and one with the negative signal wire between the proximity probe amplifier
output and the CSI 4500 Signal Input Module or 4500 MSIG channel input.
These resistors are sized to reduce the input voltage as required so that the maximum voltage seen at the CSI 4500 inputs is less then +/- 10V peak. The value
of the sensor sensitivity is adjusted in OCONFIG to correct the measured value
based on the resistor scaling.
Note
These resistors are not required for proximity probe vibration measurements, only for thrust or other DC probes.
The resistor value is calculated as follows:
Choose a maximum input voltage VMAX
Data Types
8-91
The sensor sensitivity should be adjusted as follows:
For example, with a +/- 24V input range, the resistor sum is 1598 k ohms or
1.598 Megohms and the sensor sensitivity correction factor is 0.416.
The actual resistor values to be added to each input wire are 1.598Megohms / 2
or 800Kohms
In some cases the choice of resistors will be limited. In this case, the input range
and sensor sensitivity may be calculated based on the available resistor as follows:
For example, if two 500Kohm (1Megohm total) resistors are used, the input
range would be +/-18.75V pk. The sensor sensitivity would be multiplied by
0.533.
8-92
Offset Adjustment
For thrust probes, the CSI 4500 input channel is defined as a DC Process input.
Select a suitable scaling resistor and sensor sensitivity adjustment value using
the methods described above. To set the DC offset so that the thrust reading may
be zeroed, use a DC voltmeter (or the DHM program) to measure the DC voltage
as see directly on the CSI 4500 inputs. Enter this value into the offset field in the
sensor set up page in OCONFIG.
Note
In older versions of this procedure a single correction resistor was

calculated to be added to the positive sensor wire. It has been determined that this can cause incorrect results in certain situations,
depending on the location of the sensor amplifier ground.
Using a balanced, two resistor solution should result in correct operation in all
cases.
Data Types
8-93
CSI 4500 System Calibration

The CSI 4500 system calibration consists of two steps:
1) . Calibrate the on board signal generator
2) . Calibrate the system.
The CSI 4500 G1 or G2 Processor generator should be recalibrated at least once
a year.
The CSI 4500 system should be recalibrated or if any module (other than the
power supply) has been replaced.
The CSI 4500 G1 or G2 Processor on board generator and system should be calibrated when the CSI 4500 system is commissioned, at the normal temperature
for the mounting location.
Calibrating the CSI 4500

The CSI 4500 uses internal calibration tables to compensate for slight measurement variations that can occur across the temperature, voltage ranges, and variations in individual electronic components used by processing circuitry. These
calibration tables are stored in each CSI 4500 when it is assembled and verified
at the factory. The units apply calibration connections automatically during
signal measurement and processing.
The CSI 4500 G2
For the second generation CSI 4500 hardware ("blue" units), up to four circuits
are calibrated. These are:
Test Signal Generator (TSG)
Gross Scan (GS)
Digital Signal Processor (DSP)
Transient
The CSI 4500 G1
For the first generation CSI 4500 hardware ("black" units), four slightly different circuits were calibrated. These are:
Test Signal Generator (TSG)
8-94
Gross Scan (GS)

Digital Signal Processor (DSP)
Tachometer
A key element is the Test Signal Generator circuit.This circuit provides an
extremely precise output signal, which is used as an input during GS, DSP,
Tachometer and Transient Calibrations. During calibrations, the TSG output is
routed internally in each CSI 4500, to processing electronics (GS, DSP, Tach,
Transient), and individual calibration tables for each processing circuit are created and stored in CSI 4500 memory. These tables are stored in non-volatile
memory, which means that the tables are not erased if the CSI 4500 is powereddown. Calibration circuit inputs and outputs are shown in the following table
Table 3: Calibration Circuit Inputs and Outputs

Calibration Circuit
Input
Output
TSG (Test Signal

Generator)
(external) signal
TSG table (internal) TSG

signal
GS (Gross Scan)
TSG signal
GS table
DSP (Digistal Signal

Processor)
TSG signal
DSP table
Transient
TSG signal
Transient table
It is important to note, from Table 3, that the TSG circuit provides an output
signal, which is used to create all of the other calibration tables. The TSG circuit
has its own calibration table, stored in the CPU board. If a CPU board is
replaced, then the other calibrations need to be rerun for that CSI 4500, since
their (original) calibration tables used the TSG signal from the original CPU
board.
Calibration tables may be copied from each CSI 4500 onto an online server, and
those can be downloaded into the same CSI 4500. Emerson Online Product Support personnel, and Online Systems Engineers, can assist customers with this
type of operation.
Data Types
8-95
Should it be desirable or necessary to recalibrate an installed system, it is recommended that this be accomplished with the support of the local Emerson
Online Product Support office, and that it be scheduled during an equipment
outage. Calibrations can be accomplished in less than an hour (per CSI 4500),
but during that time, the units cannot be monitoring rotating equipment.
Test Signal Generator (TSG) Calibration

All CPU boards provided by CSI are shipped with a calibrated Test Signal Generator circuit. If the CPU board is purchased as part of a system (i.e. the initial
shipment), the entire system is calibrated, using the CPU board TSG circuit.
The TSG circuit is the only element which requires an external piece of test
equipment, and special connection cables. TSG calibration requires:
Digital Multi Meter (such as the HP 34401A)
Laptop\computer configured as online server
Special calibration utility program (DHM)
Cable which connects the laptop\computer to the CSI 4500 Ethernet port
Cable which connects the laptop\computer to the Digital Multi Meter
Cable which connects the Digital Multi Meter to test points on the CPU
board
(1st generation, black CSI 4500s) extender board for the CPU board
TSG calibration is unique in that it requires a separate test instrument, unique
cables, and a laptop which is configured as an online server. It is recommended
that TSG calibration or recalibration be performed by qualified Emerson Online
Systems Engineers.
Connections for the 1st generation (G1 - black) and 2nd generation (G2 blue) units are as shown in the following two figures.
8-96
Recalibration of the TSG circuit for a 2nd generation (G2 - blue) product uses
a test port on the face of the CPU front panel. This was not the case with the 1st
generation (G1 - black) product, which required a different cable to connect
to two test points on the CPU board, and an extender board which made these
points accessible.
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
+
+
-
Ethernet Cable
(connected to rear of
laptop)
Test Point Cable (Front

Panel Connector)
DMM
DVM Cable
(connected to rear)
G2 TSG Connections
Data Types
8-97
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH1
CH2
CH3
CH4
CH5
CH6
CH7
CH8
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
CH9
CH10
CH11
CH12
CH13
CH14
CH15
CH16
+
+
-
Ethernet Cable
Test Point Cable

DMM
DVM Cable
(connected to rear)
G1 TSG Connections
Gross Scan (GS) Calibration

Gross Scan (GS) calibration:
uses a CPU board's TSG output signal
does not require that any wire harnesses be disconnected
is completed in about 10 minutes (per CSI 4500)
does not require any special cables or test equipment
uses a special calibration utility program (DHM).
GS recalibration should be performed:
annually
whenever a multiplexer (signal) circuit board is replaced
8-98
whenever a CPU board is replaced

if calibration table has a status of Unknown.
Product Support personnel, can guide a plant engineer or technician through GS
calibration over the phone.
DSP Calibration
Digital Signal Processing (DSP) calibration
is completed in about 30-40 minutes (per CSI 4500)
uses a special calibration utility program (DHM)
DSP recalibration should be performed:
annually
if calibration table has a status of Unknown
Product Support personnel, can guide a plant engineer or technician through
DSP calibration over the phone.
Transient Calibration
The CSI 4500T includes two processing boards; a CPU board and a Transient
board. Both boards include separate Digital Signal Processors. The DSP on the
Transient board uses an internal calibration table, in much the same way that the
CPU board DSP circuit does. However it is calibrated separately, it is not calibrated as part of a DSP calibration for a CPU board.
Transient calibration
Data Types
8-99
is completed in about 30-40 minutes (per CSI 4500T)

uses a special calibration utility program (DHM)
Transient recalibration should be performed:
annually
whenever a Transient board is replaced
if calibration table has a status of Unknown
Product Support personnel, can guide a plant engineer or technician through
Transient calibration over the phone.
8-100
Appendix
CSI 4500 Default Network Addressing Schema

1
Note
The network arrange shown above assumes one of the CSI 4500s
is a transient model (CSI 4500T).
Network Planning Considerations:
Separate Plant LAN / 4500 LAN

Each 4500M, 4500R, 4500MS, 4500S requires one (1) IP address
Each 4500T requires two (2) IP addresses.
A-1
A-2
CSI 4500 Default Network Addressing Schema
Appendix
Additional CSI 4500 Connections
Introduction
On the following pages are additional connections that may help you in setting
up the CSI 4500.
B-1
CSI 4500 Proximity Probe Interconnetion Diagram
B-2
CSI 4500 4-20ma Current Loop Interconnection

2
Note
CSI 4500 MUX (SIG) channels provide loop power to 4-20mA

devices. A separate source / module is required to provide loop
ower.
CSI 4500 4-20ma Current Loop Interconnection
B-3
B-4
Appendix
AC-DC Power Converter
Introduction
The AC-DC Converter is the power center of the CSI 4500 unit. If it is not
installed and maintained properly, the CSI 4500 unit may not function properly
or in the manner desired.
Warning!
must be followed.
Warning!
Power to the CSI 4500 AC-DC power converter PCB must include
a remote disconnect switch or circuit breaker. The switch or circuit
breaker must be in close proximity to the equipment and within
easy reach of the operator.
Caution!
Installation and use of the CSI 4500 AC-DC Power Converter in a

manner not specified by Emerson may impair protection offered by
the equipment.
C-1
Connecting and Maintaining the CSI 4500

General points to remember when installing the CSI 4500 and connecting power
to it:
The CSI 4500 AC-DC Power converter PCB is connected to the mains
supply through the AC Power Input terminal block located near the
bottom of the panel.
All wiring should be installed by a trained and qualified electrician.
Wiring must conform to all applicable local codes and regulations.
Normal installation of the CSI 4500 is in an orientation such that the front
panels are vertical.
Operators should use normal caution when cleaning surfaces of the CSI
4500 front panels. Abrasive cleaners or instruments should not be used.
Wipe off with a clan damp cloth.
Replacement fuses should be 2A 250V Slo-Blow type (250V 2A T).
Fuses should be replaced by qualified personnel only.
Required Tools and Parts

Velcro cable tie downs
Remote disconnect switch or circuit breaker
5 AMP fuse block (required for auxiliary 110V AC power)
# 8 ring terminals
16 GA wire strippers
Crimp tool for ring terminal
Flat tip screwdriver
C-2
CSI 4500 (with duplex receptacle)

1. . .Route power cable from right rear of enclosure into the CSI 4500 AC-DC
power converter AC input connection.
connector labels.
3. . .Splice 16 gauge wire from AC input connector to duplex receptacle.
4. . .Install 5 amp in-line fuse on hot conductor running to duplex receptacle.
5. . .Terminate wire inside receptacle.
CSI 4500 (without duplex receptacle)

1. . .Route power cable from right rear of enclosure into the CSI 4500 AC-DC
power converter AC input connection.
connector labels.
Safe Operation of the CSI 4500 AC-DC Power Converter

The CSI 4500 AC-DC Power Converter PCB is suitable for safe operation in:
Intended for indoor use.
Overvoltage Category II (Installation Category II), Pollution Degree 2
environments.
Intended temperature ranges 5C (41F) to 50C (122F).
Relative humidity: 0 to 95% non-condensing.
Altitude up to 2000m.
Power input ranges of 100 - 240 Volts, 50 - 60 hertz, 2 Amperes (maximum) and will dissipate approximately 35 Watts of power.
Note
No configuration setup of the unit is required to change operating

voltage.
Connecting and Maintaining the CSI 4500
C-3
Indicators
There are several indicators on the AC-DC Converter panel. These include two
power outputs and eleven LEDs. Below is a brief description of the indicators.
AC-DC Converter panel.

Note: The AUI LED indicator is not on newer modules.
C-4
Power Output Connectors

Two power outputs provide optional power to auxiliary external sensors (such
as proximity probes) and an external cooling fan. Both are stenciled to indicate
the maximum output voltage and current from the terminals.
Auxiliary sensor output connections

1. . .Route cable along right rear of box and up the right side pulling a service
loop.
2. . . Pull wire to the phoenix connector located just below the power status
indicators and blunt cut excess wire.
3. . . Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connector as follows:
a) +DC + ( top terminal)
b) DC (middle terminal)
c) shield Gnd (bottom terminal)
The auxiliary sensor output connector is labeled:
AUX+/24V
25V, 0.6A
Fan output connections

1. . .Route cable along right rear of box and up the right side pulling a service
loop.
2. . .Pull wire to the phoenix connector located just above the power switch
and blunt cut excess wire.
3. . .Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connector as follows:
a) +DC + ( top terminal)
b) DC (middle terminal)
c) shield Gnd (bottom terminal)
Power Output Connectors
C-5
The fan output connector is labeled:
FAN24
25V. 0.3A
LED Indicators
Eleven individual LEDs indicate the condition of internal and external
voltage signals. Ten are green and when on (illuminated) indicate that the
corresponding voltage signal is at is active level. One LED is red and
when on (illuminated) indicates that power has failed. The LEDs are
listed in the following table:
Front Panel Label
C-6
Color
Fail
Red
3.3V
Green
5V
Green
+12V
Green
12V
Green
+24V
Green
AUI
Green
AUX24V
Green
Fan24
Green
Power On
Green
AC Power
Green
Appendix
Connection Parameters
Uses and Specifications

Note
This equipment is only suitable to use in Class I, Division 2,

Groups C and D or non-hazardous locations.
Warning!
Explosion Hazard. Do not remove or replace lamps or fuses unless

you have disconnected the power or you are in a non-hazardous
area.
Warning!
Explosion Hazard. Do not disconnect equipment unless you are in

a non-hazardous area.
D-1
Specifications for equipment that supplies and receives energy:

Mux or Signal Board:
Vt = 24VDC
Vmax = +/- 24 VDC
It = 5mA
Imax = 50uA
Ca = 1-uf
Ci = 1.5uf
La = 100mH
Li = 100mH
Tach Board:
Vmax = +/- 24VDC
Imax = 100uA
Ci = 1.5uf
Li = 100mH
I/O Board:
D-2
Vt = 24VDC
Vmax = 10VDC
It = 500mA
Imax = 500mA
Ca = 10uf
Ci = 1500uf
La = 1mH
Li = 1mH
Connection Parameters
Index
Numerics
1/4"-28 taps & tap handle 3-5, 3-18, 3-30
10/100BaseT RJ45 6-14
110AC 5-3
220AC 5-3, 5-7
24 AWG gauge strippers 6-5
24 AWG wire strippers 6-2
440AC 5-3, 5-7
5 AMP fuse block 6-8
9/16" open end wrench 3-5, 3-18, 3-30
AC Power (with duplex receptacle) 6-11

AC Power (without Duplex Receptacle 6-12
AC Power Specifications
5-11
AC-DC Power Converter C-1
safe operation C-3
Actuator Dimensions 3-39
Actuator Material 3-40
AO322 Quick-Connect 3-9
AO322LC Sensor Mounting 3-23
A0322 Quick-Connect 3-11, 3-35

A0322DR 3-1
A0322DS 3-14
A0322LC 3-14
A0322LC with Quick-Connect 3-25
A0322LC-NT 3-15
A0322LC-NT Quick Release SS Nut &
Threaded Base 3-17
A0322LC-NT Quick-Connect 3-22, 3-25
A0322RA 3-1
A0322RI 3-1
A0322RM 3-27, 3-35
A0322RM Quick-Connect 3-36
A212 Mounting Pad 3-17, 3-30
A212 mounting pad 3-22
A612-I-30 cable 5-7
A680 Bundled Cable 6-16
A901-1 mounting pad 3-9
A911 3-10
A911 Quick-Connect 3-10
A92016 2-part epoxy 3-9, 3-22, 3-34
A92106 3-5, 3-17
A92106 Loctite Depend Mounting Pad Epoxy
(Epoxy Mounting Only) 3-30
cable tie down 6-2

cable tie downs 5-7
Cable Variations 5-6
Chapter 2 Pre-Installation Review 1-7
Chapter 3 System Documentation 1-7
Chapter 4 Instrumentation Installation 1-7
Chapter 5 Enclosure Mounting 1-7
Chapter 6 Cabling Requirements 1-7
Chapter 7 Wire Terminations 1-8
1-8
conduit
steel 5-2
tray or aluminum 5-2
Configuring a 4500 with Hyperterminal 7-72
Connecting 7-72
General Boot Flag Notes 7-77
Navigation 7-73
Configuring a CSI 4500 with Hyperterminal
Subnet Masks 7-78
Connecting and Maintaining the 4500R or
4500S unit C-2
Connection Parameters D-1
Contractor Kickoff Meeting 2-2
I-1
CSI 4500 5-11

Enclosure 2-7
CSI 4500 4-20ma Current Loop
Interconnection B-3
CSI 4500 AC Power Supply 7-47, 7-52
SPECIFICATIONS 7-52
CSI 4500 AC Power Supply (PN B4500AC)
Specifications 7-48
CSI 4500 and junction boxes 5-4
CSI 4500 DC Power Supply 7-42
CSI 4500 DC Power Supply Specifications
7-42
Startup Current Characteristics 7-43
CSI 4500 dedicated network segment cables
5-3
CSI 4500 Discrete Input/Outputs 4-12
CSI 4500 Enclosure 5-9
CSI 4500 Ethernet Connection 4-12
CSI 4500 G1 Processor Module 7-37
CSI 4500 G2 Processor Card LCD navigation
screens 7-78
Adjusting Contrast 7-80
Gross Scan Data 7-80
Online Boot Parameters 7-82
Online POST Information 7-81
System Status Menu 7-80
Transient Boot Parameters 7-85
Transient POST 7-84
CSI 4500 G2 Processor Module Specifications
7-12
CSI 4500 MSIG Module 7-32
CSI 4500 MSIG Module Specifications 7-33
CSI 4500 Power 4-12
CSI 4500 Power Supply 6-9
CSI 4500 Proximity Probe Interconnetion
Diagram B-2
CSI 4500 Relay Module 7-28
CSI 4500 Signal Input Module 7-17
I-2
CSI 4500 Signal Input Module Specifications

7-19
CSI 4500 Tachometer Input Module 7-23
CSI 4500 Tachometer Input Module
Specifications 7-24
CSI 4500 Transient Daughterboard 7-56
Replacing the Hard Drive 7-60
Specifications 7-57
CSI 4500 Transient Filter Board 7-62
Specifications 7-62
CSI 4500 Wiring 6-7
CSI 4500M G2 Processor Card 7-10
CSI 4500S Enclosure 2-11
D
Data Types
Analysis Type
Overall Level 7-87

Spectral 7-88
Time Waveform 7-90
CSI 4500 System Calibration 7-94

Modifying the CSI 4500 Input Ratio 7-91
Non Vibration Unit Analysis Types 7-91
Offset Adjustment 7-93
Overall Level Parameters 7-87
Spectral Scan Parameters 7-87
DC (with Fan Tray) 6-8
DC (without Fan Tray) 6-9
DC Power Specifications
5-11
Dedicated CSI 4500 Network Segment 5-10
Description 3-3, 3-15, 3-28
dielectric grease 5-7
Documentation Storage 2-13
E
EIA/TIA 568/569 5-10
Epoxy Mounting 3-9, 3-22, 3-34
Equipment
warnings, uses and specifications D-1
Mounting Bracket & Locking Nut 3-38

Mounting Sensor 3-42
Mounting Sensor Bracket 3-41
Multi-pair Bundled Cable Pulls 4-12
Mux or Signal Board D-2
Final Walk-Through 2-3

Foil Shield 6-5
Negative Conductor 6-5
O
G
G1 Processor Module Specifications 7-38
General Wiring Notes 7-65
output connections
auxiliary sensor C-5
fan C-5
Handling Instructions 3-3, 3-15, 3-28
I
I/O Board D-2
Indicators C-4
LED C-6
Power Output Connectors C-5
auxillary sensor C-5
fan output C-6
Installation 5-7
PGME07 cord grip 5-8

phoenix connector 6-8, 6-12
Positive Conductor 6-5
Power Circuit Guidelines 5-11
Prepare the CSI 4500 Cable Access Plate 4-11
Project Manager 1-3
Pull Instrumentation Wiring 5-5
R
Required Tools & Parts 3-4
RJ45 CAT5 connector 6-8, 6-14
J
Jbox 5-2
Junction Box 6-17
M
Monitoring Methods
Overall Level Monitoring 7-2
Spectral Scan 7-2
Transient Data Capture 7-2
Mount the CSI 4500 and 4500S Data
Collection Units 4-6
S
SENSOR LOCATION CARD 5-7
Sensor Mounting 3-11, 3-36
Signal Quality 7-5
Cable Terminations 7-7
Ethernet Cable Routing 7-6
Grounding and Shielding 7-6
Junction Boxes 7-7
Sensor Cable Routing 7-5
Sensor Cable Type 7-5
I-3
System Grounding 7-7

Special 1-2
Spot Face & End Mill Tool 3-29
Spot Face and End Mill Tool 3-4, 3-16
Stud Mounting 3-6, 3-18, 3-31
Surface Preparation 3-5, 3-18, 3-30
System Component Review 2-4
Additonal Information to Keep 2-4
Machine Level Diagram
2-3
Overall System Diagram
2-3
T
Tach Board D-2
terminal block 6-3
6-5
Terminate Discrete Input/Outputs 6-12
Terminate Network Connection 6-14
Torque Wrench 3-5, 3-18, 3-30
V
V425 3-37
V425 Passive Magnetic Pickup 3-37
V4500 power supply card 6-14
V680 Bundled Cable 6-5
V701 and V745 series junction 6-1
V745 junction/switch box 4-1
Velcro cable tie downs 6-8
W
wire labels 5-7, 5-9, 6-2
I-4

Rev.9 CSI 4500 System Installation

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Reference Manual

Part # 97101 Rev. 9

year from the date of purchase, and thereafter on an annual

IMPLIED, INCLUDING BUT NOT LIMITED TO ANY

Telephone assistance and communication via the

Chapter 2 Pre-Installation Review

Chapter 2 System Documentation

Chapter 3 Install Instrumentation

Chapter 4 Enclosure Mounting

Chapter 5 Cabling Requirements

Pull V680 Bundled Cable from Junction Box/CSI 4500 . . . . . . . . . . . . . . 5-9

Chapter 6 Wire Terminations

Chapter 7 System Hardware Configuration

Replacing the CSI 4500 Transient Daughterboard Hard Drive . . . . 7-60

Appendix A CSI 4500 Default Network Addressing Schema

Appendix C AC-DC Power Converter

Appendix D Connection Parameters

Normal installation for the Model CSI 4500 Machinery Health

Read This First

A note indicates special comments or instructions.

A caution indicates actions that may have a major impact on the

The Warning paragraph warns you of actions that could cause

Power to the CSI 4500 Machinery Health Monitor power converter

Use of the CSI 4500 Machinery Health Monitor AC-DC Power

Plant Appointed Project Manager

The pre-installation review could also be called installation preparation. This

System documentation is prepared before the system installation begins. This

The online system instrumentation includes the 322 family of accelerometers

This chapter covers conduit installation guidelines, network cabling guidelines,

Chapter 7 Wire Terminations

Contractor Kickoff Meeting

System Component Review

System Overview Drawings

Example of System Overview Drawing (overall)

Example of System Overview Drawing (Machine Level)

As illustrated, the system overview drawings should consist of an overall system

System Overview Drawings

Junction/Switch Boxes with Tag

Each IP address should be linked to the corresponding CSI 4500.

System Layout Drawings

System Layout Marking Guidelines

System Layout Drawings

Cable Administration Charts

Junction Box Cable Administration Chart

Cable Administration Charts

CSI 4500 Enclosure

CSI 4500M with full compliment of boards.

Cable Administration Charts

CSI 4500S and CSI 4500MS Enclosures

CSI 4500MS or CSI 4500S Board Positions

Cable Administration Charts

A0322RI, A0322RA, A0322DR

A0322RI, A0322DR Image & Outline Drawing

A0322RA Image & Outline Drawing

Do not drop, hammer, or impact sensor housing before, during, or

Do not exceed specified torque when tightening stud-mounted

Do not exert more than 5-lbs. pull force directly on sensor/cable

Required Tools & Parts

Spot Face and End Mill Tool

A901-1 Mounting Pad

A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Contractor should confirm Material Data Sheet conforms to plant

Mounting location must provide a flat surface 1/2" in diameter. If