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vbOnline Pro Condition Monitoring System

Operation and Maintenance Manual

Bently Nevada* Asset Condition Monitoring

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual Bently Nevada* Asset Condition Monitoring Document: 115M4367

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

© 2016 Bently Nevada, Inc. All rights reserved.

* Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric Company.

Keyphasor*, Proximitor*, System 1* The following are trademarks of the legal entities cited:

Velostat ® is a registered trademark of 3M Company. The information in this document is subject to change without prior notice. Printed in USA. Uncontrolled when transmitted electronically.

Contact Information

When you cannot reach your local representative, use the following information to contact us:

Mailing Address

1631 Bently Parkway South Minden, Nevada USA 89423 USA

 

1.775.782.3611

Telephone

1.800.227.5514

Fax

1.775.215.2873

Internet

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Additional Information

  • NOTE

  • This manual does not contain all the information required to operate and maintain the vbOnline Pro Condition Monitoring System. Refer to the following sources for other required information.

vbOnline Pro Condition Monitoring System Datasheet (Part Number 113M5326)

  • n Specifications

  • n Compliance and certifications

  • n Graphs and figures

System 1* Software

  • n Monitor configuration

System 1* Evolution Software Manual (Document 109M8639)

  • n Monitor configuration

  • n Error messages

  • n Display plots and status

Bently Nevada Monitor Configuration Software

  • n Monitor configuration

  • n Upgrade firmware

  • n Retrieve diagnostic data

  • n The vbOnline Pro software guide

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Contents

1. General Safety 1 1.1 Receiving Inspection 1 1.2 Handling & Storage Considerations Safe Disposal 1
1. General Safety
1
1.1
Receiving Inspection
1
1.2
Handling & Storage Considerations
Safe Disposal
1
1.3
1
2. System Overview
2
2.1
vbOnline Pro Monitor
3
2.2 Sensors
5
2.3
Available Data
State-Based Analysis
Offline Operation
7
2.4
14
2.5
15
2.6 LEDs
16
3. Hardware Installation
17
3.1 How to Mount the vbOnline Pro Monitor
18
3.2 How to Connect the Power Input Connector
3.3 How to Connect the Chassis Ground
3.4 How to Connect the Ethernet Ports
20
23
24
3.5 How to Connect the Sensor Input Connectors
26
4. Monitor Configuration
30
4.1 How to Configure Acceleration & Speed Channels
31
4.2 How to Save & Sync Configuration to the Monitor
4.3 How to Verify Sensors
38
39
5. Maintenance
40
5.1 How to Verify Installation
41
5.2 How to Clean vbOnline Pro Monitor
5.3 How to Update Firmware & User Credentials
44
45
6. Troubleshooting
46
6.1
Self Test
LED Fault Conditions
Sensor Wiring Fault Indications
System Health Event List
How to Retrieve Diagnostic Data
47
6.2
48
6.3
50
6.4
51
6.5
53

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

  • 1. General Safety

Before using your vbOnline Pro Condition Monitoring System, read and understand the following precautions thoroughly. Pay attention to all warnings and recommendations to prevent data loss or inaccuracy, damage to the device, and injury to yourself.

  • 1.1 Receiving Inspection

Visually inspect the monitor for obvious shipping damage. If you detect shipping damage, file a claim with the carrier and submit a copy to Bently Nevada, Inc.

  • 1.2 Handling & Storage Considerations

Circuit boards contain devices that are susceptible to damage when exposed to electrostatic charges. Damage caused by obvious mishandling of the board will void the warranty. To avoid damage, observe the following precautions:

  • 1. Do not discharge static electricity onto the circuit board. Avoid tools or procedures such as ungrounded soldering irons and nonconductive plastics that cause static damage to the circuit board.

  • 2. Personnel must be grounded with a suitable grounding strap such as 3M Velostat® No. 2060 before handling or maintaining a printed circuit board.

  • 3. Transport and store circuit boards in electrically conductive bags or foil.

  • 4. Use extra caution during dry weather. Relative humidity less than 30 % multiplies the accumulation of static charges on any surface.

  • 1.3 Safe Disposal

Product Disposal Statement

Customers or third parties who are not member states of the European Union are solely responsible for diligent product disposal at the end of its useful life. No person, firm, corporation, association, or agency shall dispose of the product in a way that is in violation of any applicable international, federal, state, or local regulations. Bently Nevada, Inc. is not responsible for product disposal at the end of its useful life.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

  • 2. System Overview

The vbOnline Pro Condition Monitoring System provides continuous monitoring of assets using sophisticated signal processing algorithms and machine operating states. This system is part of a condition-based maintenance program that identifies problems before assets fail.

The vbOnline Pro Condition Monitoring solution includes the following:

  • n vbOnline Pro monitor

  • n Transducers and cables

  • n System 1*

  • n Bently Nevada Monitor Configuration software

The vbOnline Pro Condition Monitoring System uses 24 bit analog / digital conversion and 40 kHz bandwidth to periodically sample acceleration sensors monitoring rolling element bearing machinery and gearing. The system’s signal processing algorithms extract measurement and health indices from each accelerometer point. Dynamic waveforms are also collected to further diagnose or predict problems with the asset.

The vbOnline Pro Condition Monitoring System communicates with System 1* via an Ethernet connection. Using System 1*, you can configure the vbOnline Pro Condition Monitoring System to specific bearing or gear box characteristics.

The following topics describe the vbOnline Pro Condition Monitoring System and how the monitor operates and collects data:

  • n vbOnline Pro monitor See vbOnline Pro Monitor on page 3.

  • n Sensors See Sensors on page 5.

  • n Available data See Available Data on page 7.

  • n Mode operation See State-Based Analysis on page 14.

  • n Offline operation See Offline Operation on page 15.

  • n LEDs See LEDs on page 16.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.1 vbOnline Pro Monitor

The following picture depicts the vbOnline Pro monitor:

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 2.1 vbOnline Pro Monitor The following picture
  • 1. Twelve Acceleration Sensor Input Connectors

  • 2. Two Speed Sensor Input Connectors

  • 3. Earth Ground Connection

  • 4. Ethernet Ports

  • 5. Buffered Outputs

  • 6. Power Input Connector

  • 7. Labels Identifying Input Channels

  • 8. Isolated Common Switch

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Sensor Input Connectors

The sensor input connectors provide wiring options for 12 channels of acceleration and two channels of Keyphasor* / speed input.

You can remove the connectors to connect the wiring easily. A multi-pin connector provides simple connection to external test rigs or external terminal blocks in marshaling cabinets.

Power Input Connector

The power input connector is for +24 Vdc nominal power inputs.

Ethernet Ports

Use Ethernet ports A and B to connect to a Bently Nevada monitoring system and System 1*.

Earth Ground Connection

Use this lug to attach a low impedance connection to protective earth.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.2 Sensors

The vbOnline Pro Condition Monitoring System supports the following sensors:

  • n Acceleration Sensors See Acceleration Sensors on page 6.

  • n Speed Sensors See Speed Sensors on page 6.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Acceleration Sensors

You can configure the vbOnline Pro Condition Monitoring System to interface with the following acceleration sensors:

  • n Straight Accelerometer AM3100T2-Z2

  • n Low Speed Right Angle Accelerometer AP3500S2-Z1

  • n Low Speed Straight Accelerometer AP3500T2-Z1

  • n Right Angle Accelerometer AS3100S2-Z2

The vbOnline Pro Condition Monitoring System also supports custom acceleration sensors. Refer to System 1* Help for how to configure a custom acceleration sensor.

The vbOnline Pro Condition Monitoring System datasheet (part number 113M5326) outlines specifications of supported acceleration sensors.

Speed Sensors

You can configure the vbOnline Pro Condition Monitoring System to use the following speed sensors:

  • n 330180 3300XL 8mm Proximitor*

  • n 330780 3300XL 11mm Proximitor*

  • n 330980 3300XL NSv Proximitor*

You can also configure other tachometers as a custom speed sensor by adjusting their threshold, hysteresis and events per revolution. Refer to System 1* Help for how to configure a custom speed sensor.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.3 Available Data

The vbOnline Pro Condition Monitoring System processes the input signal and provides the following data and statuses:

  • n Trended variable measurements See Trended Variable Measurements on page 8.

  • n Dynamic data See Dynamic Data on page 9.

  • n Monitor status See Monitor Status on page 10.

  • n Channel status See Channel Status on page 11.

  • n Measurement statuses See Measurement Status on page 12.

  • n Alarm data snapshots See Alarm Data Snapshots on page 13.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Trended Variable Measurements

For each channel, the vbOnline Pro Condition Monitoring System conditions the input signals into the following measurements collected at a configurable rate of 30 seconds or greater:

  • n Direct Direct data represents the overall zero to peak acceleration amplitude. The Direct value includes all frequency components within its frequency range of 0.5 Hz to 40,000 Hz.

  • n Bias Bias data is the transducer bias voltage in volts dc.

  • n Speed Speed data represents the running speed of an asset. The speed is displayed as revolutions per minute (rpm) by default. It is configurable as Hertz (Hz) or cycles per minute (cpm).

  • n Gap Gap data represents the physical displacement between the speed sensor and an asset. The Gap value is a dc voltage measurement.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Dynamic Data

The vbOnline Pro monitor collects dynamic data and sends it to System 1* to perform in-depth data analysis. System 1* stores the data for historical reference. The following dynamic data samples are stored at a configurable rate of 10 minutes or greater:

  • n Asynchronous Timebase Waveform This waveform is a 320 ms long snapshot of the vibration data in a timebase format. The vbOnline Pro Condition Monitoring System collects the acceleration and integrated velocity waveforms for each channel. The monitor returns the waveforms to System 1* for diagnostics. Internal calculations are made via synchronously sampled waveforms that are much longer in duration. You can configure the parameters of the waveforms in System 1*.

  • n Asynchronous Demodulated Waveform Demodulation or enveloping is a technique for the detection and analysis of very low-level, repetitive vibrations embedded in a machinery vibration signal. The ability to see these faults in their earliest stages of development facilitates early detection of failure in machine components with metal-to-metal contact such as rolling element bearings and gearbox mesh. Enveloping is most often applied to the early detection of rolling element bearing faults in accelerometer signals. The demodulation bandwidth, Fmax, and spectral lines are configurable parameters for this type of waveform.

  • n Asynchronous Spectrum System 1* converts the waveform to spectrum format for display. Refer to System 1* Help for information on asynchronous spectrum.

  • n Asynchronous Spectral Bands Asynchronous Spectral Bands are associated with any of the waveforms that the vbOnline Pro monitor returns to System 1*. You can configure each spectral band by setting the lower and upper frequencies of the band as well as the corresponding channels. The spectral band measurement averages or sums all of the energy in the band and returns a single scalar value. Multiple spectral bands can be associated with a single waveform. System 1* generates and stores spectral band measurements at the same rate at which the associated waveforms are received from the vbOnline Pro monitor.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Monitor Status

The monitor statuses show the combined statuses of all channels. When the status of a channel changes to Alert or Danger, the monitor's status changes accordingly. The LEDs are lit to indicate the new status.

The vbOnline Pro Condition Monitoring System reports its instrumentation fault to System 1*.

Instrumentation fault indicates whether the monitor is functioning correctly or not. This fault is non-latching and is updated every 30 seconds.

The Not OK status is reported for the following conditions:

  • l Module hardware failure

  • l Configuration failure

  • l Channel Not OK (sensor failure)

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Channel Status

Each channel of the vbOnline Pro Condition Monitoring System may be in one of the following states. System 1* annunciates channel statuses in the Status and Events Lists.

  • n Channel OK State Channel OK State indicates whether the monitor has detected a fault on an individual channel. The monitor performs the following checks to set this state:

    • l Transducer input voltage

    • l Transducer supply voltage

    • l Channel-specific hardware diagnostics

When any of the aforementioned checks fails, the Channel OK State is set to Not OK.

  • n Alert State A channel enters the alert state when the channel’s value exceeds its configured alert setpoint for 60 seconds. The alarm is non-latching. The Alert LED is lit while the channel remains in this state.

  • n Danger State A channel enters the danger state when the channel’s value exceeds its configured danger setpoint for 60 seconds. The alarm is non-latching. The Danger LED is lit while the channel remains in this state.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Measurement Status

The measurement status applies only to a specific measurement. You can view measurement statuses in the System Event and Alarm Lists of System 1*.

Invalid State

A measurement is invalid when the monitor determines it cannot reliably calculate the measurement value. The monitor cancels active alarms for invalid measurements.

The following events can make a measurement invalid:

  • n The input channel is Not OK.

  • n The input amplitude is too small to make the measurement.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Alarm Data Snapshots

When a measurement enters Alert or Danger states, the monitor captures and stores a snapshot of the current data across all channels . The sample snapshot includes all measurement variables, statuses, waveform and spectra. All data in the snapshot have matching timestamps.

System 1* automatically retrieves alarm data snapshots from the monitor.

If states have been configured, then the alarm snapshot will be captured for all channels belonging to the configured state groups.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.4 State-Based Analysis

The vbOnline Pro Condition Monitoring System supports state-based data collection and alarming for assets.

Each device supports a maximum of 12 device states. These states are configured using System 1*. Refer to the System 1* Help for details on state configuration.

The trigger source can be speed or any other device-calculated measurement, such as Direct or channel status.

The states are mutually exclusive and can be configured for overlap.

You can configure alarming for each mode as standard or state-based. For state-based alarming, you can configure the setpoints of the state.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.5 Offline Operation

In the event of network interruption or System 1* server maintenance, the vbOnline Pro monitor can store data in internal non-volatile memory. When configured to store waveforms with 6400 spectral lines every ten minutes, the vbOnline Pro monitor stores data for up to eight hours.

If device states are configured, the offline data storage time will depend on the number of active states and the configured storage rates.

The monitor stores all trended variables and waveforms for active channels. The System 1 Data Acquisition server uploads and stores the historical data when the network is restored.

The vbOnline Pro monitor can store data for more or less than eight hours depending on the selected storage rate and configuration of waveforms. The data storage can be less than eight hours if excessive alarm events occur. Excessive alarm events generate additional Alarm Data Snapshots.

When the internal memory is full, the vbOnline Pro monitor overwrites buffered data in the memory, beginning with the oldest stored data.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

2.6 LEDs

The vbOnline Pro Condition Monitoring System displays the operating status of the monitor using the following LEDs on the front panel:

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 2.6 LEDs The vbOnline Pro Condition Monitoring

LED

Color

Description

Power

Green

The Power Input is good.

OK

Green

The module is functioning properly, and no module or channel faults exist.

Danger

Red

An input or inputs have exceeded the danger setpoint.

Alert

Amber

An input or inputs have exceeded the alert setpoint.

Kph 1 OK

Green

A valid speed input is detected for KPH1.

Kph 2 OK

Green

A valid speed input is detected for KPH2.

Net A

Green

Network A has a valid link.

TX/RX A

Green

Network traffic is flowing on Network A.

Net B

Green

Network B has a valid link.

TX/RX B

Green

Network traffic is flowing on Network B.

See LED Fault Conditions on page 48.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

3. Hardware Installation

This chapter covers the following topics:

  • n How to mount the vbOnline Pro monitor See How to Mount the vbOnline Pro Monitor on page 18.

  • n How to connect the power input connector See How to Connect the Power Input Connector on page 20.

  • n How to connect the Ethernet ports See How to Connect the Ethernet Ports on page 24.

  • n How to connect the sensors See How to Connect the Sensor Input Connectors on page 26.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

3.1 How to Mount the vbOnline Pro Monitor

The vbOnline Pro monitor is DIN mounted. The following pictures depict the recommended minimum clearances for cable terminations and ventilation:

NOTE We recommend mounting the vbOnline Pro monitor vertically to ensure proper ventilation.
NOTE
We recommend mounting the vbOnline Pro monitor
vertically to ensure proper ventilation.
vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3.1 How to Mount the vbOnline Pro

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Enclosure

You must mount the monitor in an Electromagnetic Compatible (EMC) environment. Electromagnetic Interference or EMI can produce intermittent Not OK statuses, loss of communication and suspect readings. See Troubleshooting on page 46.

If you cannot eliminate these problems, an EMI field may be present. If you cannot control or contain the EMI, the installation may require EMI shielded conduit and grounded housings.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

3.2 How to Connect the Power Input Connector

Before connecting the Power Input Connector, verify the voltage and current capabilities of the power source. See vbOnline Pro Condition Monitoring System datasheet (part number 113M5326).

WARNING

WARNING

SHOCK HAZARD

SHOCK HAZARD

RISK OF ELECTRIC SHOCK

The +24V power inputmustbe connected to a SELV (Class 2) source in accordance with CSA 61010-1.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Follow these steps to connect your vbOnline Pro Condition Monitoring System to a power source:

  • 1. Remove pluggable connectors by turning the two retaining screws counter-clockwise.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual Follow these steps to connect your vbOnline
  • 2. Strip the wiring back 7 mm (0.27 in) before inserting it into the terminal block. Recommended wire size is 16 AWG (1.29 mm) to 15 AWG (1.45mm) for power supply wiring.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

  • 3. Open contacts by turning screws counter-clockwise. Insert wires into the slots. Ensure the polarity is correct when wiring the power input connector.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3. Open contacts by turning screws counter-clockwise.
  • 4. Tighten screws until snug plus 1/4 to 1/2 turn.

  • 5. Plug the connector into the terminal base and tighten the two retaining screws until snug plus 1/4 turn.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

  • 3.3 How to Connect the Chassis Ground

You must ground your vbOnline Pro monitor's chassis such that the following requirements are met:

  • n One end of the 16 AWG wire must connect to the vbOnline Pro Condition Monitoring System.

  • n The other end of the wire must be connected to an enclosure or permanent structure which is properly bonded to earth ground.

When the monitor is installed in a conductive enclosure, the enclosure must be properly bonded if the wire and ring terminal are secured to the enclosure.

Follow these steps to ground the chassis to earth ground:

  • 1. Use a 1.3 mm2 (16 AWG) or larger gauge wire connect the chassis to earth ground.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3.3 How to Connect the Chassis Ground

and a 5 mm (#8) ring terminal to

  • 2. Secure the ring terminal to the post using the supplied nut.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3.3 How to Connect the Chassis Ground

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

3.4 How to Connect the Ethernet Ports

You can connect the Ethernet communication link to System 1 and BNMC using Port A or Port B. We recommend connecting only one vbOnline Pro monitor at a time to a network when deploying multiple monitors. Otherwise, multiple devices will have the same IP address. After reconfiguring the network port, you can add the next unit to the network.

NOTE You can configure only Port A for DHCP.
NOTE
You can configure only Port A for DHCP.
  • NOTE

  • The default fixed IP address for Port A is 192.168.0.101. The default fixed IP address for Port B is 192.168.2.101.

Set your computer for a compatible IP address on the same subnet.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

Monitor Protection Guidelines

We recommend the following steps for network setup and configuration:

  • n Effectively segment networks and implement demilitarized zones (DMZs) with properly configured firewalls to selectively control and monitor traffic passed between zones.

  • n Minimize network exposure for all control system devices and systems. Ensure they are not accessible from the Internet.

  • n Locate control system networks and remote devices behind firewalls. Isolate them from the business network.

  • n The firewall should be configured where only required ports allow data flow between specific networks and hosts. All known default telnet or ftp ports should be blocked by the firewall.

  • n After connecting to the device for the first time, it is recommended that the user credentials are changed to ensure better security.

  • n Consider installing the device in a locked enclosure to prevent unauthorized access, modification, or other tampering.

  • n UDP ports should only be kept open for device discovery. Once the device has been commissioned, it is recommended to block the UDP ports on the firewall.

Communication Ports and Protocol

Keep the following ports and protocols open for firewall configuration. All other ports should be closed.

Functionality

Protocol Port Number

Notes

Browse

UDP

59011, 59009

UDP Browse

Command Port

TCP

60005

BNMC/System 1 Configuration Port

Data Subscription Port

TCP

60006

Handles data requests for any client services

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

3.5 How to Connect the Sensor Input Connectors

You can remove the sensor input connectors to facilitate the wiring. Follow these steps to remove the connectors and connect the signal lines:

  • 1. Remove the pluggable input connector by turning its two retaining screws counter- clockwise.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3.5 How to Connect the Sensor Input
  • 2. Slide the pluggable connector out using a screwdriver.

  • 3. Strip the sensor wiring back 7mm (0.27 in) before inserting it into the terminal block.

  • 4. Open contacts by turning screws counter-clockwise.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

  • 5. Grasp the terminal block and pull to remove. For accelerometer inputs, insert wires into slots. For negative biased sensors, connect the sensor in the following manner:

    • n Connect PWR/SIG to the A (+) terminal.

    • n Connect COM to the B (-) terminal.

  • n Connect the shield to the ground terminal. For positive biased sensors, connect the sensor in the following manner:

    • n Connect PWR/SIG to the B (-) terminal.

    • n Connect COM to the A (+) terminal.

    • n Connect the shield to the ground terminal.

vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 5. Grasp the terminal block and pull
  • 6. For the Keyphasor inputs, connect the following:

    • n Connect the power wire from the sensor to the PWR terminal.

    • n Connect the common wire from the sensor to the COM terminal.

    • n Connect the signal wire from the sensor to the SIG terminal.

    • n Connect the shield from the cable to the ground terminal.

  • 7. Tighten screws until snug plus 1/4 to 1/2 turn.

  • vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 8. Plug the connector into the terminal base.

    • 9. Tighten two retaining screws clockwise to lock the pluggable connector.

    Wiring Recommendations

    Wiring

    Size or Part Number

    Notes

    Between Accelerometers

    Use Bently Nevada part numbers 284613 or

     

    and vbOnline Pro monitor

    284622.

    Between Proximitor sensors and vbOnline Pro monitor

    Use 0.2 to 1.55mm2 (16 to 24 AWG).

    We recommend using three- conductor shielded triad cable and tinned field wiring with maximum length of 305 metres (1000 ft).

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    Sensor Mounting & Cable Routing

    To mount a sensor, refer to the installation guide of your sensor. Do not run sensor wires parallel to power cables. Otherwise, electrical noise may be introduced into the measurement signals, and false alarms are generated.

    We recommend running sensor wires through conduit to install a sensor. If conduit is not used, secure the cables to the machine case by tie-wrapping the cables to a structure or other cables. The cables should be held firmly to prevent cable movement from transmitting acceleration to the sensors.

    Do not violate the cable minimum bend radius by pulling the cables too tight.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 4. Monitor Configuration

    To configure the vbOnline Pro Condition Monitoring System, perform the following tasks:

    • 1. Configure network settings and the monitor's name using Bently Nevada Monitor Configuration software prior to connecting to System 1*. See BNMC software help for information on the default IP address, username, and password for vbOnline Pro devices.

    • 2. Configure acceleration and speed channels using System 1*. See How to Configure Acceleration & Speed Channels on page 31.

    • 3. Configure device states using System 1*. Consult the vbOnline Pro Device States topic in the System 1* Help.

    • 4. Save and sync the configuration to your vbOnline Pro monitor using System 1*. See How to Save & Sync Configuration to the Monitor on page 38.

    • 5. Map your channels to an asset using System 1*. Consult the Mapping A Point topic in the System 1* Help.

    • 6. Verify your sensors using System 1*. See How to Verify Sensors on page 39.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    4.1 How to Configure Acceleration & Speed Channels

    Follow these steps to configure these measurements using System 1*:

    • 1. Create or open an enterprise in System 1*.

    • 2. From System 1*'s main menu, select Configure workspace.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 4.1 How to Configure Acceleration & Speed

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 3. Select Instruments hierarchy. Right-click on Instruments. Hover over Import Device. Select vbOnline Pro.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 3. Select Instruments hierarchy. Right-click on Instruments

    System 1* displays the Device Connect dialog. Follow the prompts to connect to the vbOnline Pro monitor. System 1* creates a default configuration for the monitor the first time you connect to it. The default configuration includes the following:

    Parameter

    Default Value

    Acceleration Channel Type for Channels 1-12

    AM3100T2-Z2 Transducer

    Speed Channel Type for the 2 Keyphasor channels

    3300XL 8mm Proximitor

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    Each Channel has the following measurements:

    Hardware Trended Variables

    Default Collection Rate

    Every 30 seconds

    Acceleration Channel

    Direct Acceleration

    Bias

    Speed Channel

    Speed

    Gap

    Hardware Trended Waveforms

    Default Collection Rate

    Every 3 hours Configurable down to 10 minutes

    Acceleration Channel

    Asynchronous Acceleration Waveform

    Asynchronous Velocity Waveform

    Asynchronous Demodulated Waveform

     

    Speed Channel

    Speed Waveform

    You cannot disable trended variables. You can toggle waveforms active or inactive.

    • 4. Select vbOnline Pro Monitor in the Instruments hierarchy.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 5. Select the General tab. Edit the data collection rates for trend and waveforms.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 5. Select the General tab. Edit the
    • 6. Select the Measurements tab. Edit channel properties such as Transducer type and Paired Channel. You can also set the channel active or inactive.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 5. Select the General tab. Edit the

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 7. Select the Trended Variables tab to configure the properties for static measurements.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 7. Select the Trended Variables tab to
    • 8. Select the Spectrums & Waveforms tab to configure properties such as unit, Fmax, and spectral lines. For each channel, you can toggle three waveforms to active or inactive.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 7. Select the Trended Variables tab to
    • 9. To add spectral bands, select the + icon in the top right corner. Select Add Trended Variable.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 7. Select the Trended Variables tab to

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 10. Select Spectral Bands in the drop-down list for Trended Variable Type. Select the desired waveform type in the drop-down for Associated Spectrum/Waveform.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 10. Select Spectral Bands in the drop-down

    Set the properties and select points.

    Click Add Selected to add the spectral band. The spectral band is added to the Trended Variable tab.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 11. Select the Setpoints tab. Configure Severity 3 (Alert) and Severity 4 (Danger) alarms. You can also toggle the alarms to active or inactive.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 11. Select the Setpoints tab. Configure Severity

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    4.2 How to Save & Sync Configuration to the Monitor

    Follow these steps to save and sync the configuration to your vbOnline Pro monitor using System 1*:

    • 1. Select Save from the File menu.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 4.2 How to Save & Sync Configuration
    • 2. In the Instrument hierarchy, select vbOnline Pro Devices.

    • 3. Select the General tab. The Device Status indicates the device configuration is out-of-date.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 4.2 How to Save & Sync Configuration
    • 4. Select Synchronize.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 4.2 How to Save & Sync Configuration

    System 1* reestablishes the network communication and sets Device Status to communicating once the synchronization is complete.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 4.3 How to Verify Sensors

    We recommend verifying your sensors after you have configured the vbOnline Pro monitor. Follow these steps to perform a loop test using System 1*:

    • 1. Select System 1*'s Display workspace.

    • 2. Select the Instruments hierarchy.

    • 3. Expand to the vbOnline Pro Monitor.

    • 4. Select the Bar Graph tab.

    • 5. In Trended Variables, select Direct. Press Ctrl + Bias.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 4.3 How to Verify Sensors We recommend

    You can also view the bar graphs from the Asset hierarchy.

    Each of the active channels appears in the window. Sensors that are correctly wired and have no setpoints are green. The bias voltage for the default sensors is approximately -9 Vdc.

    Disconnected sensors or sensors with open wiring appear blue for the status is Not OK. The bias voltage is <-20.1 Vdc for disconnected sensors or sensors with open wiring. For sensor faults, see Troubleshooting on page 46.

    To determine whether a sensor is connected to the correct channel, disconnect the sensor and reconnect it. You can also tap the sensor lightly to see whether the channel's direct measurement increases.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    5. Maintenance

    The following topics describe how to verify the vbOnline Pro Condition Monitoring System is operating properly:

    • n How to verify installation See How to Verify Installation on page 41.

    • n How to verify channel accuracy See How to Verify Channel Accuracy on page 1.

    • n How to clean your vbOnline Pro monitor See How to Clean vbOnline Pro Monitor on page 44.

    • n How to update your firmware and user credentials See How to Update Firmware & User Credentials on page 45.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 5.1 How to Verify Installation

    You cannot repair the boards and components of the vbOnline Pro module in the field. To maintain your monitor, test the channels of the module to verify they are operating correctly.

    Required Test Equipment

    You need the following equipment for testing the channels:

    • n The function generator The function generator simulates the accelerometer vibration signal. Set the following values:

      • l For a Direct value of 0.5 g pk, set the function generator amplitude to 0.1 V pk-pk ( 0.0354 Vrms). The function generator simulates an accelerometer scale factor of 100 mV/g. For an accelerometer with 500 mv/g scale factor, set the amplitude on the function generator to 0.5 V pk-pk (0.176 Vrms).

      • l Set the function generator frequency to 24 Hz to simulate a running speed of 1440 rpm.

  • n The power supply Set the power supply to -12 Vdc for most testing. The power supply simulates the accelerometer negative bias voltage.

  • Instrumentation Setup

    The following picture depicts basic instrumentation setup for troubleshooting and shows connections to Channel 1 and KPH1. Connect to the A and B terminals to test other channels following the same process.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual Connect the test equipment to A and

    Connect the test equipment to A and B terminals.

    The DMM provides an accurate reading for the output of the power supply or the function generator.

    Use the DMM reading when verifying monitor accuracy. In System 1*, the Bar Graph tab displays the current direct vibration and bias values:

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual The Bias voltage display provides only a

    The Bias voltage display provides only a rough measurement of the bias voltage.

    When the function generator frequency is between 5 and 1000 Hz , the Direct value is calculated using the following equation:

    Where:

    • n 1.4142 factor converts from rms to peak.

    • n DMM Vrms is the AC rms reading from the DMM.

    • n The factor of 10 accounts for the expected transducer scale factor of 100 mV/g.

    • NOTE

    • We recommend verifying the functionality of the seismic sensor annually. Use a calibrated shaker table to test the accelerometer at a known amplitude and frequency. Contact Bently Nevada Services for assistance.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    5.2 How to Clean vbOnline Pro Monitor

    The vbOnline Pro monitor does not require regular cleaning. Prevent particles or liquids from entering the module ventilation holes.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual 5.2 How to Clean vbOnline Pro Monitor

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    5.3 How to Update Firmware & User Credentials

    During deployment or for maintenance, you can update the firmware and change user credentials using Bently Nevada Monitor Configuration software. See BNMC software help.

    If you forget the monitor's IP address or your user credentials, you can reset the monitor to restore network configuration and user information to default settings.

    Follow these steps to reset the vbOnline Pro monitor:

    • 1. Disconnect the monitor's ethernet cables from Port A and Port B.

    • 2. Power cycle the device. This will enable a two minute time period during which you can reset the IP address and user credentials.

    • 3. Connect each end of an ethernet cable to Port A and Port B.

    • 4. After approximately 5 to 10 seconds, the LEDs on the device will start blinking once per second for 15 seconds. During this 15 second period, power cycle the device again.

    • 5. Wait until the reset is complete. Once the monitor resets successfully, LEDs will blink simultaneously twice per second.

    • 6. Disconnect the ethernet cable and reestablish the original network cable connections to Port A and Port B.

    • 7. Reconnect to the monitor using the default IP address and user credentials.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    6. Troubleshooting

    This section describes how to troubleshoot the vbOnline Pro Condition Monitoring System or the I/O module using the information from the following sources:

    • n Self test See Self Test on page 47.

    • n LED fault conditions See LED Fault Conditions on page 48.

    • n Sensor wiring fault indications See Sensor Wiring Fault Indications on page 50.

    • n System Health Event List See System Health Event List on page 51.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 6.1 Self Test

    The vbOnline Pro monitor performs a comprehensive self test on power up and continuously monitors memory, internal node voltages, and internal temperature.

    The System Health Event List contains a record of events for possible system failures. The monitor flags the channels associated with the module as Not OK and prevents changes in alarm status for the affected channels. See System Health Event List on page 51.

    The vbOnline Pro monitor uses an internal battery to maintain the system's time and date when external power is not applied. This capability is limited to the battery's limited life.

    Should the battery fail, the system time is not kept when external power is absent. System time resets to the default value when power is reapplied. The monitor automatically synchronizes the system time to that of the computer when it communicates with System 1*.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    6.2 LED Fault Conditions

    Use the following table to diagnose and correct problems with the vbOnline Pro Condition Monitoring System using the LEDs:

    LED

    State

    Description

    Action

     

    On

    Indicates Power 1 Input is good.

    None

     

    There is no power.

     

    Power

    Off

    Or the supplied power is outside the specified range.

    Verify power supply is on. Verify power supply wiring polarity. Verify power supply output voltage.

     

    On

    All channels are operating normally.

    None

       

    Check the System Health Event List for channel not OK events. See Sensor Wiring Fault Indications on page 50.

    One or more active

    Correct wiring faults if necessary.

    OK

    Off

    channels do not comply with specifications.

    Check the System Health Event List for Processor Module or Input Module diagnostics errors.

    Correct environmental problems or replace monitor if necessary.

    Blinking

    The vbOnline Pro monitor has not been configured.

    Import the monitor to System 1* to create a default configuration. Sync the device to send the default configuration to the vbOnline Pro monitor.

     

    On

    Indicates a danger condition exists.

    View the alarm event to determine which measurements exceed the danger setpoints.

    Danger

    Off

    No danger condition exists

    None

    Alert

    On

    Indicates an alert condition exists.

    View the alarm event to determine which measurements exceed the alert setpoints.

    Off

    No alert condition exists.

    None

     

    On

    Indicates that Keyphasor signal 1 is triggering.

    None

    Kph 1

         

    OK

    Off

    Indicates the Keyphasor signal 1 is not currently triggering.

    View the waveform to verify the Keyphasor signal.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    LED

    State

    Description

    Action

     

    On

    Indicates that Keyphasor signal 2 is triggering.

    None

    Kph 2

         

    OK

    Off

    Indicates the Keyphasor signal 2 is not currently triggering.

    View the waveform to verify the Keyphasor signal.

     

    On

    Indicates Network A has a valid link.

    None

       

    Verify network cable is plugged into the monitor and is connected to a valid switch port.

    Net A

    Off

    Network A does not have a valid link.

    Verify switch is powered and operating. Check switch link light. Verify cable. Verify port has no bent/damaged pins.

     

    On/Blinking

    Indicates network traffic is flowing on Network A.

    None

    TX/RX

       

    If Network A is unused, no action is required.

    A

    Off

    Indicates no network traffic is flowing on Network A.

    If Network A is used, verify Net A LED. If Net A LED is on, check whether IP address is correct. If Net A LED is off, refer to Net A LED off actions.

     

    On

    Indicates Network B has a valid link.

    None

       

    Verify network cable is plugged into the monitor and is connected to a valid switch or computer port.

    Net B

    Off

    Network B does not have a valid link.

    Verify switch is powered and operating. Check switch or computer link light. Verify cable. Verify port has no bent or damaged pins.

     

    On/Blinking

    Indicates that network traffic is flowing on Network B.

    None

    TX/RX

       

    If Network B is unused, no action is required.

    B

    Off

    Indicates no network traffic is flowing on Network B.

    If Network B is used, verify Net B LED. If Net B LED is on, check whether IP address is correct. If Net B LED is off, refer to Net B LED off actions.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    • 6.3 Sensor Wiring Fault Indications

    Use the reported bias voltage to determine the cause of wiring faults.

    The following table lists the expected bias voltage values associated with accelerometer wiring faults:

    Expected Bias Voltage

    Fault

    0 to -1.74V

    Shorted sensor wiring

    < -20.1 V

    Open sensor wiring

    The following table lists the expected bias voltage value associated with Bently Nevada Keyphasor transducer wiring faults:

    Expected Bias Voltage

    Fault

    > -1.0 V

    Probe cable may be open or shorted.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    6.4 System Health Event List

    The vbOnline Pro monitor generates and sends the following events to System 1*. To view these events in System 1*, select the Display workspace, Events and System Health. The events appear in numerical order.

    • n If the severity of an event is zero, the message is for information only, or the system has returned to normal operation from a fault condition.

    • n If the severity of an event is one or two, a condition that requires your attention exists. The monitor stores the events in non-volatile memory even when it is not connected to System 1*. The monitor can store 10,000 events before starting to overwrite them. The following table contains a list of possible events:

    Number Event Event Name Severity

    Description

    Action

     

    Device

     

    Monitor has been

     
    • 208 Configured

    0

    configured successfully.

    None

     

    Firmware

         
    • 209 Upgrade Event

    0

    Firmware upgraded

    successfully.

    None

           

    Download the firmware again.

    Firmware

    Monitor failed to correctly

    If the firmware still does not upgrade

    • 210 Upgrade Failed Event

    0

    perform a firmware

    upgrade and is operating.

    correctly, check whether the network is

    functioning correctly. Replace the monitor if

    required.

           

    Verify whether the monitor's environment

    temperature is within its rated operating

    temperature range.

    Monitor

    The ambient temperature of

    Implement corrective action to ensure the

    Ambient

    the Processor Module is

    monitor temperature does not exceed the

    • 305 Temperature

    2

    outside the specified

    operating range for the

    limits.

    Event

    system.

    If the environment is within specification and

    the problem persists, replace the monitor.

    The event remains active while the ambient

    temperature is high.

    • 317 Reboot

    Module

    0

    The monitor has rebooted.

    None

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    Number Event Event Name Severity

    Description

    Action

     

    Processor

     

    The Monitor Processor

     

    Hardware

    Module has detected a

    • 319 Diagnostics

    2

    serious problem preventing

    Replace the monitor immediately.

    Event

    reliable alarming.

     

    Input Module

     

    The Input Module has

     

    Hardware

    detected a serious problem

    • 326 Diagnostics

    2

    preventing reliable

    Replace the monitor immediately.

    Event

    alarming.

           

    Check the System Health Event List for

    Processor Module or Input Module diagnostics

    events that may be causing the channel to be

    Not OK. Replace monitor if required.

    Check the sensor bias voltage for indication of

    open or shorted wiring. Correct wiring faults

    The channel input is outside

    if necessary. See Sensor Wiring Fault

    the OK region, or a

    Indications on page 50.

    1100

    Channel Not

    2

    hardware failure has

    occurred.

    Swap each sensor with a good sensor. If the

    OK

    problem is solved, replace the original sensor.

    Alarming is disabled for this

    Swap the Not OK channel sensor input wiring

    at the terminal block with a known good

    channel.

    channel. If the problem persists with the

    same channel, replace monitor.

    Check the timebase waveform for excessive

    noise spikes. If large noise spikes exist,

    suspect electrical noise. Move cables away

    from noise sources and provide shielding.

    vbOnline Pro Condition Monitoring System Operation and Maintenance Manual

    6.5 How to Retrieve Diagnostic Data

    The vbOnline Pro Condition Monitoring System supports retrieval of diagnostic data from the monitor. You may need the diagnostic data to troubleshoot the monitor.

    Use Bently Nevada Monitor Configuration software to retrieve diagnostic data. See BNMC software help.