* Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric
Company.
Keyphasor, System 1
Contact Information
The following contact information is provided for those times when you cannot contact your
local representative:
USA
1.775.782.3611
Telephone
1.800.227.5514
Fax 1.775.215.2873
Internet www.GEmeasurement.com
ii
Additional Information
NOTE
This manual does not contain all the information required to operate and maintain the monitoring system. The
following is a complete list of the 3500 ENCORE manuals. Refer to these manuals for other required information.
iii
3500/61E and /67E Temperature Monitor
Product Disposal Statement
Customers and third parties, who are not member states of the European Union, who are in
control of the product at the end of its life or at the end of its use, are solely responsible for the
proper disposal of the product. No person, firm, corporation, association or agency that is in
control of product shall dispose of it in a manner that is in violation of any applicable federal,
state, local or international law. Bently Nevada, Inc. is not responsible for the disposal of the
product at the end of its life or at the end of its use.
iv
Contents
v
3500/61E and /67E Temperature Monitor
vi
7.4.2 Test Alarms 54
7.4.3 Verify TC Channel Values 56
7.4.4 Test OK Limits 58
7.5 Verify Recorder Outputs 60
7.6 If a Channel Fails a Verification Test 61
8.0 Troubleshooting 63
8.1 Alarm Event List Messages 63
8.2 Self-Test 63
8.3 System Event List Messages 64
8.3.1 Example of a System Event List Message 64
8.4 Advanced Diagnostics 65
vii
Section 1.0 Receiving and Handling Instructions
WARNING
Verify the position of the PIM switch is the same on all PIMs being installed. If
the switches are not in the same position the rack may not be properly
grounded and cause a false trip.
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 in the order given.
WARNING
Machinery protection may be lost when you remove this module from the
rack.
l Do not discharge static electricity onto the circuit board. Avoid tools or procedures that
would subject the circuit board to static damage. Some possible causes of static damage
include ungrounded soldering irons, nonconductive plastics, and similar materials.
l Use a suitable grounding strap (such as 3M Velostat® No. 2060) before handling or
performing maintenance on a printed circuit board.
l Use extra caution during dry weather. Relative humidity less than 30% tends to multiply the
accumulation of static charges on any surface.
When performed properly, you may install this module into or remove this module from the rack
while power is applied to the rack. Refer to the Rack Installation and Maintenance Manual (part
number 129766-01) for the proper procedure.
1
3500/61E and /67E Temperature Monitor
2
Section 2.0 3500 ENCORE Compatibility Requirements
3500/42E
Shaft Absolute, 4.3 SP1 6.80 1.1 5.3 or Rev D 1.97
Phase Alarming
3500/50E
4.3 SP1 6.80 1.1 5.3 or Rev D 1.96
Reverse Rotation
3500/23E
Keyphasor*
4.3 SP1 6.80 1.1 5.3 or Rev D 1.96
channels 3 & 4,
Event Ratio
3
3500/61E and /67E Temperature Monitor
3500 Rack System 1 Conversion Utility Monitor System Monitor
Configuration Software Software Software Firmware Firmware
A 3300 Monitoring System Rack that has been upgraded to contain 3500 ENCORE modules. The
original 3300 I/O modules are retained. 3500/45E and 3500/42E monitors installed in a 3500
ENCORE Rack Upgrade are limited to two measurement channels.
A 3500 ENCORE Monitoring System rack designed to contain 3500 ENCORE modules including
3500 ENCORE I/O modules. 3500/45E and 3500/42E monitors installed in a 3500 ENCORE System
have four measurement channels.
4
Section 3.0 General Information
The /61E is a 6 channel monitor. It requires a vacant slot to its right in the 3300 chassis. For
example, if you insert the /61E into slot 5 of the rack, you must leave slot 6 vacant.
Note
When using a 3300 Rack, two slots are required because the 3500/61E monitor replaces the 3300/30 and 3300/35
Temperature monitors which occupied two slots.
The /67E is a 2 channel monitor. It requires only one slot in the 3300 Chassis.
Note
The 3500/61E and 3500/67E monitors have similar functionality. For simplicity, this manual refers only to the
3500/61E except when the functionality differs between the two monitors.
Note
The /67E is not compatible with the 3500 ENCORE rack.
Alarm setpoints are configured using the 3500 Rack Configuration Software. Alarm and danger
setpoints can be configured for the active static value.
The monitors ship from the factory unconfigured. Spare monitors can be re-configured for
different applications as needed.
To configure a monitor install the monitor in a 3500 ENCORE rack and follow the instructions in
the Configuration Section.
5
3500/61E and /67E Temperature Monitor
3.1 Available Data
The Temperature Monitor returns specific static values that depend upon the type of channel
that is configured. This monitor also returns both monitor and channel statuses which are
common to all types of channels.
Monitor Not OK X X X
Monitor Alert/Alarm 1 X X X
Monitor Danger/Alarm 2 X X X
Monitor Bypass X X
This indicates whether the monitor is functioning correctly. The monitor returns a Not OK status
under any of the following conditions:
l Configuration Failure
l Transducer Failure
l Slot ID Failure
l Channel Not OK
If the Monitor goes to a Not OK state, the system OK Relay on the Power Input Module goes to Not
OK (de-energized).
This indicates whether the monitor has entered Alert/Alarm 1. A monitor will enter the Alert/Alarm
1 state when any static value provided by the monitor exceeds its configured Alert/Alarm 1
6
Section 3.0 General Information
setpoint.
This indicates whether the monitor has entered Danger/Alarm 2. A monitor will enter the
Danger/Alarm 2 state when any static value provided by the monitor exceeds its configured
Danger/Alarm 2 setpoint.
This indicates when the monitor has bypassed alarming for 1 or more static values on a channel.
A condition that sets the channel bypass status will also set this monitor bypass status.
The LEDs on the front panel of the Monitor indicate the operating status of the module. Refer to
the channel type configuration sections in the appropriate channel type manual for all of the
available LED conditions.
OK
l Green - The monitor has not detected an error in its operation or the operation of its I/O
module.
l Flashing - Previously a fault existed but now the fault condition does not exist.
Alert (Amber) - An Alert condition exists and the Alert relay is in the alarm state.
Danger (Red - A Danger condition exists and the Danger relay is in the alarm state.1
Dual Relay I/O Module, both channels must be in Danger mode for the relay to enter Danger.
7
3500/61E and /67E Temperature Monitor
Table 3-2: Location of Channel Statuses
Statuses Monitor Front Via Modbus Protocol Rack Configuration Software
Channel OK X X X
Channel Alert/Alarm 1 X X X
Channel Danger/Alarm 2 X X X
Channel Bypass X X X
Channel Off X X X
Note
/61E Monitors with 6 channels are shown. The /67E Monitors are similar but have 2 channels.
8
Section 3.0 General Information
1. Color = yellow
This indicates whether the associated monitor channel has entered Alert/Alarm 1. A channel will
enter the Alert/Alarm 1 state when any static value provided by the channel exceeds its
configured Alert/Alarm 1 setpoint.
9
3500/61E and /67E Temperature Monitor
1. Color = yellow
This indicates whether the associated monitor channel has entered Danger/Alarm 2. A channel
will enter the Danger/Alarm 2 state when any static value provided by the channel exceeds its
configured Danger/Alarm 2 setpoint.
1. Color = red/orange
10
Section 3.0 General Information
This indicates that the channel is bypassed. The following conditions may cause a channel
bypass status:
11
3500/61E and /67E Temperature Monitor
1. Color is blue
This indicates whether the channel has been turned off. You may use the 3500 Rack
Configuration Software to turn off the monitor channels.
The monitor also returns a Cold Junction Compensation (CJC) value for TC channels.
12
Section 3.0 General Information
3.2 Display Control Buttons
The buttons allow you to move forward (down) and backward (up) through the pages of the
monitor display.
13
3500/61E and /67E Temperature Monitor
14
Section 4.0 I/O Module Descriptions
The 3500/67E Temperature Monitor uses one I/O module. The 3500/61E Temperature Monitor
requires an I/O Module and a Recorder Outputs Module in a 3500 Rack Upgrade .
Note
The field wiring of TC inputs must be placed in conduit to meet CE requirements.
15
3500/61E and /67E Temperature Monitor
4.1 Typical 6 Channel TC Inputs (3300)
For more information, please refer to 3300 Six Channel Temperature Monitor 3300/30
Thermocouple & 3300/35 RTD Operation Manual (Part Number 80182-01).
16
Section 4.0 I/O Module Descriptions
4.2 Typical 6 Channel TC Inputs (ENCORE System)
17
3500/61E and /67E Temperature Monitor
4.3 Typical 6 Channel RTD Inputs (3300)
1. 3-wire RTD
2. 4-wire RTD
3. Recorder Output Terminals
For more information, refer to 3300/30 Six Channel Temperature Monitor, 3300/30 Thermocouple &
3300/35 RTD Operation Manual (Part Number 80182-01).
18
Section 4.0 I/O Module Descriptions
4.4 Typical 6 Channel RTD Inputs (ENCORE System)
1. 3-wire RTD
2. 4-wire RTD
3. Recorder Output Terminals
19
3500/61E and /67E Temperature Monitor
For more information, please refer to 3300/36 Dual Temperature Monitor (Part Number 122275-01).
20
Section 4.0 I/O Module Descriptions
Note
For more information, please refer to:
3300 Six Channel Temperature Monitor 3300/30 Thermocouple & 3300/35 RTD Operation Manual (Part Number
80182-01)
21
3500/61E and /67E Temperature Monitor
22
Section 5.0 Configuration Information
23
3500/61E and /67E Temperature Monitor
Slot
Rack Type
Indicates the type of Rack Interface Module that is installed in the rack
Configuration ID
Displays an optional identifier of up to six characters, which, if present, was entered upon last
configuration download to the module.
24
Section 5.0 Configuration Information
l 3500 Rack Upgrade
l None/Dual
Verify which option is correct by examining the I/O module located behind the monitor on the
back of the rack. For more information see the section "Input/Output Module Descriptions".
Warning
For safety critical applications where the machine must not be operated without a functioning protection system,
the relays should be setup to de-energize to trip.
Plant operation requirements need to be taken into consideration when making this decision.
l OR - if either channel of a channel pair is in danger alarm, the danger alarm relay is
activated.
l AND - if both channels of a channel pair are in danger alarm, the danger alarm relay is
activated.
25
3500/61E and /67E Temperature Monitor
5.2.5 Channel Types
l Temperature
This channel type offers a simple configuration where only basic temperature
measurements are required.
Note
Please refer to the 3500 Rack Configuration Software Online Help for more information on these items.
Returns all settings on the current configuration screen and on the screens at levels below the
current screen to the default settings.
Note
Clicking on Set Defaults returns the settings on all screens at levels below the current screen to their default
settings even if the changes at lower levels were confirmed by clicking on the OK button at the lower level screen.
Click this button to assign a custom name to a channel of data. Custom names allow an operator
easily to identify which machine point is being examined. Default names are displayed as
RxxSxxCxx to denote the rack, slot, and channel source of the data.
Click this button to send a copy of the current configuration screen to the printer.
26
Section 5.0 Configuration Information
0 to 100
0 to 200
0 to 150
0 to 300
0 to 200
0 to 400 -18 to 760° C
Type J 0 to 250
0 to 500 (0 to 1400° F)
0 to 500
0 to 1000
0 to 750
Custom
Custom
27
3500/61E and /67E Temperature Monitor
Type of Thermocouple Full Scale Range (°C) Full Scale Range (°F) Custom Temperature Range
0 to 100 0 to 200
0 to 150 0 to 300
0 to 200 0 to 400
0 to 250 0 to 500 -18 to 1370° C
Type K
0 to 500 0 to 1000 (0 to 2498° F)
0 to 750 0 to 1500
0 to 1000 0 to 2000
Custom Custom
-100 to 100
-100 to 100
0 to 100
0 to 200
0 to 150
0 to 300
0 to 200
0 to 400 -100 to 1000° C
Type E 0 to 250
0 to 500 (-148 to 1832° F)
0 to 500
0 to 1000
0 to 750
0 to 1500
0 to 1000
Custom
Custom
-200 to 200
-200 to 200
-100 to 100
-122 to 2001
-50 to 2001
-100 to100
-50 to 1001 -200 to 700° C
0 to 200
100 ohm Platinum 0 to 100 (-328 to 1292° F)
0 to 300
(0.00392) 0 to 150 -50 to 700° C1
0 to 400
0 to 200 (-122 to 1292° F)1
0 to 500
0 to 250
0 to 1000
0 to 500
Custom
Custom
28
Section 5.0 Configuration Information
Type of RTD Full Scale Range (°C) Full Scale Range (°F) Custom Temperature Range
-200 to 200
-200 to 200
-100 to 100
-122 to 2001
-50 to 2001
-100 to 100
-50 to 1001
0 to 200 -200 to 850° C
0 to 100
100 ohm Platinum 0 to 300 (-328 to 1562° F)
0 to 150
(0.00385) 0 to 400 -50 to 850° C1
0 to 200
0 to 500 (-122 to 1562° F)1
0 to 250
0 to 1000
0 to 500
0 to 1500
0 to 750
Custom
Custom
-100 to 100
-100 to 100
-50 to 1001
0 to 200 -100 to 260° C
0 to 100
0 to 300 (-148 to 500° F)
10 ohm Copper 0 to 150
0 to 400 -50 to 260° C1
0 to 200
0 to 500 (-122 to 500° F)1
0 to 250
Custom
Custom
0 to 100 0 to 200
0 to 150 0 to 300
-80 to 260° C
120 ohm Nickel 0 to 200 0 to 400
(-112 to 500° F)
0 to 250 0 to 500
Custom Custom
When you select Custom Range Options, the following items are displayed:
Minimum
Maximum
Units
29
3500/61E and /67E Temperature Monitor
5.3.1.3 Clamp Value
The value sent to the Recorder Outputs and Modbus when the monitor receives invalid input.
Invalid input can be caused by:
The clamp value is not shown in the 3500 Rack Configuration software.
The screen lets you make a minor offset correction to the current reading of a temperature
sensor that is installed and measuring a known reference value. It is intended to be used with a
standard ice bath test to establish a 0 degree C reference.
The data display portion of the screen lets you observe the effect of the adjustment on the Direct
static value for the channel.
5.3.3 OK Mode
Latching
If you configure a channel for Latching OK, then once the channel has gone Not OK the status
will stay Not OK until you use one of the following methods to issue a reset:
l Issuing the reset command through the 3500 Display Interface Module
Non-latching
If you configure a channel for Non-latching OK, the OK status of that channel will track the
defined OK status of the transducer.
30
Section 5.0 Configuration Information
5.3.4 Transducer Selection
l Type J
l Type K
l Type E
l Type T
Note
The 3500 Rack Upgrade limits the selection based on the I/O type.
5.3.5 Barriers
Select External or Galvanic Isolator if there are external barriers connected between the monitor
and the transducer. Barriers are used to restrict the amount of energy that can flow into a
hazardous area. When selecting external barriers, the lower full-scale range value is -50° C for
some RTDs. Refer to the tables in section 5.3.1.1 for more information.
31
3500/61E and /67E Temperature Monitor
1. Shaft
2. Driver end
3. Driven end
4. 0°
5. 90° right
6. 180°
7. 90° left
5.3.7 Delay
Delay is the time for which a static value must remain at or above an over alarm level, or below an
under alarm level, before the monitor declares an alarm as active.
You can set the Alert time delay in 1 second increments (from 1 to 60 seconds) for all available
static values. Alert is the first level alarm that occurs when the transducer signal level exceeds the
selected Alert/Alarm 1 setpoint. You can set this setpoint on the Setpoint screen.
You can set the Danger Time Delay at 500 millisecond increments from 1 to 60 seconds. Danger is
the second level alarm that occurs when the transducer signal level exceeds the selected
Danger/Alarm 2 setpoint. You can set this setpoint on the Setpoint screen.
It is possible to set the Danger time delay at a millisecond interval that varies from 380 to 810
milliseconds, depending on the number of active channels. The millisecond danger interval is
determined as follows:
32
Section 5.0 Configuration Information
5.3.8 Alarm Mode
The options for Alarm Mode are Latching and Non-latching. You can set the Alarm Mode option
for both the Alert and Danger alarms.
5.3.8.1 Latching
Once a latching alarm is active it will remain active even after the static value drops below the
configured setpoint level. The channel will remain in alarm until you use one of the following
methods to reset it:
5.3.8.2 Non-latching
When a non-latching alarm is active, it changes to inactive as soon as the static value drops
below the configured setpoint level.
The 3500 ENCORE Monitoring System allows two Alert/Alarm 1 setpoints (one over setpoint and
one under setpoint) to be set on each Temperature static value. The channel will drive an
Alert/Alarm 1 indication if the channel's static value exceeds its setpoints.
The 3500 ENCORE Monitoring System also allows two Danger/Alarm 2 setpoints (one over
setpoint and one under setpoint) to be set for each Temperature channel. The channel will drive a
Danger/Alarm 2 indication if the channel's static value exceeds its setpoints.
Note
You can place the setpoint over and under limits only within the OK limits of the specified transducer.
Use the following screen in the Rack Configuration Software to adjust Alert/Alarm 1 and
Danger/Alarm 2 setpoints.
33
3500/61E and /67E Temperature Monitor
1 Over Alert/Alarm 1
2 Under Alert/Alarm 1
3 Over Danger/Alarm 2
4 Under Danger/Alarm 2
34
Section 5.0 Configuration Information
No changes will take effect until you press the Set button.
Configuration Mode
This switch allows you to configure the monitor. To configure the monitor, enable this switch and
set the key switch on the front of the System Monitor in the PROGRAM position. When the 3500
Rack Configuration Software downloads a configuration, it will automatically enable and disable
this switch. If the software loses its connection to the rack during the configuration process, use
this switch to remove the module from Configuration Mode.
When you enable this switch the monitor does not perform alarming functions but will still
provide all static values.
35
3500/61E and /67E Temperature Monitor
5.5.2 Channel Switches
When you enable this switch, all alert alarms are disabled. A Bypass status is indicated and the
module Bypass LED is illuminated.
Danger Bypass
When you enable this switch, all danger alarms are disabled. A Bypass status is indicated and the
module Bypass LED is illuminated.
Channel Bypass
When you enable this switch, the channel is disabled. A Bypass status is indicated and the
module Bypass LED is illuminated. Use this option to disable the channel temporarily.
Note
The cold junction temperature is always displayed for the Temperature 2 channels on the Verification Screen.
36
Section 5.0 Configuration Information
The channel switch number is used in Modbus communication.
1 Alert Bypass
2 Danger Bypass
4 Bypass
37
3500/61E and /67E Temperature Monitor
38
Section 6.0 Maintenance
6.0 Maintenance
The boards and components inside the modules cannot be repaired in the field. Rack
maintenance consists of testing module channels to verify that they are operating correctly. You
should use a spare to replace modules that are not operating correctly.
The 42E monitor can be hot-swapped but its supporting I/Os cannot. Refer to the following
manuals for the proper procedure:
1. Start with an interval of one year and then shorten the interval if either of the following
conditions apply:
2. At each interval, use the results of the previous verifications and ISO Procedure 10012-1 to
adjust the interval.
Alert
During the following procedure you must not interrupt power to the rack or remove the monitor you are upgrading
from the rack. If either of these occurs the monitor may become inoperable.
39
3500/61E and /67E Temperature Monitor
1. Start the 3500 Rack Configuration Software and connect to the rack.
2. Upload and save the current configuration of the monitor, as the upgrade process will
erase all configuration information in the monitor.
4. Select the module that you wish to update and click on the OK button.
5. The software will request you to select the file that you wish to download. Select the file and
click on the Open button. The software will now download the file.
6. After the download completes, reload the configuration to the monitor. If the process fails
then the monitor will revert to its old code. Under no circumstances should you remove the
monitor until the update process finishes.
Warning
Note
A 3500/91 EGD Communication Gateway module with version 1.20 or lower firmware has a 2 Mbyte flash.
40
Section 6.0 Maintenance
Note
A 3500/91 Multi-Protocol Gateway module with version 2.04 or greater firmware has a 4 Mbyte flash.
l The module type, firmware version, and the slot it occupies in the rack
l Monitor Serial Number
l PWA Part Number and Revision
l PWA Modification Part Number and Revision (if any)
l Firmware Part Number and Revision
l I/O Serial Number
l I/O Part Number and Revision
l I/O Modification Part Number and Revision (if any)
Note
The software checks the monitor serial number for validity. If considered invalid, the software substitutes the word
"unknown" for the normal hardware part number and revision number. You must make a physical inspection of the
board to determine those attributes.
41
3500/61E and /67E Temperature Monitor
42
Section 7.0 Verification
7.0 Verification
7.1 Required Test Equipment
The verification procedures in this section require the following test equipment.
RTD list
Thermocouple list
The 3500 Rack Configuration and Utilities Guide (part number 129777-01) explains how to perform
these operations.
Note
It is important to save the original rack configuration before doing any maintenance or troubleshooting procedures.
It may be necessary during these procedures to change some of the configuration settings which must be restored
to their original values at the conclusion of the procedures. At that time the original configuration should be
downloaded to the rack.
43
3500/61E and /67E Temperature Monitor
7.2.1 Verification Screen Setup
1. Run the 3500 Rack Configuration Software on the test computer.
Any channel bar graph value that enters Alert/Alarm 1 or Danger/Alarm 2 will cause the alarm
lines in the Channel Status box to indicate an alarm. Any channel that enters alarm will cause the
alarm lines in the Module Status box to indicate an alarm.
The bar graph display uses specific lines to indicate the following Setpoints:
44
Section 7.0 Verification
l Danger/Alarm 2 Over = Solid red line
Caution
High voltage present. Contact could cause shock, burns or death.
Alert
Tests will exceed alarm setpoint levels causing alarms to activate. This could result in a relay contact state change.
The monitor supports two RTD configurations, 3-Wire and 4-Wire. To simulate a RTD signal
connect the decade resistor to channel 1 as shown in the following figure.
45
3500/61E and /67E Temperature Monitor
1. Decade Resistor
46
Section 7.0 Verification
1. Decade Resistor
The Test Equipment outputs should be floating relative to earth ground. For external termination
I/O modules, the test setup is identical except that the test equipment outputs connect to the
external termination block. Make the lead length between the decade resistor and the I/O module
as short as possible.
47
3500/61E and /67E Temperature Monitor
1. Exceed the over Alert/Alarm 1 and Danger/Alarm 2 Setpoints
When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis
must be considered. Adjust the signal well within the alarm setpoint for the alarm to clear.
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment and Software Setup."
3. Adjust the decade resistor to produce a reading that is within the setpoint levels on the bar
graph display of the Verification screen.
4. Press the RESET switch on the System Monitor. Verify that the OK LED is on, the color of the
bar graph indicator is green, and the Current Value field contains no alarm indication.
5. Adjust the voltage/current source such that the signal just exceeds the Over Alert/Alarm 1
setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the
bar graph indicator changes color from green to yellow and that the Current Value Field
indicates an Alarm.
6. Press the RESET switch. Verify that the color of the bar graph indicator remains yellow and
that the Current Value Field still indicates an alarm.
7. Adjust the voltage/current source such that the signal just exceeds the Over Danger/Alarm
2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the
bar graph indicator changes color from yellow to red and that the Current Value Field
indicates an Alarm.
8. Press the RESET switch. Verify that the color of the bar graph indicator remains red and that
the Current Value Field still indicates an alarm.
9. Adjust the voltage/current source such that the signal reads within the Alarm setpoint
levels. If the nonlatching option is configured, observe that the bar graph indicator
changes color to green and that the Current Value Field contains no indication of alarms.
Press the RESET switch to reset latching alarms.
48
Section 7.0 Verification
10. Adjust the voltage/current source such that the signal just exceeds the Under Alert/Alarm 1
setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the
bar graph indicator changes color from green to yellow and that the Current Value Field
indicates an Alarm.
11. Press the RESET switch. Verify that the color of the bar graph indicator remains yellow and
that the Current Value Field still indicates an alarm.
12. Adjust the voltage/current source such that the signal just exceeds the Under
Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires
and verify that the bar graph indicator changes color from yellow to red and that the
Current Value Field indicates an Alarm.
13. Press the RESET switch. Verify that the color of the bar graph indicator remains red and that
the Current Value Field still indicates an alarm.
14. Adjust the current/voltage source such that the signal reads within the Alarm setpoint
levels. If the nonlatching option is configured, observe that the bar graph indicator
changes color to green and that the Current Value Field contains no indication of alarms.
Press the RESET switch on the Rack Interface Module (RIM) to reset latching alarms.
15. If you cannot verify any configured alarm, check the configured setpoints again. If the
monitor still does not alarm properly or fails any other part of this test, you must replace the
monitor. Refer to "If a Channel Fails a Verification Test" in your monitor hardware manual.
16. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on. Press the RESET switch to
reset the OK LED.
49
3500/61E and /67E Temperature Monitor
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment and Software Setup."
3. Select a minimum of three verification resistance values that are within the selected full-
scale range and that correspond to the NIST standard value, such as the tables in the
MINCO's Bulletin TS-102 (G), "Temperature Sensors & Transmitters".
4. Adjust the decade resistor to the first verification value that was selected from the tables.
5. Verify that the bar graph display and the Current Value Box is the specified accuracy for
that type of RTD of the verification values shown in the tables. If the recorder output is
configured, refer to Section "Verify Recorder Outputs" for the steps to verify the recorder
output.
6. Repeat the procedure in step 4 and 5 until all of the verification points have been tested.
7. If the readings do not meet specifications, verify that the input signal is correct. If the
monitor still does not meet specifications or fails any other part of this test, you must
replace the monitor. See the section "If a Channel Fails a Verification Test" in your hardware
manual.
8. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on. Press the RESET switch to
reset the OK LED.
Example:
Some values for Platinum (a=0.00392) have the following resistance values:
Note
All other channels in the rack must be OK or Bypassed for the OK relay to be energized.
50
Section 7.0 Verification
To test OK limits, input a simulated RTD signal (resistance value) and adjust it above the Upper OK
limit and below the Lower OK limit. This resistance value will cause a not OK condition and the OK
Relay to change state (de-energize). The Upper and Lower OK limits are displayed in the
Verification screen on the test computer.
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment Setup."
4. Adjust the decade box to a value in the middle of the OK Limits listed in "RTD Transducer OK
Limits".
5. Press the RESET switch. Verify that the monitor OK LED is on and that the Channel OK State
line in the Channel Status section of the Verification screen reads OK.
6. Verify that the OK relay on the System Monitor indicates OK (is energized). (See the
appropriate System Monitor manual for more information.)
7. Increase the decade resistor (large value) until the OK LED just goes off (upper limit). Verify
that the Channel OK State line in the Channel Status section reads not OK and that the OK
Relay indicates not OK.
Verify that the Channel OK State line in the Channel Status section reads not OK and that
the OK Relay indicates not OK.
Verify that the Upper OK limit displayed on the Verification screen is equal to or less positive
than the input signal.
8. Adjust the decade resistor to some value in the middle of the OK limits as listed in Table "RTD
Transducer OK Limits".
9. Press the RESET switch. Verify that the OK LED comes back on and that the OK relay
energizes. Verify that the Channel OK State line in the Channel Status section reads OK.
51
3500/61E and /67E Temperature Monitor
10. Gradually decrease the decade resistor (small value) until the OK LED just goes off (lower
limit).
Verify that the Channel OK State line in the Channel Status section reads not OK and that
the OK Relay indicates not OK.
Verify that the Lower OK limit displayed on the Verification screen is equal to or less
negative than the input voltage.
11. Adjust the decade resistor to some value in the middle of the OK limits as listed in Table "RTD
Transducer OK Limits".
12. Press the RESET switch. Verify that the OK LED comes back on and that the OK relay
energizes. Verify that the Channel OK State line in the Channel Status section reads OK.
13. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on and that the OK relay
energizes. Press the RESET switch to reset the OK LED.
14. If you cannot verify any configured OK limit, you must replace the monitor. Refer to "If a
Channel Fails a Verification Test" in your monitor hardware manual.
16. Return the bypass switches for all configured channels back to their original settings.
Pt (a=0.00392)-
79.961 -50° C 350.17 +700° C
1
Pt (a=0.00385)-
80.311 -50° C 390.38 +850° C
1
Ni (a=0.00672)-
86.161 -50° C 380.31 +260° C
1
52
Section 7.0 Verification
Lower OK Limit Lower OK Limit Upper OK Limit Upper OK Limit
RTD Type
(Ohms) (Degrees) (Ohms) (Degrees)
Cu (a=0.00427)-
7.1041 -50° C 19.12 +260° C
1
Warning
High voltage present. Contact could cause shock, burns or death. Do not touch exposed wires or terminals.
Alert
Tests will exceed alarm setpoint levels causing alarms to activate. This may result in a relay contact state change.
Simulate the transducer signal by connecting the precision millivolt source to the input terminal
for channel 1 with polarity as shown in the following figure.
53
3500/61E and /67E Temperature Monitor
The Test Equipment outputs should be floating relative to earth ground. For external termination
I/O modules, the test setup is identical except that the test equipment outputs connect to the
external termination block.
When varying the signal from an alarm condition to a non-alarm condition, alarm hysteresis
must be considered. Adjust the signal well within the alarm setpoint for the alarm to clear.
54
Section 7.0 Verification
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment Setup."
3. Adjust the precision millivolt source to produce a reading that is within the setpoint levels
on the bar graph display of the Verification screen.
4. Press the RESET switch on the System Monitor. Verify that the OK LED is on, the color of the
bar graph indicator is green, and the Current Value field contains no alarm indication.
5. Adjust the precision millivolt source such that the signal just exceeds the Over Alert/Alarm 1
setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the
bar graph indicator changes color from green to yellow and that the Current Value Field
indicates an Alarm.
6. Press the RESET switch. Verify that the color of the bar graph indicator remains yellow and
that the Current Value Field still indicates an alarm.
7. Adjust the precision millivolt source such that the signal just exceeds the Over
Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires
and verify that the bar graph indicator changes color from yellow to red and that the
Current Value Field indicates an Alarm.
8. Press the RESET switch. Verify that the color of the bar graph indicator remains red and that
the Current Value Field still indicates an alarm.
9. Adjust the precision millivolt source such that the signal reads within the Alarm setpoint
levels. If the nonlatching option is configured, observe that the bar graph indicator
changes color to green and that the Current Value Field contains no indication of alarms.
Press the RESET switch to reset latching alarms.
10. Adjust the precision millivolt source such that the signal just exceeds the Under Alert/Alarm
1 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires and verify that the
bar graph indicator changes color from green to yellow and that the Current Value Field
indicates an Alarm.
11. Press the RESET switch. Verify that the color of the bar graph indicator remains yellow and
that the Current Value Field still indicates an alarm.
55
3500/61E and /67E Temperature Monitor
12. Adjust the precision millivolt source such that the signal just exceeds the Under
Danger/Alarm 2 setpoint level. Wait for 2 or 3 seconds after the alarm time delay expires
and verify that the bar graph indicator changes color from yellow to red and that the
Current Value Field indicates an Alarm.
13. Press the RESET switch. Verify that the color of the bar graph indicator remains red and that
the Current Value Field still indicates an alarm.
14. Adjust the precision millivolt source such that the signal reads within the Alarm setpoint
levels. If the nonlatching option is configured, observe that the bar graph indicator
changes color to green and that the Current Value Field contains no indication of alarms.
Press the RESET switch on the Rack Interface Module (RIM) to reset latching alarms.
15. If you cannot verify any configured alarm, check the configured setpoints again. If the
monitor still does not alarm properly or fails any other part of this test, you must replace the
monitor. Refer to "If a Channel Fails a Verification Test" in your monitor hardware manual.
16. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on. Press the RESET switch to
reset the OK LED.
Note
These parameters have an accuracy specification that is dependent on the physical configuration of the system.
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment and Software Setup."
3. On the Verification screen, record the current value of the CJC bar graph. This value is the
CJC temperature at the input terminal of the monitor at the start of the test.
56
Section 7.0 Verification
4. Select a minimum of three verification voltage values (Vtable) that are within the selected
full-scale range and that corresponds to the NIST standard value, such as the tables in
Omega's "The Temperature Handbook Vol. 28" .
5. Using a Thermocouple Table, convert the CJC temperature value recorded above to the
CJC voltage. (Vcjc).
6. Adjust the value for the verification value listed in the Thermocouple Table to the voltage
that is applied in the test configuration (Vtest).
7. Adjust the precision millivolt source to the first verification value that has been adjusted
(Vtest). Adjust the verification value using Equation "Verification Temperature Value" below.
Record the current value of the Direct Value bar graph.
8. Verify that the bar graph display and the current value are within ±0.5° C (±0.9° F) of the
expected value. If the recorder output is configured, refer to Section - Verify Recorder
Outputs for the steps to verify the recorder output.
10. Record the value of the CJC bar graph. This value is the CJC temperature at the input
terminal of the monitor at the end of the test. This temperature and the temperature
recorded in step 3 cannot vary by more the 1° C (1.8° F). If it does vary, repeat steps 3
through 9.
11. If the readings do not meet specifications, verify that the input signal is correct. If the
monitor still does not meet specifications or fails any other part of this test, you must
replace the monitor. See the section "If a Channel Fails a Verification Test" in your hardware
manual.
12. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on. Press the RESET switch to
reset the OK LED.
Example 1:
57
3500/61E and /67E Temperature Monitor
Verification value 1: T1= 0° C Voltage = 0.000 mV
Example 2:
Assume that the CJC temperature measured in step 3 is 29 °C, the monitor is configured for the
type-J TC, and the desired test verification value is 100 °C.
For the CJC temperature of 29 °C the Thermocouple Table indicates this corresponds to a CJC
voltage (Vcjc) of 1.484 mV.
From the same table, the test temperature of 100° C corresponds to a voltage (Vtable) of 5.268 mV.
Vtest = 3.784 mV
Note
All other channels in the rack must be OK or Bypassed for the OK relay to be energized.
To test OK limits input a precision millivolt DC voltage and adjust it above the Upper OK limit and
below the Lower OK limit. This voltage will cause a not OK condition and the OK Relay to change
state (de-energize). The Upper and Lower OK limits are displayed in the Verification screen on the
test computer.
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect the test equipment and run the software as described in the section, "Test
Equipment and Software Setup."
4. Adjust the precision millivolt source to some value in the middle of the OK limits as listed in
the Table "Thermocouple Transducer OK Limit".
5. Press the RESET switch. Verify that the monitor OK LED is on and that the Channel OK State
line in the Channel Status section of the Verification screen reads OK.
58
Section 7.0 Verification
6. Verify that the OK relay on the System Monitor indicates OK (is energized). (See the
appropriate System Monitor manual for more information.)
7. Increase the precision millivolt source (more positive) until the OK LED just goes off (upper
limit).
Verify that the Upper OK limit voltage displayed on the Verification screen is equal to or less
positive than the input voltage.
8. Adjust the precision millivolt source to some value in the middle of the OK limits as listed in
the Table "Thermocouple Transducer OK Limit".
9. Press the RESET switch. Verify that the OK LED comes back on and that the OK relay
energizes. Verify that the Channel OK State line in the Channel Status section reads OK.
10. Gradually decrease the precision millivolt source (more negative) until the OK LED just goes
off (lower limit).
Verify that the Lower OK limit voltage displayed on the Verification screen is equal to or less
negative than the input voltage.
11. Adjust the precision millivolt source to some value in the middle of the OK limits as listed in
the Table "Thermocouple Transducer OK Limit".
12. Press the RESET switch. Verify that the OK LED comes back on and that the OK relay
energizes. Verify that the Channel OK State line in the Channel Status section reads OK.
13. Disconnect the test equipment and reconnect all field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on and that the OK relay
energizes. Press the RESET switch on the Rack Interface Module (RIM) to reset the OK LED.
14. If you cannot verify any configured OK limit, you must replace the monitor. Refer to "If a
Channel Fails a Verification Test" in your monitor hardware manual.
16. Return the bypass switches for all configured channels back to their original settings.
59
3500/61E and /67E Temperature Monitor
Table 7-2: Thermocouple Transducer OK Limit
Lower OK Limit Lower OK Limit Upper OK Limit Upper OK Limit
Thermocouple
(millivolts) (Degrees) (millivolts) (Degrees)
1. Disconnect all field wiring from the channel terminals on the Temperature I/O Module.
2. Connect a multimeter to the COM and REC channel terminals of the I/O module. The
multimeter should be able to measure 4 mA to 20 mA.
3. Set the static value for which the recorder is configured to full-scale (refer to the static value
of the channel type you are testing). Verify that the recorder output is reading 20 mA ± 1%.
4. Set the static value for which the recorder is configured to mid-scale (refer to the static
value of the channel type you are testing). Verify that the recorder output is reading 12 mA ±
1%.
5. Set the static value for which the recorder is configured to bottom-scale (refer to the static
value of the channel type you are testing). Verify that the recorder output is reading 4 mA ±
1%.
6. Set the static value so that the recorder is outside its full-scale range. Verify that the
recorder output is reading at the clamped value, as set in the software, ±1%.
7. If you cannot verify the recorder output, you should check the recorder configuration and
connections. If the monitor recorder output still does not verify properly, you will need to
replace the monitor. Go to Section "If a Channel Fails a Verification Test."
8. Disconnect the test equipment and reconnect the field wiring to the channel terminals on
the Temperature I/O Module. Verify that the OK LED comes on. Press the RESET switch to
reset the OK LED.
60
Section 7.0 Verification
7.6 If a Channel Fails a Verification Test
When handling or replacing circuit boards, always be sure to adequately guard against damage
from Electrostatic Discharge (ESD). Always wear a proper wrist strap and work on a grounded
conductive work surface.
1. Use the 3500 Rack Configuration Software to save the configuration for the module.
2. Replace the module with a spare. Refer to the installation section in the following
documents:
3500 Monitoring System Installation and Maintenance Manual (part number 129766-01)
3300 System Upgrade Manual (part number 287550-01)
3500 ENCORE Rack Installation Manual (part number 100M3415-01)
4. Use the 3500 Rack Configuration Software to download the configuration for the spare
module.
61
3500/61E and /67E Temperature Monitor
62
Section 8.0 Troubleshooting
8.0 Troubleshooting
This section describes how to use the information provided by the self-test, the LEDs, the System
Event List, and the Alarm Event List to troubleshoot a problem.
A static value in the channel has entered Alert / Alarm 1 and changed the
Entered Alert/ Alarm 1
channel Alert / Alarm 1 status
A static value in the channel has left Alert / Alarm 1 and changed the
Left Alert/ Alarm 1
channel Alert / Alarm 1 status
A static value in the channel has entered Danger / Alarm 2 and changed
Entered Danger/ Alarm 2
the channel Danger / Alarm 2 status
A static value in the channel has entered Danger / Alarm 2 and changed
Left Danger/ Alarm 2
the channel Danger / Alarm 2 status
8.2 Self-Test
To perform the monitor self-test:
1. Connect a computer running the 3500 Rack Configuration Software to the 3500 rack (if
required).
2. Select Utilities from the main screen of the 3500 Rack Configuration Software.
63
3500/61E and /67E Temperature Monitor
4. Press the Module Self-test button on the System Events screen.
Advisory
The system will lose machinery protection while the monitor is performing its self-test.
5. Select the slot that contains the monitor and press the OK button. The monitor will perform
a full self-test and the software will display the System Events screen. The list will not
contain the results of the self-test.
7. Press the Latest Events button. Software will update the System Events screen to include
the results of the monitor self-test.
8. Verify that the monitor passed the self-test. If the monitor failed the self-test, refer to
the System Event List to determine possible actions. See " List of 3500 and 3500 ENCORE
Messages" on page 1.
For a complete list of the 3500 ENCORE System Event Messages, please refer to 3500/23E System
Monitor Manual (part number 287545-01.
Device Not
0000000123 32 1 02/01/90 12:24:31:99 5L
Communicating
Sequence Number: This is the number of the event in the System Event List (for example 123).
Event Information: This provides the name of the event (for example Device Not Communicating).
Event Number: This identifies the specific event that occurred.
Class: This indicates the severity of the event. The following classes are available:
64
Section 8.0 Troubleshooting
Table 8-3: System Event List Classes
Class Value Classification
0 Severe/Fatal Event
3 Reserved
Event Date: This specifies the date that the event occurred.
Event Time: This specifies the time that the event occurred.
Event Specific: This provides additional information for the events that use this field.
Slot: This identifies the module with which the event is associated. If a half-height module is installed
in the upper slot or a full-height module is installed, the field will be 0 to 15. If a half-height
module is installed in the lower slot, then the field will be 0L to 15L. For example, a module
installed in the lower position in slot 5 would be 5L.
If the I/O module supports both RTD & TC, check the I/O
Two Adjacent module and the temperature module.
Adjacent channels are defined
Channels are not
as 1-2, 3-4, or 5-6. If the I/O module supports TC only (isolated), the problem is
OK
probably in the main monitor.
65
3500/61E and /67E Temperature Monitor
Condition Details Action
One or more
Transducer for a particular
channels are Not
channel(s) shown as Not OK
OK on the Internal
(Wiring Open)
Barrier I/O Module
66