Bently Nevada 3500 Machinery Protection Systems Hardware Modules

Today we are going to discuss Bently Nevada 3500 machinery protection and monitoring systems hardware modules which are used for the condition monitoring systems.

The 3500 System is used for continuous monitoring of machine parameters like vibration, temperature, speed & position for the protection of the machine.

Bently Nevada 3500 Machinery Protection Systems

The condition monitoring system’s modular rack-based design includes the following components:

1. 3500/05 Instrument Rack 
2. 3500/15 Power Supplies
3. 3500/22M Transient Data Interface (TDI) Module
4. One or more 3500/XX (mostly used are 3500/40M proximitor and 3500/16 temperature) Monitor Modules
5. One or more 3500/32M (4-channel) or 3500/33 (16-channel) Relay Modules
6. One or two 3500/25 Keyphasor Modules
7. One or more 3500/92 Communication Gateway Modules

Let’s discuss about each of them

Instrument Rack (3500/05)

All modules of the 3500 System resided in the 3500/05 rack which provides power to them and also enables easy installation and internal communication between the modules.

3500 racks are available in two sizes: Full-size rack i.e. 19-inch rack with 14 available module slots. Mini-rack i.e. 12-inch rack with 7 available module slots.

The power supplies and rack interface module reside in the left-most part of the rack which is not counted as a slot i.e. remaining 14 for full and 7 for mini rack are used for other module installation.

Power Supply Module (3500/15)

The 3500/15 power supply is half heightened module installed on the leftmost side of the rack and installed one above the other creating a redundant system.

The respective parts are listed below and also shown in the above figure.

1. 3500/15 AC and DC Power Supplies OK LED
2. Legacy Low Voltage DC Power Input Module
3. Legacy High Voltage DC Power Input Module
4. Legacy High Voltage AC Power Input Module
5. Legacy Low Voltage AC Power Input Module
6. Universal AC Voltage Power Input Module
7. High Voltage DC Power Input Module
8. Low Voltage DC Power Input Module

The power supply can be replaced in the running system also as long as the other power supply in the system is working.

The 3500/15 AC and DC Power Supplies accept a wide range of input voltages and convert them to voltages acceptable for use by other 3500 modules.

The following power supplies are available with the 3500 Series Machinery Protection System:

• Universal AC Power Supply (85 to 264 Vac RMS),
• High Voltage DC Power Supply (88 to 140 Vdc), and
• Low Voltage DC Power Supply (20 to 30 Vdc).

The health of the power supply module is determined by the TDI module.

Transient Data Interface Module (3500/22M)

The 3500/22M Transient Data Interface (TDI) is the interface between the 3500-monitoring system and System 1 Condition Monitoring, Diagnostic software, and 3500 System Configuration software.

The respective parts are listed below and also shown in the above figure.

1. Main Module
2. 10 Base-T/100 Base-TX (copper) Ethernet I/O Module
3. 100 Base-FX (fiber optic) Ethernet I/O Module
4. LEDs indicate the operating status of the module
5. Hardware Switches
6.  USB Configuration Port for configuring or retrieving machinery data
7. OK Relay indicates the OK status of the overall rack
8. Signal Common external grounding terminal
9. RJ-45 Ethernet Port for configuration and data collection
10. System Contacts
11. Fiber Optic Ethernet Port for configuration and data collection

The TDI module is always placed in the rack beside the power supply module. This module continuously collects data from all modules and sends them to other systems connected to this module through Ethernet

The Transient Data Interface (TDI) has the following LED’s: OK LED indicating healthy status, TX/RX LED indicating communication with other modules in a rack, TM LED indicating that rack is in trip multiply mode, and CONFIG OK LED indicating rack has a valid configuration.

Transient Data Interface (TDI) has a relay also installed on the backside of the module for healthiness monitoring of the rack.

TDI has a rack reset button also because the latching facility is used with some modules.

TDI also has a key with 2 positions RUN (normal operation only) and PROGRAM (normal operation of the rack and also allows for local or remote rack configuration)

Rack address is set from TDI module (127 address possible)

4 Channel Proximitor Module (3500/40M)

The 3500/40M Proximitor Monitor is a four-channel monitor which accepts input from Bently Nevada vibration monitoring system/proximity transducers and converts the data to vibration and position (as per configuration).

The respective parts are listed below and also shown in the above figure.

1. Main Module Front View
2. Status LEDs
3. Buffered Transducer Outputs
4. I/O modules
5. Barrier I/O module, Internal Termination
6. I/O Module, Internal Termination
7. I/O Module, External Termination
8. I/O Module, External Termination

This module has 3 LED’s: OK (indicating healthiness of module and connected transducers), TX/RX (indicating communication with TDI and other modules), and BYPASS (indicating whether any channel is bypassed or not)

16 Channel Temperature Module (3500/65)

The 3500/65 monitor provides 16 channels of temperature monitoring and accepts both resistance temperature detector (RTD) and isolated tip thermocouple (TC) temperature inputs.

The respective parts are listed below and also shown in the above figure.

1. Status LEDs
2. 3500/65 16 Channel Temperature Monitor
3. 16 CH RTD/TC (Internal Termination)
4. 16 CH RTD/TC (External Termination)

When 2 out of 3 logic are used for temperature, all 3 tags are configured in 3 different modules.

This module has 3 LED’s: OK (indicating healthiness of module and connected transducers), TX/RX (indicating communication with TDI and other modules), and BYPASS (indicating whether any channel is bypassed or not)

4 Channel Relay Module (3500/32M)

The 4-Channel Relay Module is a full-height module that provides four relay outputs which is user settable i.e. NO or NC contact from the back of the module.

Each relay utilized on the 4-Channel Relay Module includes Alarm Drive Logic.

The respective parts are listed below and also shown in the above figure.

1. Relay module
2. I/O module
3. Status LEDs
4. Relay channel LEDs
5. Relay contacts
6. Relay mode selection switch

Simple AND and OR logic is used in this module’s programming to energize the relay which can be used to generate trips in other connected systems through hardwire.

2 setpoints are given for a particular tag i.e. Alert and Danger where Alert is like a high alarm for user alert and Danger is like a High High alarm for tripping machine based on logic written.

This module has 3 LED’s: OK (indicating healthiness of module and connected transducers), TX/RX (indicating communication with TDI and other modules), and ALARMS dedicated for every channel (indicating whether any relay is in alarm condition or not)

4 Channel Keyphasor Module (3500/25)

The 3500/25 Enhanced Keyphasor Module is a half-height, two-channel module used to provide Keyphasor signals to the monitor modules in a 3500 rack.

This module receives data from the field i.e. proximity transduces system and calculates the speed of the rotating part.

The respective parts are listed below and also shown in the above figure.

1. Buffered Transducer Outputs
2. I/O Module, Isolated Internal Termination
3. I/O Module, Isolated External Termination
4. I/O Module, Non-Isolated Internal Termination
5. I/O Module, Non-Isolated External Termination
6. Barrier I/O Module, Internal Termination

The signal once per turn or multiple times per turn depends upon slots on the rotating part. This module also helps with diagnostics.

This module has 2 LED’s: OK (indicating healthiness of module and connected transducers) and TX/RX (indicating communication with TDI and other modules)

Communication Module (3500/92)

The 3500/92 Communication Gateway module allows communication with other systems using both Ethernet TCP/IP and serial (RS232/RS422/RS485) communications capabilities. 

It also permits Ethernet communications with 3500 Rack Configuration Software and Data Acquisition Software.

The respective parts are listed below and also shown in the above figure.

1. Status LEDs
2. Comm Gateway Module
3. RS485 I/O Module
4. RS232/422 I/O Module
5. Ethernet/RS232 I/O Module
6. Ethernet/RS485 I/O Module

Supported protocols include: Modicon Modbus protocol (via serial communications), Modbus/TCP protocol (a variant of serial Modbus used for TCP/IP Ethernet communications), and Proprietary Bently Nevada protocol (for communication with 3500 Rack Configuration and Data Acquisition Software packages)

This module has 3 LED’s: OK (indicating healthiness of module and connected transducers), TX/RX (indicating communication with TDI and other modules), and BYPASS (indicating whether any channel is bypassed or not)