Emerson Machinery Health Expert CSI 2600 User manual

User Guide
MHM-97453, Rev 1
April 2014
CSI 2600 Machinery Health™ Expert
User Guide

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© 2014 by Emerson Process Management. All rights reserved.
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of use under environmental conditions specified in the user documentation. 3. The product must stay in or default to an operating
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previously stored data memory. When apparent, the user may need to initiate a reset and/or restart of a data acquisition in
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Contents
Chapter 1 CSI 2600 Machinery Health Expert ..................................................................................1
1.1 CSI 2600 overview ....................................................................................................................... 1
1.2 User Guide overview ....................................................................................................................1
1.3 User Guide conventions .............................................................................................................. 2
1.4 Technical support ........................................................................................................................ 2
Chapter 2 Introduction to the CSI 2600 ...........................................................................................3
2.1 CSI 2600 out of the box ............................................................................................................... 3
2.2 Optional services ......................................................................................................................... 6
2.3 CSI 2600 monitoring requirements ..............................................................................................6
2.4 Precautions ................................................................................................................................. 6
2.5 Safety notes .................................................................................................................................7
Chapter 3 Getting started .............................................................................................................. 9
3.1 Remove the CSI 2600 from the case ............................................................................................ 9
3.2 Turn on the CSI 2600 ................................................................................................................. 10
3.3 Turn off the CSI 2600 .................................................................................................................11
3.4 CSI 2600 fuse access ..................................................................................................................11
3.5 Data collection overview ........................................................................................................... 12
3.6 Data recorder modes .................................................................................................................12
3.7 Store data on a NAS hard drive ...................................................................................................13
3.8 Network configuration .............................................................................................................. 14
3.9 System architecture .................................................................................................................. 15
3.10 Access the termination board ....................................................................................................18
3.11 Connectivity .............................................................................................................................. 19
Chapter 4 Hardware configuration: overview .............................................................................. 23
4.1 Gross Scan monitoring .............................................................................................................. 23
4.2 Spectral Scan .............................................................................................................................24
4.3 Transient data capture ...............................................................................................................24
4.4 Install a module ......................................................................................................................... 24
4.5 Remove a module ......................................................................................................................24
4.6 6560 Processor module .............................................................................................................25
4.7 CSI 2600 signal inputs ................................................................................................................28
4.8 6510 Signal Input module ..........................................................................................................29
4.9 Mounting accelerometers ......................................................................................................... 33
4.10 Mounting tachometers ..............................................................................................................41
4.11 Eddy current sensors ................................................................................................................. 44
Chapter 5 Software configuration ................................................................................................45
5.1 System overview diagram ..........................................................................................................45
5.2 Connect the CSI 2600 to the network server ..............................................................................46
5.3 Configuration overview ............................................................................................................. 46
5.4 Install AMS Machinery Manager .................................................................................................47
5.5 Configure the computer's IP address ......................................................................................... 47
5.6 Configure the FTP server to download firmware ........................................................................ 48
5.7 Configure boot parameters with a terminal emulator ................................................................51
5.8 Add an Online Server to RBM Network Administration ...............................................................58
Contents
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Chapter 6 Data collection and analysis ......................................................................................... 61
6.1 View or edit IP addresses with the unit .......................................................................................61
6.2 Verify or assign IP addresses to the database ............................................................................. 62
6.3 Database configuration: overview ............................................................................................. 62
6.4 Online Watch overview ..............................................................................................................66
6.5 Archive management ................................................................................................................ 69
6.6 Create archives manually ...........................................................................................................70
6.7 Disable archive predicates ......................................................................................................... 70
6.8 Stop transient acquisition ..........................................................................................................71
6.9 Remove an archive from the Transient Archive Status tab ..........................................................71
6.10 Change databases when moving the unit to a new machine ...................................................... 72
Appendices and reference
Appendix A Specifications ...............................................................................................................73
A.1 CSI 2600 product specifications .................................................................................................73
A.2 Module specifications ................................................................................................................74
Appendix B System calibration ....................................................................................................... 83
B.1 The CSI 6560 Processor module .................................................................................................83
Appendix C Data types ................................................................................................................... 87
C.1 Gross Scan analysis .................................................................................................................... 87
C.2 Spectral analysis ........................................................................................................................ 88
C.3 Time Waveform analysis ............................................................................................................89
C.4 Non-Vibration unit analysis types .............................................................................................. 90
C.5 Set DC offset ..............................................................................................................................90
Appendix D Internal wiring of the CSI 2600 ..................................................................................... 93
D.1 Rear termination panel .............................................................................................................. 93
D.2 Internal wiring diagram for the CSI 2600 ....................................................................................96
D.3 Terminal descriptors ..................................................................................................................97
D.4 Rear terminal power connections ............................................................................................ 100
D.5 CSI 2600 DIP switch settings ....................................................................................................100
Appendix E Troubleshooting ........................................................................................................ 101
Index ................................................................................................................................................103
Contents
ii MHM-97453, Rev 1

1 CSI 2600 Machinery Health Expert
Topics covered in this chapter:
•CSI 2600 overview
•User Guide overview
•User Guide conventions
•Technical support
1.1 CSI 2600 overview
The CSI 2600 Machinery Health™ Expert is a portable, online analyzer that simultaneously
and continuously monitors and records up to 24 vibration or process channels and up to 4
speed inputs.
The CSI 2600 is available with one or two 6510 signal input modules. Each 6510 module
has 12 analog channels, 2 tachometer channels, and 2 relay channels. Emerson sells the
CSI 2600 as a 12/2/2 channel or a 24/4/4 channel analyzer.
The CSI 2600 comes in non-Transient and Transient configurations. A non-Transient unit is
designated by an "M", such as A2600M, and a Transient unit is designated by "T", such as
A2600T. The analog channel count is also part of the name; a 12 channel unit is designated
by the number "7", and a 24 channel unit is designated by the number "8". Available models
are:
•A2600M7—non-Transient, 12 channel
•A2600M8—non-Transient, 24 channel
•A2600T7—Transient, 12 channel
•A2600T8—Transient, 24 channel
This manual will assume that the CSI 2600 is an A2600T8—a Transient, 24 channel system.
Use Emerson's AMS Suite: Machinery Health™ Manager software to view orbits, shaft
center lines, Bode, polar, cascade, waveform, and spectrum plots live and simultaneously,
or to archive for future reference.
1.2 User Guide overview
The CSI 2600 Machinery Health Expert User Guide is written for Vibration Analysts,
Reliability Data Collection Technicians, and Reliability Engineers who monitor rotating
machines in a process plant environment. This user guide describes how to set up the unit,
collect data, and transfer the data to AMS Machinery Manager for storage and analysis.
CSI 2600 Machinery Health Expert
MHM-97453, Rev 1 1

1.3 User Guide conventions
The following conventions are used throughout this User Guide.
Note
A note paragraph contains special comments or instructions.
CAUTION!
A caution paragraph alerts you to actions that may have a major impact on the equipment or
stored data.
WARNING!
A warning paragraph alerts you to actions that may have extremely serious consequences for
equipment and/or personnel.
1.4 Technical support
When you contact Technical Support, be ready with a screen capture of the error message
and details such as when and how the error occurred.
Hardware Technical Help
Have the number of the current version of your firmware ready when you call.
Software Technical Help
Provide the software version numbers of both your Microsoft® Windows operating system
and AMS Suite: Machinery Health Manager, and your AMS Machinery Manager serial
number. To find AMS Machinery Manager version and serial numbers, select Help > About.
Be at your computer when you call. We can serve you better when we can work through
the problem together.
Software Technical Support
Emerson provides technical support through the following for those with an active support
agreement:
•Telephone assistance and communication via the Internet.
•Mass updates that are released during that time.
•Interim updates upon request. Please contact Emerson Technical Support for more
information.
Contact us
For Emerson Technical Support and Customer Service Toll Free numbers, email addresses,
and hours of operation, please visit http://www.sureservice.com and select Technical
Support and Customer Service.
CSI 2600 Machinery Health Expert
2MHM-97453, Rev 1

2 Introduction to the CSI 2600
Topics covered in this chapter:
•CSI 2600 out of the box
•Optional services
•CSI 2600 monitoring requirements
•Precautions
•Safety notes
2.1 CSI 2600 out of the box
CSI 2600 front viewFigure 2-1:
Introduction to the CSI 2600
MHM-97453, Rev 1 3

CSI 2600 back viewFigure 2-2:
Introduction to the CSI 2600
4MHM-97453, Rev 1

CSI 2600 accessoriesFigure 2-3:
•CSI 4500/6500/2600 Machinery Health Monitor firmware DVD
•AMS Suite Operating Manuals & Extras DVD
•1 Ethernet cable
•1 serial cable
•1 package of replacement filters
•1 standard IEC 320 C13 to NEMA 5-15P power cord
•1 3-pin screw mount connector plug
•3-piece international AC adapter kit
Optional accessories
•Sensors
Introduction to the CSI 2600
MHM-97453, Rev 1 5

•Mounting pads
•BNC connectors
•Extension cords
Optional firmware
•PeakVue
•Modbus
Optional software
•Object Linking and Embedding for Process Control (OPC)
2.2 Optional services
•Training in the Online Prediction Operation and Maintenance course and rolling
element bearing vibration.
•Remote analysis.
•Turbomachinery diagnostic training and AMS Machinery Manager transient analysis
training.
2.3 CSI 2600 monitoring requirements
The CSI 2600 portable transient monitoring requires:
•Field wiring to installed sensors
•AC line power wiring
•Connection points (usually a buffered output panel) for cabling to the CSI 2600
monitoring unit
•Computer
•CSI 2600 firmware (loaded on Online Server, downloaded into CSI 2600 monitoring
unit)
•Machinery Health Manager online software
•Online Database
•Ethernet cable
2.4 Precautions
Cleaning
The CSI 2600 is dust resistant. Use a damp, clean cloth for cleaning. Do not use cleaning
fluids, abrasives, or aerosols, as they could enter the device, causing damage, fire or
electrical shock.
Introduction to the CSI 2600
6MHM-97453, Rev 1

Avoid water
Avoid direct contact with water, wet surfaces, or condensing humidity. Keep away from
wet locations such as sinks, laundry, wet basements, swimming pools, and so on. If the
device is subjected to these conditions, adverse operation may result. If the surface of the
device becomes wet, allow it to dry thoroughly before operation.
Avoid damage or injury
Follow these guidelines to avoid costly damage or injury:
•Place the device on a solid, stable surface when not in use and do not place any
heavy objects on it.
•Use only accessories recommended by Emerson Process Management.
•Keep liquids and foreign objects away from your CSI 2600.
•Never operate your CSI 2600 if any liquid or foreign object has entered it.
•The enclosure should never be subjected to direct sunlight for long periods of time.
2.5 Safety notes
This document is intended as a guide only. No instructions given here are intended to
supersede any locally issued directions or safety instructions.
WARNING!
Do not operate the CSI 2600 in a hazardous area.
Introduction to the CSI 2600
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Introduction to the CSI 2600
8MHM-97453, Rev 1

3 Getting started
Topics covered in this chapter:
•Remove the CSI 2600 from the case
•Turn on the CSI 2600
•Turn off the CSI 2600
•CSI 2600 fuse access
•Data collection overview
•Data recorder modes
•Store data on a NAS hard drive
•Network configuration
•System architecture
•Access the termination board
•Connectivity
3.1 Remove the CSI 2600 from the case
CAUTION!
The CSI 2600 should be placed on a dry, level, cool surface where the vents and fans are not
blocked. Avoid hot, wet surfaces and do not block the vents or fans.
Note
The CSI 2600 cannot be used while in the case.
Procedure
Reach down along the top and bottom of the CSI 2600 and extract the device straight up
from its case.
Getting started
MHM-97453, Rev 1 9

Remove the CSI 2600 from the caseFigure 3-1:
3.2 Turn on the CSI 2600
The CSI 2600 has two toggle switches, and both must be toggled in order to turn the unit
on and off.
Prerequisites
WARNING!
Ensure that physical contact with unbuffered sensor signals will not interfere with other
monitoring or protection systems.
Procedure
1. Plug the power cord into a standard 120 - 240 VAC input. Attach one of the provided
adapters if necessary.
The unit automatically senses the correct voltage.
2. Press the toggle switch located at the rear of the case to On.
3. Press the toggle switch located at the front of the case to On.
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3.3 Turn off the CSI 2600
Prerequisites
Make sure that the computer has been connected long enough to allow all of the desired
data to be transferred to the computer for storage. Check the time stamps of the data
being reported in Online Watch. Once the times have progressed past the time range
needed, data collection can be stopped and the CSI 2600 can be powered off.
Procedure
1. Turn the toggle switch located on the front of the unit to the Off position.
After a couple seconds, the light will turn off. Wait for the light to turn off before
continuing with the next step.
2. Turn the toggle switch located on the back of the unit to the Off position.
3. Unplug the power cord.
3.4 CSI 2600 fuse access
CAUTION!
Turn off the power to the CSI 2600 and unplug the unit before accessing the fuses.
Two 10 A fuses for the power input are accessible through a small access panel between
the receptacle and the power switch. The access panel can be opened with a flathead
screwdriver.
Fuse accessFigure 3-2:
The AC power input is located on the unit's faceplate.
A. Fuse access panel
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MHM-97453, Rev 1 11

3.5 Data collection overview
The CSI 2600 is a continuously monitoring online system. Once configured, it will collect
both periodic predictive data (Trend, Spectra, and Waveform snapshots, multiplexed two
channels at a time) and Transient measurements (continuous unbroken waveforms for
extended periods on up to all 24 channels). Predictive data can be stored in an AMS
Machinery Manager database. Sections of the transient waveforms can also be extracted
into archives either on-demand or based on alarm events.
For the Transient channels, the CSI 2600 continuously stores waveform measurements on
a Hard Disk Drive (HDD). This can be either the internal 80 GB HDD or an external NAS
drive (up to 250 GB). When the drive fills up, the system will begin overwriting the oldest
measurements in a First In First Out (FIFO) manner.
Data is stored at a rate of approximately 40 MB per hour per channel. The following
method can be used for estimating the amount of time that data can be streamed to the
HDD before it begins to FIFO. First determine the number of channels that will be
commissioned for Transient operation; then use this equation:
Storage Time (in hours) = HDD size / (number of Transient channels x 40 MB/hr).
For example, consider a pump monitoring system which has a total of 14 sensors. This
could include 4 pairs of radial shaft vibration probes, 2 thrust probes, 1 case expansion
sensor, 1 eccentricity sensor, and 2 horizontal accelerometers. In addition to collecting
periodic prediction data, the 8 shaft vibration probes are also commissioned for Transient
data collection.
80,000 MB / (8 channels x 40 MB/hr) = 250 hours (approximately 10 days)
So, the internal HDD will store data for approximately ten days before starting to FIFO.
The CSI 2600 is both a continuous monitoring system and a portable monitoring system. It
can be moved from one piece of equipment to another, with data from each piece stored
in separate databases. See Section 6.10 for more information.
CAUTION!
Changing databases will reinitialize the Transient HDD, which eliminates all stored data.
Extract any data before changing databases.
3.6 Data recorder modes
Data collection to CSI 2600 internal memory
When the CSI 2600 is running and the computer is disconnected, the unit runs in DAT
recorder mode, optimized for turbomachinery transient data. Waveforms from up to 24
channels, including tach striping, are recorded continuously and simultaneously. If all 24
channels are streaming transient data, the internal 80 GB HDD will store approximately 90
hours of data before it begins to FIFO.
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With the computer disconnected, the periodic predictive data is also buffered in the CSI
2600’s internal RAM. The amount of time it will take to fill up the CSI 2600’s internal RAM
depends on how periodic predictive data storage settings are configured in the database.
This data will also begin to FIFO when the memory buffer is full.
Data extraction from the CSI 2600
If the computer is reconnected while the CSI 2600 is in DAT recorder mode, any buffered
periodic predictive data that has not been deleted by the FIFO process will automatically
be transferred from internal memory to the database. Transient data will only be written to
the database if a transient alarm event has occurred and the associated data has not been
deleted by the FIFO process. Each transient channel can transfer a configurable amount of
data (up to 30 minutes before and after) when a predefined transient alarm event has
occurred.
When the computer is reconnected, portions of recorded data can be extracted on
demand with AMS Machinery Manager Vibration Analysis. Field-based processing of
multiplexed predictive data continues as usual while Vibration Analysis extracts data.
CAUTION!
If the computer is not connected, data may be lost or overwritten.
3.7 Store data on a NAS hard drive
The default streaming location is the internal hard drive. However, an external NAS drive
can be used as an alternative transient streaming location. The CSI 2600 supports NAS
drives up to 250 GB in size. You can use a NAS hard drive as the primary drive for transient
storage or as a failover drive.
Prerequisites
Connect the NAS drive to the same port that is used to connect to the computer. The NAS
drive must be capable of continuous write speeds of >20 MB/s, 100 Base-T minimum, and
rated for a 100% duty cycle.
Procedure
1. In the AMS Machinery Manager Online Configuration tree structure, click one of the
units to display the Unit Properties dialog.
2. Configure values in the External Network Folder Specifications field.
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MHM-97453, Rev 1 13

Online Configuration—External Network Folder SpecificationsFigure 3-3:
External Network Folder Specifications dialog fieldsTable 3-1:
Field Values Explanation
UNC Path (variable) Specifies the to the NAS drive folder where the unit
should stream transient data.
Allowed Drive Space 1–250 GB Specifies the limit for transient data on the NAS
drive. The data will begin to FIFO when it reaches
this limit.
Use Drive Space As Primary Indicates that the NAS drive is to be used as the
primary streaming location (replacing the internal
hard drive.
Failover Indicates that the NAS drive is to be used as a fail-
safe location in the event that the internal hard
drive fails.
Credentials Username and Password Specifies the username and password that will
access the NAS drive folder named in UNC Path.
Example: Storage
If a 250 GB NAS drive is storing data from 24 transient channels, then it can store
approximately 260 hours of data before it begins to overwrite the oldest measurements. If
only 12 channels are streaming data, about 520 hours can be stored.
3.8 Network configuration
IP addresses are unique addresses that systems on a network use to communicate with
each other.
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Example CSI 2600 system IP addressesTable 3-2:
CSI 2600 Main Processor IP 192.168.0.10
CSI 2600 Transient Processor IP 192.168.0.11
Computer IP 192.168.0.1
Notes
•The IP addresses shown are defaults. If two or more systems will be used, each should be
given a unique IP address.
•IP addresses should be given subnet masks. Transient extraction may fail without them. See
Section 5.7.6 for information on specifying subnet masks.
The computer's Ethernet port is connected to the CSI 2600. The port has an address. The
CSI 2600 has two processing boards, both of which communicate using the same physical
Ethernet connection on the CSI 2600 front panel. These boards have IP addresses that are
stored in non-volatile memory (memory that does not get cleared when you turn the unit
off). For a CSI 2600 system to communicate:
•the IP address of the computer must match a value stored in non-volatile memory in
each CSI 2600 processing board.
•the IP address of the CSI 2600 Main Processor board must match a value listed in
AMS Machinery Manager software, which is associated with the database in use.
In short, the CSI 2600 must “know” its server address, and the computer must “know” the
IP address of any CSI 2600.
3.9 System architecture
3.9.1 CSI 2600 online database diagram
The structure of an online database is designed to mirror the structure of the equipment
being monitored. The database structure for prediction processing diagram shows the
relationships of the various elements of an online database.
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MHM-97453, Rev 1 15

Online database diagramFigure 3-4:
Collection criteria
•Analysis Parameter (AP) Set—Defines a particular way to collect spectral data, and
specifies:
-the number of lines of resolution.
-any averaging modes and windowing.
-whether to be order-based.
-what FMax to use.
-what parameters are to be collected.
•Alarm Limits (AL) Set—Each AL Set is associated with a specific AP Set. There may be
multiple AL Sets defined for any given AP Set to accommodate changing monitoring
conditions. The alarm limit definition determines when alarms occur, data is stored,
and output relays are set.
•Predicate—A collection predicate is an expression that compares the conditions of
vibration levels, input relay states, and/or machine speeds to determine when data
is collected and transient auto-archives are extracted.
Getting started
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