Emerson AMS 6500 User manual

Reference Manual
MHM-97125-PBF-EN, Rev 0
May 2017
AMS 6500 Machinery Health Monitor
A6560R Processor Module and A6510 Signal Input Module

Copyright
© 2017 by Emerson. All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any
language in any form by any means without the written permission of Emerson.
Disclaimer
This manual is provided for informational purposes. EMERSON MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Emerson shall not be liable for errors, omissions, or inconsistencies that may be contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is
subject to change without notice and does not represent a commitment on the part of Emerson. The information in this manual is
not all-inclusive and cannot cover all unique situations.
Trademarks and Servicemarks
See http://www2.emersonprocess.com/siteadmincenter/PM Central Web Documents/marks.pdf
All other marks are property of their respective owners.
Patents
The product(s) described in this manual are covered under existing and pending patents.

Contents
Chapter 1 Introduction ...................................................................................................................1
1.1 About this manual ........................................................................................................................1
1.2 Documentation conventions .......................................................................................................1
1.3 Technical Support and Customer Service ..................................................................................... 2
1.5 China RoHS Compliance ...............................................................................................................3
Chapter 2 Product Introduction ......................................................................................................5
2.1 AMS 6500 front view ....................................................................................................................6
2.2 System walkthrough .................................................................................................................... 7
2.3 System documentation ................................................................................................................7
Chapter 3 Sensor installation ........................................................................................................13
Chapter 4 Enclosure mounting ..................................................................................................... 15
4.1 Junction boxes ........................................................................................................................... 15
4.2 Wall mount enclosures .............................................................................................................. 18
4.3 AMS 6500 rack chassis ............................................................................................................... 19
Chapter 5 Cabling requirements ...................................................................................................25
5.1 Guidelines for conduit installation ..............................................................................................25
5.2 Online instrumentation cable .....................................................................................................26
5.3 Pull cable from the junction box to the unit ................................................................................27
5.4 Physical network segment for the unit ....................................................................................... 28
5.5 Power circuit guidelines for the unit enclosure ...........................................................................28
5.6 Recommendations for improving signal quality ......................................................................... 30
Chapter 6 Wire terminations ........................................................................................................33
6.1 Terminate instrumentation wiring ............................................................................................. 33
6.2 Terminate bundled cable ........................................................................................................... 36
6.3 Wire termination at the AMS 6500 .............................................................................................37
6.4 Signal routing from the monitoring panel to the prediction panel ..............................................43
6.5 Terminate discrete I/O ............................................................................................................... 44
6.6 Rear shield/Adapter panel—A6500-M-RSH .................................................................................46
6.7 Terminate +24 V power for the A6560 and A6510 modules ....................................................... 46
6.8 Eddy Current sensor: -24 V power supply ................................................................................... 47
6.9 SysFail relay termination ............................................................................................................ 48
6.10 Loop interconnection for 4-20 mA current ................................................................................. 48
6.11 Terminate Ethernet connection ................................................................................................. 49
6.12 Default schema for network addressing .....................................................................................50
Chapter 7 Hardware configuration ...............................................................................................53
7.1 Hardware configuration: overview ............................................................................................. 53
7.2 The A6560R and A6510 modules ............................................................................................... 54
7.3 Configure the A6560R with a terminal emulator ........................................................................ 62
Chapter 8 Software configuration ................................................................................................ 67
8.1 System overview diagram .......................................................................................................... 67
8.2 System configuration overview ..................................................................................................68
8.3 Install AMS Machinery Manager ................................................................................................. 69
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8.4 Configure the FTP server to download firmware .........................................................................69
8.5 Connect the A6560R CPU to AMS Machinery Manager ...............................................................73
Chapter 9 Data collection and analysis ..........................................................................................75
9.1 Online database diagram .......................................................................................................... 75
9.2 View or edit IP addresses with the unit ....................................................................................... 77
9.3 Verify or assign a unit IP address to the Online Server in RBM Network Administration ...............78
9.4 Add a unit's IP address to the Online Server in RBM Network Administration .............................. 79
9.5 Online database configuration: overview ................................................................................... 79
9.6 Online Watch overview .............................................................................................................. 83
9.7 Archive management ................................................................................................................ 86
9.8 Create an archive manually ........................................................................................................ 87
9.9 Disable archive predicates ..........................................................................................................87
9.10 Stop transient acquisition .......................................................................................................... 88
9.11 Remove an archive from the Transient Archive Status tab ..........................................................88
9.12 Change databases when moving the AMS 2600 to a new machine .............................................89
Chapter 10 Specifications ...............................................................................................................91
10.1 AMS 6500 Machinery Health™ Monitor specifications ................................................................ 91
10.2 Environmental specifications ..................................................................................................... 92
10.3 A6560R Processor module LEDs .................................................................................................92
10.4 A6510 Signal Input module LEDs ............................................................................................... 95
Chapter 11 System calibration ....................................................................................................... 97
11.1 System calibration overview ...................................................................................................... 97
Chapter 12 Data types ..................................................................................................................101
12.1 Gross Scan analysis .................................................................................................................. 101
12.2 Spectral analysis .......................................................................................................................102
12.3 Time Waveform analysis .......................................................................................................... 103
12.4 Non-Vibration unit analysis types .............................................................................................104
12.5 Set DC offset ............................................................................................................................104
Index ................................................................................................................................................107
Contents
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1 Introduction
Topics covered in this chapter:
•About this manual
•Documentation conventions
•Technical Support and Customer Service
•Disclaimer
•China RoHS Compliance
1.1 About this manual
This document covers the standard system components of the prediction system. For
some installations, non-standard components may be purchased with the online system;
for each of these components, Emerson will include an installation guide supplement. If
the product component cannot be found in the installation guide, please contact your
project manager to request an installation guide supplement.
Other available manuals detail protection capabilities.
WARNING!
All wiring should be installed by a qualified electrician. Wiring must conform to all applicable
local codes and regulations. Local codes and regulations regarding wire type, wire size, color
codes, insulation voltage ratings, and any other standards must be followed.
1.2 Documentation conventions
The following conventions are used throughout:
Note
A note paragraph contains special comments or instructions.
CAUTION!
A caution paragraph alerts you to actions that can have a major impact on the equipment or
stored data.
WARNING!
A warning paragraph alerts you to actions that can have extremely serious consequences for
equipment and/or personnel.
Introduction
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1.3 Technical Support and Customer Service
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 Machinery 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.
Customer Service
Contact Customer Service for all non-technical issues, such as ordering replacement parts.
Contact us
For Emerson Technical Support and Customer Service Toll Free numbers, email addresses,
and hours of operation, please visit
http://www2.emersonprocess.com/en-US/brands/sureservice/Pages/TechnicalSupport.aspx
1.4 Disclaimer
This manual is provided for informational purposes. EMERSON MAKES NO WARRANTY OF
ANY KIND WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Emerson shall not be liable for errors, omissions, or inconsistencies that may be contained
herein or for incidental or consequential damages in connection with the furnishing,
performance, or use of this material. Information in this document is subject to change
without notice and does not represent a commitment on the part of Emerson. The
information in this manual is not all-inclusive and cannot cover all unique situations.
Introduction
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1.5 China RoHS Compliance
Our products manufactured later than June 30, 2016 and which are sold in the People's
Republic of China are marked with one of the following two logos to indicate the
Environmental Friendly Use Period in which it can be used safely under normal operating
conditions.
Products without below mentioned marking are either manufactured before June 30 or are
non Electrical Equipment Products (EEP).
Circling arrow symbol with "e": The product contains no hazardous substances over
the Maximum Concentration Value and it has an indefinite Environmental Friendly
Use Period.
Circling arrow symbol with a number: This product contains certain hazardous
substances over the Maximum Concentration Value and it can be used safely under
normal operating conditions for the number of years indicated in the symbol. The
names and contents of hazardous substances can be found in folder "China RoHS
Compliance Certificates" on the documentation CD or DVD enclosed with the
product.
Introduction
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Introduction
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2 Product Introduction
Topics covered in this chapter:
•AMS 6500 front view
•System walkthrough
•System documentation
Product Introduction
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2.1 AMS 6500 front view
AMS 6500 front view with A6560R and A6510 modulesFigure 2-1:
A. Front power switch
B. A6560R Status LEDs
C. A6510 Status LEDs
D. Module name
E. 2 Ethernet ports — NIC and Hub
F. Serial port
G. Handles
Product Introduction
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2.2 System walkthrough
Perform a system component review to ensure that the proper system components have
been shipped, and that nothing has been lost or damaged during shipment. Unpack and
inspect to confirm all system components are present. After installation, physically walk
through each part of the installation to review:
□Sensor mounting locations
□Cable pulls
□Conduit/cable tray use
□Enclosure mounting locations
□Environmental concerns
2.3 System documentation
Typical system documentation includes at least a System Overview Drawing, System
Layout Drawings, a Cable Administration Chart.
2.3.1 System overview drawings
AMS 6500 system documentation should include system overview drawings that illustrate
how system components interconnect. Create system overview drawings for your system
and update them as you make any changes to your system.
Product Introduction
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Example system overview drawingFigure 2-2:
A system overview drawing typically includes the following information:
•AMS 6500 units
•Junction/switch boxes
•Cables
•AMS 6500 Network Segment Cables
•Tags for each AMS 6500, junction/switch box, and cable
2.3.2 System layout drawings
The system layout drawings illustrate exact locations for enclosure mounting, conduit
installation, cable pulls, and sensor mounting. The most common method for preparing
these drawings is to copy blueprints of the plant floor/production line and mark the system
installation locations. Use color-coded highlights and symbols to mark the different types
of cable runs and enclosure mountings.
Product Introduction
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Example system layout marking guidelinesTable 2-1:
Symbol Description Labels
Enclosure Type: 701 (2,3), 745, 6500
Tag: defined by plant
Instrumentation Type: sensor part #
Tag: defined by plant
Location:
•I—Inboard
•O—Outboard
•A—Axial
•H—Horizontal
•V—Vertical
——————— Exposed cable
– – – – – – – – Cable in conduit
— - — - — - — Cable tray
Example system layout marking guidelinesTable 2-1:
Color codes Cable type
Red Instrumentation
Blue Multi-pair bundled cable
Green AMS 6500 network cabling
2.3.3 Cable administration charts
Cable administration charts document wire terminations within system enclosures. Tag
names should be consistent and represent physical locations or machines. For instance,
instead of naming a sensor 23001, use a name like FAN1OV (fan number 1 outboard
vertical) to make system maintenance and troubleshooting easier. After tags are assigned,
document them in cable administration charts. All enclosures for the system need cable
administration charts.
There are two types of cable administration charts for the online system: junction box and
AMS 6500 enclosure.
Junction box cable administration chart
The online system junction boxes provide a junction between the instrumentation cable
and the multi-pair bundled cable that is pulled back to the AMS 6500. The cable
administration chart for a junction box documents the channel number, wire tag, sensor
type, and sensor location if the wire tag does not contain location information. Figure 2-3
shows a typical installation.
Product Introduction
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Junction box cable administration chartFigure 2-3:
AMS 6500 enclosure cable administration chart
The AMS 6500 has cable terminations for sensors, tachometers, discrete I/O, network, and
power; it also has configurable DIP switches and jumpers.
The cable terminations and DIP switch settings should be documented in cable
administration charts or CAD drawings.
Example AMS 6500 cable administration chartTable 2-2:
Processor module
AMS 6500 tag name:
A6560R CPU module MAC address:
Network cable tag:
MSIG #1 sensor inputs
Channel # Junction box
tag
Wire tag Sensor type DIP setting Sensor location
1
2
3
4
5
6
7
8
9
10
11
12
Product Introduction
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Example AMS 6500 cable administration chart (continued)Table 2-2:
Tachometer inputs
1
2
Discrete I/O
1
2
MSIG #2 sensor inputs
Channel # Junction box
tag
Wire tag Sensor type DIP setting Sensor location
1
2
3
4
5
6
7
8
9
10
11
12
Tachometer inputs
1
2
Discrete I/O
1
2
2.3.4 Documentation storage
Make copies of system overview drawings, system layout drawings, and mechanical and
electrical drawings. Keep them in the system enclosure to allow easy reference by analysts
and service personnel.
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Product Introduction
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3 Sensor installation
Ensure sensors are installed according to instructions provided by the sensor manufacturer
and industry best practices.
Sensor installation
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Sensor installation
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4 Enclosure mounting
Topics covered in this chapter:
•Junction boxes
•Wall mount enclosures
•AMS 6500 rack chassis
4.1 Junction boxes
Junction boxes are used to terminate online instrumentation wiring. Emerson
recommends junction boxes with 12 channels, housed in a fiberglass or stainless steel
enclosure. They should consist of individual, 3-lug terminal blocks mounted on a DIN rail.
4.1.1 Mount junction boxes
1. Ensure the chosen mounting location is well lit and allows proper clearance for
maintenance access.
Enclosure mounting
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Junction box access requirementsFigure 4-1:
Junction boxes require a 180° opening.
2. Prepare the mounting bracket using the outline drawing as a template for the
mounting hole locations.
3. Use the machine screws to attach the mounting feet to the back of the enclosure.
Align mounting feet vertically to ensure proper access.
Torque screws to 31 in-lb.
4. Using bolts provided by the contractor, attach the enclosure to the mounting
bracket.
4.1.2 Junction box wiring notes
CAUTION!
Never cross-connect shields from different sensors in junction boxes.
Enclosure mounting
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