Nidec Kato Engineering KRM2000 User manual

User Manual
KRM2000
Kato Rotor Monitoring System
Protected by Patents:
US #6794883B2
EP #1499903A4
Revision 1.0.5
January 5, 2018
Manual # 352-56001-09
PLEASE READ THIS MANUAL AND ALL INCLUDED MANUALS IN ITS ENTIRETY BEFORE UNPACKING,
INSTALLING, AND OPERATING THE KRM2000TM SYSTEM. IF YOUR MANUAL CAME ON A CD, READ ALL THE
FILES INCLUDED ON THE CD.

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This page intentionally left blank (back of front cover).

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Copyright © 2013 Kato Engineering
Because of rapid changes in design and processes
and the variability of Kato Engineering’s products,
information in this manual must not be regarded
as binding and is subject to change without notice.
Kato Engineering Inc.
P.O. Box 8447
Mankato, MN USA 56002-8447
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.kato-eng.com

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WARNING:IN ORDER TO PREVENT INJURY OR EQUIPMENT DAMAGE,
EVERYONE INVOLVED IN THE INSTALLATION, OPERATION, AND MAINTANCENCE OF THIS
PRODUCT MUST BE QUALIFIED AND TRAINED OF THE CURRENT SAFETY STANDARDS
THAT GOVERN HIS OR HER WORK.

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Table of Contents
1Revision History ............................................................................................................ 9
2Introduction.................................................................................................................... 9
2.1 Safety Instructions................................................................................................... 9
2.2 System Description ............................................................................................... 10
2.2.1 Inductive Power Loop Antenna ..................................................................... 12
2.2.2 Dipole Receiver Antenna............................................................................... 12
2.2.3 Receiver ......................................................................................................... 12
2.2.4 Power Supply................................................................................................. 12
2.2.5 Transmitter..................................................................................................... 12
3Specifications............................................................................................................... 13
3.1 Dimensions............................................................................................................ 13
3.2 Electrical................................................................................................................ 15
3.3 Environmental ....................................................................................................... 15
3.4 Certifications ......................................................................................................... 15
4Installation.................................................................................................................... 16
4.1 Mounting ............................................................................................................... 16
4.1.1 Receiver ......................................................................................................... 16
4.1.2 Transmitter..................................................................................................... 17
4.1.3 Inductive Power Loop Antenna ..................................................................... 17
4.1.4 Dipole Antenna .............................................................................................. 17
4.1.5 Power Supply................................................................................................. 18
4.2 System Connections .............................................................................................. 19
4.2.1 Receiver ......................................................................................................... 19
4.2.2 Transmitter..................................................................................................... 20
4.2.3 Loop Antenna................................................................................................. 20
4.2.4 Power Supply................................................................................................. 21
4.2.5 System Diagram............................................................................................. 21
4.3 Electrical Installation............................................................................................. 22
4.3.1 Relay Outputs, Receiver ................................................................................ 22
4.3.2 Digital Outputs, Receiver............................................................................... 23
4.3.3 Loop Antenna Output, Receiver .................................................................... 24
4.3.4 Communication Interfaces, Receiver............................................................. 24
4.3.5 Transmitter..................................................................................................... 25
4.3.6 Power Supply................................................................................................. 25
5Feature Description...................................................................................................... 26
5.1 Functional Block Diagram .................................................................................... 26
5.2 Theory of Operation .............................................................................................. 26
5.3 Setup Features ....................................................................................................... 28
5.3.1 Loop Tuning Type ......................................................................................... 28
5.3.2 Loop Tuning Step Size................................................................................... 28
5.3.3 Communications Setup .................................................................................. 28
5.3.4 EEPROM ....................................................................................................... 30
5.4 Protection Features................................................................................................ 30
5.4.1 Service Fault .................................................................................................. 30
5.4.2 Malfunction.................................................................................................... 30

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5.4.3 Ground Fault .................................................................................................. 31
5.4.4 PWM Re-enable Time Limit ......................................................................... 31
5.4.5 Loop Undervoltage ........................................................................................ 31
5.4.6 Loop Overcurrent........................................................................................... 31
5.4.7 Radio Link Error............................................................................................ 31
5.4.8 Diode Fault..................................................................................................... 31
5.5 Monitoring Features .............................................................................................. 32
5.5.1 Data Points..................................................................................................... 32
6Maintenance................................................................................................................. 33
7Troubleshooting ........................................................................................................... 34
8Appendix...................................................................................................................... 35
8.1 Configure TCP/IP Settings of Communication Modules...................................... 35
8.2 Ethernet/IP............................................................................................................. 37
8.2.1 CIP Object Dictionary.................................................................................... 37
8.3 Data Tables............................................................................................................ 49
8.4 Flash Programming Updates ................................................................................. 51
8.5 Sensing Filter Option ............................................................................................ 53
List of Figures
Figure 1 Typical Location of Rotor Monitoring System Components................................ 11
Figure 2 Receiver Dimensions............................................................................................. 13
Figure 3 Transmitter Dimensions ........................................................................................ 14
Figure 4 Power Supply Dimensions .................................................................................... 14
Figure 5 Receiver DIN Rail Mounting Provision Option 1................................................. 16
Figure 6 Receiver DIN Rail Mounting Provision Option 2................................................. 16
Figure 7 Transmitter Mounting............................................................................................ 17
Figure 8 Dipole Antenna Mounting..................................................................................... 18
Figure 9 Power Supply Mounting........................................................................................ 18
Figure 10 Terminal Connections, Receiver ......................................................................... 19
Figure 11 Terminal Connections, Transmitter..................................................................... 20
Figure 12 Terminal Connections, Loop Antenna ................................................................ 20
Figure 13 Terminal Connections, Power Supply................................................................. 21
Figure 14 System Diagram, Example .................................................................................. 21
Figure 15 Receiver Relay Outputs Wiring Detail................................................................ 22
Figure 16 Receiver Digital Outputs Wiring Detail.............................................................. 23
Figure 17 Receiver Digital Output Internal Circuit ............................................................. 23
Figure 18 Receiver Loop Antenna Wiring Detail................................................................ 24
Figure 19 Transmitter Wiring Detail ................................................................................... 25
Figure 20 24VDC Power Supply Wiring Detail.................................................................. 25
Figure 21 KRM2000TM Functional Block Diagram ........................................................... 26
Figure 22 Anybus IPConfig Scan Example......................................................................... 36
Figure 23 TCP/IP Configurable Settings ............................................................................. 36
Figure 24 Flash File Selection ............................................................................................. 51
Figure 25 Flash Port Configuration ..................................................................................... 52
Figure 26 Flash Download Window.................................................................................... 52
Figure 27 Sensing Filter Wiring/Installation Detail ............................................................ 53

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List of Tables
Table 1 Revision History ....................................................................................................... 9
Table 2 Terminal Connection Descriptions, Receiver......................................................... 19
Table 3 Supported Active Network Modules ...................................................................... 28
Table 4 Replacement/Spare Parts ........................................................................................ 33
Table 5 Troubleshooting Guide ........................................................................................... 34
Table 6 CIP Instance Attributes Model ............................................................................... 37
Table 7 Ethernet/IP CIP Object Dictionary ......................................................................... 37
Table 8 General Control Register ........................................................................................ 49
Table 9 Part Numbers Table Index ...................................................................................... 49
Table 10 Unsigned 32 Bit Integer Min/Max Value Table ................................................... 49
Table 11 Floating Point Min/Max Value Table................................................................... 49
Table 12 GPIO Test Mode Enable Min/Max Table............................................................. 50
Table 13 GPIO Test Mode Data Min/Max Table ................................................................ 50

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1Revision History
The following table contains the Revision History which pertains to this document only.
Table 1 Revision History
Revision
Date
Description
Engineer
1.0.0
11/2013
Original
KMM
1.0.1
2/2014
Modified figures 14 and 15
KMM
1.0.2
3/2014
Added vibration to environmental section
KMM
1.0.3
3/2014
Updated power supply ratings
KMM
1.0.4
7/2014
Added DFD LED/output toggling info to diode
fault protection features section and to
troubleshooting table. Also corrected DFD
output levels related to malfunction and diode
fault
AMG
2Introduction
This manual contains the instructions to properly install, operate, and maintain Kato Engineering’s
KRM2000TM. The KRM2000TM is a rotor monitoring system for series redundant brushless exciters
that also monitors insulation resistance and detects ground failures utilizing wireless telemetry. This
system is primarily used on large turbine driven synchronous generators.
2.1 Safety Instructions
In order to prevent injury or equipment damage, everyone involved in installation, operating, and
maintenance of the KRM2000TM system described in this manual must be qualified and trained in the
current safety standards that govern his or her work.
While “common-sense” prevention of injury or equipment damage cannot be completely defined by
any manual (nor built into any piece of equipment), the following paragraphs define warnings,
cautions, Notices, and Important as they are used in this manual.
WARNING: Warnings identify an installation, operating or maintenance procedure,
practice, condition, or statement that, if not strictly followed, could result in death or serious injury to
personnel.
CAUTION:Cautions identify a hazardous situation that if not avoided could result in
minor or moderate injury.
NOTICE:Notices identify an installation, operating or maintenance procedure, practice,
condition, or statement that, if not strictly followed, could result in destruction of or damage to
equipment or serious impairment of system operation.
IMPORTANT:Important messages are informational only.

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2.2 System Description
The KRM2000TM rotor monitoring system utilizes 5 components to provide the basic functions as
described previously.
(1) Stationary induction power loop antenna
(2) Stationary dipole receiver antenna
(3) Non-rotating receiver
(4) Power supply
(5) Rotor mounted transmitter
Figure 1 demonstrates these components and their general location. This diagram does not
demonstrate every application, but is provided as a generic guide to how the system is laid out.
WARNING: WHEN WORKING OR MOUNTING ANY COMPONENTS, MAKE SURE
THE PRIMEMOVER AND GENERATOR ARE NOT CAPABLE OF BEING ENERGIZED. USE
APPROPRIATE LOCK OUT/TAG OUT PROCEDURES. FAILURE TO DO SO MAY RESULT IN
SERIOUS INJURY.

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5
1
2
4
3
Figure 1 Typical Location of Rotor Monitoring System Components
WARNING: WHEN OPERATING THE KRM2000TM, MAKE SURE ALL PROTECTIVE
GUARDS ARE IN PLACE. FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR DEATH.

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2.2.1 Inductive Power Loop Antenna
The loop antenna provides power to the rotor mounted transmitter through inductive coupling. The
loop antenna is powered by the receiver, which is connected through the loop antenna connection
block.
2.2.2 Dipole Receiver Antenna
The dipole receiver antenna is used to collect the data wirelessly from the rotor mounted transmitter
back to the stationary mounted receiver. This antenna is mounted to the loop antenna bracket, and
is connected to the receiver through BNC connectors and a coaxial cable.
2.2.3 Receiver
The stationary mounted receiver collects the data from the rotor mounted transmitter through the
dipole antenna. The radio operates at 418MHz. The DSP based receiver is able to translate this
data and can indicate the status of the ground fault and diode fault (optional) detectors. Utilizing the
on board communications, the end-user can also collect data for diagnostic purposes.
2.2.4 Power Supply
The power supply provides 24 Vdc regulated power to the KRM2000TM receiver. The input power
range is 85 Vac to 263 Vac (50-60Hz), making it suitable for applications worldwide.
2.2.5 Transmitter
The transmitter is mounted on the shaft of the rotor, and is capable of monitoring the insulation
resistance between the brushless exciter, generator field, and the rotor shaft (ground). It also
measures the main field voltage and has an optional auxiliary channel for monitoring an optional
rotating diode fault detector. This data is transmitted wirelessly to the stationary receiver. The
transmitter is powered through the inductive loop antenna.

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3Specifications
This section contains all of the dimensional, electrical, and environmental specifications, as well as
the certifications for the KRM2000TM.
3.1 Dimensions
Figure 2 Receiver Dimensions

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Figure 3 Transmitter Dimensions
Figure 4 Power Supply Dimensions

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3.2 Electrical
CONTROL POWER (RECEIVER)
DC Voltage: 18 – 31V
DC Burden: 12.5W
Polarity Protected: No
RELAY OUTPUTS (RECEIVER)
Type: Form A x 3 Sealed
Contact Material: AgSnO2
Operate Time: 10ms
Release Time: 10ms
Minimum Load: 100mA@5VDC
Maximum Load: 2A@250VAC Resistive (120000 Operations)
DIGITAL OUTPUTS (RECEIVER)
Type: Source/Sink x 3
Internal Source Resistance: Open Drain with internal pull up resistance of 10kΩ to V+
Maximum Sink Current: 250mA
3.3 Environmental
TEMPERATURE
Operating: -40 to +70°C
Storage: -40 to +85°C
SHOCK
TBD
VIBRATION
MIL-STD-167-1A
3.4 Certifications
UL RECOGNITION
UL recognized under standard 508, UL file number E233284.

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4Installation
This section describes the mechanical and electrical installation requirements for the KRM2000TM
rotor monitoring system.
4.1 Mounting
The mounting requirements for the transmitter, receiver, inductive power loop antenna, power supply,
and the dipole antenna are described in this section.
4.1.1 Receiver
The KRM2000TM receiver can be DIN rail mounted in the horizontal direction, with a minimum of 3” of
space from the terminal blocks to allow for easy removal. There are two optional locations for the
DIN rail mount, as shown in Figure 5 and 6.
Figure 5 Receiver DIN Rail Mounting Provision Option 1
Figure 6 Receiver DIN Rail Mounting Provision Option 2

4.1.2 Transmitter
The transmitter is typically mounted on the diode wheel at the end of the shaft on the rotor. The
figure below shows the typical mounting requirements.
Black Wire
Connects to
Diode Wheel
DC minus –
Terminal
KATO
ROTOR MONITOR SYSTEM
Blue Wire Connects
to DC Plus Terminal
--Bus Partial View
Diode Wheel Rim
Use Mounting Bolts M6-1x60 mm, 1/4x20x1.75, or
if spacer is used 1/4x20x3.00, Small Outline Flat
Washer, Locktite # 242 on Threads. Torque to 50
in lbs
Figure 7 Transmitter Mounting
4.1.3 Inductive Power Loop Antenna
The inductive power loop antenna is mounted to a loop antenna bracket, which is typically located on
the end frame at the exciter end of the generator. Various loops sizes are available to best fit the
application.
4.1.4 Dipole Antenna
The dipole antenna is mounted to the antenna bracket through a BNC connector. The antenna
bracket is found on the loop antenna bracket.

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BNC
Connectors
Dipole Antenna Lead
to Receiver
Antenna
B kt
Figure 8 Dipole Antenna Mounting
4.1.5 Power Supply
The power supply is DIN rail mountable. For proper cooling of the power supply, there must be 3.15
inches of space above and below the power supply, and 1.97 inches for both of the sides.
-
+
L
G
N
Typical DIN Rail
Mounting
Figure 9 Power Supply Mounting

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4.2 System Connections
The following section demonstrates the terminal requirements as well as overall system connections
required for the KRM2000TM rotor monitoring system. Connections are to be made as instructed in
this manual and/or by any outside system drawings as governed by Kato Engineering only.
4.2.1 Receiver
Table 2 Terminal Connection Descriptions, Receiver
TERMINAL NAME
TERMINAL #
DESCRIPTION
+24V
TB1-1
+24V power supply input
COM
TB1-2
Power supply common
MF RLY
TB1-3
Malfunction relay
GF RLY
TB1-4
Ground fault relay
SERVICE RLY
TB1-5
Service relay
RLY COM
TB1-6
Relay common
GF OUT
TB1-7
Ground fault signal output (source/sink)
DF OUT
TB1-8
Diode fault signal output (source/sink)
MF OUT
TB1-9
Malfunction signal output (source/sink)
N/C
TB1-10
No connect
ANT-H
TB1-11
Loop antenna driver high
ANT-L
TB1-12
Loop antenna driver low
ANTENNA
BNC CONNECTOR
Coax connector for receiver antenna
PORT-A
-
Communications port (Bluetooth)
PORT-B
-
Communications port (USB, see Note 1)
Note 1: See Kato Engineering for supported communication options.
Figure 10 Terminal Connections, Receiver

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4.2.2 Transmitter
Diode
Wheel
Rim
View Left Side
View Right Side
Diode
Wheel
Rim
Right Side
•DFM (+) (Red Wire)
•DFM
(- ) (Green Wire)
•Diode Wheel (- )
(Black Wire)
•Rotor Ground
(Connect To
Mounting Bolt)
(White Wire)
Left Side
•Diode Wheel (+)
(Blue Wire)
Trans-
mitter
Transmitter
Figure 11 Terminal Connections, Transmitter
4.2.3 Loop Antenna
Figure 12 Terminal Connections, Loop Antenna