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.