VibroSystM ZPU-5000 User manual

ZPU™-5000
Acquisition and Processing Unit with ZOOM Version 7.4
User’s Manual
P/N: 9483-06M1A-240

Safety Information
This product is designed and tested in accordance with EN 61010-1 (2001) standards. The following manual
contains information and warnings. They must be followed in order to keep the instrument in a working
condition and ensure safe operation
Safety and Electrical Symbols
Warning - Danger - Identifies conditions or practices that could cause physical harm.
Caution - Identifies conditions or practices that could result in permanent loss of data or
damage the equipment.
Important Information - Must be read and followed.
Alternating current
GND or earth ground
Protective conductor terminal
Electronics common - not linked to earth ground
Isolated common - not linked to earth ground, nor electronics common
Shield connection location
CAT I
Overvoltage (installation or measurement) Category 1
NOTICE: Trademarks referenced herein are trademarks and registered trademarks of VibroSystM Inc. or third parties, and are the property of their respective
owners. Third party trademarks are used for identification purposes only and shall not be construed as indicative of any relationship or endorsement between
VibroSystM Inc. and the third parties.
This manual is provided solely for guidance. VibrosystM Inc. takes no responsibility or liability for any damage caused by accidents, improper installation or
misuse. Liability is limited to the repair and/or replacement of defective products.
VibroSystM Inc. 2727 Jacques-Cartier E. Blvd, Longueuil, QC, Canada J4N 1L7 | Phone: [phone] | U.S. Toll-free Line: 800 663-8379
email: [email protected] | www.vibrosystm.com
2 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

Safety Precautions
Warning - Danger Caution
•Although most instruments and accessories are normally used at
non-hazardous voltage levels, hazardous conditions may still be present in some situations.
•This product is intended to be used by qualified operators and maintenance personnel who
recognize shock hazards and are familiar with the safety precautions required to avoid
possible injury. Carefully read and follow all installation, operation, and maintenance
information before using this product.
•Install and use this product only as specified in this manual or the protection provided by this
instrument might be impaired.
•Do not use this product in wet environments.
•When in doubt that safety protection has been impaired, make this instrument inoperative
and secure it against any unintended operation.
•Have this instrument serviced by qualified service personnel only.
•To avoid shock hazards, connect the power supply to a properly grounded power source. If a
two-conductor power cord is used, a protective grounding wire must be connected between
the ground terminal and earth ground before connecting the power cord or operating the
instrument.
•Never remove the cover or open the case without first turning off the main power source.
•Never operate this instrument with the cover removed or the case open.
•Use caution when working with voltages above 30 VAC RMS or 42 VDC. These voltages can
cause shock hazards.
•Only use the replacement fuse(s) specified in this manual.
•Do not operate this instrument around explosive gas, vapor, or dust.
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 3

TABLE OF CONTENTS
1. OVERVIEW OF THE ZPU-5000 7
1.1 Supported software and types of measurements 7
1.2 Features and functions 8
1.3 ZPU-5000 components 8
1.3.1 ZPU-5000 unit - Front view 9
1.3.1.1 Front panel display 9
1.3.1.2 Keypad 9
1.3.1.3 Front panel LED indicators 9
1.3.1.4 USB port 10
1.3.2 ZPU-5000 unit - Rear view 11
1.3.2.1 Analog I/O modules 11
1.3.2.2 Control module 11
1.3.2.3 Communication module 12
1.3.2.4 Power input 12
1.3.2.5 Protection fuse 12
1.3.2.6 Protective conductor terminal 12
2. INSTALLATION 13
2.1 Installing the ZPU-5000 in a cabinet or enclosure 13
2.1.1 Connecting the power cord and chassis grounding wire 13
2.1.2 Installing modules in the ZPU-5000 unit 15
2.2 Dual-channel analog I/O modules 16
2.2.1 Analog I/O module - Input 17
2.2.1.1 4 to 20 mA current input modules 17
2.2.1.2 Fiber optic accelerometer (FOA) input modules 18
2.2.1.3 Piezoelectric accelerometer (ICP) input modules 19
2.2.1.4 Voltage input modules 20
2.2.2 Analog I/O module - Outputs 21
2.3 Control module 22
2.3.1 SYNCHRO 1/rev. inputs 22
2.3.2 SYNCHRO 1/rev. output 23
2.3.3 Control inputs 23
2.3.4 Relay driver outputs 25
2.4 Communication module 26
2.4.1 USB Port 26
2.4.2 Ethernet Port 26
2.4.3 RS-485/422 Port 26
4 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

3. OPERATION 28
3.1 Startup (boot-up sequence) 28
3.2 Using the keypad 30
3.3 Overview of the display in monitoring mode 31
3.3.1 View spectral band parameters 32
3.3.2 View air gap parameters 33
3.4 Overview of the options in the Menu mode 34
3.4.1 Import a configuration 35
3.4.2 Export a configuration 35
3.4.3 View information about VibroSystM 36
3.4.4 View the ZPU-5000 system information 36
3.4.5 View the modules information 36
3.4.6 Export alarms 36
3.4.7 View or acknowledge alarms 36
3.4.8 Acknowledge all alarms 36
3.4.9 View System OK information 36
3.4.10 Adjust the front panel brightness 37
3.4.11 Change the power saving option 37
3.4.12 Attribute a unit address 37
3.4.13 Change the IP address protocol (enable or disable DHCP) 37
3.4.14 View or edit communication port settings 37
3.4.15 Select the Network or Standalone mode 38
3.4.16 Create access codes and attribute access rights 38
3.4.17 View or delete existing access codes assigned to users 39
3.4.18 Export log files 39
3.4.19 Restart the unit 40
3.4.20 Uninstall the firmware 40
3.5 Firmware update to version 7.4 with a prepared USB key 40
4. CONFIGURING THE ZPU-5000 WITH ZOOM SOFTWARE 42
4.1 Module firmware and spectral analysis processing 42
4.2 Processes for Trend outputs 42
5. TROUBLESHOOTING 43
5.1 Power supply 43
5.2 Boot-up 43
5.3 Network connection 43
5.4 Analog input/output modules 44
5.5 CTRL-100 module 45
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 5

6 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

1. OVERVIEW OF THE ZPU-5000
The ZPU-5000 is a multi-channel acquisition and processing unit designed for monitoring large rotating units
such as turbo-generators, hydroelectric generators, and large motors. Each ZPU-5000 unit can simultaneously
monitor up to 16 high-speed parameters.
The modular construction of the ZPU-5000 unit supports up to eight two-channel analog input/output modules.
Each analog input/output module accomplishes several functions:
•Applies a selected process on each input signal;
•Detects alarms (performs comparisons between alert and danger threshold levels);
•Determines the alarm type (increasing or decreasing value);
•Controls four alarm relay driver outputs;
•Outputs a processed raw value on two analog outputs (4 to 20 mA, and 0 to 10V);
•Outputs a trend value on two analog outputs (4 to 20 mA, and 0 to 10V).
ZPU-5000 units are usually installed in a network configuration that includes at least a server and a database
engine. The network can also include workstations from which users can trigger manual measurements, view
in real-time the data collected, or analyze measurements.
The ZPU-5000 can also operate in a standalone configuration for basic real-time monitoring. In standalone
mode, the ZPU-5000 unit uses relay driver outputs to transmit notifications of alarm.
1.1 Supported software and types of measurements
Important Information
•The information presented throughout this manual applies to ZOOM version 7.4 only.
When installed in a network configuration, ZPU-5000 units are linked to a server for connection to a database,
and to establish communication with other equipment. All operations are managed through ZOOM software
services:
ZOOM Server
to connect the ZPU-5000 unit to the database and to other ZOOM software
components.
ZOOM Application
to transmit the user’s commands for triggering measurements, display data
through real-time graphic displays, and provide software tools for analysis.
ZOOM Configuration
& ZOOM Update
to make configuration changes and transmit firmware updates that will be stored in
the ZPU-5000 internal memory.
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 7

The internal memory of a ZPU-5000 unit also supports the firmware and tables needed by four ZOOM data
acquisition and communication services:
Available plug-ins
ZOOM ZPU5000
ZOOM ThermaWatch® Stator
ZOOM Modbus®
ZOOM OPC
ZPU-5000 units collect data in one of four measurement types:
Possible Measurements
Pole
Sampling
Trending
Alarm
1.2 Features and functions
The ZPU-5000 executes various types of measurements in both automatic and manual mode, and transmits
information to the server running the ZOOM software for rapid display and analysis of collected data.The
ZPU-5000 uses high-speed TCP/IP communication protocols to communicate with the server.
The ZPU-5000 can synchronize the acquisition of all parameters with the passing of each rotor pole for salient
pole units. It tracks up to 16 high speed inputs (air gap, displacement, vibration, etc.) from standstill to
over-speed conditions. It is also possible to interconnect additional ZPUs to extend monitoring range and
capabilities.
The ZPU-5000 is linked via its 10/100 Mbps Ethernet port to a network that includes the server. It can also be
operated locally in a standalone configuration without connection to a server.
1.3 ZPU-5000 components
A complete ZPU-5000 unit is made of:
•one ZPU-5000 processing unit
•one control module
•one communication module
•at least one (and up to eight) analog/digital acquisition module
8 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

1.3.1 ZPU-5000 unit - Front view
The front panel user interface includes a front panel display, a seven-button keypad, four LED indicators, and
one USB port.
1.3.1.1 Front panel display
The front panel display shows messages on a 256 x 128 dot grid. In Menu mode, the display shows
configuration information. In Monitoring mode, the display shows real-time measurement values, text and bar
graphs.
1.3.1.2 Keypad
The 7-button keypad allows browsing through the various displays.
1.3.1.3 Front panel LED indicators
ALARM ACKNOWLEDGE provides a visual notification that a new alarm has been triggered.
• Turns Orange upon startup, then turns Green to confirm that no new alarm has been triggered and that
all prior alarms have been acknowledged.
• Turns Orange when an event has triggered an alarm awaiting to be acknowledged.
CHANNELS ALERT/ DANGER provides an instant visual notification of preset alarm threshold violations
on selected processed input channels.
• Turns Red upon startup, then turns OFF until an alarm event occurs.
• Turns Yellow when an alert type event (a measurement has reached the first threshold) has occurred and
remains Yellow as long as the alert condition remains.
• Turns Red when a danger type event (a measurement has reached the second threshold) has occurred
and remains Red as long as the alert condition remains.
SYSTEM OK confirms the operational status of the ZPU-5000 and of its interactions with the ZOOM
system.
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 9

• Turns Yellow upon startup, then turns Green as long as the system is operating correctly.
•Green indicates that the ZPU-5000 is properly connected to its ZOOM ZPU5000 service through the
ZOOM server.
• Turns Orange when a system component malfunction occurs, such as a ZOOM plug-in interruption, a
network connection error, or other malfunction type.
• Flashes Yellow while files are copied from a USB key, and turns Yellow once the copying process is
completed.
CHANNELS OK confirms the integrity of the measuring chains (sensors and cables) and of the input
of all analog I/O modules.
• Turns Yellow upon startup, then turns Green after the firmware has completed the boot-up sequence and
all measuring chains are confirmed as functional.
• Remains Green as long as all measuring chains are functional.
• Turns Orange when one measuring chain or more becomes saturated (defective sensor, faulty
connection).
1.3.1.4 USB port
The USB port allows connection of a portable storage device to copy or save the configuration or update the
firmware. An entire system configuration and system firmware can be stored on the drive to be copied or
upgraded. The drive can be inserted into the USB port while the unit is running.
Important Information
•U3 USB smart drives are not compatible with the ZPU-5000’s operating system. Apart from this restriction,
any portable USB flash drive formatted to FAT32 can be used.
A storable system configuration includes:
• System related information:
- Analog input/output firmware;
- Control module firmware;
- Operating system;
- All plug-in installations.
• Analog input/output parameters:
- Input sensor type;
- Input range;
- Input units of measurement;
- Processing;
- Output range;
- Output units;
- Alarm thresholds.
10 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

1.3.2 ZPU-5000 unit - Rear view
Terminal block connectors with removable female screw terminal connectors allow permanent wiring of cable
harnesses with the advantage of quick connect/disconnect.
Format
Location
Recommended Wire Size
3-pos.
ZPU-5000 Power Input
1,5 mm2[16 AWG] (300 V rating)
1-pos.
ZPU-5000 Protective Conductor Terminal
1,5 mm2[16 AWG], up to 6 mm2[10 AWG]
3-pos.
Analog I/O Modules
0,5 - 0,34 mm2[20 - 22 AWG]
14-pos.
Analog I/O Modules
0,5 - 0,34 mm2[20 - 22 AWG]
6-pos.
Communication Module
0,5 - 0,34 mm2[20 - 22 AWG]
4-pos.
Control Module
0,5 - 0,34 mm2[20 - 22 AWG]
5-pos.
Control Module
0,5 - 0,34 mm2[20 - 22 AWG]
7-pos.
Control Module
0,5 - 0,34 mm2[20 - 22 AWG]
9-pos.
Control Module
0,5 - 0,34 mm2[20 - 22 AWG]
1.3.2.1 Analog I/O modules
Up to eight dual-channel analog I/O modules can be present to receive and process signals from various
sensors and conditioners. Each channel also provides four analog outputs and four open-collector outputs for
controlling remote alarm relays.
1.3.2.2 Control module
One control module is dedicated to the management of the control and synchronization signals for the
ZPU-5000 unit. Related inputs and outputs include:
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 11

• Synchronization inputs;
• Synchronization output;
• Alarm inhibit;
• External trigger;
• Acquisition trigger;
• Rotation;
• “System OK” relay driver;
• “Channels OK” relay driver;
• Two relay drivers for optional configurations (configurable in the ZOOM software).
1.3.2.3 Communication module
This module enables communication to various instruments:
• One Ethernet 10/100 Mbps port for communication with a server;
• One USB port (same function as the one on the front);
• One serial port for half-duplex RS-485 (TWS and Modbus RTU) or full-duplex RS-422 (Modbus RTU)
communication.
1.3.2.4 Power input
A 3-position removable female type screw terminal connector allows power input wiring. The ZPU-5000 unit
should be installed in compliance with national and local electrical standards.
1.3.2.5 Protection fuse
The ZPU-5000 acquisition unit is protected by a fuse accessible from outside the back panel. Replace only
with the same type of fuse: 3.15A / 250V slow-blow, 5x20 mm.
1.3.2.6 Protective conductor terminal
The protective conductor terminal on the rear panel must be connected to a grounding point in compliance
with local regulations. Grounding through the protective conductor terminal is essential for safety purposes. It
also provides better efficiency against ESD and EMI disturbances.
12 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

2. INSTALLATION
ZPU-5000 units are usually delivered pre-installed and pre-cabled inside a cabinet. ZPU 5000 units can also
be ordered separately as an addition to an existing installation. When ZPU-5000 units are added to a standard
cabinet from VibroSystM, pre-wired harnesses are available.
2.1 Installing the ZPU-5000 in a cabinet or enclosure
The following guidelines will help you plan your equipment cabinet configuration:
• Allow sufficient clearance around the cabinet or enclosure for maintenance;
• Make sure the internal temperature inside the enclosure does not exceed 50°C [122°F];
• Cables must be kept away from electrical noise sources, such as power lines and fluorescent lighting
fixtures.
• Keep signal cables separated from power cables;
• The unit must be kept away from electrically conductive dust, water or moisture;
• When mounted in an enclosed cabinet, it is suggested to allow a space of at least 5 1/4” (3U) above each
component for ventilation;
• Side support angles are required to install the unit in a cabinet.
2.1.1 Connecting the power cord and chassis grounding wire
Warning - Danger Caution
• The ZPU-5000’s power supply and grounding connection should be installed in accordance with national
and local electrical norms.
• To ensure protection, the chassis grounding wire (protective conductor terminal) must be of a gauge
heavier or equal to the gauge of the AC input wires.
The protective conductor terminal must be connected to a grounding point
in compliance with local regulations. Grounding is essential for safety
purposes as well as to provide better efficiency against ESD and EMI
disturbances.
For safety purposes, a 15A circuit breaker should be included in the circuit supplying power to the ZPU-5000.
Several instruments may be connected to a circuit protected by a circuit breaker, but each instrument must
have its own disconnect device.
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 13

A 3-position panel header and a mating connector are provided for power input.
* Note: Newer models of ZPU-5000 units are protected by a single fuse, and are offered in various AC and
DC power input ranges.
14 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

2.1.2 Installing modules in the ZPU-5000 unit
Modules of the correct type must be placed in the correct slots. Slot 9 is dedicated to the Control module, and
slot 10 is dedicated to the Communication module. Slots 1 to 8 are reserved for Analog I/O modules and the
location of each must match the ZPU-5000 Hardware Configuration form.
To install a module, carefully align the module in the
top and bottom guide rails, push the module in the
ZPU-5000, and tighten the two thumb screws.
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 15

2.2 Dual-channel analog I/O modules
Dual-channel analog I/O modules convert input signals according to selected processes and generate
corresponding analog signals. All analog I/O modules have the same pinout, but each module is
factory-configured for a specific input source.
Important Information
•The processed raw output does not correspond to the sensor’s signal: the frequency content of the
processed raw output signal is present, but is adapted according to the sensor configuration as set with
the ZOOM Configuration software.
•The modules do not supply power to the measuring chains. An external power supply is required.
16 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

2.2.1 Analog I/O module - Input
Each channel received an input signal on a 3-position panel header with a mating connector. Each module is
factory-configured for a specific input source.
2.2.1.1 4 to 20 mA current input modules
Module
Input Range
Maximum Processed Range (BW)
AGM-4/20
4 to 20 mA
According to Air Gap Measuring Chain (DC to 1000 Hz)
CIM-4/20
4 to 20 mA
According to Measuring Chain (DC to 1000 Hz)
Connection
Input channel characteristics
•Input impedance: 200 Ω
Jumpers on the circuit allow a grounded or ungrounded 4 to
20 mA loop.
Important Information
•Modules are shipped with JP1 and JP2 jumpers installed.
JP2 - Channel 1: jumper installed = grounded
jumper removed = ungrounded
JP1 - Channel 2: jumper installed = grounded
jumper removed = ungrounded
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 17

2.2.1.2 Fiber optic accelerometer (FOA) input modules
Module
Input Range
Input Sensitivity
Maximum Processed Range (BW)
Acceleration
Velocity
Displacement
FIM-40-100
0 to 40 g Peak
100 mV/g
40 g Peak
(15 to 1000 Hz)
100 mm/s Peak
(30 to 1000 Hz)
2000 µm Peak to Peak
(30 to 1000 Hz)
FIM-40-100(LF)
0 to 40 g Peak
100 mV/g
(not applicable)
30 mm/s Peak
(10 to 1000 Hz)
(not applicable)
Connection
18 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual

2.2.1.3 Piezoelectric accelerometer (ICP) input modules
Module
Input Range
Input Sensitivity
Maximum Processed Range (BW)
Acceleration
Velocity
Displacement
ICPM-1.13-500
1.13 g Peak
500 mV/g
1.13 g Peak
(0.7 to 1000 Hz)
28 mm/s Peak
(0.7 to 1000 Hz)
2000 µm Peak-to-Peak
(0.7 to 1000 Hz)
ICPM-5.65-500
5.65 g Peak
500 mV/g
5.65 g Peak
(0.7 to 1000 Hz)
56 mm/s Peak
(0.7 to 1000 Hz)
2000 µm Peak-to-Peak
(0.7 to 1000 Hz)
ICPM-1.13-100
1.13 g Peak
100 mV/g
1.13 g Peak
(0.7 to 1000 Hz)
28 mm/s Peak
(0.7 to 1000 Hz)
2000 µm Peak-to-Peak
(0.7 to 1000 Hz)
ICPM-5.65-100
5.65 g Peak
100 mV/g
5.65 g Peak
(0.7 to 1000 Hz)
28 mm/s Peak
(0.7 to 1000 Hz)
2000 µm Peak-to-Peak
(0.7 to 1000 Hz)
Connection
ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual 19

2.2.1.4 Voltage input modules
Module
Input Range
Maximum Processed Range (BW)
VIM 0/+5
0 to 5 V
According to Measuring Chain (DC to 1000 Hz)
VIM -5/+5
-5 to 5V
According to Measuring Chain (DC to 1000 Hz)
VIM 0/10
0 to 10 V
According to Measuring Chain (DC to 1000 Hz)
VIM -10/+10
-10 to 10 V
According to Measuring Chain (DC to 1000 Hz)
VIM -2/-18
-2 to -18 V
According to Measuring Chain (DC to 1000 Hz)
Connection
20 ZPU-5000 Acquisition and Processing Unit with ZOOM Version 7.4 - User’s Manual