Vibrosystm Zpu-5000 User manual

P/N 9483-06M1A-221

ZPU™-5000

Acquisition Unit

User’s Manual for ZOOM Version 7.2

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ZPU-5000 Acquisition Unit - User’s Manual

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

Windows Server® is a registered trademark of Microsoft Corporation in the U.S. and/or other countries.

Modbus® is a registered trademark of Schneider Electric and/or such related companies.

ICP® is a registered trademark of PCB Group Inc.

The VibroSystM logo, ZOOM®, ThermaWatch®, and ZPU™are registered trademarks or trademarks of VibroSystM Inc.

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: 450 646-2157 | U.S. Toll-free Line: 800 663-8379

Email: [email protected] | www.vibrosystm.com

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

iso

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Safety Precautions

Measurement Category

This instrument is intended to be used with low-voltage measurements in Measurement Category I

environment circuits.

Measurement, control and data I/O signals are either protected secondary circuits derived from mains or not

directly connected to main voltages or voltage sources. This instrument is protected against transients up to

26V max.

Never connect this instrument to Measurement Category II, III or IV environment circuits.

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 instrument only as specified in this manual or the protection provided by this

instrument might be impaired.

•Do not use this instrument 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.

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1. GENERAL DESCRIPTION................................................................................................... 7

1.1 Available Software, Plug-ins, and Possible Measurements ....................................................................... 7

1.2 Features and Functions................................................................................................................................ 8

1.3 Front View .................................................................................................................................................. 8

1.4 Rear View ................................................................................................................................................... 10

1.5 Typical Module Installation ........................................................................................................................ 11

2. INSTALLATION.................................................................................................................... 12

2.1 Preliminary Considerations Before Installing the ZPU-5000 in a Cabinet or Enclosure ........................... 12

2.2 Powering the ZPU-5000 Unit .................................................................................................................... 12

2.2.1 Main Power Input............................................................................................................................... 13

2.2.2 Protective Conductor Terminal .......................................................................................................... 13

2.3 Dual-Channel Analog Input / Output Modules........................................................................................... 14

2.3.1 Processes for Trend Outputs............................................................................................................... 15

2.3.2 Input Types and Module Specifications............................................................................................. 16

2.3.3 Output Connections and Specifications ............................................................................................. 20

2.4 Control Module ........................................................................................................................................... 21

2.4.1 Control Module Connections and Specifications............................................................................... 21

2.5 Communication Module ............................................................................................................................. 25

3. USING THE ZPU-5000 UNIT................................................................................................ 27

3.1 Front Panel LED Indicators ........................................................................................................................ 27

3.2 Startup (Boot Sequence) ............................................................................................................................. 28

3.3 Manual Firmware Update ........................................................................................................................... 30

3.4 Display During Normal Operation.............................................................................................................. 32

3.4.1 Accessing Frequency Band Parameters ............................................................................................. 34

3.5 ZPU-5000 Controls ..................................................................................................................................... 35

3.5.1 User Interface ..................................................................................................................................... 35

3.5.2 Keypad................................................................................................................................................ 35

3.6 ZPU-5000 Menus........................................................................................................................................ 36

3.6.1 Browsing Through the Menus............................................................................................................ 36

4. TROUBLESHOOTING ......................................................................................................... 42

4.1 Power Supply .............................................................................................................................................. 42

4.2 Boot-Up....................................................................................................................................................... 42

4.3 Network Connection ................................................................................................................................... 42

4.4 Analog Input / Output Modules .................................................................................................................. 43

4.5 CTRL-100 Module...................................................................................................................................... 43

5. GENERAL SPECIFICATIONS ............................................................................................. 45

5.1 Electrical Characteristics............................................................................................................................. 45

5.2 Environmental Characteristics .................................................................................................................... 46

5.3 Dimensions.................................................................................................................................................. 47

TABLE OF CONTENTS

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1. GENERAL DESCRIPTION

The ZPU-5000 is a multi-channel acquisition unit designed for monitoring and protecting large rotating

machines such as turbo-generators, hydroelectric generators, and large motors. it can simultaneously

monitor multiple parameters and communicate with the ZOOM®software.

The ZPU-5000 is usually installed in a network configuration that includes a server and executes complete

online monitoring, analysis, protection, alarm management, and trending of large rotating machines. The

ZPU-5000 can also be run in a standalone configuration.

1.1 Available Software, Plug-ins, and Possible Measurements

Important Information

•The information found throughout this manual applies to ZOOM version 7.2 only.

ZOOM Software Suite

ZOOM Server

ZOOM Configuration

ZOOM Application

ZOOM Server Status

ZOOM Update

Available Plug-ins

ZOOM ZPU5000

ZOOM ThermaWatch®Stator

ZOOM Modbus®

ZOOM OPC

Possible Measurements

Pole

Sampling

Trending

Alarm

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1.2 Features and Functions

The ZPU-5000 executes various types of measurements in both automatic and manual mode. It also

processes data, verifies alarm conditions and transmits information to the server running the ZOOM software

for rapid data interpretation of machine condition. 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 machines. 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 Front View

1Vacuum Fluorescent Display (VFD)

The vacuum fluorescent display illustrates messages on a 256 x 128 dot grid. In Menu mode, the screen

displays configuration information organized as browser menus. In Monitoring mode, real-time

measurement values, text and bar graphs are displayed for identification.

2Keypad

The 7-button keypad is ideal for browsing through the various displays. It allows the user to configure specific

parameters.

The MENU button gives access to the unit’s configuration menu for reviewing or changing configuration

parameters. Once the unit has completed its boot-up routine and starts running in Monitoring mode, press

the MENU button to toggle between Monitoring and Menu modes. In Menu mode, use the ENTER button

to access sub-menu levels, register a selection, or enable/disable a feature. The CANCEL button is used to

cancel a selection when a confirmation is requested. It is also used to move back within the menu, one sub-

menu at a time.

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3 Alarm Trigger LEDs

The ALARM ACKNOWLEDGE LED provides a visual notification that an alarm has been triggered.

The CHANNELS ALERT/DANGER LED provides an instant visual notification of preset alarm threshold

violations on selected processed input channels.

4OK LEDs

The CHANNELS OK LED confirms the integrity of the measuring chains (sensors and cables) and the input

condition of all analog I/O modules. The SYSTEM OK LED confirms the integrity of the system’s operation.

5 USB Port

The USB port allows connection of a portable storage device to copy or save the configuration or update the

firmware.

Portable USB Flash Drive

The front panel features a USB port that accepts a portable flash drive. 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.

A storable system configuration includes:

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.

•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.

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1.4 Rear View

6 Analog I/O Modules

There are up to eight dual-channel analog I/O modules that receive and process signals from various sensors

and conditioners. Each module is factory-configured to receive either current, voltage, or ICP (piezoelectric

sensor) signals from two different sources to which a digital process is applied.

Each channel also provides four analog outputs and four open-collector outputs for controlling remote alarm

relays.

Removable female screw terminal connectors allow quick connection for permanent wiring.

7 Control Module

This plug-in module supervises control and synchronization signals for the ZPU-5000 unit. Related inputs and

outputs include:

•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).

8Communication 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.

6789aJ aA

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9 Power Input

Provides an AC-input connection to the power supply.

A 3-position removable female type screw terminal connector allows AC power input wiring. The ZPU-5000

unit should be installed in compliance with national and local electrical standards.

aJ Protection Fuses (2)

The ZPU-5000 acquisition unit relies on a dual fuse protection system. Replace only with the same type of

fuse: 3.15A / 250V slow-blow, 5x20 mm.

aA 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.

1.5 Typical Module Installation

It is important to properly align the module before inserting it in the ZPU-5000. Follow appropriate guides

located on the built-in rails. See illustration below for reference.

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2. INSTALLATION

Although it is normally delivered installed, pre-cabled in a cabinet and part of a complete system, the ZPU-

5000 acquisition unit can also be ordered separately as an addition to an existing installation.

2.1 Preliminary Considerations Before 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 an electrical noise source, 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.

2.2 Powering the ZPU-5000 Unit

For safety purposes, a 15A circuit breaker should also be included in the AC-input wiring. Several instruments

may be connected to a circuit protected by a circuit breaker. Each instrument must however have its own

disconnection device.

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 must be of a heavier or equal gauge than the wire

associated with the AC input.

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2.2.1 Main Power Input

The ZPU-5000’s main power input is equipped with a 3-position panel header and a threaded flange. It also

comes with a mating connector and a screw flange. See illustration below for reference.

Electrical Characteristics

Input voltage range: 100-240 VAC

Line frequency: 50-60 Hz

Power consumption: 65W Max.

Fuse replacement: 3.15A / 250V slow-blow, 5x20mm

Recommended wire size: 1,5 mm2[16 AWG] (300V rating)

2.2.2 Protective Conductor Terminal

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.

Electrical Characteristics

Wire size: at least 1,5 mm2[16 AWG], up to 6 mm2[10AWG]

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2.3 Dual-Channel Analog Input / Output Modules

Analog input/output modules are two-channel electronic cards capable of converting input signals according

to selected processes and generating corresponding analog signals. A ZPU-5000 unit can accept up to eight

analog input/output modules. For each input channel, the data is processed according to the sensor’s

configuration in ZOOM. Processed raw and trend outputs are then available in both 4 to 20 mA and 0 to 10V

formats for real-time monitoring.

Each channel on the analog input/output module accomplishes five tasks:

•Performs a selected process on an input signal;

•Detects alarms (performs comparisons between alert and danger threshold levels);

•Determines the alarm type (increasing or decreasing value);

•Produces an analog output (4 to 20 mA and 0 to 10V) that represents the processed raw value;

•Produces an analog output (4 to 20 mA and 0 to 10V) that represents the trend value.

Important Information

•The raw output does not correspond to the sensor’s signal and is called processed raw in this manual;

•The processed raw output signal’s frequency content is still present, but adapted according to the sensor’s

configuration in the ZOOM software.

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2.3.1 Processes for Trend Outputs

The trend outputs oversee 8 different value types that can be selected one at a time:

•Raw signal value (no process applied, linear output);

•Air gap or blade tip value;

•RMS value;

•Peak value;

•Peak to peak value;

•Maximum value;

•Minimum value;

•Average.

A) Raw Signal: The output signal from certain types of measuring chains comprised of both AC and DC

components or slow evolving parameters comprised of a slow DC component such as temperature, meter

levels, etc.

In such cases, the “raw signal value” can be selected for an unprocessed signal.

B) Air Gap or Blade Tip: The minimum of each pole (or blade) is detected by the air gap pole detector. This

detector does not have a finite window as it uses the signal’s shape to find the corresponding minimum for

each pole (or blade).

C) RMS: Some applications favor the use of RMS (Root Mean Square) values of acceleration and velocity

readings for vibration measurements. The RMS value process uses only the AC component of the input

signal.

D) Peak: Some applications favor the use of the peak value of acceleration and velocity readings for vibration

measurement. The peak value process uses only the AC component of the input signal.

E) Peak-to-Peak: Some applications favor the use of the peak-to-peak value of displacement readings for

vibration measurement. The peak-to-peak value process uses only the AC component of the input signal.

F) Maximum: Some applications require the maximum value measured by a sensor. The maximum process

detects and returns only the maximum values during a pre-determined time period.

G) Minimum: Some applications require the minimum value measured by a sensor. The minimum process

detects and returns only the minimum values during a pre-determined time period.

H) Average: Some applications require the average value measured by a sensor. The average process

determines the average value during a pre-determined time period.

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2.3.2 Input Types and Module Specifications

All analog I/O modules have the same pinout but each module is factory-configured for a specific input

source.

Input channel connectors are equipped with a 3-position panel header with a threaded flange as well as a

mating connector with a screw flange.

Recommended wire size: 0,5 - 0,34 mm2[20 - 22 AWG]

A) 4 to 20 mA Current Input Module

Note: The modules do not supply power to the measuring chain. An external power supply is required.

Connection

Input Channel Characteristics

•Input Impedance: 200 Ω

Jumpers are available on the circuit to allow a grounded or ungrounded 4 to 20 mA loop. See illustration

below.

JP2 - Channel 1: jumper installed = grounded

jumper removed = ungrounded

JP1 - Channel 2: jumper installed = grounded

jumper removed = ungrounded

Module Input Range Maximum Processed Range (BW)

AGM-4/20 4 to 20 mA According to Air Gap Measuring Chain (DC to 1000Hz)

CIM-4/20 4 to 20 mA According to Measuring Chain (DC to 1000Hz)

Important Information

•Modules are shipped with JP1 and JP2 jumpers

installed.

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B) Fiber Optic Accelerometer (FOA) Input Module

Note: The modules do not supply power to the measuring chain. An external power supply is required.

Connection

Module Input Range Input Sensitivity

Maximum Processed Range (BW)

Acceleration Velocity Displacement

FIM-40-100 0 to 40g Peak 100 mV/g 40g Peak

(15 to 1000Hz)

100 mm/s Peak

(30 to 1000Hz)

2000 um Peak-to-Peak

(30 to 1000Hz)

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C) Piezo Electric Accelerometer (ICP) Input Module

Note: ICP accelerometers are powered by the analog module with a constant current voltage source.

Connection

Module Input Range Input Sensitivity

Maximum Processed Range (BW)

Acceleration Velocity Displacement

ICPM-1.13-500 1.13g Peak 500 mV/g 1.13g Peak

(0.7 to 1000 Hz)

28 mm/s Peak

(0.7 to 1000 Hz)

2000 um Peak-to-Peak

(0.7 to 1000 Hz)

ICPM-1.13-100 1.13g Peak 100 mV/g 1.13g Peak

(0.7 to 1000 Hz)

28 mm/s Peak

(0.7 to 1000 Hz)

2000 um Peak-to-Peak

(0.7 to 1000 Hz)

ICPM-5.65-100 5.65g Peak 100 mV/g 5.65g Peak

(0.7 to 1000 Hz)

28 mm/s Peak

(0.7 to 1000 Hz)

2000 um Peak-to-Peak

(0.7 to 1000 Hz)

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D) Voltage Input Module

Connection

Module Input Range Maximum Processed Range (BW)

VIM 0/+5 0 to 5V According to Measuring Chain (DC to 1000Hz)

VIM -5/+5 -5 to 5V According to Measuring Chain (DC to 1000Hz)

VIM 0/10 0 to 10V According to Measuring Chain (DC to 1000Hz)

VIM -10/+10 -10 to 10V According to Measuring Chain (DC to 1000Hz)

VIM -2/-18 -2 to -18V According to Measuring Chain (DC to 1000Hz)

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2.3.3 Output Connections and Specifications

•Raw Outputs: Analog outputs that represent the processed raw signal (See Important Information

under section 2.3“Dual-Channel Analog Input / Output Modules” on page 14) from the

sensor on the corresponding input channel.

•Trending Outputs: Analog outputs representing the selected processed signal from the sensor on the

corresponding input channel.

•Voltage Output

- Output range: 0 to 10V

- Load: 10 kΩmin.

- Processing range: According to ZOOM Configuration

•Current Output

- Output range: 4 to 20 mA

- Load: 500 Ωmax.

- Processing range: According to ZOOM Configuration

•Relay Driver Outputs

- Output type: Bipolar FET, ± 30V / 25 mA max. isolated ground

- Output state: Transistor OFF = no alarm

Transistor ON = alarm detected

The output channel connector is equipped with a 14-position panel header with a threaded flange as well as

a mating connector with a screw flange.

Recommended wire size: 0.5 - 0.34 mm2[20 - 22 AWG]

The following schematic illustrates a summarized view of the possible connections available on the 14-

position output channel connector.

Raw Out. (0/10 V)

GND

Raw Out. (4/20 mA)

GND

Trend Out. (0/10 V)

GND

Trend Out. (4/20 mA)

GND

Relay Driver (LO)

Relay Coil

24 Vdc

Relay Driver (LOLO)

Relay Driver (HI)

Relay Driver (HIHI)

GND ISO

Shield

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