Windrock Spotlight A3910 User manual

Engine Spotlight Monitoring System:
Spotlight Controller
Engine Spotlight PUC Module
USER MANUAL

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Doc No. A3940_UM Rev 1.0
Legal Notices
Copyright ©2018 Windrock Incorporated. All rights reserved.
No part of this manual may be reproduced or transmitted in any form or by any mean without the
written permission from Windrock Incorporated.
Software and Firmware License Notice
Your license agreement with Windrock Incorporated authorizes the number of copies which can
be made and the computer systems on which they may be used. Any unauthorized duplication or
use of Windrock software or firmware in whole or in part, in print, or in any other storage and
retrieval system, is forbidden.
Disclaimer
The manual is provided for informational purposes. Windrock Incorporated 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. Windrock Incorporated shall not be liable
for errors, omissions, or inconsistencies which 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 Windrock Incorporated. Any software described in this document is
furnished under a license agreement or nondisclosure agreement. The software may be used or
copied only in accordance with the terms of the agreement.
Important Safety Notices
When used in accordance with the instructions in this manual and the associated control
drawings, Windrock Spotlight is approved for use in Class 1 Division 2 and unclassified areas.
Failure to follow this manual may result in an explosion hazard when used in hazardous
locations or improper operation.
The examples and diagrams in this manual are included for illustrative purposes. Because of the
many variables and requirements associated with any particular installation, Windrock Inc.
cannot assume responsibility or liability for actual use based upon examples and diagrams.
For any questions, problems, or service for any Windrock products, including Windrock
Spotlight, visit the Windrock web site at www.windrock.com. Inquiries may also be directed to
[email protected] or 1-865-330-1110.
Windrock, Inc
1832 Midpark Drive, Suite 102
Knoxville, TN 37921
www.windrock.com

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Table of Contents
1A3910 Spotlight Controller 5
1.1 Connections 5
1.2 Operation 6
2Spotlight Peripheral Universal Connection (PUC) Module 7
2.1 Features 7
2.2 Connections 7
2.3 Operation 7
3Included Accessories 7
3.1 General 7
3.2 External Accelerometers 7
3.3 Magnetic Pickup Sensor 8
3.4 Controller WiFi Antennas 8
3.5 Spotlight Trunk Cable 9
3.6 Spotlight Magnetic Pickup Cable 9
3.7 Spotlight Armored Accelerometer Cable 9
3.8 Worm Drive Clamp Kits 9
3.9 Base Plate with 1/4-20 Stud and Adhesive 10
3.10 Accelerometer Isolation Pads with 1/4-28 Stud and Adhesive 10
4Optional Accessories 10
4.1 General 10
4.2 Spotlight Armored Accelerometer Extension Cable 10
4.3 Spotlight Controller Diagnostic Tool 10
4.4 Spotlight Mag Pickup (MPU) Extension Cable 10
4.5 T-Adapter Connector 11
4.6 Magnet 11
4.7 Portable Analyzer 11
4.8 Shaft Encoder 11
4.9 A3934 Spotlight Shaft Encoder Cable 11
4.10 Strobe (Timing) Light 11
5System Installation 11
5.1 General 11
5.2 Hazardous Locations 11
5.3 Installation Overview 13

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5.4 Magnetic Pickup Mounting 17
5.5 Controller Mounting 18
5.6 Power Requirements 18
5.7 Gateway Mounting 19
5.8 PUC Mounting 20
5.9 Shaft Encoder 20
5.10 Environment 20
6Maintenance and Cleaning 21
7Appendix. 21
7.1 CD-A3910-01 Controller Specification 21
7.2 CD-A3940-01 PUC Module Specification 21
7.3 Controller Mounting Options 21
7.4 PUC Module Mounting Options 21
PRESSURE WASH WARNING. Use of harsh cleaning chemicals, solvents, and degreasers may impare the
functionality of the system. When pressure washing, be cautious on length of time and intensity of spray on all
parts of the system, including sensors and cabling. If parts of a Spotlight system were removed in order to
perform cleaning and/or maintenance, contact Windrock Product Support at 865-330-1100 and ask for
Spotlight Installation Support to verify operation.
IMPORTANT: POWER REQUIREMENTS. If voltage and power requirements are not
met, system integrity will be compromised. Review power requirements and
warnings as laid forth in this document. For additional details, refer to the Spotlight
Datasheet.

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1A3910 Spotlight Controller
THE A3910 IS FOR USE WITHIN A WINDROCK SPOTLIGHT SYSTEM ONLY.
LE A3910 DOIT ÊTRE UTILISÉ DANS UN SYSTÈME WINDROCK SPOTLIGHT
UNIQUEMENT.
THE A3910 CONTAINS NO USER SERVICEABLE COMPONENTS. ANY ATTEMPT
TO MODIFY THIS DEVICE, USE FOR OTHER THAN ITS INTENDED PURPOSE, OR
SUBSTITUTION OF COMPONENTS MAY DAMAGE THIS DEVICE LEADING TO
UNRELIABLE OPERATION AND DECREASED PROTECTION FOR THE DEVICE
BEING MONITORED.
LE A3910 NE CONTIENT AUCUNS RÉPARABLE. TOUTE TENTATIVE DE
MODIFIER CE DISPOSITIF, UTILISER D'AUTRE QUE SA DESTINATION, OU
LA SUBSTITUTION DE COMPOSANTS PEUT ENDOMMAGER CET
APPAREIL MENANT À UNE OPÉRATION PEU FIABLE ET A DIMINUÉ LA PROTECTION DU DISPOSITIF SURVEILLÉ.
1.1 Connections
Connections marked with in this manual or on the product are incendive and possible explosion hazards when installed in
a hazardous environment. Other connections are non-incendive when installed in accordance with this manual, the associated
control drawings in the appendix, the National Electrical Code and/or Canadian Electrical Code, and the authority having
jurisdiction. Consult the control drawing for proper and safe connection to field devices.
PWR - Power is applied via the integral power cable. NOTE: EQUIPMENT SHALL BE POWERED BY AN APPROVED SELV LPS
POWER SOURCE.Power connection and mounting requirements are both detailed in Section 5, System Installation.
PUC 1, PUC 2, PUC 3, PUC 4 – Non-incendive 8-pin output to PUC Modules. Four connectors are provided on the Controller
unit, one for each PUC Module. PUCs are connected using Spotlight Trunk Cables. Connection to any other equipment or
using any other cables other than those specified by Windrock may compromise system integrity.
TDC Input – Non-incendive 3-pin input for TDC. In order for the Windrock Spotlight system to operate properly, an accurate
TDC signal is required. Use ONLY magnetic pickup sensors with entity parameters as described in control drawings. The
magnetic pickup generates a signal as it crosses an artifact (pin or hole) in a spinning steel disk such as the flywheel. The
Spotlight Magnetic Pickup Cable connects from TDC Input of this Controller to the magnetic pickup sensor.
Multiple Controller Note: The Spotlight system is capable of monitoring more than sixteen (16) accelerometers
per engine. Use a T-Adapter to connect a Spotlight Magnetic Pickup Cable to separate controllers using MPU
Extension cable (sold separately).
For further information regarding magnetic pickup sensors, see Section 3.3, Magnetic Pickup Sensor.
TDC Output – This 3-pin connector outputs a non-incendive TDC signal that allows a Windrock Portable Analyzer system to
monitor Spotlight.
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – AVANT DE DECONNECTOR L’EQUIPMENT, COUPER LE
COURENT OU S’ASSURER QUE L’EMPLACEMENT EST DESIGNE NON DANGEREUX.
WARNING: EXPLOSION HAZARD. Input voltage must not exceed Vmax of any associated device
connected to sensor inputs on A3940.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – TENSION D'ENTRÉE NE DOIT PAS DÉPASSER VMAX DE
N'IMPORTE QUEL DISPOSITIF ASSOCIÉ AUX ENTRÉES CAPTEUR A3940.
Figure 1-1. A3910 Controller

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•Portable Analyzer Measurements. Connecting TDC Output to a Windrock Shaft Encoder enables convenient
monitoring using a Windrock Portable Analyzer (Shaft Encoder and Portable Analyzer sold separately). A Spotlight
Shaft Encoder Cable (sold separately) is used to connect from TDC output to the TDC connection on a Shaft Encoder.
CAUTION: BUFFERED OUTPUTS HAVE A COMMON GROUND WITH THE REST OF THE WINDROCK SPOTLIGHT
SYSTEM. USE OF A PORTABLE MONITOR SUCH AS WINDROCK’S 6420 IS RECOMMENDED. CONNECTING THE
BUFFERED OUTPUT GROUND TO EQUIPMENT AT A DIFFERENT POTENTIAL WILL RESULT IN IMPROPER
OPERATION.
ADVERTISSEMENT –SORTIES DE TAMPONNÉ ONT
UN TERRAIN D'ENTENTE AVEC LE RESTE DU
SYSTÈME WINDROCK SPOTLIGHT. UTILISATION
D'UN MONITEUR PORTABLE COMME DE
WINDROCK 6420 EST RECOMMANDÉ. BRANCHER
LA SORTIE TAMPONNÉE AU SOL À L'ÉQUIPEMENT
À UN POTENTIEL DIFFÉRENT SE TRADUIRA PAR UN
FONCTIONNEMENT INCORRECT.
WiFi - The Windrock Spotlight Controller has two RP-SMA
connectors located on the top of the unit for connection
to WiFi antennas. The standard Spotlight Controller
includes two WiFi antennas.
1.2 Operation
The Controller does not have a local display. Under normal operation, no configuration is needed.
There is one method provided for local status indication. If a Spotlight Controller Diagnostic Tool was included with your
system, it may be used for troubleshooting purposes. Connect the Diagnostic Tool to any available Spotlight Trunk Cable on the
system. During the periodic controller polling, LEDs on the tool will light up to indicate activity. Refer to Table 1-3 below for
specific pattern identification
PUC ACTIVITY PATTERN
MEANING
Slow clockwise rotation of LEDs
sampling in progress
Brief clockwise rotation
no error, just delay between samples
Ping pong between outer LEDs
NO TDC SIGNAL. (Note: this display will persist until the next polling
interval even after TDC is restored. Polling interval is initially set to 5
minutes during commissioning; it will be changed by Windrock
Product Support remotely once the system is brought up.)
Ping pong between inner LEDs
not connected to WiFi
Table 1-3, Diagnostic Tool Status Indication Patterns
For installation sequence, refer to Section 5, System Installation.
WARNING: If the Controller is not operating properly, then unit must be returned to Windrock for repair
service. Contact your sales representative or Windrock directly.
AVERTISSEMENT : Si le contrôleur ne fonctionne pas correctement, puis doit être renvoyé à Windrock des
réparations. Contactez votre représentant commercial ou Windrock directement.
Figure 1-2 Controller Connections - Top

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2Spotlight Peripheral Universal Connection (PUC) Module
2.1 Features
•Multiple mounting options (bolt-down, or epoxy)
•Four (4) external accelerometer cables
2.2 Connections
Note: All connections to the Spotlight PUC Modules are non-incendive.
Controller connection – Non-incendive 8-pin output to Controller shown in Figure 2-2. Connect using
Spotlight Trunk Cable. Connection to any other equipment or using any other cables other
than those specified by Windrock may compromise system integrity.
Accelerometer Connections (x4) – Non-incendive 2-pin input used to connect to accelerometer
cables. Connection to any other equipment or using any other cables other than those specified by Windrock may
compromise system integrity.
For further information, see Spotlight Datasheet.
2.3 Operation
Under normal and proper operation, the PUC Module is used by the
Controller to gather sensor readings.
It is not necessary to interact with the A3940 locally as its operation can
be observed within the Windrock Enterprise software.
For installation sequence, refer to Section 5, System Installation.
WARNING: If A3940 is not operating properly, then unit must
be returned to Windrock for repair service. Contact your sales
representative or Windrock directly.
AVERTISSEMENT : Si A3940 ne fonctionne pas correctement,
puis doit être renvoyé à Windrock des réparations. Contactez
votre représentant commercial ou Windrock directement.
3Included Accessories
3.1 General
Spotlight systems have ONLY been approved for use using the accessories listed in Section 3 and Section 4.
NOTE: THE SAFETY OF ANY SYSTEM INCORPORATING THE EQUIPMENT IS THE RESPONSIBILITY OF THE INSTALLER
OF THE SYSTEM.
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED
BY THE EQUIPMENT MAY BE IMPAIRED.
3.2 External Accelerometers
Each PUC Module connects to four (4) industrial accelerometers that employ a shear sensing geometry with a ceramic sensing
element. This ceramic sensing element provides excellent resolution and durability in noisy environments, and is designed to
supply low-frequency and high-frequency measurements. Shear sensing geometry is preferred because of the inherent
insensitivity to adverse environmental influences, such as case or base strain and thermal transients.
Dynamic expectations are application-specific and refer to the frequency range of measurement and the anticipated amplitudes
of vibration. After careful review of the machinery to be monitored, minimum and maximum measurement frequency range
along with proper output range may be established. The minimum measurement frequency is normally related to any sub-
Figure 2-1, A3940 PUC Module
TO
CONTROLLER
Figure 2-2, A3940 Controller Connection

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harmonics of running speed or any lower frequencies where vibration data is to be collected. The maximum measurement
frequency of interest is determined by the maximum number of harmonics of an event like running speed, bearing frequencies,
or gear mesh impacting. This measurement frequency range should be well within the specified frequency range of the sensor.
The sensor measurement range (output) can be found by determining the maximum peak vibration amplitude that will be
measured. Allow overhead in case the vibration is a little higher than expected. The accelerometers should be torqued to 3ft-lbs
when installed.
Amplitude range refers to the anticipated levels of vibration to be measured. These values are related to the alarm levels set for
the machine. By carefully evaluating the idiosyncrasies of the machinery, the predictive maintenance engineer can estimate the
minimum expected vibration levels and ensure that the electrical noise floor of the accelerometer is less than those levels.
3.3 Magnetic Pickup Sensor
The system is designed to accept inputs from Windrock-approved magnetic pickup sensors.Magnetic pickups are sold
separately. Other magnetic pickup brands may be used as well. Please contact Windrock for questions regarding magnetic
pickup compatibility.
Further information regarding magnetic pickup sensors:
At the heart of a VRS/Magnetic pickup is a permanent target that creates a magnetic field. An output is generated by changing
the strength of this field, which is caused by the approach and passing of a ferrous metal target near the sensing area. The
target is typically either a magnet, a hole in a ferrous metal disk, or a protrusion such as a bolt. The amplitude and waveform of
the sensor output is affected by the speed of the sensed device and the shape of the target.
Proper TDC detection is the most important factor when measuring the performance of reciprocating machines, so a reliable
TDC signal is essential. The sensor must be rigidly held within close proximity from the target. The mount must not move as
the machine vibrates, and should not be located where routine maintenance is likely to move it. The target does not have to be
located at TDC, as a fixed offset may be applied in software. It is essential that only one target be “seen” per revolution of the
machine.
The output signal should have a magnitude of approximately 2V peak-to-peak. In order to achieve this output, Windrock
recommends epoxying a small 1/4” target diameter magnet into the target area. It may be necessary to move the sensor closer
or farther from the target. Slow speed machines need closer and larger targets than high speed machines.
With an A6400 Portable Analyzer and A6420 Shaft Encoder, you can verify the offset of the target from TDC and enter this into
the geometry setup in the Windrock MD software. TDC should be marked on the flywheel sufficient for the timing light to
illuminate when the machine is running. TDC offset may be advanced or retarded in software to correct any discrepancies.
COMPATIBLE MAG PICKUPS
Windrock Part Num.
OEM
OEM p/n
Thread
Thread Length
Notes
A3012-10-00
Dynalco
M231
5/8-18 UNF-2A
4”
Intrinsically safe; CSA Approved
A3012-00-00
Honeywell
A3042A
5/8-18 UNF-2A
1.4”
Intrinsically safe
NOT SOLD BY WRI
Honeywell
3090A35
5/8-20 UNF-2A
4.8”
Intrinsically safe
Incorrect connector pin polarity will cause installation problems, however
polarity can be changed in the setup. Refer to Table 3-1, Spotlight Mag Pickup
Compatibility List for Spotlight-tested compatible mag pickups. For installation
sequence, refer to Section 5, System Installation.
3.4 Controller WiFi Antennas
The Controller uses two WiFi antennas as shown in Figure 3-2. Antennas are
installed after the unit is mounted. Refer to Section 5, System Installation.
Table 3-1, Spotlight Mag Pickup Compatibility List
Figure 3-2, Controller with WiFi Antennas

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3.5 Spotlight Trunk Cable
The Controller connects to each PUC Module using the Spotlight Trunk Cable. This circular 8-position cable has male and
female ends. This allows for connecting multiple cables together if a longer length of cable is required for installation. Contact
your Windrock representative to purchase additional Spotlight Trunk Cables.
3.6 Spotlight Magnetic Pickup Cable
The Spotlight Magnetic Pickup Cable connects on one end to the magnetic pickup. On the opposite end, the 3-position
connector can either connect directly to the TDC IN of the Controller, or to a Spotlight MPU Extension Cable, or a T-Adapter to
split the signal to multiple Controllers (Section 4.6).
3.7 Spotlight Armored Accelerometer Cable
Each accelerometer Controller connects to each PUC Module using the Spotlight Armored Accelerometer Cable. This circular 2-
position cable has two female ends, one bayonet and one threaded. The bayonet end connects to a PUC Module and the
threaded end screws onto an accelerometer. Contact your Windrock representative to purchase additional cables.
3.8 Worm Drive Clamp Kits
Worm drive clamps are included with new systems to aid installers in routing cabling in order to meet local codes and proper
wiring methods. Refer to Section 5, System Installation for further details.
EXTERNAL WIFI
The A3910 controller is designed to permit use of an external WiFi antenna, connected to the controller ANT2 jack, if
needed to improve connectivity with the A3930 gateway. Such an antenna must be designed for use with 2.4 GHz
frequency (compatible with IEEE 802.11 b/g standards); the cable must terminate in an RP-SMA connector to mate with
the ANT2 jack. In the United States, if a directional WiFi antenna with gain higher than 6 dBi is used with the controller,
FCC regulations require that the transmit power of the controller be reduced by 1 dB for every 3 db that the directional
gain of the antenna exceeds 6 dBi. This rule applies only if the equipment is used for fixed, point-to-point operation;
greater power reduction may be required when directional WiFi antennas are used in other circumstances. The operator
of the equipment, or if the equipment is professionally installed, the installer, is responsible for ensuring that this power
reduction is implemented and that the system is used exclusively for fixed, point-to-point operations. (Reference: Title
47, Code of Federal Regulations, part 15.247.) In general, it is the responsibility of the installer and operator,
respectively, to ensure that legal requirements for installation and operation are followed.Contact Windrock for
information on how to reduce controller transmitter power.
WIRE MARKERS
Spotlight Trunk Cable Wire markers were included loose with the system. During installation, it is recommended to attach
wire markers to cables that correspond to the PUC numbers on the controller (ie. PUC1 Controller cables should be
marked with a “1”, etc.). Clip wire markers on at both ends of each trunk cable. If using more than one trunk cable per
PUC, repeat the same wire marker on the extension as well. This way, it will simplify troubleshooting as well as installation
when routing cables around equipment.
WIRE MARKERS
Wire markers are installed onto Spotlight Armored Accelerometer Cables at the factory. Markers on these cables will have
a letter and a number at each end. Marker numbers indicate corresponding Controller PUC channel number (ie. “1” for
PUC1, “2” for PUC2, etc.). Marker letter corresponds to one of the four local PUC channels, “A” through “D”. Refer to the
Engine Spotlight information sheet included with your system for further details. If an Accelerometer extension cable was
included with the order, mark the cable you are extending in the same fashion. By marking all cables this way, it will
simplify troubleshooting as well as installation when routing cables around equipment.

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3.9 Base Plate with 1/4-20 Stud and Adhesive
Engine PUCs are typically mounted using Base Plate 1/4-20 Studs. Controllers can be mounted using these as well. Loctite 330
is used to affix the plates to the Engine. Refer to Section 5, System Installation for further details.
3.10 Accelerometer Isolation Pads with 1/4-28 Stud and Adhesive
Isolation Pads are included with each system and are used to fasten the accelerometer to the Engine. Pads have a rough side
and a smooth side. The rough side is used to affix the pad to the engine (using Loctite 330, 1/4-28 studs, or a recommended
combination of both). The smooth side should be used for threading and mounting an accelerometer. Refer to Section 5,
System Installation for further details.
4Optional Accessories
4.1 General
Spotlight systems have ONLY been approved for use using the accessories listed in Section 3and Section 4.
Items listed in Section 4 are not standard and therefore must be purchased separately. If interested, contact Windrock Sales for
a quote.
NOTE: THE SAFETY OF ANY SYSTEM INCORPORATING THE EQUIPMENT IS THE RESPONSIBILITY OF THE INSTALLER
OF THE SYSTEM.
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED
BY THE EQUIPMENT MAY BE IMPAIRED.
4.2 Spotlight Armored Accelerometer Extension Cable
Optional Spotlight Armored Accelerometer Extension Cables allow for a longer length between each PUC Module and
accelerometer than using the standard accel cable by itself. This circular 2-position cable has male and female ends. Extension
cables do not come pre-marked. See the Wire Marker note in Section 3.7 for information.
Do not exceed entity parameter limits shown on the control drawing when using extension cables. If necessary, contact
Windrock Product Support for further information.
4.3 Spotlight Controller Diagnostic Tool
To assist with the installation and troubleshooting of the Spotlight system, use the Spotlight Controller Diagnostic Tool. This
tool connects to a Controller using any Spotlight Trunk Cable.
Under normal and proper operation, the PUC Module is used by the Controller to gather sensor readings. Periodically, the
controller unit collects and records data from connected sensors.
PUCs do not have local status indicators for sensors or power. Therefore, during the periodic controller polling, users do not
have a visual indication of activity. The Diagnostic Tool contains four (4) LEDs that turn on in a specific pattern to give an
installer feedback on system status. A single LED is also provided for power.
Refer to Section 2.3 for more information.
4.4 Spotlight Mag Pickup (MPU) Extension Cable
The Spotlight MPU Extension Cable is a 3 position cable with male and female ends. The cable is used in two possible ways:
1) Controller expansion: The MPU Extension Cable connects from the T-Adapter to the TDC IN of the Controller.
See Section 5, Installation Overview for details. In addition, multiple MPU Extension Cables can be connected
together to accommodate larger cable runs.
2) Magnetic Pickup Cable expansion: The MPU Extension Cable extends the reach of the A3932 MPU Cable to the
Spotlight Controller.