Advancements in Transmitter-Based Monitoring Systems AM2005 San Diego, California Wednesday, May 11 from 3:00 - 4:00 PM

1. Advancements in Transmitter-Based Monitoring SystemsAM2005San Diego, CaliforniaWednesday, May 11 from 3:00 - 4:00 PMFrank HowardPresident

2. Transmitter Strategy • Enable users to make use of their existing PLC and DCS Systems for Machinery Condition Monitoring • Offer Wonderware HMI systems where the users DCS or PLC is inadequate or will be upgraded in the future

3. Transmitter Based Systems • Advantages: • Low Cost (1/2 Legacy Systems) • Simple to Install • Can make use of existing sensors • Distributive Architecture • 4-20 mA noise free • Digital to save wiring costs • Choice of Protocol • Easy repair and replacement • Local Dynamic Signal w/BNC • Disadvantages: • No Remote Dynamic or Transient Data

4. Large centralized “Rack” based systems • Control Room mounted • Originally Capital Projects • OEM supplied sensors • All sensors wired to “Rack” • Requires lots of instrument wire and conduit (2x cost) • Large Racks do nothing that a PLC or DCS system cannot do • Overall Values • Time Delay • Power up inhibit • OK Circuit • 99% not wired to “Shutdown” • Many are ‘Obsolete” Legacy Systems

5. What’s Changed ? • Hardware • PLC and DCS Systems are faster, cheaper and more common. • Many Plants are upgrading to New DCS and PLC Systems. • HMI Systems like Wonderware are available. • People • Vibration and machinery specialists are retiring, or spread out. • A lot of specialty work is contracted. • Engineers and Technicians are forced to be “Jack of All Trades”. • Operators are being assigned more tasks “OCM”. • Users want smarter, simpler and easier to maintain systems. • Users are more budget conscious. • Engineers and Technicians are more computer oriented. • Major machine flaws have been fixed.

6. Hard or Soft Alarms (Hardware or Software) • Transmitters or Monitors are local to machine • Analog to Digital Converters (ADC) new or existing • Communications in users preferred protocol • Modbus RS-485 • Modbus TCP/IP • Hundreds of others • Make use of existing networks • Make use of existing Historians • Keeps overhead and bandwidth requirement low • Make use of Operators existing CRT’s ! • Instrumentation people understand 4-20 mA ! • No proprietary protocols • Use all available hardware like Industrial Radio Modems • Easy repair or replacement Distributive Systems

7. Types of Transmitter Based Systems • Transmitters • OK Circuit • BNC Output • 4-20 mA Output • Transmitters with Analog to Digital Converter • Same as above + • Digital Output (Choice of Protocol) • Choice of Protocol • Transmitters w/ADC and Wonderware HMI • Same as above + • Wonderware license • Custom Wonderware runtime

8. Why 4-20 mA • Extremely accurate • Low voltages (typically 24 VDC) • Long distances can be handled • Voltage has resistance losses • 4-20 mA Current constant anywhere on loop • Noise immunity • Very common in process measurements • Instrument Technicians understand

9. 3-Wire Transmitter

10. 25 Channel System +24 VDC

11. 25 Channel System 4-20 mA

12. 4-20 mA Compliance • Compliance – “The total amount of resistance in the circuit that the 4-20 mA Transmitter is able to power”. • Calculate by adding together: • Shunt Resistor • 100 Ω (.4 TO 2.00 Volts DC) • 250 Ω (1 to 5 Volts DC) • Wire Resistance (at 68° F) • 18 AWG 6.385 Ω per 1,000’ • 20 AWG 10.15 Ω per 1,000’ • 22 AWG 16.14 Ω per 1,000’ • Power Protection Resistor (If used)

13. Protocols

14. Ethernet TCP/IP • TCP - Transmission Control Protocol, provides a reliable stream delivery and virtual connection service to applications through the use of sequenced acknowledgement with retransmission of packets when necessary (TCP/IP). • Ethernet - is a widely used data communications network standard developed by DEC, Intel, and Xerox. It uses a bus topology and CMSA/CD access method. The terms Ethernet and the IEEE 802.3 standard are often used interchangeably.

15. CMCP500 Series Transmitters • CMCP560 RTD Temperature • CMCP565 Thermocouple • CMCP570 Solid State Temperature • CMCP575 Speed • CMCP580 Process Variable • CMCP585 Eccentricity • CMCP525 Acceleration (Accelerometer) • CMCP530 Velocity (Accelerometer) • CMCP535 Displacement (Velocity) • CMCP540 Radial Vibration (Eddy Probe) • CMCP545 Thrust Position (Eddy Probe) • CMCP547 Differential Expansion • CMCP548 Case/Shell Expansion • CMCP549 Valve Position

16. CMCP500 and CMSS500 Transmitter Features • Compact Size • Din Rail Mountable • OK Circuit (<2 mA) • Optional Filters • ISO Standards • CE Approved • BNC Buffered Output • Terminal Buffered Output (CMU) • 24 VDC Powered (NEC Low Voltage) • Selectable Range

17. CMCP500 and CMSS 500 Monitor Features • OK, Alert and Danger Relays • Selectable as Latching or Non-Latching • Trip Multiply • Reset terminal • Bypass terminal • Selectable Time Delay • Connector for optional display • BNC w/switch to set alarm levels • Can be added later

18. Case History #1

19. Case History #1 • Problem • Coal Crushers with embedded accelerometers needed monitoring • User wanted to use existing DCS system • Existing system was not working properly • User unwilling to pay for conduit and instrument wire • Low Speed Bearings needed Enveloping • Solution • Velocity and Enveloping Transmitters Used (some slow speed) • 16 Channel ADC using Modbus TCP/IP Ethernet used • Industrial Ethernet Radio Modem used • No lost packets. Very robust. • Both Modbus RS-485 and TCP used

20. Case History #1 Master Radio Slave Radio

21. Case History #2

22. Case History #2 • Problem: • TSI System for GE Turbine Generator Set. • Customer wanted to use existing New DCS System. • Wanted local display for operators. • Intermediate terminals to save installation time. • Solution: • CMCP500 Series Transmitters. • Pre-wired Integrated Custom Panel. • 4-20 mA Loop to DCS. • Custom Mimic Panel w/Displays.

23. Case History #2

24. Case History #2

25. Case History #3

26. Case History #3 • Problem: • 6 IRD/Entek 5815 Monitors mounted in outdoor cabinets. • Critical service on high temperature furnace fans. • IRD/Entek no longer supported. • Primary competition: BNC • 1 Vibration Channel. • 8 Temperature Channels. • Solution: • CMCP530 Transmitter. • ADC with direct RTD input. • 15” Industrial Touch Screen Rack Mount Computers. • Custom Wonderware HMI w/Bargraphs.

27. Case History #3

28. Case History #3

29. Case History #3

30. Case History #3

31. Case History #3

32. Case History #3 Main Screen Alarm List Historical Trend Real Time Trend Real Time Trend Setup

33. Case History #4

34. Case History #4 • Problem: • Large Kinetic UPS System Monitoring. • Vibration, Enveloping, Temperatures, Speed, Pressures. • Flywheel Diameter Calculation. • Solution: • CMSS530, CMSS590, CMCP540 and CMCP545 Transmitters. • Process Variables direct to ADC. • 12.1” Touch Screen Rack Mount Industrial Computer. • Custom Wonderware HMI.

35. Case History #4

36. Case History #4

37. Case History #4 Main Screen Alarm List Historical Trend Real Time Trend Real Time Trend Setup

38. Other Transmitter Based Systems

39. Transmitter Tips • Be sure to program in Time Delays. (3 second standard). • OK Circuits should be designed into transmitter (<2 mA). • BNC Buffered Output. • Peak or RMS. • True RMS (is it really, pseudo, quasi, ?). • Optional Filters (Low Pass, High Pass). • 24 VDC (NEC low voltage). • Optional Displays. • ISO Standards are available.

40. Go Wireless ! Industrial Radios • Features Include: • Class I, Div II, Group’s A,B,C,D. • Superior noise immunity - advanced frequency hopping spread spectrum technology. • Worldwide Unlicensed 2.4 GHz. • Ethernet (TCP/IP, Ethernet/IP, Modbus/TCP, etc.) • MODBUS RTU RS-485, RS-422, RS-232. • 32 Frequency Channels. • Up to 16 mile range w/ Hi Gain Antennas. • Can be extended with Repeaters. • 250 Kbps RF Data Rate. • Configurable to Master/Repeater/Remote with Windows setup / diagnostics software. Ethernet Model

41. Thank You Questions ?