CSI 4500 Machinery HealthTM Monitor - n Automated, continuous
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Product Data Sheet
0-4500-091306
Machinery Health Management TM
September 2006
TM
CSI 4500 Machinery Health Monitor
n Automated, continuous,
predictive machinery health
monitoring of your plant’s
most critical rotating
machines
n Real-time machinery health
feedback integrates to
process control so you can
run your process with confi-
dence
n Field-based intelligence
and event-based adaptive
monitoring transforms
vibration monitoring into
predictive machinery health
alerts
n PeakVue® provides
unique bearing fault detec- Delivers real-time machinery health information so you can
run your process with confidence.
tion capabilities to mainte-
nance personnel
Five percent of the machines the machine itself and saving
n Transient analysis for
in every plant have the ability to the production schedule. Prediction
turbines empowers
bring production to a halt. These is protection for your bottom line.
decisions through the
critical machines require special The CSI 4500 Machinery Health
live turbine dashboard like
attention by both maintenance and Monitor provides machinery
nothing on the market
operations – and almost always prediction that complements
have shutdown protection in place an existing protection system
to prevent catastrophic failure. providing real-time feedback to
But is that really enough to ensure both maintenance and operations.
production schedules will be met? As part of Emerson’s PlantWeb®
Is the plant really protected? digital plant architecture, the CSI
Today more facilities are upgrading 4500 delivers real-time machinery
their protection systems with health information when and where
prediction capabilities. With it is needed. Integration with the
prediction, the machine can be plant’s process automation system
allowed to continue performing and AMS™ Suite: Machinery Health
within acceptable parameters Manager software empowers
and repaired at the time most decision-making and reduces
economically convenient to the
plant. Adding prediction is the
difference between just saving
www.assetweb.com
Product Data Sheet
September 2006
machinery health faults. When
both prediction and protection are
required, Emerson delivers with
a complete asset management
strategy for your most critical
rotating machines.
Real-time Machinery Health
Feedback to Process
Automation
Machinery health information
is nothing new–maintenance
personnel have long benefited
from the predictive capabilities
of vibration analysis and other
integrated technologies. But
without vibration monitoring
feedback to process automation,
operators don’t know the effects
their actions have on the health
of rotating machines. In fact,
40% of machine faults are the
result of process variations.
PlantWeb Alerts give clear, powerful indications of developing problems to an
operator at a DeltaV station. The CSI 4500 and the AMS
Machinery Manager send real-time
overall vibration levels to opera-
tors. If process adjustments are
made, operators see the live
impact on machinery health. With
vibration data integrated with
process automation, informed
real-time decisions are possible.
For example, if a mill operator
adjusts a stretch roll on the paper
machine and cocks the roll, vibra-
tion increases immediately.
Feedback to the operator is pro-
vided and further adjustments
head-off premature failure of the
roll.
The CSI 4500 provides machinery prediction that complements an
existing protection system.
Page 2
Machinery Health Management TM
PlantWeb Alerts provide
actionable information.
There are certain process variations
that impact rotating machines in
negative ways. For instance, low
tank or head levels may increase-
vibration on a pump or hydro
turbine. Faulty valves, incorrect
process running conditions,
upstream loads or downstream
backups may also impact
machinery health.
Process event monitoring with
adaptive automated vibration
analysis will send PlantWeb Alerts,
containing information about the
fault, to operators at Emerson’s
DeltaV™ digital automation system.
As an example, when a tank level
sensor indicates the level has
exceeded a designated low set
point, the CSI 4500 detects and
automatically adapts its monitoring Machinery Health feedback integrates to process automation systems,
strategy to begin “watching” for a such as Emerson’s Ovation® and DeltaV digital automation systems.
cavitation parameter to exceed a
defined fault level. A PlantWeb
Alert labeled cavitation is then
delivered to the operator at the
DeltaV station. The operator can
take action such as adjusting the
level of an upstream tank to
decrease vibration and increase
efficiency on a pump, adjusting
tank levels
to stop cavitations, or increasing
speed of a machine to eliminate
a resonance condition.
Page 3
Product Data Sheet September 2006 Calendar rolls, winders, nip rolls, vacuum rolls, and changing machine speeds require event-based adaptive monitoring. Information for fast, and critical turbo machinery. Much like a process automation accurate decision-making. AMS Machinery Manager also system, the CSI 4500's built-in As plant personnel go about their integrates with AMS™ Suite: Production State processor more daily activities, the CSI 4500’s Asset Portal™ where machine accurately monitors process events built in, exception-based proces- health is combined with other such as speed inputs, changing sor collects and distributes infor- asset condition and performance load, temperature, tank level or mation to the right system or user information for a plant-wide view. relay closures. The CSI 4500 only when machinery health Event-based monitoring Machinery Health Monitor process- changes. The CSI 4500 continu- links vibration information es events, adapts its monitoring, ously monitors the health of your to process states. and produces a real alarm when machine, but sends alerts or new A machine that is in its normal machine health changes versus a trend data to Emerson’s DeltaV or operating mode, or production false alarm when the load changes. Ovation automation system on an state, is far from operating in a Alarms are much tighter and false exception basis when health steady state" condition. With other alarms are decreased. This adap- changes. In addition, the CSI monitoring systems, an increasing tive strategy is not limited to adjust- 4500 and the AMS Machinery load means increasing vibration ing alert levels; analysis types and Manager with the GT2 processor levels and false alarms. This can the frequency of analysis can auto- option can deliver transient analy- necessitate setting vibration matically be adapted as well. sis and live views specifically alarms extremely high to account designed for large for all process scenarios or events. Page 4
Machinery Health Management TM
Through AMS Suite: Machinery Health Manager, the PeakVue technology allows
clear spikes to poke through the noise floor providing early fault
detection of a Yankee dryer gearbox.
Predictive Machinery Health through powerful analysis tools Other bearing tools on the market
Monitoring for such as transient analysis for use demodulation techniques,
Early Warning and Planning turbines, PeakVue bearing health which subtract carrier frequencies
for the Maintenance technology, and customizable and use low pass filters. These
Department reporting capabilities. processes have adverse effects on
PeakVue technology is the original peaks that PeakVue
Exception-based reporting
best-available bearing and maintains. If the carrier frequency
drives you to the problem and
gearbox anomaly detector during demodulation is amplitude
reduces troubleshooting time
PeakVue technology provides modulated, then the amplitude of
Exception-based reporting allows
early, accurate and trendable roller the resultant bearing energy is
the CSI 4500 to keep a close
bearing and gearbox anomaly changing and will be less than the
watch on the assets, but only
detection unmatched by all other original bearing energy collected.
alert your maintenance staff
bearing health tools on the market. Furthermore, the amplitude of
when the machine health
PeakVue’s patented method of the bearing energy after the low
changes. Exception-based
processing preserves the peak pass filter has been applied,
reporting produces specific alerts
amplitude of the stress wave will increase as the frequency
and decreases the amount of data
emitted from a bearing or gear of the defect increases.
required for review when it is time
to troubleshoot the alert. With defect. Preserving this peak
the CSI 4500, troubleshooting amplitude allows trendable
time can be reduced 90% bearing health diagnostics.
Page 5
Product Data Sheet
September 2006
CSI 4500T Turbine Monitor
n Live Turbine Dashboard
n 60 hour Data Recorder
n Turbine Replay
n 3D Turbine Graphical
Representation
To illustrate the results from
Emerson’s Machinery Health
technologies working together
to provide turbine protection,
here is a short scenario.
The AMS Machinery Manager shows live cascade and orbit
plots for visual comparison provided from the GT2 Processor.
scenario
When the Turbine Trips
You are comfortably home for
the evening when the phone rings
and you learn the turbine just
tripped. The decision to restart the
equipment is yours. Although you
feel the pressure, you are confi-
dent because you have two pow-
erful tools to rely on–all the nec-
essary data was captured to
assess the event and a live tur-
bine dashboard will provide assur-
AMS Machinery Manager allows users to select ance during start-up.Information
live plots for all bearings simultaneously. before, during and after the tur-
bine trip is waiting for you. As you
drive to the site, you review the
facts:
1. You have the proper setup to
capture the right data surrounding
the event. With virtually no setup,
you can be assured the right data
and the anomalous event will
be captured.
Data extraction session for post processing events or
baseline comparisons.
Machinery Health Management TM
In this scenario, the CSI 4500
along with the AMS Machinery
Manager allowed the user to
easily see the information to make
a confident decision. Emerson’s
predictive technologies, such as
the AMS Suite of applications
and the CSI 4500 along with
complementary PlantWeb
Services, allow you to maximize
availability and performance of
key production assets to ensure
operational excellence.
2. Real-time continuous data deeper into the problem. You look waveform and spectrum, on all
recording ensures events will not at the quick views and then extract bearings, allow a turbine specialist
be missed. With the CSI 4500, the region of interest for more to make real-time decisions.
a 60 hour running history is details, which quickly drives you Simple Windows displays make
recorded all of the time. The to your decision. manipulating screens and plots
CSI 4500’s continuous data You review the data, compare with easy. Dual monitor mode helps
recorder will record and buffer from baseline, and confirm the vibration you organize your views
60 hours to over one week, is isolated to one bearing. The so you are staged for the startup.
depending on the number of sen- shaft centerline plots tell you the You can overlay baseline plots
sor inputs. Auto archiving of data bearing clearance was not exceed- (from portable or online systems)
is also included so that small, one ed. After fixing the oil flow issue, on known good start-up plots
hour, snapshots can be perma- you advise restarting the turbine to view the differences.
nently and automatically saved to as you watch the live turbine dash- With the transient live turbine
a network server. board. dashboard, you can make real-
3. The live turbine dashboard will The live turbine dashboard pro- time decisions with operators and
enable real-time decisions during vides real-time decision-making production staff to bring the
start up. during start-up. turbine up for critical production
When you arrive on site, they have needs or to shut down again
The live turbine dashboard, avail-
already found a plugged oil line to to save the asset.
able with the CSI 4500 transient
the bearing. Now the question is system,provides live plots that
“how much damage was done, were not possible before the GT2
and can we restart?” processor. Live real-time plots
Multi-channel, continuous data such as overall levels, orbits, shaft
recording saves you from ever centerline, Bode/ Nyquist, cascade,
missing an event and ensures the
right information is available to dig
Page 7
Product Data Sheet
September 2006
Chassis Options
CSI 4500M Monitor
The CSI 4500M Monitor is the
most common model for applica-
tions in power, refining, oil & gas,
petrochemical, chemical, pulp and
paper, and offshore industries.
The CSI 4500M Monitor (with up
to 32 sensor input channels, 16
tachometer input channels and up
to16 relays) offers the best choice
in flexibility and cost per channel.
The CSI 4500M Monitor includes
the Trip Advisory Monitor for tier 2
critical machines, The Production
State Monitor for continually
changing machine operating
states, and is upgradeable to the CSI 4500M Monitor with G2 Processor.
CSI 4500T Monitor, which
For more information visit
includes transient analysis for tur- http://www.mhm.assetweb.com/technology/online.html
bines.
CSI 4500MS Monitor
The CSI 4500MS ("S" denoting
small rack size) Monitor has the
same functionality as the CSI
4500M Monitor, but with a smaller
rack footprint of 12 sensor inputs,
2 tachometer inputs, and 2 relays.
The CSI 4500MS Monitor is the
best choice for remote machines
or for machine centric monitoring
applications. The CSI 4500MS
Monitor is perfect for OEM applica-
tions, or when a machine needs
dedicated monitoring and requires
fewer sensor inputs.The CSI
4500MS is not upgradable to the
transient option.
CSI 4500MS Monitor for small channel-count applications.
Page 8
Machinery Health Management
TM
CSI 4500Q Monitor
The CSI 4500Q Monitor
is a Factory Mutual,
Class I Div II, Groups C and D rated
monitor for applications in power,
refining, oil & gas, petrochemical,
chemical, and offshore industries.
The CSI 4500Q Monitor (with 32
sensor input channels, 16 tachome-
ter input channels and 16 relays)
includes the same functionality as
the CSI 4500M -- the Trip Advisory
Monitor for balance of plant critical
machines, the Production State
Monitor for continually changing
machine operating states, but is not
upgradeable to the CSI 4500T
Monitor. The CSI 4500Q Monitor's
only power supply option is the
24VDC source.
CSI 4500 Machinery Health Monitor
Enclosure Specifications
PN A4500Mx, Where x = 1, 2, 3, 4, 5, 6, 7, 8
PN A4500Q
PN A4500Tx, Where x = 3, 4, 7, 8
PN A4500MS
Overall System Characteristics
Enclosure Dimensions 22.25"
o
width x 26.00" height x 11.56" depth
180 opening required for enclosure door
Environmental for CSI 4500M, 0 to 110°F (-17 to 43°C); 0 to 120°F (-17 to
CSI 4500MS, CSI 4500Q 48°C) w/ fan tray accessory (PN B4500FT)
0 to 95% R.H. noncondensing
Environmental for CSI 4500T 0 to 86°F or 0 to 30°C with Fan tray (fan tray
required) CSI 4500T is best suited for
computer room, control room environment
Ratings CE EN50081-2 Emissions
CE EN50082-2 Immunity
Ordering Information
x = 1, 16 sensor input, 0 tachometer, 0 relays
x = 2, 32 sensor input, 0 tachometer, 0 relays
x = 3, 16 sensor input, 16 tachometer, 0 relays
x = 4, 32 sensor input, 16 tachometer, 0 relays
x = 5, 16 sensor input, 0 tachometer, 16 relays
x = 6, 32 sensor input, 0 tachometer, 16 relays
x = 7, 16 sensor input, 16 tachometer, 16 relays
x = 8, 32 sensor input, 16 tachometer, 16 relays
Page 9
Product Data Sheet
September 2006
CSI 4500M Machinery Health Monitor
Overall System Characteristics
Input Power 120 – 240 VAC 50/60 Hz
System Power Dissipation < 25 watts for 32 signals, 16 tachometers,
16 relays
< 55 watts with optional fan tray and aux
power fully loaded
< 80 watts with optional transient processor
Optional Accessory Output Power -24 vdc @ 0.6A for displacement probes
CSI 4500 Chassis Dimensions 13.975" width x 12.2" height x 8" depth
Chassis Card Slots Total 6 slots: 2 slots for sensor cards,
1 slot for tachometer card,
1 slot for relay card,
1 slot for Machinery Health processor card,
1 slot for power supply card
For Latest Server Requirements click here.
Options
PeakVue® Bearing and Gearbox PN A474504
Fault Detection Technology
Fan Tray PN B4500FT
19” Rack Mount Option D25051 (Qty 2 per rack)
Page 10Machinery Health Management TM
CSI 4500M Machinery Health Monitor Processor Card
Specifications PN B4532MB
G2 General
Memory Capacity 3 2 Mb SDRAM, 8 Mb Flash
Network Communications 10/100 BaseT Ethernet NIC
HUB May be used for daisy chain
type network architecture
Local Communications HUB for laptop or local display, and serial port
Local Display Includes overall vibration readout and internal
chassis temperature
Onboard Test Generator All sensor channels, tachometer channels,
AC, DC amplitude and phase
CSI 4500 Rack Health Relay One relay will change states based loss of
power or rack reboot
G2 Trip Advisory Monitor
Sensor Channel Scan: 16 ch rms per 500 msec
Overall Vibration Scan Peak to Peak with Transient Option
DC Scan Rate Simultaneously scanned with overall vibration scan
(includes DC Gap, temperature, and
accelerometer bias)
The G2 second generation
Overall Level and DC Accuracy 100 dB, all ranges
transient live display and
Spectral Resolution 100 to 6400 lines
analysis
Analysis Bandwidth Fmax 10 Hz to 40 kHz, discrete steps
Spectral Scan Rate 1 second per two channels, 400 lines, n Dual processors; one
400 Hz, 1 avg. (depends on analysis configuration) dedicated for protection and
Amplitude AccuracyProduct Data Sheet
September 2006
CSI 4500M Machinery Health Monitor Sensor Input Card
Specifications PN B4532MX
B4532MX Specifications
Sensor Input Types Dynamic displacement probe, accelerometer,
velocity probe, AC input custom definable
(Flux, dynamic pressure sensor, dynamic basis
weight input, etc.), DC input custom definable
(temperature or other process input), 4-20 mA
signal. The CSI 4500T has true
peak to peak input.
Number of Sensor Inputs 16 inputs per card, 2 cards per rack, multiple
racks linked by Ethernet
Analysis Bandwidth DC to 40 kHz and DC to 2Khz with Transient
Option
AC Coupling Corner Frequency < 0.5 Hz
AC Channel AccuracyMachinery Health Management
TM
CSI 4500M Machinery Health Monitor Power Supply Card
Specifications PN A4532AC
B4532AC Specifications
Input Power 120 – 240 VAC 50/60 Hz
System Power Dissipation < 25 watts for 32 signals, 16 tachometers,
16 relays
< 55 watts with optional fan tray and aux
power fully loaded
< 80 watts with optional transient processor
Optional Accessory Output Power -24 vdc @ 0.6 A for displacement probes
Supplies Power to the Rack 5 vdc, 12 vdc, 24 vdc, 3.3 vdc, -12 vdc
Supplies Power to +24 vdc, 0.3 A output for optional fan tray
Auxiliary Equipment ±24 vdc, 0.6 A auxiliary output for displacement
transducers or other
CSI 4500M Machinery Health Monitor Fan Tray
Specifications PN B4500FT
B4500FT Specifications
The fan tray is intended to be used where ambient air temperature around the
stainless steel enclosure of the CSI 4500 rack is between 110°F and 120°F.
When ordered with a new CSI 4500 Monitor, the fan tray will be delivered
installed
Power to the fan tray is provided by a fan tray power auxiliary output from
the front panel of the Power Supply card of the CSI 4500 Monitor.
NOTE: In conditions above 120°F ambient, active cooling or conditioned
plant air should be installed.
NOTE: Fan tray required with the CSI 4500T. The CSI 4500T is the CSI
4500M with the transient option. The CSI 4500T should be installed in a con-
trol room / computer room environment not to exceed 86F or 30C
Page 13Product Data Sheet
September 2006
CSI 4500M Machinery Health Monitor Tachometer Card
Specifications PN B4532TA
B4532TA Specifications
Number of Tachometer Channels 16 inputs per rack, 1 card per rack,
multiple racks linked by Ethernet
Tachometer Frequency Inputs 0.1 Hz to 2 kHz (6 RPM to 120,000 RPM)
Tachometer Frequency Accuracy 0.1%
Tachometer Resolution 0.002 Hz @ 60 Hz (0.1RPM)
Tachometer Types Eddy current displacement probe,
TTL, passive magnetic
Tachometer Input and trigger pulse range ±0.5 v to ±24 v,
±25 v CM
Pulse Characteristics 1 pulse per revolution, 500 µS/min. pulse width,
tach divider on card
Modes Volt compare, automatic adaptive, divide by N
Input Impedance 1 MΩ (differential)
CSI 4500M Machinery Health Monitor Relay Card
Specifications PN B4532IO-x (x = 1, 2, 3, 4 or 5)
B4532IO Specifications
Number of Channels 16 input or output relay channels, 1 card per
rack, multiple racks linked together by Ethernet
Relay Types Each channel socketed for a standard
Opto22 style digital plug in module.
These 4 KV optically isolated modules are
available in AC/DC inputs or outputs from
4 V to 280 V or dry contact outputs.
Auto Resetting Voting configurable for thrust or radial
0 to 10s programmable time delay for 2 sensor
voting logic
Response Time 50 µsec to 50 msec depending on module
System Interface Software polled or interrupt driven
Interrupt Output Interrupt on pattern match or change
Ordering Information
x = 1, [4] inputs IDC5B & [12] outputs ODC5
(standard)
x = 2, [12] inputs IDC5B & [4] outputs ODC5
x = 3, [8] inputs IDC5B & [8] outputs ODC5
x = 4, [16] inputs IDC5B
x = 5, [16] outputs ODC5
Page 14Machinery Health Management
TM
CSI 4500MS Machinery Health Monitor Enclosure
Specifications PN A4500MS
Overall System Characteristics
Enclosure Dimensions 11" width x 16.00" height x 11.56" depth
180° opening required for enclosure door
Environmental 0 to 100°F (-17 to 50°C); 0 to 120°F
(-17 to 60°C) w/ fan tray accessory
(PN B4500FT)
0 - 95% R.H. noncondensing
Ratings CE EN50081-2 Emissions
CE EN50082-2 Immunity
Options
PeakVue® Bearing and Gearbox PN A474514
Fault Detection Technology
Mounting Kit for 4500MS PN A4500SK
Without Enclosure
Page 15Product Data Sheet
Machinery Health Management TM
September 2006
CSI 4500MS Machinery Health Monitor Sensor Card
Specifications PN B4532MM-X
B4532MX Specifications
Number of Sensor Channels 12 sensor inputs, specifications same as
B4532MX
Number of Tachometer Channels 2 tachometer inputs, specifications same as
B4532TA
Number of Relay Channels 2 relay channels, specifications same as
B4532IO
Number of Cards Per Rack 1 sensor/tachometer/relay card,
1 processor card, 1 power supply card,
multiple racks can be linked by Ethernet
Ordering Information
Relay Options B4532MM-x, where x = 2, 3, 4
x = 2, [2] inputs IDC5B
x = 3, [2] outputs ODC5
x = 4, [1] inputs IDC5B & [1] outputs ODC5
CSI 4500T Machinery Health Monitor Transient Specifications
PN B4532DB
B4532DB Specifications (includes all B4532MB Specifications)
Number of Channels Up to 32 channels
Memory Capacity 64 Mb SDRAM, 8 Mb Flash
AC Channel Accuracy 80 dB
Number of Tach Channels 4 fixed channels from the B4532TA tachometer
card. Requires at least 1 of 4
Data Recorder 60+ hours
Communication 10 \100base-T Ethernet HUB and NIC
100 BaseT recommended for Transient
CSI 4500 Rack Health Relay Relay will change states based on loss
of power or rack reboot
For more information visit http://www.mhm.assetweb.com/technology/online.html
Emerson Process Management ©2006, Emerson Process Management.
Asset Optimization Division The contents of this publication are presented for informational purposes only, and while every effort has
been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express
835 Innovation Drive or implied, regarding the products or services described herein or their use or applicability.
All sales are governed by our terms and conditions, which are available on request. We reserve the
Knoxville, Tennessee 37932 right to modify or improve the designs or specifications of our products at any time without notice.
T (865) 675-2400 Emerson Process Management, PlantWeb, AMS, DeltaV, Ovation, PeakVue, CSI and Machinery Health are
marks of one of the Emerson Process management family of companies. The Emerson logo is a trademark
F (865) 218-1401 and service mark of Emerson Electric Co. All other marks are the property of their respective owners.
Online Machinery Health
Management powers PlantWeb
through condition monitoring of
mechanical equipment to improve
availability and performance.
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