Part Number Revision A, January Monitoring System Rack Configuration and Utilities Guide

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1 Part Number Revision A, January Monitoring System Rack Configuration and Utilities Guide

2 Copyright 1995 Bently Nevada Corporation All Rights Reserved. No part of this publication may be reproduced, transmitted, stored in a retrieval system or translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, chemical, manual, or otherwise, without the prior written permission of the copyright owner, Bently Nevada Corporation Post Office Box 157 Minden, Nevada Copyright infringement is a serious matter under the United States of America and foreign copyright laws.

3 Contents Introduction Setting Up a New Rack... 1 Installing the Software Computer Requirements... 3 Installation Instructions... 3 Running the Configuration Software Ways to Use Rack Configuration Software... 6 Configuring a New Rack... 6 Building a Rack Configuration... 6 Modifying a Rack Configuration... 7 Using the Main Configuration Screen... 8 Connecting a Computer to a 3500 Rack Direct Connection S RS Direct Connection S RS Remote Communication Network Connection Initiating Communication with a 3500 Rack Discontinuing Communication with a 3500 Rack Uploading and Downloading Configurations Opening and Saving Configuration Files Printing Catalog Numbers Copying Configuration Information Copying Monitor Channel Configurations Copying Channel Setpoints Copying Module Configurations Configuring the Modules in a Rack Configuring the Rack Interface Module Configuring Keyphasor Modules Configuring Monitors Setting Monitor and Channel Options Setting Alarm Setpoints Configuring Relay Modules Configuring Communication Gateway Modules iii

4 Defining the Contents of Registers Setting Communication Gateway Communication Parameters Configuring a Triple Modular Redundant Rack Software Operation for TMR Systems Configuring TMR Functions Using the Rack Configuration Utilities Setting Module and Channel Switches Setting the 3500 Rack Date and Time Disabling Alarms Enabling Trip Multiply Rack Reset Viewing the System Event List Viewing the Alarm List Verifying the Operation of a 3500 Rack Running the Test Utilities Starting the Utilities RIM Host Port Test Utility Setting Up Communications Displaying Test Data Communication Gateway Port Test Setting up Communications Displaying Test Results Files Used by Configuration Software Description by File Extension List of Files Cable Part Numbers and Diagrams Cable Part Numbers Cable Pin Out Diagrams Modem File Programming Information iv

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6 Introduction Introduction This manual shows how to use the following software that comes with the 3500 Monitoring system. Software Name Rack Configuration RIM Host Port Test Comm Gateway Port Test Function Set operating parameters so that all the modules in a 3500 monitoring rack work together. Test the output of the CONFIGURATION PORT on the Rack Interface Module (front of the rack) and the Host Connector on the Rack Interface I/O Module (rear of the rack). Test the HOST and RACK ports on the Comm Gateway I/O module. Setting Up a New Rack Use the following procedure to set up, configure, and verify a new rack. If your rack has a custom configuration from the factory, skip step Set the hardware switches and jumpers on the Rack Interface Module (RIM), the backplane, the 3500/42 Monitors, and the relay modules. The 3500 Monitoring System Rack and Installation Manual shows how to set the jumper on the backplane. The other jumper settings are described in the operation and maintenance manuals for the RIM, the 3500/42 Monitor, and the relay modules. 2. Connect the field wiring to the rack as described in the operation and maintenance manuals for all the modules installed in the rack and in the 3500 Field Wiring Diagram Package (part number ). 1

7 Rack Configuration and Utilities Guide 3. Test all of the communication ports on the rack by using the test utilities listed in the following table: Port to be Location of Utility to use... Refer to page... tested... port... CONFIGUR- Rack Interface RIM Host Port 47 ATION PORT Module Test Utility HOST Rack Interface RIM Host Port 47 I/O Module Test Utility HOST and Comm Gateway Comm Gateway 50 RACK I/O Module Port Test Utility 4. Configure the rack using the 3500 Rack Configuration Software. 5. Adjust the zero position voltage and scale factor for all monitors in the rack by using the Adjust Button on the channel options screens. 6. Use the verification procedures in the operation and maintenance manuals for the modules in the rack and the Verify option in the Rack Configuration Software to verify that the rack is configured and operating correctly. 2

8 Installing the Software Installing the Software The 3500 Rack Configuration Software, the test utilities, and the configuration tutorial are shipped on a set of diskettes labeled 3500 Monitoring System Rack Configuration Software. One installation program installs all of these programs. Computer Requirements The Configuration and test utilities require a 386/ computer or better, 4 megabytes of RAM, 25 megabytes of unused hard disk space, a VGA monitor, and an RS232 serial port. The computer must also have one of the following versions of Microsoft Windows installed and running: Windows 3.1, Windows for Workgroups 3.11, or Windows NT 3.5. Installation Instructions To install the configuration, test utilities, and configuration tutorial on your computer: 1. Start Windows and choose the Run command from the File menu. 2. Insert the disk labeled "3500 Monitoring System Rack Configuration Software", (disk 1) into drive A or B. 3. In the Command Line box, type a:setup if you put the disk into drive A or b:setup if you put the disk into drive B. 4. When the installation program starts, follow the instructions on your screen. If you do a complete installation, the installation program will create a new group called 3500 Software in the Program Manager and add the following icons to the group: 3

9 Rack Configuration and Utilities Guide Running the Configuration Software A 3500 rack can contain a variety of modules that can be set up to operate different ways. The process of setting system, module, and channel options so that all the modules in a 3500 rack work together is called configuration. Configuring a 3500 rack consists of using the Rack Configuration Software to set options and then downloading the settings to the rack. You can use the program two ways: You can run the program at any convenient place, save the settings in configuration files, and then later download the configuration to the rack. Or you can connect the computer to the rack first and then upload and download the configuration as required. In this Section... topic page topic page Ways to Use Rack Configuration Uploading and Downloading Software 6 Configurations 17 Using the Main Configuration Opening and Saving Configuration Display 8 Files 19 Connecting a Computer to a 3500 Copying Configuration Rack 10 Information 20 Initiating Communication with a 3500 Rack 15 4

10 Running the Configuration Program Ways to Use Rack Configuration Software The following lists illustrate the typical uses of the Rack Configuration Software. Configuring a New Rack A 3500 Monitoring Rack cannot operate without a valid configuration. Use this process after you have installed the rack, set all switches and jumpers, and connected transducers. If your rack came with a custom configuration from the factory, you can skip this procedure. Process step... Refer to page... Connect the computer to the rack 10 Initiate communication 15 Upload the default configuration from the rack 17 Modify the default Configuration Download the configuration to the rack 17 Discontinue communication 17 Disconnect the computer from the rack Building a Rack Configuration Use this process if you choose to prepare a series of configuration files at your desk and then download the files to the racks at a later time. Process step... Refer to page... Identify the modules in slots 1 through 15 8 Set Rack Interface Module options 24 Set Keyphasor options 26 Set Monitor options 27 Set channel options for monitor modules 27 Set Comm Gateway options 33 Set alarm setpoints for monitor modules 29 Set alarm drive logic for relay channels 31 Save the configuration file 19 5

11 Rack Configuration and Utilities Guide Modifying a Rack Configuration Use this process to change the configuration of a 3500 rack that is installed and operating. Process step... Refer to page... Connect the computer to the rack 10 Initiate communication 15 Upload the configuration from the rack 17 Modify the Configuration Download the configuration to the rack 17 Discontinue communication 17 Disconnect the computer from the rack 6

12 Running the Configuration Software Using the Main Configuration Screen The following figure lists the parts of the Main Configuration Screen and summarizes how to use them. Menu Bar S access commands to connect to a rack, manipulate configuration files, copy configuration settings from one module to another, and control the operation of the rack. Reference Information S helps you keep track of which rack and rack file you are configuring. Mode Buttons and Indicator S control how the Rack Configuration Software operates. Rack Diagram S shows the modules that are installed in the rack. Use this diagram and the Options and Setpoints mode buttons to move to configuration screens. 7

13 Rack Configuration and Utilities Guide Although you can enter most configuration settings in any order you choose, we recommend that you create a rack configuration by using the mode buttons on the Main Configuration display from top to bottom as suggested in the following figure. Because these buttons control how the Configuration Software operates, be sure that the correct button is depressed before you proceed with an operation. Build a rack. Place modules in slots 1 through 15 by clicking on a slot and then selecting a module from the drop down list. Set module and channel options. Enter the Module Option screen by clicking the Options button and then clicking on the module to be configured. Set alarm setpoints for channels in monitor modules Enter the Alarm Setpoint screen by clicking on the Setpoints push button and then clicking on the monitor module to be configured. 8

14 Running the Configuration Software Connecting a Computer to a 3500 Rack You can connect a computer to a 3500 Monitoring rack the following three ways: Method for Connecting Direct Remote Network Use this method... to temporarily connect your computer when the computer is near the 3500 rack. Direct connection can use RS232 or RS422 protocol. to connect a 3500 rack to a computer that is located off site. The computer must have a modem and the 3500 rack must have access to a dedicated phone line. if your computer is connected to a network that has a station that is connected to the HOST connector on the Rack Interface I/O module of a 3500 rack and is running the Data Acquisition DDE Server Software. 9

15 Rack Configuration and Utilities Guide Direct Connection S RS232 Connect the computer directly to the rack by using an RS232 cable (Bently Nevada part number XXXX-XX) as shown in the following figure. If the Rack Interface I/O Module does not have an internal modem, you can also connect the RS232 cable to the Rack Interface I/O Module by using the port labeled HOST. Set the switch below the port to the RS232 position. Using the CONFIGURATION PORT lets you configure only the rack that your computer is connected to. Using the HOST port on the Rack Interface I/O Module lets you use the rack address to configure all of the racks connected in the daisy chain. Direct Connection to the Rack Interface Module 10

16 Running the Configuration Software Direct Connection S RS422 If the Rack Interface I/O Module does not have an internal modem, you can connect the computer directly to the rack using RS422 communication. Install an RS232-to-RS422 converter between the computer and the rack. The cable from the converter should be connected to the port on the rear of the Rack Interface I/O Module labeled HOST. Set the switch below the port to the RS422 position. Direct Connection Using RS422 Protocol An alternate method of direct connection to RS422 is to install an RS422/485 Data Aquisition Card (Bently Nevada part number ) in your PC, and using the Host to 3500 Rack RS422 Interface Cable (Bently Nevada part number XXXX-XX for PVC insulation or XXXX-XX for Teflon insulation). Connect the cable from the RS422 Card to the port on the rear of the Rack Interface I/O Module labeled HOST. Set the switch below the port to the RS422 position. 11

17 Rack Configuration and Utilities Guide Remote Communication The 3500 Monitoring Rack has two versions of the Rack Interface I/O Module: one with a RS232/422 terminal and one with an internal modem. The internal modem will operate at speeds up to 14.4 kbaud. With Internal Modem With RS232/422 connector. Connecting the Computer to a Rack using a Modem Many laptop computers and some desktop models also contain internal modems. Baud rates on these modems can vary from 4800 to 28.8 kbaud. The modem-tomodem communication speed is determined by the quality of the phone connection and the protocol of the information being transmitted. The speed at which the computer communicates with the modem does not have to be identical to the modem-to-modem communication rate. To use modems to connect the computer and the rack: 1. Verify that you have dedicated telephone communications available at the computer and rack locations. 12

18 Running the Configuration Program 2. At the computer: Connect the phone line to the internal or external modem phone port. If you use an external modem, connect a standard modem cable between the computer serial COM port and the modem. 3. At the rack: Connect the phone line to the internal modem on the Rack Interface I/O Module. If you use an external modem, connect the standard modem cable to the port labeled CONFIGURATION PORT on the front of the RIM or to the port labeled HOST on the Rack Interface I/O Module. Verify that the RS232/RS422 switch on the I/O module is set to the RS232 position. The following figures show some of the ways for using modems to connect the computer to the rack. Standard modem cable 3500 Rack with Internal Modem Standard modem cable 3500 Rack with External Modem Note: The Rack Interface Module (RIM) configuration must be set to indicate a modem is present on the front or rear 3500 RIM port. 13

19 Rack Configuration and Utilities Guide Network Connection If the configuring computer has network access to a Data Acquisition DDE Server as shown in the following figure, you can configure all racks that are daisy chained to the server by using the Network connection. Dynamic Data Exchange (DDE) is a method of exchanging or providing data to and from Windows applications. This method lets multiple devices access the data simultaneously. Configuring Computer Data Acquisition DDE server Daisy-chained 3500 racks Ethernet cable Initiating Communication with a 3500 Rack After you have connected the computer to the rack and started the Rack Configuration Software, use the following procedure to initiate communication between the rack and the computer: 1. Select the Connect option in the File menu. A list of connection methods will appear (Direct, Remote, and Network). 2. Select the connection method that corresponds to how your computer is connected to the rack(s) that you will configure. Refer to the previous section for information about these methods. 3. Enter the appropriate communication parameters into the connect dialog box using the following table for reference: 14

20 Running the Configuration Software Communication Parameter Connect Password Rack Address Com Port Baud Phone Number Description The password on the 3500 rack to be configured. This password is set when the RIM options are configured. The setting on the RACK ADDRESS switch on the Rack Interface Module in the 3500 rack to be configured. The connector on the configuring computer used to communicate with the 3500 rack. The rate of the computer-to-modem or Computer-torack communication. The phone number of the modem for the 3500 rack to be configured Data Acquisition (DDE) The network name of the computer that is running Server Computer Name 3500 Data Acquisition software and that is connected to the daisy-chained 3500 racks to be configured. 4. Initiate communication by clicking on Connect. A successful connect to the rack is indicated by the message "Connection established". Discontinuing Communication with a 3500 Rack Before you disconnect the cable between the configuring computer and the rack, discontinue communication by clicking on the Disconnect command in the File menu. This command initiates the following actions: C return any module that is still in configuration mode to run mode (under user control) C release the configuration token if the configuring computer has the token C hang up the modem if the computer was using remote communication 15

21 Rack Configuration and Utilities Guide Although disconnecting the cables without invoking the Disconnect command causes no harm, we recommend using the command when you're finished communicating with a rack. Uploading and Downloading Configurations You transfer configuration settings between the configuring computer and the rack to be configured by using a process called uploading (rack to computer) or downloading (computer to rack). The Upload and Download commands are in the File menu. To upload a configuration: 1. Connect the configuring computer to the rack to be configured. (Refer to page 10 of this manual.) 2. Establish communication with the rack by using the procedure in the "Initiating Communication with a 3500 Rack" section. 3. Click on the Upload command in the File menu. A prompt will appear that indicates the progress of the upload and indicates if the upload was successful. 4. Terminate communication with the rack by clicking on the Disconnect command in the File menu. 5. Disconnect the configuring computer from the rack. If an error occurs while uploading a configuration from the rack, the upload will continue and the default configuration will be loaded for the module where the error occurred. 16 To download a configuration: 1. Connect the configuring computer to the rack to be configured. (Refer to page 10 of this manual.) 2. Establish communication with the rack by using the procedure in the "Initiating Communication with a 3500 Rack" section. 3. Move the configuration keylock on the front panel of the Rack Interface Module from Run to Program. (All functions of the rack will continue operating with the keylock set to Program.)

22 Running the Configuration Software 4. Click on the Download command in the File menu. The Download Configuration screen will appear. 5. Choose which module configurations to download by marking the check box next to the module name. 6. Initiate the download by clicking OK. 7. Set the keylock on the front panel of the Rack Interface Module from Program to Run. 8. Terminate communication with the rack by clicking on the Disconnect command in the File menu. 9. Disconnect the configuring computer from the rack. If an error occurs while downloading a configuration to the rack, the downloading will stop and you can choose whether to download the portion of the configuration that is correct or to abort the download. 17

23 Rack Configuration and Utilities Guide Opening and Saving Configuration Files Use the Open command in the File menu to load a configuration file that has been stored on disk into the Rack Configuration Software. Use the Save command to store the current configuration in the Rack Configuration Software to a file on disk. We recommend that you save the configuration of all 3500 Monitoring Racks to files on disk. All rack configuration files contain a maximum of 8 characters and end with a file name extension of.rak. The default directory for configuration files is \3500\trains\primcfg. Although you can place the files in any directory, keep the following special considerations in mind: C If multiple 3500 racks are daisy chained together, place the rack configuration files for these racks in the same directory. C If the 3500 Data Acquisition Software is to provide historical trend data, place all rack configuration files for the racks daisy chained to the Data Acquisition computer in the \3500\trains\primcfg directory. Printing Catalog Numbers The Print menu lets you print a list of the catalog numbers of all the modules that are displayed on the Main Configuration screen. This option makes it easy to order a new 3500 rack or to order replacement modules for an existing rack. 18

24 Running the Configuration Software Copying Configuration Information The 3500 Rack Configuration Software makes it easy to copy the configuration settings of channels and modules. Copying Monitor Channel Configurations The arrow buttons let you copy channel settings between channels in a channel pair or from one channel pair to another. An equal sign between the arrow buttons indicates that the configuration of the channels or channel pairs are the same. "Copy" indicates that the configuration of the channels or channel pairs are not the same. The arrow buttons copy the monitor options but not the alarm setpoints. 19

25 Rack Configuration and Utilities Guide Copying Channel Setpoints The Copy button on the Setpoint Configuration screens lets you copy the alarm setpoints from one channel in a monitor to another channel of the same type. Copying Module Configurations The Copy menu lets you copy the configuration parameters from one module to another module of the same type. This command copies both the module options and the alarm setpoints. 20

26 Running the Configuration Software Use the upper row of buttons to choose the slot of the module with the configuration that you want to copy. Use the lower row of buttons to choose the slot or slots that you will copy the configuration to. If the slot or slots chosen in the lower row of buttons do not contain the same type of module as in the slot chosen in the upper row, the program will replace the module before it copies the configuration parameters. 21

27 Rack Configuration and Utilities Guide Configuring the Modules in a Rack Configure a 3500 rack by setting the operating parameters for all modules in the rack and for all channels in each module. You set these parameters by using dialog boxes that appear when you click on the Options button and then on a module. The dialog boxes use conventional Windows selection tools like check boxes, radial buttons, and drop down lists. If you are not familiar with these tools, refer to your Windows documentation. The online help system for the Rack Configuration Software contains definitions of all the configuration options. In this section... topic page topic page Configuring the Rack Interface Configuring Relay Modules 31 Module 24 Configuring Keyphasor Configuring Comm Gateway Modules 33 Modules 26 Configuring a Triple Modular Configuring Monitors 27 Redundant Rack 37 22

28 Configuring the Modules in a Rack Configuring the Rack Interface Module The option display for the Rack Interface Module (RIM) lets you set options for the power supply and the RIM. The screen looks like this: The following table defines the configuration parameters for the RIM: Configuration Parameter Description Rear Port / Front The Rack Configuration Module has two ports for accessing Port the information in the 3500 rack. These ports can operate simultaneously and can transmit and receive messages using a Bently Nevada proprietary protocol. Use these fields to identify how devices are connected to these ports. I/O Option Identifies the type of Rack Interface I/O Module that is installed in the rack: RS232/RS422 I/O Module or Internal Modem I/O Module. External Modem When the rack is equipped with an RS232/RS422 module, this field lets you identify the type of external modem connected to 3500 rack. 23

29 Rack Configuration and Utilities Guide Configuration Parameter Byte Timeout Connect Password Configuration Password Dynamic Signal Option Description The number of bytes of communication line "dead time" needed to signal an end of message. Each port on the Rack Interface Module may have a different Byte Timeout setting. A password that "gates" all access to the 3500 rack. Without this password, the Rack Interface Module will not accept commands or requests from an external personal computer. A password that "gates" configuration information to be downloaded to a 3500 rack. Without this password, the Rack Interface Module will not accept any configuration commands from an external personal computer. The monitors that will provide data to the External Dynamic Data Interface (DDIX) or the External Transient Data Interface (TDIX). The DDIX and TDIX are Bently Nevada communication processors. Agency Approval The agency approval for the 3500 rack. The option selected in this field must match the approval rating of the rack. Mounting Option The mounting configuration of the rack being configured. The option selected in this field must match the mounting option of the rack. Power Supply Top / Bottom The power supplies that are installed in the rack. 24

30 Configuring the Modules in a Rack Configuring Keyphasor Modules Configure Keyphasor modules by completing the configuration parameters on the Keyphasor screen. The following table defines the configuration parameters for the Keyphasor Module: Configuration Parameter Signal Polarity Type Hysteresis Threshold Description The type of mark observed by the Keyphasor transducer S notch or projection. The type of Keyphasor transducer connected to the Keyphasor I/O Module The voltage level above and below the threshold value which is required to trigger the conditioned Keyphasor signal. The voltage level of the input signal from the Keyphasor transducer where the conditioned Keyphasor signal is triggered. 25

31 Rack Configuration and Utilities Guide Configuration Parameter Events Per Revolution Orientation Description The number of pulses in a Keyphasor signal for each shaft rotation. The location of the Keyphasor transducer on the machine. Upper RPM The upper limit of the full scale range for the Keyphasor rpm. Limit The Keyphasor Module will scale the rpm value between 0 and this value. RPM Clamp Value I/O Module The value that the data provided through the Communication Gateway will be clamped to when a Keyphasor transducer goes invalid. The type of I/O module connected to the Keyphasor Module. Configuring Monitors The two steps for configuring monitors are setting monitor and channel options and setting alarm setpoints. Setting Monitor and Channel Options Monitors have two dialog boxes for setting options. The first box is for setting monitor options and looks similar to the following screen. 26

32 Configuring the Modules in a Rack The second box is for setting options for each channel in the monitor module and looks like this: 27

33 Rack Configuration and Utilities Guide Setting Alarm Setpoints An alarm setpoint is the level of the proportional value at which an alarm will occur if the value moves above or below the level. To set alarm setpoints, use the monitor option displays to enable alarms and use this approach: Choose up to two proportional values that will have setpoints for danger alarms. Adjust all alarm setpoints except phase by either clicking and dragging the bargraph......or by entering the setpoint value in the number boxes. The alarm will occur if the value moves outside of the colored area in the bar graph. 28

34 Configuring the Modules in a Rack Adjust the phase angle for 1X or 2X acceptance regions by entering the angles into the number boxes above or below the angle diagrams. The acceptance region is indicated by the yellow or red area in the circle. If the red or yellow area is outside of the intended acceptance region, reverse the angle values in the number boxes. 29

35 Rack Configuration and Utilities Guide Configuring Relay Modules Use the Relay Association screen to enter the alarm logic that controls what alarms cause the relays to activate. Enter the Relay Association screen by clicking on the Options pushbutton and then clicking on the relay module to be configured. To enter the alarm logic: Click on a module......the list of alarms for the module will be displayed here. The number of alarms depends on what channels are active and which alarms are configured. Choose the relay channel to configure in this group box. The alarm logic in the Relay Association window contains the logic that controls when a relay channel is activated. The logic consists of alarm codes, AND (*) and OR (+) symbols, and parentheses. The AND operator has precedence over the OR operator and parentheses are used to control the order of the operators for complex logic. When the logic is true, the relay for that channel will activate. This figure shows the meaning of the digits in alarm codes: S02C03A2 Alarm level (2) / Danger Channel number (3) Slot number (2) S02C##A2 Code applies to all channels in in the monitor slot 30

36 Configuring the Modules in a Rack To enter alarm logic for the channel: Add an alarm code by clicking on the code and then clicking Enter or by double clicking on the code. The alarm code will appear in the Alarm Drive Logic box. Add AND, OR, and parentheses to the alarm logic by clicking on these buttons. Use the left arrow button to backspace one character in the string. Use the CLR button to clear the alarm logic box and start over. 31

37 Rack Configuration and Utilities Guide Configuring Communication Gateway Modules The Communication Gateway screen lets you enable a Distributed Control System (DCS) computer to scan 3500 racks more efficiently and set the communication parameters of the HOST and RACK ports on the Comm Gateway I/O Module. Defining the Contents of Registers Registers to Modbus (0 to 447 decimal) in the Communication Gateway Module are reserved for the primary proportional values from monitors and Keyphasor Modules. The Communication Gateway screen lets you place these primary proportional values into contiguous registers so that a DCS can scan 3500 racks efficiently. You can reduce the scan time by including only those values required by the DCS and excluding the contents of unnecessary or empty registers. All the other data that is available from the monitors and Keyphasor Modules is stored in fixed registers on the Communication Gateway Module. All fixed and programmable registers of the Communication Gateway Modules are described in the Communication Gateway Operation and Maintenance Manual (part number ). To define the contents of the reserved registers, enter integers from 0 to 32 into the number boxes in the columns labeled "Positions Reserved". The integer indicates the number of channels in the modules whose primary proportional value will be included in the message. Enter the number of channels whose primary values will be included in the message The number in parenthesis indicates number of channels in the module that have proportional values. Enter 0 to include no values from the module. Enter 4 to include the primary proportional value from all 4 channels in a module. Enter a number that is 32

38 Configuring the Modules in a Rack greater than the number shown in parenthesis to insert zeros into the successive registers of the message. Press Use Module Defaults to include the primary proportional value from all channels in all modules in the rack that have proportional values available. For example, the above display would include the following values in the Communication Gateway registers: Register Address The register contains the primary proportional value from... Decimal Modbus Slot # Channel # none zero none zero to to none 439 zeros 33

39 Rack Configuration and Utilities Guide To determine which values are the primary proportional value for each module, refer to the operation and maintenance manual for that module. Setting Communication Gateway Communication Parameters The Port 1 and Port 2 buttons on the Communications Gateway screen let you set communication parameters for the HOST and RACK connectors on the Communication Gateway I/O Module. When you click on Port 1 or Port 2, the following window will appear. The following table describes the fields in this window: Communication Description Parameter Active Address Connection Turn a port on (: ) or off (9 ). When a port is turned off, no machinery data is available. The address of the modbus port on the Communication Gateway I/O Module. The type of connection between the 3500 rack and the Distributed Control System (DCS) computer. 34

40 Configuring the Modules in a Rack Communication Parameter Config Allowed Parity Description Specify if the 3500 rack can be configured from the DCS computer. Check (:)the box for yes; clear (9) the box for no. Refer to the Communication Gateway Operation and Maintenance Manual for a list of items which can be configured through the Communication Gateway ports. The type of communication verification contained in each message byte. The parity setting in a Communication Gateway Module must agree with the setting at the external device connected to the module. Each Communication Gateway port may be set up with a different parity setting. Stop Bits The number of bits which will be added to each 3500 Communication Gateway message. Each byte within a message will contain 1 start bit, 8 data bits, and either 1 or 2 stop bits. The Stop Bits setting in the Communication Gateway Module must agree with the setting at the external device connected to the module. Each Communication Gateway port can have a different Stop Bits setting. Baud Rate Byte Timeout Full Scale Data Range The rate at which messages are transmitted and received from the 3500 Communication Gateway. Specifically, it represents the number of bits which can be transmitted and received from the Communication Gateway in 1 second. The Baud Rate setting in the Communication Gateway Module must agree with the setting at the external device connected to the module. Each Communication Gateway port can have a different Baud Rate setting. The amount of time that the Communication Gateway module will wait to determine that a command has been received on the DCS link. This value is expressed as the time required to send x bytes at the current baud rate. The value used to scale the proportional data. 35

41 Rack Configuration and Utilities Guide Communication Parameter Description Numeric Format The number system that the communication protocol uses to send and receive data. For the Modbus protocol, the system is Hex. 36

42 Configuring the Modules in a Rack Configuring a Triple Modular Redundant Rack A triple modular redundant (TMR) rack contains a TMR Rack Interface Module and redundant power supplies, monitors, and TMR relay modules. To identify the rack as TMR: 1. Click on the Slot button. 2. Click on the Rack Interface Module. A drop down list will appear. 3. Choose "TMR" from the list. Software Operation for TMR Systems The Configuration Software operates differently to help you configure TMR racks more easily. Take note of the following items when you configure a TMR rack: C Since the program automatically inserts groups of three monitors into a TMR rack, be sure that the two slots to the right of the monitor to be inserted are empty. C For groups of TMR monitors that use the TMR I/O (Bussed) option: set the monitor options, channel options, and alarm setpoints for all monitors in the group by configuring the left-most monitor only. The Rack Configuration Software automatically copies these configuration settings to the other monitors in the group. C Enter alarm drive logic for just one of the two TMR Relay Modules. The Rack Configuration Software automatically copies the alarm drive logic from one TMR Relay Module to the other. You can enter or edit the alarm drive logic in either the upper or lower relay. C The alarm logic for channels in relay modules uses alarm codes from the left-most monitor in a TMR group. Although the alarm code includes the slot number for the left-most monitor in the group, the alarm logic applies to all the monitors in the group. 37

43 Rack Configuration and Utilities Guide Configuring TMR Functions TMR racks have the following additional functions that must be configured: I/O module and Voting. TMR I/O Options Monitors in a TMR group can have input from redundant transducers (TMR I/O: Discrete) or from a single transducer (TMR I/O: Bussed). The following figures show the channel 1 input for the TMR I/O options: Discrete and Bussed. TMR I/O: Discrete TMR I/O: Bussed Voting Options The TMR Rack Interface Module continuously checks the output of monitors in a rack by using 2 out of 3 voting. The configuration settings used to control this voting are Comparison and % Comparison. Comparison: The enabled proportional value used in the 2 out of 3 voting. 38

44 Configuring the Modules in a Rack % Comparison: The highest allowed percent difference between the middle value of the three monitors in a TMR group and the individual values of each monitor. 39

45 Rack Configuration and Utilities Guide Using the Rack Configuration Utilities This section describes the options in the Utilities menu. You must be connected to a 3500 rack to use these options. Setting Module and Channel Switches Module and channel switches let you temporarily bypass or inhibit module and channel functions. A checked box (:) indicates that the switch is enabled. A cleared box (9) indicates that the switch is disabled. The functions of these switches are defined in the individual module manuals and in the help system of the Rack Configuration Software. 40

46 Using the Rack Configuration Utilities Setting the 3500 Rack Date and Time Use this dialog box to read or reset the date and time on the clock in a 3500 Monitoring rack. The date and time are used to time stamp data collected from monitor channels and items entered into the Alarm and System Event lists. Clicking on the Send button will set the rack date and time as follows: If the Send Host Data and...the Send Time command will.. Time to Rack box is... selected not selected send the current data and time of the computer to the rack send the date and time that is shown in the Date and Time box to the rack Clicking on the Read button will cause the configuration software to read and display the date and time from the 3500 rack. When this dialog box is initially displayed, it will contain the computer's date and time. Disabling Alarms Alarm Inhibit lets you disable alarms (both alert and danger) and relay activation in the rack. This feature is useful when you service and verify your 3500 rack. The current status of Rack Alarm Inhibit 41

47 Rack Configuration and Utilities Guide (hardware contact and software) are displayed at the top of this screen. Enabling Trip Multiply Trip Multiply lets you extend monitor alarm setpoints by the trip multiply value specified in the monitor option. This feature is useful during machine ramp-up or ramp-down. The current status of Trip Multiply (hardware contact and software) are displayed at the top of this screen. Rack Reset Rack Reset lets you reset latched alarms, latched not OK's and timed OK defeat. This feature is useful when you service and verify your 3500 rack. Viewing the System Event List System events are actions or occurrences such as configuration changes, module errors, and status messages. The System Event List is filled in a round robin fashion and may contain up to 500 entries. The help system in the Rack Configuration Software defines all the system events. 42

48 Using the Rack Configuration Utilities You can run a self-test on any module in a 3500 rack by using the Module Selftest button on the System Events screen. The results of the self-test are posted in the list. The help system in the Rack Configuration Software explains how to run a self-test. The configuration software uploads 20 events at a time from the 3500 rack. You can scroll through these 20 events by dragging the vertical scroll bar up and down or by clicking the up and down arrows. Display additional 20-event pages by pressing the Page Up, Page Down, or Latest Events buttons. Viewing the Alarm List The Alarm List is a chronological list of alarms, not OK events, and tripped relays. The list is filled in a round robin fashion and contains up to 1000 entries. The configuration software uploads 20 events at a time from the 3500 rack. You can scroll through these 20 events by dragging the vertical scroll bar up 43

49 Rack Configuration and Utilities Guide and down or by clicking the up and down arrows. Display additional 20-event pages by pressing the Page Up, Page Down, or Latest Events buttons. Verifying the Operation of a 3500 Rack The Verification screens display information about the status and output of the modules in a 3500 rack. Use the output of these screens and the procedures in the operation and maintenance manuals that come with the 3500 modules to verify the operation of a 3500 rack. 44

50 Running the Test Utilities Running the Test Utilities The two test utilities that come with the Rack Configuration Software are the RIM Host Port Test Utility and the Comm Gateway Port Test Utility. This section shows how to run the utilities and explains how each utility displays data. Starting the Utilities If you installed the 3500 Rack Configuration Software and test utilities by using a normal installation, icons for the configuration software and test utilities will be placed in a group called 3500 Software. Start a test utility by double clicking on the icon for that utility. The opening displays of the utilities show how to connect the computer running the utility to a 3500 rack. 45

51 Rack Configuration and Utilities Guide RIM Host Port Test Utility The Host ports on the Rack Interface Module and the Rack Interface I/O Module are used for communication between a computer that runs the Rack Configuration Software or the Data Acquisition/DDE Server Software and a 3500 rack. The ports are also used to daisy chain up to twelve 3500 racks. The RIM Host Port Test Utility lets you verify that the HOST ports are operating properly. The options in the menu bar operate as described in the following table: Option Name File Start Display Program Exit Com Set Up Help Program Information About Description Open the screen that displays the output of the communication port being tested. End the utility. Set options that control the communication between the test computer and the rack. Display a screen that explains what the utility does. Display a screen that contains copyright information and the version number of the utility. 46

52 Running the Test Utilities Setting Up Communications The Program Set Up display of the RIM Host Port Test Utility contains the following options: Option Name Use this option to... Run Mode Com Port Baud Rate Modem Identify the type of connection between the computer and the rack. Direct: RS232 cable. Modem: modem and telephone line. Identify the computer port that is connected to the rack. Choose the rate of communication between the computer and the rack. Identify the type of modem connected to the test computer and the telephone number of the rack to be tested. Use this field only if you are using a modem to connect the test computer to the rack. Displaying Test Data To display the output of the RIM Host Port, click on Start Display Program in the File menu. The RIM Host Port Test Utility will continue to scan the selected 3500 racks until you click on Stop Scan. The utility displays the information as shown in this display. 47

53 Rack Configuration and Utilities Guide The following table describes the fields in the Test Data Display: Field Name Address Family # RIM # Firmware Rack Status Bytes Description The address of the rack being tested. The name of the device being tested. The model number of the Rack Interface Module in the rack being tested. The version number of the firmware that is running in the Rack Interface Module being tested. An 8-bit word that contains information about the operating condition of the communication port being tested. When you click on a byte number button, the utility displays additional information about the meaning of the bits: 48

54 Running the Test Utilities Communication Gateway Port Test The HOST and RACK ports on the Communications Gateway I/O Module let you connect 3500 Monitor Racks to a process control system that uses Modbus communication protocol. The Comm Gateway Port Test Utility lets you verify that these ports are operating properly. The options in the menu bar operate as described in the following table: Option Name File Scan Program Data Display Manual Program Exit Com Set Up Help Program Information Description Display the communication parameters of any Comm Gateway Module in a Modbus daisy chain. Display all proportional values for a monitor. Send messages to the Comm Gateway and display the response in hex values. End the utility. Set options that control the communication between the test computer and the rack. Display a screen that explains what the utility does. About Display a screen that contains copyright information and the version number of the utility. 49

55 Rack Configuration and Utilities Guide Setting up Communications The Com Set Up display of the Comm Gateway Port Test Utility contains the following options: Option Name CGM Port Address Comm Port Baud Rate Parity Use this option to... Identify the port address of the Communication Gateway Module. Identify the computer port used to communicate between the test computer and Comm Gateway Module. Choose the rate of communication between the computer and the Comm Gateway Module. Choose the type of communication verification contained in each message byte. The parity setting within the Communication Gateway Module must agree with the setting at the external device connected to the module. Each Communication Gateway port can have a different parity setting. Stop Bits Set the number of bits which will be added to each 3500 Communication Gateway message. Each byte within a message will contain 1 start bit, 8 data bits, and either 1 or 2 stop bits. The Stop Bits setting must agree with the setting at the external device connected to the Communication Gateway. Each Communication Gateway port may be set up with a different Stop Bits setting. If you don't know the communication settings for a Comm Gateway Module, you can have the Scan Program under the File menu automatically detect these settings. Displaying Test Results The Comm Gateway Port Test Utility lets you display test results three ways: Scan Program, Data Display, and Manual Program. 50

56 Running the Test Utilities Scan Program lets you display the communication parameters of any Comm Gateway Module in the Modbus daisy chain. Enter the address of the rack at the prompt. Data Display lets you display all proportional values for a monitor as a percent of full scale. The proportional value as a percent of full scale. The number label for the proportional value. Use the tables in the Appendix A of the Communication Gateway Module Operation and Maintenance manual (part number ) and the operation and maintenance manuals of the 3500 monitors to determine what proportional value corresponds to the numbers on the Data Display. Manual Program is for advanced communication diagnostics. This test lets you compose messages to send to the Comm Gateway Module and then displays the response to the message in decimal values. 51

57 Rack Configuration and Utilities Guide Use this portion of the display to compose the message to send to the Comm Gateway Module. The response to the message appears here in decimal value. Appendix A of the Communication Gateway Operation and Maintenance manual (part number ) describes the structure of the messages that are composed and received on the Manual Program display. 52

58 Files Used by Configuration Software Files Used by Configuration Software The installation program adds files to your hard disk that are used by the Rack Configuration Software. Do not modify or move any of the files listed in this section except for the rack configuration files (.RAK). Description by File Extension Extension File Type Use.DEF Default Default configuration settings..dat Modem data files Modem and modem initialization strings..tbl DSP Table files Tables of DSP coefficients that the software uses to configure corner frequencies..dll Windows Dynamic Assist the Rack Configuration Software in a Link Libraries number of ways..ini Initialization Stores startup information such as customer name, customer location, and ship date..vbx Microsoft Visual Basic The Rack Configuration Software uses these files application to create the user interface. development files.rak Rack Configuration Store user-defined rack configurations. Files.EXE Executable software The main configuration program and product and utilities service utilities..hlp Help files The 3500 Rack Configuration help file. 53

59 Rack Configuration and Utilities Guide List of Files The 3500 installation program adds the following files to your hard drive: ** This file comes with MS Windows. The installation program adds this file only if it is not found or if the version on the hard disk is older than the one on the installation disks. 54

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