Product Data Sheet

0-4500-091306 September 2006

Machinery Health Management

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CSI 4500 Machinery Health Monitor

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Automated, continuous, predictive machinery health monitoring of your plants most critical rotating machines Real-time machinery health feedback integrates to process control so you can run your process with confidence Field-based intelligence and event-based adaptive monitoring transforms vibration monitoring into predictive machinery health alerts PeakVue provides unique bearing fault detection capabilities to maintenance personnel Transient analysis for turbines empowers decisions through the live turbine dashboard like nothing on the market
Delivers real-time machinery health information so you can run your process with confidence.

Five percent of the machines in every plant have the ability to bring production to a halt. These critical machines require special attention by both maintenance and operations and almost always have shutdown protection in place to prevent catastrophic failure. But is that really enough to ensure production schedules will be met? Is the plant really protected? Today more facilities are upgrading their protection systems with prediction capabilities. With prediction, the machine can be allowed to continue performing within acceptable parameters and repaired at the time most economically convenient to the plant. Adding prediction is the difference between just saving

the machine itself and saving the production schedule. Prediction is protection for your bottom line. The CSI 4500 Machinery Health Monitor provides machinery prediction that complements an existing protection system providing real-time feedback to both maintenance and operations. As part of Emersons PlantWeb digital plant architecture, the CSI 4500 delivers real-time machinery health information when and where it is needed. Integration with the plants process automation system and AMS Suite: Machinery Health Manager software empowers decision-making and reduces

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Product Data Sheet

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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 newmaintenance personnel have long benefited from the predictive capabilities of vibration analysis and other integrated technologies. But without vibration monitoring feedback to process automation, operators dont know the effects their actions have on the health of rotating machines. In fact, 40% of machine faults are the result of process variations. The CSI 4500 and the AMS Machinery Manager send real-time overall vibration levels to operators. 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, vibration increases immediately. Feedback to the operator is provided and further adjustments head-off premature failure of the roll.

PlantWeb Alerts give clear, powerful indications of developing problems to an operator at a DeltaV station.

The CSI 4500 provides machinery prediction that complements an existing protection system.
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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 increasevibration 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 Emersons 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 strategy to begin watching for a 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.

Machinery Health feedback integrates to process automation systems, such as Emersons Ovation and DeltaV digital automation systems.

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Calendar rolls, winders, nip rolls, vacuum rolls, and changing machine speeds require event-based adaptive monitoring.

Information for fast, accurate decision-making. As plant personnel go about their daily activities, the CSI 4500s built in, exception-based processor collects and distributes information to the right system or user only when machinery health changes. The CSI 4500 continuously monitors the health of your machine, but sends alerts or new trend data to Emersons DeltaV or Ovation automation system on an exception basis when health changes. In addition, the CSI 4500 and the AMS Machinery Manager with the GT2 processor option can deliver transient analysis and live views specifically designed for large

and critical turbo machinery. AMS Machinery Manager also integrates with AMS Suite: Asset Portal where machine health is combined with other asset condition and performance information for a plant-wide view. Event-based monitoring links vibration information to process states. A machine that is in its normal operating mode, or production state, is far from operating in a steady state" condition. With other monitoring systems, an increasing load means increasing vibration levels and false alarms. This can necessitate setting vibration alarms extremely high to account for all process scenarios or events.

Much like a process automation system, the CSI 4500's built-in Production State processor more accurately monitors process events such as speed inputs, changing load, temperature, tank level or relay closures. The CSI 4500 Machinery Health Monitor processes events, adapts its monitoring, and produces a real alarm when machine health changes versus a false alarm when the load changes. Alarms are much tighter and false alarms are decreased. This adaptive strategy is not limited to adjusting alert levels; analysis types and the frequency of analysis can automatically be adapted as well.

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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 Monitoring for Early Warning and Planning for the Maintenance Department
Exception-based reporting drives you to the problem and reduces troubleshooting time Exception-based reporting allows the CSI 4500 to keep a close watch on the assets, but only alert your maintenance staff when the machine health changes. Exception-based reporting produces specific alerts and decreases the amount of data required for review when it is time to troubleshoot the alert. With the CSI 4500, troubleshooting time can be reduced 90%

through powerful analysis tools such as transient analysis for turbines, PeakVue bearing health technology, and customizable reporting capabilities. PeakVue technology is best-available bearing and gearbox anomaly detector PeakVue technology provides early, accurate and trendable roller bearing and gearbox anomaly detection unmatched by all other bearing health tools on the market. PeakVues patented method of processing preserves the peak amplitude of the stress wave emitted from a bearing or gear defect. Preserving this peak amplitude allows trendable bearing health diagnostics.

Other bearing tools on the market use demodulation techniques, which subtract carrier frequencies and use low pass filters. These processes have adverse effects on the original peaks that PeakVue maintains. If the carrier frequency during demodulation is amplitude modulated, then the amplitude of the resultant bearing energy is changing and will be less than the original bearing energy collected. Furthermore, the amplitude of the bearing energy after the low pass filter has been applied, will increase as the frequency of the defect increases.

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CSI 4500T Turbine Monitor

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Live Turbine Dashboard 60 hour Data Recorder Turbine Replay 3D Turbine Graphical Representation

To illustrate the results from Emersons 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 confident because you have two powerful tools to rely onall the necessary data was captured to assess the event and a live turbine dashboard will provide assurance during start-up.Information before, during and after the turbine 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.

AMS Machinery Manager allows users to select live plots for all bearings simultaneously.

Data extraction session for post processing events or baseline comparisons.

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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. Emersons 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 recording ensures events will not be missed. With the CSI 4500, a 60 hour running history is recorded all of the time. The CSI 4500s continuous data recorder will record and buffer from 60 hours to over one week, depending on the number of sensor inputs. Auto archiving of data is also included so that small, one hour, snapshots can be permanently and automatically saved to a network server. 3. The live turbine dashboard will enable real-time decisions during start up. When you arrive on site, they have already found a plugged oil line to the bearing. Now the question is how much damage was done, and can we restart? Multi-channel, continuous data recording saves you from ever missing an event and ensures the right information is available to dig

deeper into the problem. You look at the quick views and then extract the region of interest for more details, which quickly drives you to your decision. You review the data, compare with baseline, and confirm the vibration is isolated to one bearing. The shaft centerline plots tell you the bearing clearance was not exceeded. After fixing the oil flow issue, you advise restarting the turbine as you watch the live turbine dashboard. The live turbine dashboard provides real-time decision-making during start-up. The live turbine dashboard, available with the CSI 4500 transient system,provides live plots that were not possible before the GT2 processor. Live real-time plots such as overall levels, orbits, shaft centerline, Bode/ Nyquist, cascade,

waveform and spectrum, on all bearings, allow a turbine specialist to make real-time decisions. Simple Windows displays make manipulating screens and plots easy. Dual monitor mode helps you organize your views so you are staged for the startup. You can overlay baseline plots (from portable or online systems) on known good start-up plots to view the differences. With the transient live turbine dashboard, you can make realtime decisions with operators and production staff to bring the turbine up for critical production needs or to shut down again to save the asset.

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Chassis Options CSI 4500M Monitor

The CSI 4500M Monitor is the most common model for applications 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 4500T Monitor, which includes transient analysis for turbines.

CSI 4500M Monitor with G2 Processor. For more information visit http://www.mhm.assetweb.com/technology/online.html

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 applications, 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.

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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 tachometer 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 Environmental for CSI 4500M, CSI 4500MS, CSI 4500Q Environmental for CSI 4500T 22.25" width x 26.00" height x 11.56" depth o 180 opening required for enclosure door 0 to 110F (-17 to 43C); 0 to 120F (-17 to 48C) w/ fan tray accessory (PN B4500FT) 0 to 95% R.H. noncondensing 0 to 86F or 0 to 30C with Fan tray (fan tray required) CSI 4500T is best suited for computer room, control room environment CE EN50081-2 Emissions CE EN50082-2 Immunity

Ratings

Ordering Information x x x x x x x x = = = = = = = = 1, 2, 3, 4, 5, 6, 7, 8, 16 32 16 32 16 32 16 32 sensor sensor sensor sensor sensor sensor sensor sensor input, 0 tachometer, 0 relays input, 0 tachometer, 0 relays input, 16 tachometer, 0 relays input, 16 tachometer, 0 relays input, 0 tachometer, 16 relays input, 0 tachometer, 16 relays input, 16 tachometer, 16 relays input, 16 tachometer, 16 relays
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CSI 4500M Machinery Health Monitor

Overall System Characteristics Input Power System Power Dissipation 120 240 VAC 50/60 Hz < 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 Chassis Card Slots 13.975" width x 12.2" height x 8" depth 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 Fault Detection Technology Fan Tray 19 Rack Mount Option PN A474504 PN B4500FT D25051 (Qty 2 per rack)

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CSI 4500M Machinery Health Monitor Processor Card Specifications PN B4532MB

G2 General Memory Capacity 3 Network Communications HUB Local Communications Local Display Onboard Test Generator CSI 4500 Rack Health Relay G2 Trip Advisory Monitor Sensor Channel Scan: Overall Vibration Scan DC Scan Rate 2 Mb SDRAM, 8 Mb Flash 10/100 BaseT Ethernet NIC May be used for daisy chain type network architecture HUB for laptop or local display, and serial port Includes overall vibration readout and internal chassis temperature All sensor channels, tachometer channels, AC, DC amplitude and phase One relay will change states based loss of power or rack reboot 16 ch rms per 500 msec Peak to Peak with Transient Option Simultaneously scanned with overall vibration scan (includes DC Gap, temperature, and accelerometer bias)

Overall Level and DC Accuracy <1% software corrected Overall Level and DC Resolution 16 bits Data Acquisition Event Bases G2 Production State Monitor Data Collection Data Collection Interval Data Storage Interval ADC Resolution Dynamic Range Spectral Resolution Analysis Bandwidth Fmax Spectral Scan Rate Amplitude Accuracy Frequency Accuracy THD Phase Accuracy Analysis and Trend Types Relay input (polled or interrupt driven), RPM, DC, AC or software controlled Event based, adaptive Event based and/or time based Exception based and/or time based 24 bit, 2 channel simultaneous >100 dB, all ranges 100 to 6400 lines 10 Hz to 40 kHz, discrete steps 1 second per two channels, 400 lines, 400 Hz, 1 avg. (depends on analysis configuration) <1% software corrected 0.01%, crystal based <-90 dB, all ranges 2% Total Energy, Energy in a range, non-sync energy in a range, sync energy in a range, sync peak, sync phase, true peak, HFD, waveform peak to peak, RPM, gap, orbit, configurable with user defined parameter names Multiple analysis types per machine and per sensor Normal, PeakVue, Order Tracking, Synchronous Time Averaging English, Metric, Hz, CPM, Order Linear, log, dB Hanning, uniform

The G2 second generation processor provides:

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The G2 includes a Trip Advisory Monitor and a Productin State Monitor An optional third processor, the GT2, is available for real-time, simultaneous, transient data recording and transient live display and analysis Dual processors; one dedicated for protection and one dedicated for prediction 5 times faster processing gets you results faster 7 times the dynamic range increases ability to detect anomalies earlier Twice as much built-in memory increases network and server fault tolerance

Analysis Setup Averaging Units Scaling Windows

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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. 16 inputs per card, 2 cards per rack, multiple racks linked by Ethernet DC to 40 kHz and DC to 2Khz with Transient Option < 0.5 Hz <1% software corrected 1 per channel (acceleration to velocity or velocity to displacement) <2% (frequency and amplitude), software corrected 0.5 v, 1.0 v, 5 v, 10 v, AC or DC rms, 24 vdc, 24 vdc common mode auto-ranging or software selectable Accelerometer and velocity probes by each sensor channel, and displacement probes by built-in aux. power supply on power supply card >4 mA constant current with 22 v compliance per channel 500 KW (single ended)

Number of Sensor Inputs Analysis Bandwidth AC Coupling Corner Frequency AC Channel Accuracy Analog Integration Analog Integrator Accuracy Input Ranges

Powered Sensor Types

Sensor Power Powered ch Input Impedance

Non Powered ch Input Impedance 1 M (differential) Non Powered Sensor Types RMS to DC Converter Mux Card Analog Outputs Displacement, AC or DC process 1 per channel, 1 Hz to 40 kHz ChX, ChY, RMS, DC/Process (Peak to Peak with Transient Option

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CSI 4500M Machinery Health Monitor Power Supply Card Specifications PN A4532AC
B4532AC Specifications Input Power System Power Dissipation 120 240 VAC 50/60 Hz < 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 Supplies Power to Auxiliary Equipment 5 vdc, 12 vdc, 24 vdc, 3.3 vdc, -12 vdc +24 vdc, 0.3 A output for optional fan tray 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 110F and 120F. 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 120F 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 control room / computer room environment not to exceed 86F or 30C

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CSI 4500M Machinery Health Monitor Tachometer Card Specifications PN B4532TA

B4532TA Specifications
Number of Tachometer Channels Tachometer Frequency Inputs Tachometer Frequency Accuracy Tachometer Resolution Tachometer Types Tachometer Pulse Characteristics Modes Input Impedance 16 inputs per rack, 1 card per rack, multiple racks linked by Ethernet 0.1 Hz to 2 kHz (6 RPM to 120,000 RPM) 0.1% 0.002 Hz @ 60 Hz (0.1RPM) Eddy current displacement probe, TTL, passive magnetic Input and trigger pulse range 0.5 v to 24 v, 25 v CM 1 pulse per revolution, 500 S/min. pulse width, tach divider on card Volt compare, automatic adaptive, divide by N 1 M (differential)

CSI 4500M Machinery Health Monitor Relay Card Specifications PN B4532IO-x (x = 1, 2, 3, 4 or 5)

B4532IO Specifications Number of Channels Relay Types 16 input or output relay channels, 1 card per rack, multiple racks linked together by Ethernet 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. Voting configurable for thrust or radial 0 to 10s programmable time delay for 2 sensor voting logic 50 sec to 50 msec depending on module Software polled or interrupt driven Interrupt on pattern match or change 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

Auto Resetting

Response Time System Interface Interrupt Output Ordering Information

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CSI 4500MS Machinery Health Monitor Enclosure Specifications PN A4500MS

Overall System Characteristics Enclosure Dimensions Environmental 11" width x 16.00" height x 11.56" depth 180 opening required for enclosure door 0 to 100F (-17 to 50C); 0 to 120F (-17 to 60C) w/ fan tray accessory (PN B4500FT) 0 - 95% R.H. noncondensing CE EN50081-2 Emissions CE EN50082-2 Immunity PN A474514 PN A4500SK

Ratings Options PeakVue Bearing and Gearbox Fault Detection Technology Mounting Kit for 4500MS Without Enclosure

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Machinery Health Management

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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 Number of Cards Per Rack 2 relay channels, specifications same as B4532IO 1 sensor/tachometer/relay card, 1 processor card, 1 power supply card, multiple racks can be linked by Ethernet 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

Ordering Information Relay Options

CSI 4500T Machinery Health Monitor Transient Specifications PN B4532DB

B4532DB Specifications (includes all B4532MB Specifications) Number of Channels Memory Capacity AC Channel Accuracy Frequency Range Up to 32 channels 64 Mb SDRAM, 8 Mb Flash <1%, software corrected, 3% Mag/Phase DC to 40 kHz Production State Monitor DC to 2Khz with Transient Monitor, Peak to Peak rectification configurable 16 bits 200 lines - 6400 lines >80 dB 4 fixed channels from the B4532TA tachometer card. Requires at least 1 of 4 60+ hours 10 \100base-T Ethernet HUB and NIC 100 BaseT recommended for Transient Relay will change states based on loss of power or rack reboot

ADC Resolution Spectral Resolution Dynamic Range Number of Tach Channels Data Recorder Communication CSI 4500 Rack Health Relay

For more information visit http://www.mhm.assetweb.com/technology/online.html

Emerson Process Management Asset Optimization Division 835 Innovation Drive Knoxville, Tennessee 37932 T (865) 675-2400 F (865) 218-1401

2006, Emerson Process Management. 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 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 right to modify or improve the designs or specifications of our products at any time without notice. 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 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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