GEInstallation and Maintenance Manual

Copyright 1995. Bently Nevada, LLC. 

All rights reserved.

The information contained in this document is subject to change without notice. 

The following are trademarks of General Electric Company in the United States and other 

countries: 

Bently Nevada, System 1, Keyphasor 

The following are trademarks of the legal entities cited: 

Velostat is a trademark of 3M Company. 

Windows is a tradmemark of Microsoft Corporation. 

Modbus is a trademark of Modbus-IDA. 

Notice:

This manual does not contain all the information required to operate and maintain 

the product. Refer to the following manuals for other required information. 

3500 Monitoring System Rack Configuration and Utilities Guide 

(129777-01) 

• guidelines for using the 3500 Rack Configuration software for setting the operating 

parameters of the module 

• guidelines for using the 3500 test utilities to verify that the input and output 

terminals on the module are operating properly 

3500 Monitoring System Computer Hardware and Software Manual 

(128158-01) 

• instructions for connecting the rack to 3500 host computer 

• procedures for verifying communication 

• procedures for installing software 

• guidelines for using Data Acquisition / DDE Server and Operator Display Software

• procedures and diagrams for setting up network and remote communications 

3500 Field Wiring Diagram Package (130432-01) 

• diagrams that show how to hook up a particular transducer 

• lists of recommended wiring 

Operation and Maintenance Manuals for all the modules installed in the 

rack 

Product Disposal Statement

Customers and third parties, who are not member states of the European Union, who are 

in control of the product at the end of its life or at the end of its use, are solely 

responsible for the proper disposal of the product. No person, firm, corporation, 

association or agency that is in control of product shall dispose of it in a manner that is 

in violation of any applicable federal, state, local or international law. Bently Nevada LLC 

is not responsible for the disposal of the product at the end of its life or at the end of its 

use. 

1. Receiving and Handling Instructions 

This will be a short overview of the entire section. 

1.1 Receiving Inspection 

Visually inspect the system for obvious shipping damage. If you detect shipping 

damage, file a claim with the carrier and submit a copy to Bently Nevada, LLC. 

1.2 Handling and Storage Considerations 

Proper handling and storing of printed circuit boards is extremely critical. Circuit 

boards contain devices that are susceptible to damage when exposed to 

electrostatic charges. Damage caused by obvious mishandling of the board will 

void the warranty. To avoid damage, observe the following precautions in the 

order given. 

Application Advisory 

Machinery protection will be lost when 

you remove all power from the rack. 

• Do not discharge static electricity onto the circuit board. Avoid tools or 

procedures that would subject the circuit board to static damage. 

Some possible causes of static damage include ungrounded soldering 

irons, nonconductive plastics, and similar materials. 

• Use a suitable grounding strap (such as 3M Velostat® No. 2060) to 

ground yourself before handling or performing maintenance on a 

printed circuit board. 

• Transport and store circuit boards in electrically conductive bags or 

foil. 

• Use extra caution during dry weather. Relative humidity less than 30% 

tends to multiply the accumulation of static charges on any surface. 

When performed properly, you may remove modules from or install modules into 

the rack while power is applied to the rack. Refer to << Section reference to 

“Module Installation in section 4 >> for the proper procedure. 

2. General Information 

Monitoring and computerized vibration information systems provide the 

information you need to assess the mechanical condition of rotating and 

reciprocating machinery. These systems continuously measure and monitor 

various supervisory parameters and provide crucial information for early 

identification of machinery problems such as imbalance, misalignment, shaft 

crack, and bearing failures. As such, these systems are an efficient and effective

means of satisfying plant management, engineering, and maintenance concerns 

for: 

• Increasing plant safety by minimizing the occurrence of hazardous 

conditions or catastrophic failures. 

• Improving product quality by minimizing process variances caused by 

improperly operating equipment. 

• Maximizing plant availability by servicing only those machines that 

require it and providing more efficient turnarounds. 

• Reducing plant operating costs by minimizing unplanned shutdowns 

and by making more efficient use of maintenance resources. 

For protection of critical machinery, we highly recommend that you permanently 

install continuous monitoring systems. The term "protection" means that the 

system can shut down machinery on alarm, without human interaction. These 

systems include applicable transducers, each with its own dedicated monitoring 

circuitry and alarm setpoints. The 3500 Monitoring System is the newest addition 

to the family of continuous monitoring systems offered by Bently Nevada, LLC. 

2.1 3500 Monitoring System 

The 3500 is a full-feature monitoring system whose design incorporates the latest 

in proven processor technology. In addition to meeting the above stated criteria, 

the 3500 adds benefit in the following areas: 

• Enhanced operator information 

• Improved integration to plant control computer 

• Reduced installation and maintenance cost 

• Improved reliability 

• Intrinsic Safety (IS) option 

The following sections discuss these benefits in more detail.

2.1.1 Enhanced Operation Information 

The 3500 design includes features to both enhance the operator's information 

and present this information so that the operator may easily interpret it. These 

features include: 

• Improved data set 

- Overall amplitude 

- Probe gap voltage 

- 1X amplitude and phase 

- 2X amplitude and phase 

- Not 1X amplitude 

• Windows®-based Operator Display Software 

• Data displayed at multiple locations 

2.1.2 Improved Integration to Plant Control Computer

The 3500 improves integration to the plant control computer with: 

• Communication Gateways supporting multiple protocols 

• Time synchronized vibration and process information 

2.1.3 Reduced Installation and Maintenance Costs 

The 3500 system provides the following cost-saving features: 

• Reduced cabling costs 

• Downward product compatibility 

• Improved space utilization 

• Easier configuration 

• Reduced spare parts 

• Improved serviceability 

2.1.4 Improved Reliability 

The 3500 offers several features to improve system reliability. 

• Redundant power supplies available 

• Triple Modular Redundant (TMR) monitors and relay cards available

2.1.5 Intrinsic Safety Option 

If you wish to monitor equipment that is located in hazardous atmospheres, the 

3500 Monitoring System has a range of I/O modules with internal zener barriers. 

These modules provide an Intrinsically Safe interface between the 3500 rack and 

the transducers located in the hazardous area. 

2.1.6 Multiple Output Interfaces 

You can conveniently adjust monitor options (such as full scale ranges, 

transducer inputs, recorder outputs, alarm time delays, alarm voting logic, and 

relay configuration) in the field via software. Modular system design employs 

plug-in components which allow easy servicing and expansion. 

The following three independent interfaces are available with the 3500 system: 

• Data Manager Interface (Transient Data Interface External or Dynamic 

Data Interface External) 

• Configuration/Data port 

• Communications Gateway (support for Programmable Logic 

Controllers, Process Control Computers, Distributed Control Systems,

and PC-based Control Systems) 

These interfaces allow you to easily view monitored parameters and their 

statuses in the following ways: 

• System 1® Software 

• Bently Nevada™ 3500 Operator Display Software 

• Remote display panel 

• DCS or PLC display 

Convenient front panel coaxial connectors provide dynamic transducer signals 

and allow you to connect diagnostic or predictive maintenance instruments. 

2.2 Common Features 

The common features of the modules in the 3500 rack include hot insertion or

removal of modules and external and internal termination of the wiring. 

2.2.1 Hot Insertion or Removal of Modules 

When performed properly, you can remove and replace any module while the 

system is under power without affecting the operation of any unrelated modules. 

If the rack has 2 power supplies, removing or inserting a power supply will not

disrupt the operation of the 3500 rack. See <<Section reverence: “Module 

Installation in section 4 >> for the proper procedure. 

2.2.2 External and Internal Termination 

External termination uses multi-conductor cables to connect the I/O modules to 

the terminal blocks. These blocks simplify connecting many wires to the rack in 

tight areas. External termination is not available on I/O modules with internal 

zener barriers

3500 System Components 

The 3500 Monitoring System consists of modules that fit into a rack. Figure 2-3 

shows a full-size 3500 system rack and system components. Note that the fullsize rack has 14 monitor slot positions. The Mini-rack (not shown) is similar, but 

has 7 monitor slot positions to the right of the power supplies and Rack Interface 

Module. 

1. 1 or 2 power supplies

2. Rack Interface Module (standard, Transient Data Interface, (TDI), Triple Modular Redundant (TMR) and TMR TDI) 

3. Monitoring slot positions: 

- Monitor module

- Keyphasor® module (2 maximum) 

- Relay module 

- Communication Gateway module

- Display module. For the System Face Mount you must install the Display Interface Module in Slot 15.

- 3500/04-01 Earthing Module. Intallations that use Inernal Barrier I/Os require 1 Earthing Module per rack. 

Figure 2-3: 3500 Rack (Full-Size) 

The following sections list the function of each module. Refer to the individual 

operation and maintenance manuals for available options, detailed description, 

operation and maintenance. 

2.3.1 Weatherproof Housing 

The weatherproof housing protects the 3500 rack from adverse environmental 

effects, such as excessive moisture, dirt and grime, and even unclean air. The 

weatherproof housing will not accommodate a Display Unit or VGA Display. 

2.3.2 Rack 

2 types of 3500 racks are available: the full-size 19-inch rack and the compact 12-

inch Mini-rack. Each rack requires you to install the Power Supplies and Rack 

Interface Module (RIM) in specific locations. The full-size version offers 14 

additional rack positions and the Mini-rack offers 7 additional rack positions. You 

may use these positions to install any combination of modules. Both racks 

support Standard (non-redundant) and Triple Modular Redundant (TMR) 

configurations. 

2.3.3 Power Supply 

The Power Supply is a half-height module available in ac and dc versions. You 

can install 1 or 2 power supplies in the rack. Each power supply can power a fully 

loaded rack. When you install 2 power supplies in a rack, the supply in the lower 

slot acts as the primary supply and the supply in the upper slot acts as the 

backup supply. If the primary supply fails, the backup supply will provide power to 

the rack without interrupting rack operation. The 3500 design allows you to 

install any combination of power supply types. 

Overspeed Detection and TMR Monitors require dual power supplies. 

2.3.4 Rack Interface Module 

The Rack Interface Module (RIM) is a full-height module that communicates with

the host (computer), a Bently Nevada™ Communication Processor, and the other 

modules in the rack. The Rack Interface Module also maintains the System Event 

List and the Alarm Event List. You can daisy-chain this module to the Rack 

Interface Modules in other racks and to the Data Acquisition / DDE Server 

Software. The 3500 Monitoring System Computer Hardware and Software Manual

shows how to daisy chain the Rack Interface Modules together. Rack Interface 

Modules are available in Standard, Triple Modular Redundant and Transient Data 

Interface versions. 

2.3.5 Communication Gateway Module 

The Communication Gateway Module is a full-height module that allows external 

devices (such as a DCS or a PLC) to retrieve information from the rack and to set 

up portions of the rack configuration. You can install more than one 

Communication Gateway Module in the same rack. Communication Gateway 

Modules are available for a variety of network protocols. 

2.3.6 Monitor Module 

The Monitor Modules are full-height modules that collect data from a variety of 

transducers. You can install any combination of Monitor Modules in the 3500 

rack. 

2.3.7 Relay Module 

Relay Modules provide relays that you can configure to close or open based on 

channel statuses from other monitors in the 3500 rack. Relay modules are 

available in 4-channel, 16-channel, and 4-channel Triple Modular Redundant 

(TMR) versions. 

The TMR Relay Module is a half-height 4-channel module that operates in a TMR

system. 2 half-height TMR Relay Modules must operate in the same slot. If you 

remove the upper or lower Relay Module or the system declares one of the 

modules as Not OK, then the other Relay Module will control the Relay I/O Module. 

2.3.8 Keyphasor® Module 

The Keyphasor Module is a half-height module that provides power for the 

Keyphasor transducers, conditions the Keyphasor signals, and sends the signals 

to the other modules in the rack. The Keyphasor Module also calculates the rpm 

values sent to the host (computer) and external devices (DCS or PLC) and provides 

buffered Keyphasor outputs. Each Keyphasor Module supports 2 channels. You 

may place up to 2 Keyphasor Modules in a 3500 rack for a maximum of 4 

Keyphasor channels. If you use 2 Keyphasor Modules, you must place them in the 

same full-height slot and the modules will share a common I/O module. 

2.3.9 Display Module 

The 3500 system offers multiple display options. 

The Display Interface Module can display rack data on an LCD-based Interface 

unit or a 3rd-party Modbus® based display unit. 

The VGA Display Module will display rack data on certain touch screen VGA 

Displays. 

The Integrated PC display is a complete rack mount touch screen PC pre-loaded 

with rack configuration software and display utilities. 

2.3.10 Earthing Module 

The Earthing Module is a full-height module that provides a low resistance 

connection (must be less than 1 Ω) from the 3500 rack to the plant’s intrinsically 

safe earth ground. The module operates in conjunction with the 3500 internal 

zener barrier I/O modules. Your application will require 1 Earthing Module per rack 

when internal barrier I/O modules are used. 

2.4 Standard Rack Relay Options 

You can configure the standard (or non-TMR) 3500 rack to have individual relays, 

bussed relays, or a combination of individual and bussed relays. 

2.4.1 Individual Relays 

A rack with individual relays contains 1 or more relay cards for each monitor 

module. You can configure the monitor and relay modules within a 3500 rack in 

many ways. 

Example 1: The application uses 1 relay module 1 monitor module. 

Table 2-1: 1 Relay Module Used With 1 Monitor Module 

2.5 Intrinsic Safety — The 3500 Internal Barrier System 

To provide Intrinsically Safe (IS) vibration and process variable monitoring, the 

3500 system has a range of I/O modules with internal zener barriers. When you 

install these modules in a 3500 rack with a 3500/04-01 Earthing Module, they 

provide an integrated solution for explosion protection for approved Bently 

Nevada transducer systems that are located within all classifications of 

hazardous areas (surface industries other than mining). 

2.5.1 3500 Internal Barrier System Restrictions 

• You must install 1 earthing module in each rack in the internal barrier 

system. The earthing module occupies 1 slot position in the rack when it 

uses Internal Barrier I/O modules.

• You must change the grounding configuration of the 3500/15 Power 

Supplies from the default factory setting. See the 3500/15 Operation and 

Maintenance Manual (PN 129767-01) for instructions. 

• You must isolate any RS-232 connection to any 3500 module. Monitors 

that support RS232 connections include Rack Interface Modules, 

Communication Gateways, and the 3500/95 PC Display. See the 3500/20 

Operation and Maintenance Manual (PN 129768-01) for instructions. This 

restriction does not apply to RS422 and RS485 connections to the rack. 

Monitors that support RS422 and/or RS485 connections include the 

3500/20, 3500/90, 3500/92, 3500/93, and 3500/95. 

• You must not use the 3500/94 VGA Display in internal barrier systems. 

• You must not use bussed transducers, as internal barrier systems do not 

allow bussed transducers. See the TMR section of this manual for more 

information. 

2.5.2 3500 Internal Barrier System Features 

• The earthing module supports dual IS Earth connections for cables with 

cross-sectional areas up to 10 mm2. This module lets you test IS Earth

continuity online. 

• The design of the internal barrier I/O modules provides the 2 inches (50 

mm) of separation required between safe and hazardous area field wiring. 

• The connectors for safe areas and hazardous areas have different field 

wiring colors (green for safe and blue for hazardous) and connector 

pitches. This helps to avoid incorrect field wiring installation. 

• Quick connect/disconnect connectors simplify field wiring installation and 

removal. 

4.3 Replacing Modules 

When replacing modules, whether main or I/O, you need not remove power from 

the rack if the following procedures are followed. Refer to applicable steps in the 

procedures above for removing or installing a module. 

4.3.1 Main Modules 

This assumes that you will replace only the main module of a monitor or power 

supply. Before you remove any module, refer to the applicable manual to see how 

this may affect rack behavior, and to identify any special handling requirements 

that you may require for personal safety. 

1. If necessary, upload and save the configuration of the module to be 

replaced. 

2. Remove the main module from the rack. 

3. Install the new main module into the rack. 

4. If necessary, configure the new main module. 

5. Verify operation. 

4.3.2 I/O Modules 

This assumes that you will replace only the I/O module of a monitor or the PIM of 

a power supply. Before you remove any module, refer to the applicable manual to 

see how this may affect rack behavior, and to identify any special handling 

requirements that you may require for personal safety. 

1. If necessary, upload and save the configuration of the module to be 

replaced. 

2. Remove the main module from the rack. 

3. Remove the field wiring from the I/O module. 

4. Remove the old I/O module from the rack. 

5. Install the new I/O module into the rack. 

6. Connect the field wiring to the new I/O module. 

7. Install the main module into the rack. 

8. If necessary, re-configure the main module. 

9. Verify operation

5.1 General Maintenance Instructions 

You cannot repair the boards and components inside of 3500 modules in the field. 

3500 rack maintenance consists of testing module channels to verify that they 

are operating correctly. You should replace modules that are not operating 

correctly with a spare. 

When performed properly, you may remove modules from or install modules into 

the rack while power is applied to the rack. Refer to Section 3 for the proper 

procedure. 

The 3500 Monitoring System is a high precision instrument that requires no 

calibration. The functions of the 3500 modules, however, require verification at

regular intervals. You should verify all modules in the 3500 Monitoring System at 

these maintenance intervals. The procedures in the Maintenance and 

Troubleshooting sections of the module manuals describe the verification and 

troubleshooting process. 

5.2 Choosing a Maintenance Interval 

Use the following approach to choose a maintenance interval: 

1. Start with an interval of 1 year and then shorten the interval if any of the 

following conditions apply: 

• the monitored machine is classified as critical, or 

• the 3500 rack is operating in a harsh environment such as in 

extreme temperature, high humidity, or a corrosive atmosphere. 

2. At each interval, use the results of the previous verifications and ISO 

Procedure 10012-1 to adjust the interval.