3500/22M Transient Data Interface Technical Guide: Introduction, Configuration, Installation and Maintenance

Chapter 1: Introduction – The Strategic Position of TDI in Machinery Health Management Systems

1.1 Industry 4.0 and the Rise of Predictive Maintenance
With the advancement of Industry 4.0 and smart manufacturing, plant management is shifting from traditional scheduled and reactive maintenance towards predictive maintenance. The core of predictive maintenance lies in using data to predict failures, which is founded on acquiring high-quality, timely operational data from equipment. Vibration analysis is one of the most effective methods for monitoring the condition of rotating machinery, enabling early identification of issues such as unbalance, misalignment, bearing wear, gear faults, and surge.

1.2 The 3500 Monitoring System: A Two-Tier Architecture for Protection and Management
The Bently Nevada 3500 system is a modular, programmable machinery protection and management system. It employs a two-tier architecture:

• Protection Layer: Its core function is to monitor critical parameters (such as vibration, displacement, temperature) in real-time. If safe setpoints are exceeded, it immediately triggers relay actions (e.g., shutdown) to prevent catastrophic incidents. This is "hard" protection.

• Management Layer: Its core function is to collect, store, and analyze detailed operational data of the machine (including steady-state and transient data) for performance evaluation, fault diagnosis, and trend prediction, supporting maintenance decisions. This is "soft" management.

The 3500/22M TDI is the core interface module that enables this "soft" management layer. It is installed in slot 1 of the 3500 rack (next to the power supplies). While it does not participate in the critical protection path (ensuring its failure does not affect the safety shutdown function), it is the aggregation point, processing station, and transmission hub for all management data.

1.3 The Core Mission of TDI
The mission of the TDI can be summarized in two points:

1. Configuration Portal: Acts as a bridge between the host computer (running configuration software) and the 3500 rack, used for downloading configuration parameters for the rack and its modules.

2. Data Engine: Efficiently collects, buffers, processes machine data from various monitoring modules within the rack (e.g., vibration, Keyphasor, temperature modules), and transmits it to the upper-level data acquisition computer and asset management software (e.g., System 1).

   
   

Chapter 2: TDI Hardware Overview and Core Features

2.1 Physical Composition and Installation
The TDI module itself occupies one full-height slot. Its operation relies on a matching I/O module, primarily of two types:

• 10/100 BASE-T Ethernet I/O Module: Provides an RJ-45 interface, uses standard Category 5 cable, and supports 10M/100M auto-negotiation.

• 100 BASE-FX Ethernet I/O Module: Provides an MT-RJ fiber optic interface for long-distance or high electromagnetic interference environments.
  Additionally, an optional Buffered Signal Output Module can be installed for direct access to the buffered output signals from the monitor modules.

The module must be installed in a Management Ready 3500/05 rack, identifiable by the Bently Nevada Orbit logo on the left side of the bezel.

2.2 Front Panel Layout and Indicators
The front panel is the first window into the TDI's status, containing the following key elements:

• Status LED Indicators:

• OK LED: Green. Solid ON indicates the TDI and I/O modules are operating correctly; blinking indicates a fault.

• TX/RX LED: Yellow. Blinking indicates the module is communicating with other modules in the rack.

• TM LED: Red. Illuminated indicates the entire rack is in "Trip Multiply" mode.

• Config OK LED: Green. Solid ON indicates all rack configuration is valid; OFF indicates a module is unconfigured or has a configuration error; blinking at 5Hz indicates a security option condition has been met.

• Hardware Switches and Ports:

• Key Switch: Toggles between "RUN" and "PROGRAM" modes to prevent unauthorized configuration changes.

• Rack Reset Button: Clears latched alarms in all modules within the rack.

• 7-Position DIP Address Switch: Sets the rack network address (1-127).

• RS-232 Configuration Port: Used for initial configuration or connecting a host when the network is unavailable.

2.3 Core Functional Features of TDI

1. Communication Ports:

• Front panel RS-232 port.

• Rear panel Ethernet port (primary), supporting TCP/IP protocol.

2. System Contacts:

• Provide dry contact inputs via the I/O module for "Trip Multiply", "Alarm Inhibit", "Rack Reset", etc., allowing external systems (e.g., DCS) to control the rack.

3. OK Relay:

• This is a critical hardware output contact used to report the overall "health status" of the entire 3500 system to external systems (e.g., control room indicators, DCS). Any module fault, configuration error, communication loss, or violation of security rules will cause the OK relay to de-energize (NOT OK).

4. Event Lists:

• System Event List: Logs events related to system operation, such as module insertion/removal, communication faults, power anomalies.

• Alarm Event List: Logs alarm status changes (entering/leaving alarm, OK/Not OK) from monitor and relay modules.

2.4 Triple Modular Redundant (TMR) Support
For critical applications demanding extremely high safety (e.g., nuclear power, certain petrochemical processes), the 3500 system supports a TMR configuration. This requires the TMR version of the TDI. In addition to standard functions, the TMR TDI continuously compares the outputs of three redundant monitor modules. If the output from one module diverges (beyond a configured percentage) from the other two, it flags that module as faulty and logs an event in the System Event List.

Chapter 3: TDI Data Collection Mechanism – From Signal to Insight

Data collection is the core value of the TDI. It can collect various types of data to address different machine operating states.

3.1 Classification of Data Content
3.1.1 Static Values
Static values are scalar values extracted after signal processing, typically updated once per second.

• Protection Values: Generated by the monitor modules themselves, used for comparison against setpoints and triggering protective actions, e.g., overall vibration amplitude, gap voltage. All 3500 monitor modules (regardless of age) can provide protection values via TDI.

• Management Values: Additional values generated by the TDI processing dynamic waveforms from M-Series monitor modules. The most important are nX order amplitude and phase. The TDI can calculate up to 4 user-defined nX values per channel (e.g., 1X running speed, 2X), which are crucial for identifying specific faults like unbalance, misalignment, and looseness.

• Software Variables: Advanced diagnostic parameters calculated by upper-level software (e.g., System 1) after performing further calculations (e.g., demodulation analysis, peak-to-peak calculations) on the raw waveform data received from the TDI.

3.1.2 Dynamic Data (Waveform Data)
Dynamic data is the raw, high-density time-domain signal, fundamental for advanced diagnostics like spectrum analysis, orbit plots, and modal analysis. Only "M-Series" monitor modules can provide dynamic data.

• Synchronous Waveforms: Sampling is synchronized to the once-per-turn Keyphasor signal. Users can configure samples per revolution (16x to 1024x), balancing waveform detail (high sample rate) against spectral resolution (low sample rate). Synchronous waveforms are essential for analyzing speed-related faults and plotting shaft orbits.

• Asynchronous Waveforms: Sampled at a fixed frequency (from 25.6 Hz to 64 kHz), independent of shaft speed. Each waveform comprises 2048 points, used to generate an 800-line spectrum. Asynchronous data is anti-alias filtered, suitable for analyzing high-frequency characteristic faults like those in bearings and gears.

• Integrated Data: The TDI can be configured to return integrated waveform data, converting velocity signals to displacement for analysis under certain standards.

3.2 Data Collection Modes
The TDI collects data in different modes and densities based on varying machine states and trigger conditions.

3.2.1 Current Values
The host software can request the TDI to send current static values and waveforms at any time. This is used for:

• Real-time Display: Showing live data on operator stations.

• Historical Trending: Collecting static values at 1-second intervals to build long-term trend plots.

• Scheduled Waveform Capture: Automatically collecting and storing waveforms at user-defined intervals (e.g., hourly) to establish baseline data.

3.2.2 Alarm Data
When any measurement point within the rack triggers an alarm (Alert or Danger), the TDI automatically captures data before and after the event for all points in the associated "Collection Group". This is an extremely powerful diagnostic function as it records complete data from the moment of the fault and the period surrounding it.

• Trigger Methods: Protection alarm or software alarm.

• Data Content: Includes high-density static data 20 seconds before the event (0.1s interval), standard static data 10 minutes before (1s interval), waveform data 2.5 minutes before (10s intervals), and corresponding data periods after the event. All data is time-synchronized within the collection group.

3.2.3 Transient Data (Startup/Coastdown Data)
Machine startup (run-up) and shutdown (coastdown) processes contain rich diagnostic information. The TDI has a dedicated transient data collection mode.

• Entry Trigger: Defined via "Collection Group Enablers", which are speed ranges (e.g., "slow roll to running speed" and "overspeed range"). When machine speed enters this range, the TDI automatically enters transient mode.

• Collection Trigger: Defined via "Collection Control Parameters":

• Delta RPM (Δ Speed): Collects a data set when the speed changes by a set amount (configurable separately for increasing and decreasing speed).

• Delta Time (Δ Time): Collects data at fixed time intervals.

• Data Playback: Before entering transient mode, the TDI retains the last 200 data sets in an internal buffer. Upon entry, it immediately sends these 200 "historical" sets along with subsequent real-time data to the host, thus completely recreating the transient process.

3.3 Data Flow and Synchronization Mechanism
The TDI does not simply forward data. It organizes data through the concept of "Collection Groups". Users assign related measurement points (e.g., X and Y direction vibration, Keyphasor signal for the same shaft) to the same collection group. The TDI ensures:

1. Waveforms for all channels in the group are sampled at the same instant, guaranteeing time coherence for orbit plots and channel waveforms.

2. Static values for all channels in the group are collected at the same instant.

3. Both alarm and transient data are collected and packaged per collection group, ensuring contextual consistency for data analysis.

   
   

Chapter 4: TDI Configuration and Systems Engineering Considerations

Configuring the TDI is a systems engineering process involving hardware matching, network setup, software coordination, and more.

4.1 Prerequisites and Limitations

• Hardware Requirements: The rack must be Management Ready; monitor modules providing dynamic data must be M-Series with PWA revision G or higher; a specific Keyphasor module version is required for multi-event per revolution signals.

• Software Requirements: Specific minimum versions of 3500 Configuration, Data Acquisition, Display, and System 1 software are needed.

• Unsupported Items: The TDI cannot communicate with legacy TDXnet, TDIX networks, nor can it be configured through a 3500/92 Communications Gateway.

4.2 Configuration Process Overview

1. Physical Installation: Insert the TDI into rack slot 1 and install the corresponding I/O module.

2. Network Initialization: Using the front panel RS-232 port and 3500 Configuration software, set the TDI's Ethernet parameters (device name, IP address, subnet mask, gateway).

3. Rack Configuration: Via the Ethernet port, complete the configuration of the entire 3500 rack (including monitor modules, relay modules, etc.) and download it to the rack. It is essential to save the generated rack configuration file.

4. System 1 Integration: In System 1 configuration, add this 3500 rack and import the rack configuration file saved in the previous step.

5. Management Layer Configuration: In System 1, complete the detailed data acquisition configuration, including:

• Creating and defining Collection Groups.

• Assigning channels to Collection Groups.

• Configuring synchronous/asynchronous sample rates.

• Defining transient collection enablers and control parameters (Δ RPM, Δ Time).

• Configuring alarm data capture options.

4.3 Key Configuration Options in Detail
4.3.1 Security Options
To prevent misoperation, the TDI provides multi-layered security:

• Password Protection: Connect password (read-only) and Configuration password (read-write).

• Key Switch: Physically locks configuration privileges.

• Software Security Options (selectable):

• Change Setpoints in Program Mode Only.

• Disable Front Communication Port of TDI.

• Drive Rack NOT OK Relay If Rack Address is Changed in Run Mode.

• Drive Rack NOT OK Relay If a Module is Removed From or Inserted Into the Rack.

• Drive Rack NOT OK Relay If Key Switch is Changed From Run to Program Mode.

4.3.2 Collection Control Parameter Optimization
The manual specifically warns that improper configuration can cause data floods. For example, setting a Δ RPM of 0.1 for a 30,000 rpm machine will generate a massive amount of data during startup, potentially overwhelming TDI memory and the network.

• Optimization Formula: The manual provides a formula to estimate a suitable Δ RPM value, considering machine speed range, ramp time, TDI internal waveform storage capacity (35 sets), and data acquisition computer capability.

4.4 Configuration Consistency is Paramount
The physical configuration of the 3500 rack, the configuration in the 3500 Configuration software, and the configuration in System 1 must be completely consistent. Any discrepancy (e.g., rack file mismatch with physical modules, inconsistent Keyphasor assignment) will cause data collection to stop or produce errors.

Chapter 5: Installation, Maintenance, and Troubleshooting

5.1 Receiving and Electrostatic Discharge (ESD) Protection
Modules contain ESD-sensitive components. Handling must follow ESD protection guidelines: use a grounding strap, transport and store in conductive bags or foil, with extra caution in dry environments.

5.2 Maintenance Operations

• Firmware Upgrade: Can be performed via 3500 Configuration software. Power must not be interrupted and modules must not be removed during the upgrade, as this may damage the module. Always back up the current configuration before upgrading.

• Verification Test: Use the verification utility in the configuration software to test the communication functionality of the TDI's host ports.

5.3 Troubleshooting Guide
The TDI provides rich diagnostic information, which is the first resource for problem-solving.

5.3.1 Diagnosing via LED Status

• OK LED blinking at 5Hz: Internal fault, check the System Event List.

• TX/RX LED not blinking: TDI communication abnormal, check the System Event List.

• Config OK LED OFF: A rack module has a configuration error.

• Config OK LED blinking at 5Hz: A security option triggered (e.g., module inserted/removed), press the Rack Reset button to clear.

5.3.2 Diagnosing via Event Lists
The System Event List is a powerful "black box", logging all system-level events. The manual details dozens of event codes, their meanings, and recommended actions. Examples:

• Event 11: Flash Memory Failure – Replace TDI as soon as possible.

• Event 32: Device Not Communicating – Check the module in the indicated slot or the rack backplane.

• Event 1018: Invalid Management Monitor Revision – Identify and replace the M-Series monitor not meeting PWA revision requirements.

5.3.3 Management Event List
Specifically logs events related to the data collection management function; does not affect protection system operation but impacts data upload.

• Event 1002: Management Keyphasor Faulted – Check Keyphasor signal quality.

• Event 1008/1009: Management System Halted/Online – Usually normal during operations (e.g., restarting DAQ); if occurring otherwise, may require TDI replacement.