The ABE040 204-040-100-012 is a premier 19‑inch industrial rack purpose‑built to house Vibro‑Meter’s VM600 series of machinery protection systems (MPS) and condition monitoring systems. This rack embodies decades of field‑proven expertise in rotating machinery safeguarding, offering a rugged, modular, and functionally safe platform for critical asset monitoring in harsh industrial environments. Designed for permanent installation in standard 19‑inch cubicles or panels, the ABE040 204‑040‑100‑012 delivers exceptional mechanical rigidity, superior electrical integrity, and efficient thermal management, ensuring uninterrupted operation even in settings characterised by high vibration, wide temperature swings, and significant electromagnetic interference.
The ABE040 204‑040‑100‑012 is the standard configuration of the ABE04x family, distinguished from its sibling ABE042 solely by the positioning of its mounting brackets. This standard variant provides maximum flexibility for most cubicle designs and is the preferred choice for new installations and retrofits alike. Its robust aluminium construction not only guarantees long‑term dimensional stability but also contributes to effective shielding against external noise, preserving the fidelity of sensitive transducer signals.
At the core of the ABE040 204‑040‑100‑012 lies a sophisticated backplane architecture that simultaneously supports a VME bus for high‑speed data exchange, a raw signal bus for direct analogue signal routing, a dedicated tacho bus for speed‑related measurements, and an open collector relay bus for reliable alarm actuation. This multi‑bus design ensures deterministic, low‑latency communication between all installed cards while maintaining the galvanic separation required for safety‑critical applications.
The rack accepts up to fifteen single‑width VM600 series cards, with the ability to mix single‑width and multiple‑width modules according to application needs. This modularity empowers system engineers to tailor protection and monitoring strategies precisely—from a single‑channel overspeed trip to a comprehensive, multi‑parameter condition monitoring solution covering vibration, position, temperature, and speed.
Factory‑configured and thoroughly tested prior to shipment, the ABE040 204‑040‑100‑012 arrives as a ready‑to‑use system, dramatically reducing on‑site commissioning time and eliminating configuration errors. For additional flexibility, the system can be reprogrammed at site using the MPS1 or MPS2 software packages (running under Windows), allowing adjustments to alarm thresholds, relay logic, and channel scaling without hardware changes.
The ABE040 204‑040‑100‑012 also supports redundant power supply configurations via dual RPS 6U units, available in multiple AC and DC input voltages. This redundancy ensures that the protection system remains operational even in the event of a single power supply failure—a critical attribute for facilities demanding high availability.
Key Features
Industrial‑Grade 19‑Inch Rack Construction – Fabricated from robust aluminium, the ABE040 204‑040‑100‑012 is engineered for permanent mounting in standard cubicles and panels, providing excellent mechanical stability, corrosion resistance, and electromagnetic shielding.
Standard 6U Rack Height – Conforming to internationally recognised form factors, the rack integrates seamlessly into existing infrastructure and simplifies planning for new control cabinets.
Modular Card Architecture – The rack accommodates up to fifteen single‑width VM600 series cards, supporting a mix of signal processing, acquisition, CPU, I/O, and relay cards. Unused slots can be covered with blank panels to maintain proper airflow and EMI integrity.
Integrated VME Backplane – The built‑in VME backplane ensures high‑speed, deterministic electrical interconnection among all installed modules, facilitating real‑time data exchange and synchronised alarm generation.
Multi‑Bus Support – Beyond the VME bus, the backplane incorporates a raw signal bus for direct analogue signal distribution, a tacho bus for speed and phase reference signals, and an open collector relay bus for flexible alarm routing.
Redundant Power Supply Capability – The rack can be powered by a single RPS 6U unit or by two units in redundant configuration. Various RPS 6U versions are available for AC (110/230 VAC) and DC (24, 48, 72, 110 VDC) inputs, accommodating diverse site power infrastructures.
Rear‑Accessible I/O Interfaces – All field wiring connections are conveniently located at the rear of the rack, where IOC input/output cards provide screw terminal strips or connectors for transducers, conditioners, and external control systems. This design simplifies installation, troubleshooting, and maintenance.
Factory Pre‑Configuration Option – Racks are typically configured and tested at the factory, delivering a turnkey system that minimises on‑site setup and ensures that all cards and backplane connections are verified before shipment.
Blank Panel Coverage – Any unused front or rear slot can be fitted with a blank panel (available in 1‑, 2‑, and 4‑slot widths), preserving proper cooling airflow, preventing dust ingress, and maintaining a professional appearance.
Safety‑Certified Design – The ABE040 204‑040‑100‑012, as part of the VM600 MPS, holds TÜV NORD certification for functional safety, meeting IEC 61508 SIL 1 and ISO 13849‑1 Performance Level c requirements when configured according to the safety manual.
Safety Certification and Compliance
The ABE040 204‑040‑100‑012 is an integral component of the VM600 Machinery Protection System, which has been independently certified by TÜV NORD to IEC 61508 Safety Integrity Level 1 (SIL 1) and ISO 13849‑1 Performance Level c (PL c). This certification validates that the rack, when populated with the specified VM600 modules and configured according to the functional safety manual, is suitable for use in safety‑related applications where the failure of the protection system could lead to personnel injury, environmental damage, or significant economic loss.
For such safety‑related applications, the ABE040 204‑040‑100‑012 must be operated with strict adherence to the following mandatory configuration rules:
De‑Energised to Trip – All output relays utilised for the safety function must be configured such that they are energised when all monitored parameters are within their normal operating ranges. Upon detection of an alarm condition, the relay is de‑energised, opening the contact and initiating a trip. This fail‑safe approach ensures that any loss of power, internal fault, or wiring break results in a safe state (trip) rather than masking a dangerous condition.
Latching Alarms – Safety‑related alarms must be set to latching mode. This requires a manual reset after a trip event, preventing automatic re‑arming of the protection circuit without operator acknowledgement and investigation.
Prohibited Functions – The VM functions “danger bypass” and “trip multiply” are expressly forbidden in safety configurations, as they could compromise the integrity of the protection logic.
Relay Contact Protection – Each relay output used for safety must be protected by an external 5A(T) fuse. This measure prevents the relay contacts from welding due to inadvertently high currents, which would render the trip circuit ineffective.
Proof Testing – An offline proof test must be performed at intervals not exceeding five years. This test verifies that all safety‑related channels and relays operate correctly and that no dangerous undetected faults have developed. The proof test includes cold start verification, continuity checks of relay contacts, and threshold validation using simulated input signals.
The ABE040 204‑040‑100‑012 achieves a worst‑case safety response time of less than 100 milliseconds from the moment the measured parameter exceeds the preset alarm threshold until the associated safety relay opens. This rapid response is essential for protecting high‑speed rotating machinery, where transient events can lead to catastrophic failure within milliseconds.
The rack’s backplane provides the necessary galvanic separation between input circuits and output relays, and an optional variant (ordering number 204‑040‑100‑111) offers enhanced separation in accordance with IEC/CEI 60255‑5 for applications requiring the highest level of electrical isolation.
System Integration and Configuration
The ABE040 204‑040‑100‑012 serves as the mechanical and electrical backbone of the VM600 MPS. It houses all necessary cards and provides the interconnections required for a fully functional protection and condition monitoring system.
Supported Modules – The rack accepts the following key VM600 cards:
MPC4 Machinery Protection Card – A four‑channel plus two auxiliary channels card that processes transducer signals, applies alarm logic, and generates relay outputs. Multiple MPC4 cards can be installed to monitor multiple machines or multiple parameters on a single machine.
IOC4T Input/Output Card – One IOC4T is required for each MPC4 card. It provides the physical interface for field wiring, including screw terminal strips for transducer connections and output signals to external systems.
RLC16 Relay Expansion Card – An optional card that adds additional relay outputs, expanding the number of independent trip or warning circuits available.
RPS6U Power Supply Unit – Provides the necessary DC power to the rack. Single or redundant configurations are supported, with input voltage options covering both AC and DC mains.
CPU and Communication Cards – For systems that require advanced data acquisition, trending, or communication with plant DCS/PLC, optional CPU and communication cards can be installed.
Configuration Workflow – The system is configured using the MPS1 (supplied) or MPS2 (optional) software running on a Windows PC. The process involves:
Defining alarm thresholds and hysteresis for each monitored channel.
Assigning relay outputs to specific alarms and defining their logic (e.g., OR, AND, majority voting).
Selecting the appropriate measurement modes (e.g., absolute bearing vibration, relative shaft vibration, shaft position).
Uploading the configuration to each MPC4 card via the VME bus.
For safety‑related applications, a mandatory configuration verification step is required. This involves downloading the configuration back from the MPC4 card and comparing it with the original uploaded file using a file comparison tool. Only when the two files match identically (apart from timestamp differences) is the configuration considered valid for SIL 1 operation.
Factory Pre‑Configuration – To simplify on‑site commissioning, the ABE040 204‑040‑100‑012 is typically delivered with the required cards already installed and the system pre‑configured according to the customer’s specifications. This reduces the risk of installation errors and ensures that the system is ready for operation as soon as it is powered up.
Installation and Commissioning
The ABE040 204‑040‑100‑012 is designed for straightforward installation in standard 19‑inch cabinets or panels. Its robust aluminium construction provides the mechanical rigidity required for industrial environments while remaining light enough for easy handling.
Mounting – The rack is equipped with standard mounting brackets that allow secure attachment to cabinet rails. The bracket position on the ABE040 differs from that on the ABE042, making the ABE040 the preferred choice for applications where the standard bracket location offers better access or clearance.
Power Supply Installation – The rack can be equipped with one or two RPS 6U power supplies. Redundant power supplies should be connected to separate mains circuits to ensure continued operation in the event of a single supply failure. Both AC and DC input versions are available, and the choice should be based on the site’s available power infrastructure.
Card Insertion – VM600 cards are inserted from the front of the rack and guided into position by precision‑machined slots. The cards mate with the backplane connectors automatically, ensuring reliable electrical contact. Each card is secured with retaining screws to prevent loosening under vibration.
Field Wiring – All field wiring connections are made at the rear of the rack. The IOC4T cards feature screw terminal strips that accept solid or stranded wires. Shielded cables should be used for transducer signals to maintain signal integrity. The rear‑access design allows for neat cable routing and easy troubleshooting.
Commissioning Procedure – Commissioning must be carried out by competent and authorised personnel, following the site‑specific procedures and the guidelines provided in the MPS Hardware Manual. The process includes:
Power‑up verification and LED status checks.
Verification of transducer signals and proper scaling.
Functional testing of each alarm channel by injecting simulated signals at sub‑threshold and super‑threshold levels.
Verification of relay outputs and their correct interface with the plant’s safety instrumented system.
For safety‑related installations, the commissioning must be integrated into the overall SIS (safety instrumented system) commissioning plan, with documented evidence of all tests and verifications.
Environmental Suitability
The ABE040 204‑040‑100‑012 has been designed and tested to operate reliably in the harsh environmental conditions commonly found in industrial power generation, oil and gas, marine, and heavy manufacturing facilities. Compliance with IEC 68.2 recommendations ensures that the rack can withstand:
Temperature Extremes – Both operating and storage temperature ranges are defined in the system hardware manual, with the rack’s aluminium construction providing efficient heat dissipation and thermal stability.
Humidity – The rack is suitable for operation in non‑condensing humid environments, with appropriate IP protection levels maintained through the use of blank panels in unused slots.
Vibration – The rigid mechanical design and secure card retention ensure that the rack can tolerate moderate vibration levels without intermittent electrical contact or mechanical damage.
Shock – The rack is capable of withstanding the mechanical shocks associated with normal industrial handling and installation.
Proper installation and adherence to the recommended clearances around the rack for ventilation are essential to maintain the specified environmental performance.
To order the ABE040 204‑040‑100‑012, the following details must be specified:
TYPE AND DESIGNATION | ORDERING NUMBER |
ABE040 Standard 19″ rack, height 6U, including backplane | 204‑040‑100‑012 |
ABE040 19″ rack, height 6U, including backplane, separate circuits in accordance with IEC/CEI 60255‑5 | 204‑040‑100‑111 |
ABE040 19″ rack, height 6U, including backplane, CSA standard | 204‑040‑100‑211 |
Optional Accessories – Blank Panels:
DESCRIPTION | ORDERING NUMBER |
Blank panel for rear of rack, 1 slot wide | 200‑505‑001‑011 |
Blank panel for rear of rack, 2 slots wide | 200‑505‑002‑011 |
Blank panel for rear of rack, 4 slots wide | 200‑505‑003‑011 |
Blank panel for front of rack, 1 slot wide | 200‑505‑005‑011 |
Blank panel for front of rack, 2 slots wide | 200‑505‑006‑011 |
Blank panel for front of rack, 4 slots wide | 200‑505‑007‑011 |
Power Supplies (RPS 6U series): Refer to the separate RPS 6U data sheet for detailed ordering codes. Available input voltages include 24 VDC, 48 VDC, 72 VDC, 110 VDC, and 110/230 VAC.
Support and Documentation
Vibro‑Meter provides comprehensive documentation and global technical support for the ABE040 204‑040‑100‑012:
MPS Hardware Manual (Standard Version) MAMPS‑HW/E – Covers installation, wiring, maintenance, and troubleshooting.
MPS1 Software Manual MAMPS1‑SW/E – Details the configuration software operation.
VM600 Functional Safety Manual MAVM600‑FS/E – Provides essential safety‑related parameters, certification details, and proof test instructions.
Product Data Sheet for ABE04x Racks – Contains mechanical drawings, environmental specifications, and ordering information.
Disposal and Environmental Responsibility
At the end of its service life, the ABE040 204‑040‑100‑012 must be disposed of in an environmentally sound manner. In European Community countries, the Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC applies, mandating separate collection, treatment, and recycling of electronic waste. The rack contains valuable materials such as aluminium, copper, and electronic components that can be recovered and reused, reducing the environmental footprint.
