Symphony Plus

S+ Turbine: Machinery Condition Monitoring MCM800

Product Guide
Symphony Plus

S+ Turbine: Machinery Condition Monitoring MCM800

Product Guide
NOTICE
The information in this document is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this document.
In no event shall ABB be liable for direct, indirect, special, incidental or consequential
damages of any nature or kind arising from the use of this document, nor shall ABB be
liable for incidental or consequential damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be reproduced or copied without written permission
from ABB, and the contents thereof must not be imparted to a third party nor used
for any unauthorized purpose.
The software or hardware described in this document is furnished under a license and
may be used, copied, or disclosed only in accordance with the terms of such license.
This product meets the requirements specified in EMC Directive 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright © 2014 by ABB.
All rights reserved.
Release: April 2014
Document number: 2VAA000341R6200

TRADEMARKS
All rights to other trademarks reside with their respective owners.
ABOUT THIS BOOK Overview

ABOUT THIS BOOK ................................................................................................. 8

1.1 Overview .............................................................................................................. 8

1.2 Use of Warnings, Caution, Information, and Tip Icons .................................... 9

1.3 Terminology ......................................................................................................... 9

1.4 Related Documentation ...................................................................................... 9

2. INTRODUCTION ............................................................................................ 10

2.1 Product Overview .............................................................................................. 10

2.1.1 MPM810 Overview ......................................................................................... 10

2.1.2 TBU850 Overview .......................................................................................... 10

2.2 MCM800 Details ................................................................................................. 10

2.2.1 MPM810 Module ............................................................................................ 10

2.2.2 Termination Base Unit (TBU850) ................................................................... 10

2.3 Prerequisites and Requirements...................................................................... 10

2.4 Product Features ............................................................................................... 11

2.4.1 Field I/O Capabilities ......................................................................................11

2.4.2 Communication .............................................................................................. 11

3. INSTALLATION ............................................................................................. 12

3.1 Cabinet Installation ........................................................................................... 12

3.2 Termination Base Unit (TBU850) ...................................................................... 12

3.3 Termination Base Unit Connections ................................................................ 12

3.4 Module (MPM810) .............................................................................................. 12

3.5 Module Interconnection .................................................................................... 13

3.6 Power Supply Installation ................................................................................. 13

3.7 Redundant Power Supply Configuration ......................................................... 14

3.8 Power Distribution and Grounding .................................................................. 14

4. CONFIGURATION ......................................................................................... 16

4.1 Before You Start ................................................................................................ 16

2VAA000341R6200 5
Overview ABOUT THIS BOOK

4.2 Termination Base Units .................................................................................... 16

4.2.1 Signal Input Configuration .............................................................................. 18

4.2.2 Relay Output Configuration ............................................................................ 19

4.2.3 Event Marker Input Configuration................................................................... 20

4.3 DIP Switch Configuration ................................................................................. 21

4.3.1 Profibus/Modbus Address Dipswitch .............................................................. 21

4.3.2 Address Option Switch ................................................................................... 22

4.3.3 Option Dipswitch ............................................................................................ 22

4.3.4 Profibus Termination Dipswitch (S3) .............................................................. 23

4.3.5 MPM810 ......................................................................................................... 23

4.4 MCM800 Configuration via Profibus & Ethernet ............................................. 23

4.4.1 Module Specific Parameters sent to MCM800 ............................................... 24

4.4.2 Channel Specific Parameters sent to MCM800.............................................. 25

4.4.3 Active Data Sent To the MCM800 .................................................................. 27

4.4.4 Active Data Reported By the MCM800 .......................................................... 29

4.4.5 Structure of Packed Booleans ........................................................................ 33

5. OPERATION .................................................................................................. 34

5.1 General Description .......................................................................................... 34

5.2 I/O Conditioning Functions .............................................................................. 34

5.2.1 Signal Inputs .................................................................................................. 34

5.2.2 Event Marker Inputs ....................................................................................... 34

5.2.3 Optional Digital Input ...................................................................................... 35

5.2.4 Relay Outputs ................................................................................................ 35

5.3 Functions ........................................................................................................... 36

5.3.1 Vibration ......................................................................................................... 36

5.3.2 Eccentricity ..................................................................................................... 37

5.3.3 Thrust (Rotor) Position ................................................................................... 38

5.3.4 Differential Expansion .................................................................................... 38

6 2VAA000341R6200
ABOUT THIS BOOK Overview

5.3.5 Case Expansion ............................................................................................. 38

5.3.6 Dual Probe ..................................................................................................... 39

5.3.7 SMAX ............................................................................................................. 40

5.3.8 Complementary Position ................................................................................40

5.3.9 Waveform Capture Settings ........................................................................... 41

5.4 Functional Safety (SIL 2) ................................................................................... 41

5.5 Module Reset ..................................................................................................... 41

6. MAINTENANCE ............................................................................................. 42

6.1 Preventive Maintenance .................................................................................... 42

6.2 Hardware Indicators .......................................................................................... 42

6.2.1 MPM810 I/O Module LEDs............................................................................. 42

6.3 Troubleshooting ................................................................................................ 43

6.4 Diagnostics ........................................................................................................ 44

6.5 Module Replacement......................................................................................... 44

6.5.1 General ..........................................................................................................44

6.5.2 Replacement .................................................................................................. 45

6.5.3 Returning a Module ........................................................................................ 45

6.6 Firmware Upgrade ............................................................................................. 45

7. SPECIFICATIONS ......................................................................................... 46
7.1 MCM800 Product Specifications ...................................................................... 46

8. REVISION HISTORY ..................................................................................... 47

2VAA000341R6200 7
Overview ABOUT THIS BOOK

ABOUT THIS BOOK

1.1 Overview
This book provides a description of the MCM800 modules and termination units. It provides instructions for installation,
start-up, and information regarding capacity and performance. This book is not intended to be the sole source of
instruction for the MCM800 Machinery Condition Monitoring.

This section provides introductory and background information including guidelines about how to find information in the
manual related documentation.

The Introduction section provides a product and functional overview.

The Installation section provides installation guidance.

The Configuration section provides details for customizing the units to meet the requirements of individual
applications. The main information is structured as follows:

Design considerations and guidelines.

Capacity and performance.

The Operation section describes the various start modes and operating modes available for each installation.

The Maintenance section focuses on detecting faults using built-in diagnostics. It explains system status displays in
operator stations and LEDs on modules.

In the Specifications section you will find a data sheet that lists the capacities of all of the components of the MCM800
module.

8 2VAA000341R6200
ABOUT THIS BOOK Use of Warnings, Caution, Information, and Tip Icons

1.2 Use of Warnings, Caution, Information, and Tip Icons

This publication includes Warning, Caution, and Information statements where appropriate to point out safety related
or other important information. It also includes Tip to point out useful hints to the reader. The corresponding symbols
should be interpreted as follows:

An electrical warning icon indicates the presence of a hazard, which

could result in electrical shock.

A warning icon indicates the presence of a hazard, which could result

in personal injury.

A caution icon indicates important information or a warning related to

the concept discussed in the text. It might indicate the presence of a
hazard, which could result in corruption of software or damage to
equipment/property.

An information icon alerts the reader to pertinent facts and conditions.

A tip icon indicates advice on, for example, how to design your project
or how to use a certain function.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or
property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance, leading to personal injury or death. Therefore, comply fully with all
Warning and Caution notices.

1.3 Terminology
The following is a list of terms associated with the MCM800 that you should be familiar with. The list contains terms and
abbreviations that are unique to ABB or have a usage or definition that is different from standard industry usage.

Term Description

MPM810 MCM Processor Module for the MCM800

Orders The amplitude and phase of vibration at a specific frequency being a multiple
of the shaft speed.

TBU850 Terminal Base Unit for the MPM810

VAC Alternating Current Voltage (value is rms unless otherwise stated)

VDC Direct Current Voltage

1.4 Related Documentation

The following is a listing of all documentation related to the I/O system.

Title Description

3BUA000258R5 ABB Site Planning Guide

2VAA000341R6200 9
Product Overview INTRODUCTION

2. INTRODUCTION
This documentation contains the description of the Machinery Condition Monitoring Module MCM800, which provides a
complete set of functions for comprehensive Rotating Machinery Diagnostics. These functions include:
Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.
The MCM800 system is part of a distributed modular I/O system. The MCM800 components provide easy installation
and reliable performance using advanced control technology.

2.1 Product Overview

The MCM800 is comprised of a Processing Module (MPM810) and a Termination Mounting Unit (TBU850).
Its main function is to provide rotating machinery monitoring and protection capability independent from any master
DCS or PLC. This independence results in higher reliability and faster response time.
The MCM800 system implements widely used monitoring and protection algorithms available in the industry. Each
function also has a set of software configuration parameters.
The MCM800 system has a built-in Profibus-DP Communication Interface to facilitate integration with external control
systems or other Profibus compatible devices.

2.1.1 MPM810 Overview

The Processor Module (MPM810) plugs into the slot of the Termination Base Unit (TBU850).
The MPM810 performs the following functions:
Executes the selected functions of the MCM800 system.
Communicates to the control system via Profibus DP or Modbus RTU.

2.1.2 TBU850 Overview

The TBU850 contains terminals for power, field connections, and communication. It houses the MPM810 module.

2.2 MCM800 Details

2.2.1 MPM810 Module

The MPM810 resides in an open ventilated plastic enclosure. On the front of the MPM810 module there are eleven
LEDs indicating the module and I/O status. Refer to Section 6.2.1 MPM810 I/O Module LEDs for the status indication of
the LEDs.
MPM810 module can be easily replaced in a fully operational I/O station. The design of the module and TBUs protect
the module from being damaged by excessive voltage or current.

2.2.2 Termination Base Unit (TBU850)

The Termination Base Unit (TBU850) is an active base unit that receives and conditions the analog signals for use by
the MPM810. It contains the power and field I/O terminals, Profibus communication connectors, serial interface ports,
and relay output terminals.
The TBU850 can be mounted on a standard DIN rail. It has a mechanical latch to lock the TBU850 to the DIN rail. The
latch can be released with a screwdriver.

2.3 Prerequisites and Requirements

Before operation a complete set of parameters must be downloaded using Profibus DP or the Ethernet Configuration
tool. The Profibus master must configure the module before operation can occur.

10 2VAA000341R6200
INTRODUCTION Product Features

2.4 Product Features

2.4.1 Field I/O Capabilities

Power Input
+24VDC, -24VDC, Common.
Parallel terminals for use in daisy-chaining modules.
Analog Inputs
Channels 1-4 System Power: +24VDC, -24VDC current limited to 30mA.
Voltage Inputs range from ±20 volts DC
10 volts AC (pk-pk), 1.5 volts AC (RMS).
Current Inputs range from 4 to 20 milliamps.
Constant current 4.7mA available for +24VDC.
Event Marker Input
System Power: -24 VDC current limited to 30mA.
Relay Outputs
Alert Dry Contact (Form C) 2A @ 24 VDC / VAC (resistive load)
Normally de-energized/energized
selectable
Danger Dry Contact (Form C) 2A @ 24 VDC / VAC (resistive load)
Normally de-energized/energized
selectable
DIP Switches
Profibus Address Seven switches for address selection; one for mode selection.

Option Switch Used for calibration, startup mode, diagnostics, and power option.

Profibus termination Two switches for termination of Profibus line A and line B.

2.4.2 Communication
RS-485
Profibus DP V1 Configuration, Control, and Reporting Values.

Modbus Reporting Values.

Ethernet
10/100 BaseT TCP/IP Configuration, Control, and Reporting Values.
Transmission of machinery diagnostic information.
Firmware Upgrades.
RS-232
Debug Debugging and Firmware Upgrades.
Note: a special cable is required.

2VAA000341R6200 11
Cabinet Installation INSTALLATION

3. INSTALLATION

3.1 Cabinet Installation

Refer to the ABB Site Planning Guide (3BUA000258R5001) and the MCM800 Installation Guide for more information
about cabinet installation.

3.2 Termination Base Unit (TBU850)

The Termination Base Unit (TBU850) is designed to connect to a standard 35mm DIN rail. First verify that the locking
mechanism is set to the unlocked position. Use a flat head screwdriver if necessary to set the locking mechanism to the
unlocked position.

Figure 3-1 TBU850 Locking Mechanism

Then insert the edge of the DIN rail into the angled tabs located on the metal base. Once inserted, apply pressure on
the TBU850 so the metal cover lies flat against the DIN rail. While holding in place, use the flat head screwdriver to set
the locking mechanism to the sliding position by turning the device clockwise 90 degrees. Position the TBU850 to the
desired location and set the locking mechanism to the locked position by turning another 90 degrees.

Although the locking mechanism is in the locked position, it is possible that the unit
may slide given enough force, especially if mounted on a vertical DIN rail. To
further secure the modules, it is recommended to install a DIN rail end-bracket, or
place machine screws through the secure tabs on the TBU850.

3.3 Termination Base Unit Connections

A TBU850 provides a slot for the MPM810 module.
Two DSUB9 connectors are located on the right and left side of the TBU for Profibus and Modbus communication.
A standard Profibus or Modbus connector for line A (PA1) is connected on the left side of the unit and line B
(PB2) on the right side. The TBUs are designed to connect together passing the communication through the
system and out the opposite port.

The RJ-45 connector on the front of the unit provides proprietary Ethernet communication using TCP/IP protocol.

3.4 Module (MPM810)

Install module by aligning the connectors of the TBU and module, and then pushing the units together.

Ensure that the module is fully engaged into the TBU. Partial engagement may
produce unexpected results

After connection to the TBU, lock the I/O module in place using the I/O Module Locking device.

12 2VAA000341R6200
INSTALLATION Module Interconnection

3.5 Module Interconnection

On each side of the TBU are two DSUB9 connectors. The TBU is designed to plug together. Place the TBUs on the
DIN rail and slide the TBUs together until they are fully engaged. Use a screwdriver to turn the latch to secure the TBUs
in place.

Figure 3-2 MCM800 Module Interconnection

3.6 Power Supply Installation

The terminals of the TBU850 provide the connections for power of the MCM800. Table 3-1 lists the terminals used by
the MCM800 for the power connection. Figure 2-3 shows a typical power supply configuration. Refer to the MCM800
Installation Guide for more information.

Terminal Description

1 +24VDC Power (in)

2 Power Common (in)

3 -24VDC Power (in)

4 +24VDC Power (out)
5 Power Common (out)

6 -24VDC Power (out)

Table 3-1 TBU850 Power Terminals

Figure 3-3 Typical Power Connection

2VAA000341R6200 13
Redundant Power Supply Configuration INSTALLATION

3.7 Redundant Power Supply Configuration

To configure the power supplies for redundancy, three voting units are required.
Note: There is a positive and two negative voting units one for +24VDC and two for -24VDC.

Figure 3-4 Redundant Power Supply Configuration

3.8 Power Distribution and Grounding

It is important to provide proper power distribution and grounding to the MCM800 module. Since the MCM800 mon itors
frequencies related to the AC power it is necessary to eliminate any line frequency noise from the system.

The MCM800 requires +24VDC and -24VDC. The -24VDC is often confused with
Common. Be careful NOT to connect the -24VDC to the Common.

Figure 3-5 Power Distribution and Grounding (Loop)

14 2VAA000341R6200
INSTALLATION Power Distribution and Grounding

Figure 3-6 Power Distribution and Grounding (Star)

2VAA000341R6200 15
Before You Start CONFIGURATION

4. CONFIGURATION

4.1 Before You Start

Read this manual thoroughly before landing wires to the Termination

Unit and applying power to the modules.

4.2 Termination Base Units

The Termination Base Unit (TBU850) has several connectors for power and field inputs. The figure below shows the
relative position and numbering of connectors on the TBU850. (Note: the numbers do not appear in the TBU850).

Figure 4-1 Connector Positions

There are four input channels that can handle a wide variety of sensors. Table 3-1 describes the use of each of the
terminals.

Terminal Description
1 Transducer Power (+24) (out)

2 Constant Current (4.7mA)

3 Transducer Common

4 Transducer Signal
5 Transducer Power (-24) (out)
6 Earth Ground (Shield)

Table 4-1 TBU850 Signal Terminals Channels 1- 4

16 2VAA000341R6200
CONFIGURATION Termination Base Units

The Event Marker Terminal is used for the once per revolution phase marker. It is intended to be used with proximity
probes as the input sensor. This signal is common to each of the four input channels used to determine the various
orders calculations of vibration and it is used to report the speed of the shaft. The signal may be daisy chained to other
MCM800 modules or may drive a TTL signal for third part devices that cannot handle proximity probe inputs.

Terminal Description
1 EM Out (+) TTL
2 EM Out (-) TTL

3 Transducer Common
4 EM Signal (out)

5 EM Common (out)
6 EM Signal (in)
7 EM Common (in)

8 Transducer Power (-) (out)

9 Earth Ground (Shield)

Table 4-2 TBU850 Event Marker Terminals

There are two on-board relays that may be used for Alert and Danger indication. Each relay has a Normally Open (NO)
and Normally Closed (NC) contact. Any alarm from the four input channels may activate the relays using an OR
function.

These relays will not drive high voltage, high current or inductive
loads, so an interposing relay may be required for these applications.

Terminal Description
1 Alert Normally Closed

2 Alert Common
3 Alert Normally Open
4 Danger Normally Closed

5 Danger Common

6 Danger Normally Open

Table 4-3 TBU850 Relay Contacts

2VAA000341R6200 17
Termination Base Units CONFIGURATION

4.2.1 Signal Input Configuration

The MCM800 signal input terminals are designed to interface to a variety of sensors. Figures 4-2 through 4-5 show the
different TBU850 wiring configurations associated with the different type of sensor.

Figure 4-2 Eddy Current Probe Configuration

Figure 4-3 Piezoelectric velocity probes and accelerometers

Figure 4-4 Moving Element Velocity Probes

18 2VAA000341R6200
CONFIGURATION Termination Base Units

Figure 4-5 DC LVDTs

4.2.2 Relay Output Configuration

The MCM800 relay output terminals may interface directly to low power switching configurations or high power
switching devices using interposing relays. Figure 4-6 shows the TBU850 configuration for the on-board relay contacts.

Figure 4-6 Relay Terminal Connections

2VAA000341R6200 19
Termination Base Units CONFIGURATION

4.2.3 Event Marker Input Configuration

The TBU850 has an Event Marker input that typically interfaces to an eddy current probe. Figures 4-7 and 4-8 show the
TBU850 wiring configurations associated with these probes.

1 TTL +

2 TTL -

6 Signal

7 COM Probe
Driver
8 -24V PWR

9
Shield

Figure 4-7 Event Marker with single TBU850

Additional TBU850's
First TBU850

1 TTL + 1 1

2 TTL - 2 2

3 3 3
Signal Signal
4 4 4
Common Common
5 5 5

6 Signal 6 6

7 COM Probe 7 7
Driver
8 -24V PWR 8 8

9 9 9
Shield

Figure 4-8

20 2VAA000341R6200
CONFIGURATION DIP Switch Configuration

4.3 DIP Switch Configuration

The TBU850 requires proper Dipswitch setting prior to operation.

4.3.1 Profibus/Modbus Address Dipswitch

Determine the Profibus/Modbus address of the module and set Dipswitch S1 to the proper address. Valid Profibus
addresses range from 0 to 125; however addresses 0 & 1 are reserved for the Profibus Master. Therefore, valid
MCM800 addresses range from 2 to 125.
Note: System Redundancy requires a slave backup address to be n+64; therefore the highest possible primary
address with System Redundancy enabled is 61 for a backup address of 125.
Table 4-4 shows the switch settings for addresses 0 63. The switch settings for addresses 64 127 correspond to
the first 63 settings in the table, with switch 2 (S1) set to the 1 position.

Switch Profibus Switch Profibus Switch Profibus Switch Profibus

2345678 Address 2345678 Address 2345678 Address 2345678 Address
0000000 0 0010000 16 0100000 32 0110000 48
0000001 1 0010001 17 0100001 33 0110001 49
0000010 2 0010010 18 0100010 34 0110010 50
0000011 3 0010011 19 0100011 35 0110011 51
0000100 4 0010100 20 0100100 36 0110100 52
0000101 5 0010101 21 0100101 37 0110101 53
0000110 6 0010110 22 0100110 38 0110110 54
0000111 7 0010111 23 0100111 39 0110111 55
0001000 8 0011000 24 0101000 40 0111000 56
0001001 9 0011001 25 0101001 41 0111001 57
0001010 10 0011010 26 0101010 42 0111010 58
0001011 11 0011011 27 0101011 43 0111011 59
0001100 12 0011100 28 0101100 44 0111100 60
0001101 13 0011101 29 0101101 45 0111101 61
0001110 14 0011110 30 0101110 46 0111110 62
0001111 15 0011111 31 0101111 47 0111111 63
A 1 corresponds to the switch position labeled ON or CLOSED.

Table 4-4 Profibus/Modbus Address Selection

Figure 4-9 Address and Option Dipswitch

2VAA000341R6200 21
DIP Switch Configuration CONFIGURATION

4.3.2 Address Option Switch

Switch 1 of Dipswitch S1 is reserved in Profibus protocol and used for the baud rate in Modbus protocol.

4.3.3 Option Dipswitch

Operating Mode
Switches 1 & 2 of Dipswitch S2 set the start-up and operating mode of the MCM800.

Switch 1 Switch 2 Description

0 0 Normal Mode

1 0 Low Speed Mode

0 1 Diagnostic Mode

1 1 Calibration Mode

Normal Mode should be selected for most applications.

Diagnostic mode is used to run diagnostics on the MCM800 module.
Low Speed Mode is used for slower applications such as Hydro Turbines.
Calibration Mode is used to calibrate the module.

Refer to the MCM800 Release Notes for limitations of Low Speed Mode.

Configuration Retention
Switch 3 determines if the MCM800 retains its configuration on restart or resets all configurations to the default settings.

Switch 3 Description

0 Use and store Default settings at start-up.

1 Store configuration and use at start-up.

Reset IP Address
To reset the IP address to the default (192.168.222.111) set Switch 3 to 0 and the Address switch (S1) to 127 and the
redundancy to 0 (S1 = 01111111). Reset the module.

Module Communication Protocol

Switch 4 determines the communication protocol for ports PA 1 & 2 and PB 1 & 2.

Switch 4 Description

0 Modbus RTU protocol.

1 Profibus DP-V1 protocol.

22 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

Modbus Baud Rate Selection

When the Modbus Protocol is selected (Switch 4 of S2 = 0), switch 1 of S1 determines the baud rate.

Switch 1 Description

0 38400 Baud

1 19200 Baud

4.3.4 Profibus Termination Dipswitch (S3)

The Profibus Termination Dipswitch (S3) is used to terminate the Profibus bus. There is a switch for Line A and one
from Line B.

Figure 4-10 Terminate Profibus Lines

4.3.5 MPM810
There are no configurable settings on this board.

4.4 MCM800 Configuration via Profibus & Ethernet

The MCM800 system uses Profibus DP for communication with the control system
Refer to the Profibus Users Guide for more information.

2VAA000341R6200 23
MCM800 Configuration via Profibus & Ethernet CONFIGURATION

4.4.1 Module Specific Parameters sent to MCM800

Description Range Units Type
IP Address NNN.xxx.xxx.xxx 0 to 255 None I
IP Address xxx.NNN.xxx.xxx 0 to 255 None I
IP Address xxx.xxx.NNN.xxx 0 to 255 None I
IP Address xxx.xxx. xxx.NNN 0 to 255 None I
Subnet Mask NNN.xxx.xxx.xxx 0 to 255 None I
Subnet Mask xxx.NNN.xxx.xxx 0 to 255 None I
Subnet Mask xxx.xxx.NNN.xxx 0 to 255 None I
Subnet Mask xxx.xxx. xxx.NNN 0 to 255 None I
English/Metric EU 0, 1 None B
Angular Position of Event Marker
-360 to 360 Degrees I
probe
Event Marker Detect Voltage 0 to 15 Volts I
Normal Alert relay state 0,1 None B
Normal Danger relay state 0,1 None B

IP Address and Subnet Mask The IP Address and Subnet Mask are required for the module to communicate over
Ethernet. It is a unique address for a specific network. The default values are 192.168.222.111 and 255.255.0.0. The
configuration tools will allow a new address to be set. Once set the user must switch to the new address for proper
communication.
English/Metric Set this value to a 0 if the engineering units are English and a 1 if they are in metric.
Angular Position of Event Marker probe This value is the angular position of the Event Marker from a fixed
reference point, typically vertical.

Event Marker Detect Voltage This value is the minimum pulse height (pk-pk) of the Event Marker pulse. Setting the
value to 0 converts the signal as a Digital Input, which may be used as a Trip Multiplier.

Normal Alert/Danger relay state Set to 0 for normally De-energized (energize to activate relay), and 1 for Normally
Energized (de-energize to activate relay).

24 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

4.4.2 Channel Specific Parameters sent to MCM800

Description Range Units Type
Channel type
This value specifies the operation of the channel.
0 = None (Valid for all channels)
1 = Vibration (Channels 1-4 only)
2 = Eccentricity (Channels 1-4 only)
3 = Thrust (Rotor) Position (Channels 1-4 only)
4 = Differential Expansion (Channels 1-4 only)
5 = Case Expansion (Channels 1-4 only)
6 = Dual Probe - Relative (Channels 1 & 3 only)
7 = Dual Probe Seismic (Channels 2 & 4 only)
8 = Dual Probe Absolute (Channels 5 & 6 only)
For channel 5, channel 1 must be set to Relative (6), and
channel 2 must be set to Seismic (7).
For channel 6, channel 3 must be set to Relative (6), and 0 to 10 None I
channel 4 must be set to Seismic (7).
9 = SMAX (Channels 5-7only)
For channel 5, channel 1 & 2 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 6, channel 3 & 4 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 7, channels 5 & 6 must be set to Dual Probe
Absolute.
10 = Complementary Position (Channels 5 & 6 only)
For channel 5, channel 1 & 2 must be set to Thrust (3) or
Differential Expansion (4).
For channel 6, channel 3 & 4 must be set to Thrust (3) or
Differential Expansion (4).
Block output select
Value of the output (valid for all channels).
0 = Peak-to-Peak.
1 = Peak.
0 to 5 None I
2 = RMS.
3 = Average.
4 = Calculated Peak-to-Peak.
5 = Calculated Peak.
Probe type
Type of probe (valid for channels 1 - 4 only).
0 = None.
1 = Proximity Probe.
2 = DC LVDT.
0 to 8 None I
3 = Accelerometer.
4 = Moving Element velocity probe.
5 = Piezoelectric velocity probe.
6 = Complementary proximity probe.
7 = Ramped proximity probe.

2VAA000341R6200 25
MCM800 Configuration via Profibus & Ethernet CONFIGURATION

Description Range Units Type

8 = Ramped complementary proximity probe.
Probe Sensitivity
Full mv/EU R
S - 4 only)
Integration
Sets the type of integration (valid for channels 1-4 only).
0 = None. 0 to 2 None I
1 = Velocity to displacement (velocity probes only).
2 = Acceleration to velocity (accelerometers only).
Angular Position of Probe (see note pg 26) -360 to 360 Degrees I
Ramp Angle (see note pg 26) 0 to 90 Degrees R
Probe DC Voltage High Failure Threshold (see note pg 26)
Note: The Overall Value will report bad quality when the probe DC -24 to +24 Volts R
voltage is greater that this limit.
Probe DC Voltage Low Failure Threshold (see note pg 26)
Note: The Overall Value will report bad quality when the probe DC -24 to +24 Volts R
voltage is less that this limit.
N for Nth Order
3 to 10 None I
User defined order calculation from 3 to 10
Dual Vote Enable 0,1 None B

Angular Position of probe This value is the angular position of the probe from a fixed reference point, typically
vertical.

Ramp Angle This value specifies the ramp angle for ramped differential expansion.

Probe DC Voltage High/Low Failure Thresholds This value is the voltage beyond which the module will report bad
quality for that channel. The High Failure Limit should be set to approximately one volt less than the upper limit of the
linear range. Likewise, the Low Failure Limit should be set to approximately one volt greater than the lower limit of the
linear range.

26 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

4.4.3 Active Data Sent To the MCM800

Description Range Units Type
Shaft Rotational Direction
Indicates the rotation of the shaft.
0,1 None B
0 = Clockwise.
1 = Counter-clockwise.
Set Alert Relay
Forces the relay to the active state.
0,1 None B
0 = Normal operation.
1 = Force relay active.
Set Danger Relay
Forces the relay to the active state.
0,1 None B
0 = Normal operation.
1 = Force relay active.
Reset Diagnostic Function
A transition from 0 to 1 forces a reset of the Ethernet
communication interface. 0,1 None B
0 = Normal Operation.
1 = Forces Ethernet Network close and restart.
High Danger Threshold
The values determine the point above which the corresponding Full EU R
action will occur. (Valid for all channels).
High Alert Threshold
The values determine the point above which the corresponding Full EU R
action will occur. (Valid for all channels).
Low Alert Threshold
The values determine the point below which the corresponding Full EU R
action will occur. (Valid for all channels).
Low Danger Threshold
The values determine the point below which the corresponding Full EU R
action will occur. (Valid for all channels).
Alert Delay
Determines the delay in seconds the condition must exist before
activating Alert status. Note: If the value exceeds the Danger set 0.1 to 300 Seconds R
point before the Alert delay expires, the module will immediately
set the Alert status. (Valid for all channels).
Danger Delay
Determines the delay in seconds the condition must exist before 0.1 to 300 Seconds R
activating Danger status. Note: If the value exceeds the Danger
2VAA000341R6200 27
MCM800 Configuration via Profibus & Ethernet CONFIGURATION

Description Range Units Type

set point before the Alert delay expires, the module will
immediately set the Alert status. (Valid for all channels).
Alert Enable
Enables the alert action. (Valid for all channels).
0,1 None B
0 = Action disabled.
1 = Action enabled.
Danger Enable
Enables the danger action. (Valid for all channels).
0,1 None B
0 = Action disabled.
1 = Action enabled.
Filter Low Cutoff Frequency (High Pass filter)
Sets the cutoff frequency below which the signal is attenuated.
The value specified is the -3dB point of a 4-pole Butterworth filter. 1 to 1,000 Hz I
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types). (See note 1)
Filter High Cutoff Frequency (Low Pass Filter)
Sets the cutoff frequency above the signal is attenuated. The 30 to
value specified is the -3dB point of a 4-pole Butterworth filter. Hz I
15,000
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types). (See note 1)
Null Position in Engineering Units
The null or zero point of a position measurement. It is a known
starting point of the shaft from which the shaft will deviate either
from thermal growth or load conditions. Typically it is determined Full EU R
when the shaft is cold or a no load condition. This value can be
set to zero or some measured value. (Valid for channels 1 - 4,
Thrust, Differential or Case Expansion channel types).
Null Position Voltage
The voltage of the null or zero point of a position measurement
describe above. When the voltage measured by the probe is
equal to this value the output will display the Null Position set in -24 to +24 Volts R
Engineering Units. When the voltage changes the output value
will change based on the Sensitivity parameter. (Valid for
channels 1 - 4, Thrust, Differential or Case Expansion channel
types).
Set Null Position Voltage
Forces the MCM to set the internal NVRAM to correspond to the
Null Position EU and Voltage. (The MCM uses the locally stored
0,1 None B
values to determine position.)
0 = Normal operation.
1 = Set Null Position.
Waveform Capture
When the values changes from 0 to 1 the specific waveform file 0,1 None B
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
Run-up Capture
When the values changes from 0 to 1 the specific waveform file 0,1 None B
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
Rundown Capture
When the values changes from 0 to 1 the specific waveform file 0,1 None B
will be captured for analysis. Refer to the Waveform Historian
28 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

Description Range Units Type

manual for more information.
Event Capture
When the values changes from 0 to 1 the specific waveform file 0,1 None B
will be captured for analysis. Refer to the Waveform Historian
manual for more information.

Note 1: There may be some restriction to the cutoff frequencies. For example, the cutoff frequencies may affect integration
and RMS signals. Refer to the MCM800 Release Notes for more information.

4.4.4 Active Data Reported By the MCM800

Description Range Units Type
Module Alert
Indicates the Alert alarm status.
0,1 None B
0 = Normal.
1 = Alert / Danger Active.
Module Danger
Indicates the Danger alarm status.
0,1 None B
0 = Normal.
1 = Alert / Danger Active.
Dual Vote Alert Ch 1&2
Indicates if both channels are active when Dual Voting is enabled.
0,1 None B
0 = Normal.
1 = Alert / Danger Active (Both channels).
Dual Vote Danger Ch 1&2
Indicates if both channels are active when Dual Voting is enabled.
0,1 None B
0 = Normal.
1 = Alert / Danger Active (Both channels).
Dual Vote Alert Ch 3&4
Indicates if both channels are active when Dual Voting is enabled.
0,1 None B
0 = Normal.
1 = Alert / Danger Active (Both channels).
Dual Vote Danger Ch 3&4
Indicates if both channels are active when Dual Voting is enabled.
0,1 None B
0 = Normal.
1 = Alert / Danger Active (Both channels).
Dual Vote Alert Ch 5&6 Indicates if both channels are active when
Dual Voting is enabled.
0,1 None B
0 = Normal.
1 = Alert / Danger Active (Both channels).
Dual Vote Danger Ch5&6
Indicates if both channels are active when Dual Voting is enabled.
0,1 None B
0 = Normal
1 = Alert / Danger Active (Both channels).
MCM Mode
Reflects the operational mode of the MCM800 based on Dipswitch
S2. 0,1 None B
0 = Normal.
1 = Low Speed.

2VAA000341R6200 29
MCM800 Configuration via Profibus & Ethernet CONFIGURATION

Description Range Units Type

Calibration Active
Calibration status.
0,1 None B
0 = Not calibrating (Normal).
1 = Module is calibrating.
Diagnostic Error
Indicates the diagnostic status.
0,1 None B
0 = Diagnostics successfully passed.
1 = Diagnostics failed.
Orders Active
Orders are being calculated.
0,1 None B
0 = Orders are not being calculated.
1 = Orders are being calculated.
Event Marker Status
Indicates Event Marker Status / Digital Input Status
0,1 None B
0 = Event Marker Failed / Digital Input is low
1 = Event Marker OK / Digital Input is high
Zero Speed Indicator
Indicates if shaft has stopped.
0,1 None B
0 = Speed is >= 1 RPM or bad quality (Event Marker Status = 0).
1 = Speed is < 1 RPM and good quality (Event Marker Status = 1).
Invalid IP Address
Indicates if the IP address or subnet mask is invalid.
0,1 None B
0 = IP Address and Subnet mask are valid.
1 = IP Address or Subnet mask is invalid.
Profibus Active
Indicates a Profibus Master is communicating.
0,1 None B
0 = Profibus not communicating.
1 = Profibus is communicating.
Software Version Major
0 to 255 None I
Indicates the software major version.
Software Version Minor
0 to 255 None I
Indicates the software minor version.
Software Version Revision
0 to 255 None I
Indicates the software version revision.
Software Version Pre-Release
0 to 255 None I
Indicates the software version pre-release.
Speed
0 to 30,000 RPM R
The current speed in RPM.
Overall Output
The overall movement or position in Engineering Units according Full EU R
to channel type. (Valid for all channels).
DC Voltage
The current DC component of the output value in Volts. (Valid for -24 to +24 Volts R
channels 1 - 4).

30 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

Description Range Units Type

DC Relative Gap
The current DC component of the output value in Engineering Full EU R
Units according to channel type. (Valid for channels 1 4,
Ethernet Only).
Order 0.5x Amplitude
Half Order Vibration component in Engineering Units. (Valid for Full EU R
channels 1 6, Vibration only).
Order 0.5x Phase
Half Order phase angle in degrees. (Valid for channels 1 6, 0 to 359 Degrees I
Vibration only).
Order 1x Amplitude
First Order Vibration component in Engineering Units. (Valid for Full EU R
channels 1 6, Vibration only).
Order 1x Phase
First Order phase angle in degrees. (Valid for channels 1 6, 0 to 359 Degrees I
Vibration only).
Order 2x Amplitude
Second Order Vibration component in Engineering Units. (Valid Full EU R
for channels 1 6, Vibration only).
Order 2x Phase
Second Order phase angle in degrees. (Valid for channels 1 6, 0 to 359 Degrees I
Vibration only).
Order Nx Amplitude
th
Indicates the N Order Vibration component in Engineering Units. Full EU R
(Valid for channels 1 6, Vibration only).
Order Nx Phase
th
The N Order phase angle in degrees. (Valid for channels 1 6, 0 to 359 Degrees I
Vibration only).
Order Not1x Amplitude
Not First Order Vibration components in Engineering Units. (Valid Full EU R
for channels 1 6, Vibration only).
N for Nth Order
th
The N Order phase angle in degrees. (Valid for channels 1-6, 0 to 359 Degrees I
Vibration only).
Critical Error
Any module error detected by the system.
0,1 None B
0 = Normal.
1 = Error.
Configuration Error
A channel is configured improperly.
0,1 None B
0 = Normal.
1 = Error.
Probe Voltage Error
The channels DC voltage is out of limits.
0,1 None B
0 = Normal.
1 = Error.

2VAA000341R6200 31
MCM800 Configuration via Profibus & Ethernet CONFIGURATION

Description Range Units Type

Bad Data
The overall value is out of the specified probe failure limits.
0,1 None B
0 = Normal.
1 = Bad Quality.
Suspect Data
The Overall value is within 5% of the specified limit.
0,1 None B
0 = Normal.
1 = Suspect Quality.
Alert Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Alert.
Alert Low Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Alert.
Alert High Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Alert.
Danger Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Danger.
Danger Low Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Danger.
Danger High Active
The Overall value has exceeded the specified range.
0,1 None B
0 = Normal.
1 = Danger.
Time Waveform Buffer Full
Indicates Capture buffer is full.
0,1 None B
0 = Normal.
1 = Buffer Full.
Time Waveform Capture Complete
Indicates a single capture has completed.
0,1 None B
0 = Normal.
1 = Complete.
Time Waveform Run-up Active
The MCM800 is actively capturing respective waveform data.
0 = Normal. 0,1 None B
1 = Active.

32 2VAA000341R6200
CONFIGURATION MCM800 Configuration via Profibus & Ethernet

Description Range Units Type

Time Waveform Rundown Active
The MCM800 is actively capturing respective waveform data.
0 = Normal. 0,1 None B
1 = Active.

Time Waveform Event Log Active

The MCM800 is actively capturing respective waveform data.
0 = Normal. 0,1 None B
1 = Active.

4.4.5 Structure of Packed Booleans

Packed Boolean Outputs Packed Status Inputs

Bit Digital Selection 1 Digital Selection 2 Bit Module Status Channel Status

0 Dangeren2 Spare 0 IP Error Halt

1 Dangeren3 Spare 1 Zero Speed Config Error
2 Dangeren4 Spare 2 Event Marker Active Fail
3 Dangeren5 Spare 3 Orders Active Bad
4 Dangeren6 Spare 4 Profibus Active Suspect
5 Dangeren7 Spare 5 Mode WF Capture Active
6 Set_null1 Spare 6 Calibration Active Buffer Full
7 Set_null2 Spare 7 Diagnostic Error Runup Active
8 Alerten1 Set_null3 8 Alert (Relay) Rundown Active
9 Alerten2 Set_null4 9 Danger (Relay) Event Log Active
10 Alerten3 Rotation 10 Alert 1-2 Danger
11 Alerten4 Set_alert 11 Alert 3-4 Alert
12 Alerten5 Set_danger 12 Alert 5-6 Danger High
13 Alerten6 Reset_Ethernet 13 Danger 1-2 Alert High
14 Alerten7 Space 14 Danger 3-4 Alert Low
15 Dangeren1 spare 15 Danger 5-6 Danger Low

2VAA000341R6200 33
General Description OPERATION

5. OPERATION

5.1 General Description

The MCM800 Symphony Plus technology platform. Data exchange occurs between the
controller and the module. However, the MCM800 operates independently from the main DCS controller using its built-
in processors. The functions of the MCM800 provide dedicated monitoring and protective features, including:
Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.
The MCM800 System includes an MPM810 and a TBU850. The TBU850 conditions the field signals and passes the
conditioned signals to the MPM810 controller. The MPM810 uses the field data in the execution of its functions.
In the next sections of this manual, the MCM800 system is divided into three main functional areas for analysis
purposes:
I/O Functions
Protective Functions
Testing Functions.
These functions include both hardware and software components.

5.2 I/O Conditioning Functions

I/O Conditioning functions convert the field electrical signals into digital data, which transfers to the micro-controller in
the MPM810.

5.2.1 Signal Inputs

The MCM800 can accept up to four signal inputs. They can range from approximately +20 volts to 20volts. They pass
through over-voltage protection devices then into a differential input to reduce common mode noise. The signal passes
through a four-pole low-pass anti-aliasing filter with a corner frequency of about 20 kHz. This filter reduces high
frequencies that may be falsely interpreted. Finally, the signal is passed to the MPM810 where it is processed.
Internally the signal is separated into an AC and a DC component. The AC component is used for vibration and
eccentricity measurements. The DC component is used for Thrust, Differential Expansion, Case Expansion, and for
Signal Quality.
The AC signal is filtered using the frequency parameters set by the user to reduce unwanted frequencies. The filters
used are digital 4-pole Butterworth high-pass and low-pass filters. The output of the filter may be integrated from
velocity to displacement or acceleration to velocity. The signal is finally analyzed and output as a peak, Peak-to-Peak,
RMS or average value.
The signal is filtered to remove the AC component providing a steady DC value. For all type of configurations the DC
voltage provides ranging from +24 volts to 24 volts. This signal is used to determine signal quality as specified by the
user. It is also used for all position measurements. The position is determined from a null position previously set.

5.2.2 Event Marker Inputs

The MCM800 accepts a once-per-revolution pulse with a minimum pulse height of 1.7 v and a minimum pulse width of
100 µsec (larger signals are preferred). The Event Marker has two functions:
Shaft speed .
Orders calculations.

to bad quality.
For orders calculations, the module uses the event marker to determine the running speed of the shaft.
The calculations produce an amplitude of 1 times running speed (1X), 2 times running speed (2X), one-half
times running speed (half-X), and N times running speed (NX). N is a number between 3 and 10 specified
by the user. In addition, a Not 1X value is calculated. A phase angle is produced for half-X, 1X, 2X, and
NX.
34 2VAA000341R6200
OPERATION I/O Conditioning Functions

5.2.3 Optional Digital Input

An optional Digital Input is available when the Event Marker Detection voltage is set to 0. When the DC voltage on the

Additionally, if the high and low alarm limits are set to a positive value, and the Alert and Danger alarms are enabled; the
relays activate when the overall vibration goes above the low limit when set to 0 and they will activate when the overall
vibration goes above the high limits when set to 1.
When DI = 0; Low Alert and Low Danger are active
When DI = 1; High Alert and High Danger are active
Notes:
This feature is only available for vibration channels.
The maximum pulse height may be between 5 to 24 volts.

5.2.4 Relay Outputs

For each signal channel there are up to four alarm levels available.
High Danger
High Alert
Low Alert
Low Danger
If enabled, the MCM800 will activate on-board relays indicating a problem exists. There is one relay for Alert and one
relay for Danger. Time delays of 0.1 to 300 seconds are available to avoid false alarms.
The relays are Form-C providing Normally Open (NO) and Normally Closed (NC) contacts. In addition, parameters
enable the user to specify normally energized and normally de-energized relays.

The features must be used carefully to ensure expected results.

2VAA000341R6200 35
Functions OPERATION

5.3 Functions
The MCM800 System provides all the common rotating machinery diagnostic functions. These functions can be
individually configured for maximum flexibility. The sections below list typical parameter settings for the various
functions. Some parameters are application specific and may deviate from those listed. Not all parameters are used for
every function and are ignored. For those parameters, the default setting is recommended.

5.3.1 Vibration
This function measures shaft vibration.
Typical Vibration Configuration (valid for channels 1-4)

Channel Type 1 = Vibration

Output Select 0 = Peak-to-Peak
1 = Peak
2 = RMS
3 = Average
4 = Calculated Peak-to-Peak
5 = Calculated peak
Probe Type 1 = Proximity Probe
3 = Accelerometer
4 = Moving Element velocity probe
5 = Piezoelectric velocity probe
Probe Sensitivity Millivolts / EU
Integration 0 = None
1 = Velocity to displacement (velocity probes only)
2 = Acceleration to velocity (accelerometers only)

Angular Position
of Probe

High Failure Typical settings

Threshold Proximity Probe = -2.0
Accelerometer = 20.0
Moving Element velocity probe = 20.0
Piezoelectric velocity probe = 20.0
Low Failure Typical settings
Threshold Proximity Probe = -20.0
Accelerometer = 2.0
Moving Element velocity probe = -20.0
Piezoelectric velocity probe = 2.0
N for Nth Order 3 10 (User specified)
Filter Low Cutoff User defined (recommendations listed below)
Frequency Proximity Probe = 1
Accelerometer = 10
Moving Element velocity probe = 10
Piezoelectric velocity probe = 10
Integrated signals with low frequency noise = 40

36 2VAA000341R6200
OPERATION Functions

Filter High Cutoff User defined (recommendations listed below)

Frequency Low Speed (< 1000 RPM) = 200
Medium Speed (1000-5000 RPM) = 300 to 1000
1500/1800 RPM = 300
3000 RPM = 500
3600 RPM = 600
High Speed (> 5000 RPM) = up to 2000
Highest speed of interest in Hertz times 10
Note: refer to the Release Notes for limitations
when selecting Low Speed Mode.

Shaft Rotation Shaft rotation is determined looking axially from the

Direction driver to driven direction.
0 = Clockwise
1 = Counter-clockwise

5.3.2 Eccentricity
This function measures shaft eccentricity.
Typical Eccentricity Configuration (valid for channels 1 - 4)

Channel Type 2 = Eccentricity

Output Select 0 = Peak-to-Peak
Probe Type 1 = Proximity Probe
Probe Sensitivity Millivolts / EU

Angular Position
of Probe

High Failure
Proximity Probe = -2.0
Threshold
Low Failure
Proximity Probe = -20.0
Threshold

2VAA000341R6200 37
Functions OPERATION

5.3.3 Thrust (Rotor) Position

This function measures Thrust or Rotor Position.
Typical Thrust Configuration (valid for channels 1 - 4)

Channel Type 3 = Thrust

Probe Type 1 = Proximity Probe
6 = Complementary proximity probe
Probe Sensitivity Millivolts / EU
High Failure
Proximity Probe = -2.0
Threshold
Low Failure
Proximity Probe = -20.0
Threshold
Null Position in
User defined.
Engineering Units
Null Position
Set by user.
voltage

5.3.4 Differential Expansion

This function measures Differential Expansion. See Complementary Position for complementary applications
Typical Differential Expansion Configuration (valid for channels 1 - 4)

Channel Type 4 = Differential Expansion

Probe Type 1 = Proximity Probe
2 = DC LVDT
6 = Complementary proximity probe
7 = Ramped Complementary proximity probe
Probe Sensitivity Millivolts / EU
Ramp Angle
(for probe type 7 only)

High Failure Proximity Probe = -2.0

Threshold DC LVDT = probe dependent
Low Failure Proximity Probe = -20.0
Threshold DC LVDT = probe dependent
Null Position in
User defined.
Engineering Units
Null Position
Set by user.
voltage

5.3.5 Case Expansion

This function measures Case Expansion.
Typical Case Expansion Configuration (valid for channels 1 - 4)

Channel Type 5 = Case Expansion

Probe Type 1 = Proximity Probe
2 = DC LVDT
Probe Sensitivity Millivolts / EU
38 2VAA000341R6200
OPERATION Functions

High Failure Proximity Probe = -2.0

Threshold DC LVDT = probe dependent
Low Failure Proximity Probe = -20.0
Threshold DC LVDT = probe dependent
Null Position in
User defined.
Engineering Units
Null Position
Set by user.
voltage

5.3.6 Dual Probe

This function measures shaft vibration using a Dual Probe.
The Dual Probe application combines a Relative Probe (channel 1) with a Seismic Probe (channel 2) producing an
Absolute signal (channel 5). Likewise, channel 3 (Relative) and channel 4 (Seismic) produces channel 6 (Absolute).
The individual hardware channels (1 - 4) are configured similar to the vibration settings.
Typical Dual Probe Configuration

Parameter Relative (1/3) Seismic (2/4) Absolute (5/6)

Channel Type 6 = Relative 7 = Seismic 8 = Absolute
Output Select 0 = Peak-to-Peak 0 = Peak-to-Peak 0 = Peak-to-Peak
Probe Type 1 = Proximity Probe 4 = Moving Element N/A
velocity probe
5 = Piezoelectric
velocity probe
Probe Millivolts / EU Millivolts / EU N/A
Sensitivity
Integration 0 = None 1 = Velocity to N/A
displacement

Angular 0 0 N/A
Position of
Probe
High Failure Proximity Probe = -2.0 velocity probe = 20.0 N/A
Threshold
Low Failure Proximity Probe = -20.0 Moving Element velocity
Threshold probe = -20.0
Piezoelectric velocity
probe =2.0
N for Nth 3 10 (User specified) Same as relative Same as relative
Order
Filter Low User defined User defined N/A
Cutoff (recommendations (recommendations
Frequency listed below) listed below)
1 to 10 Hz 5 to 10 Hz
Filter High User defined Same as relative N/A
Cutoff (recommendations
Frequency listed below)
Low Speed (< 1000
RPM) = 200
Medium Speed (1000-
5000 RPM) = 300 to
1000
High Speed (> 5000
RPM) = up to 2000
Highest speed of
interest in Hertz times
10
2VAA000341R6200 39
Functions OPERATION

5.3.7 SMAX
This function measures shaft vibration using two probes in an X/Y configuration. It determines the maximum
displacement of the shaft by trigonometrically combining the two signals.
The SMAX application combines an X (channel 1) with a Y (channel 2) producing an SMAX signal (channel 5).
Likewise, channel 3 (X) and channel 4 (Y) produces channel 6 (SMAX). In addition, if two Dual Probes are placed in an
X/Y configuration SMAX is calculated using channel 7.
The X and Y designators are arbitrary. What is more important is the probe angles and direction of rotation.
Typical SMAX Configuration (valid channels 5 - 7)
Configure the X and Y channels as vibration channels or dual probes.

Channel Type 9 = SMAX

Output Select 0 = Peak-to-Peak
1 = Peak

5.3.8 Complementary Position

This function measures Thrust or Differential Expansion in a complementary position.
The Complementary Position application compares the signals from channels 1 and 2 to output channel 5, or channels
3 and 4 for channel 6.
Typical Complementary Position Configuration (valid channels 5 & 6)

Channel Type 10 = Complementary Position

Set Sensitivity for

channel 1 or 3 to
mV / EU and 2 or 4
to (-) mV /EU

Set Sensitivity for

channel 1 or 3 to
(-)mV / EU and 2 or
4 to mV /EU

Set Sensitivity for

channel 1 or 3 to
mV / EU and 2 or 4
to (-) mV /EU

Set Sensitivity for

channel 1 or 3 to
(-)mV / EU and 2 or
4 to mV /EU

The value of the Complementary output depends on the quality of each of the two hardware inputs. The quality is
based on the High and Low failure voltages. Refer to the section that explains the Probe Failure Voltage setting.
40 2VAA000341R6200
OPERATION Functional Safety (SIL 2)

The two probes can be mounted in such a way that the probes are either overlapping or non-overlapping as shown
below. It is preferred to mount the probes such that their ranges overlap. If this is not possible due to longer shaft
movement the range in the middle of the shaft movement will report bad quality, as shown below.

5.3.9 Waveform Capture Settings

The MCM800 has 4 logic signals that control when time waveform data is captured. Controller logic can be written to
capture a single time waveform or capture a series of time waveforms during a run-up, a rundown or during an event
such as a plant trip.
Capture Waveform
On a transition from false to true the current waveform will be captured and transmitted to the Data Server. Once
captured, the Capture Time Waveform flag becomes true. At least 5 waveforms can be retained in a buffer to await
transfer. If the buffer fills, the Buffer Full flag becomes true and the MCM800 will not capture additional waveforms until
buffer space is available. If Capture Waveform remains true, no additional waveforms will be captured. While it is not
normally necessary, DCS logic can check the Capture Time Waveform and Buffer Full flags.
Run-up Capture
When Runup Capture is true, the current waveform will be stored every time speed increases by Delta RPM or more.
Runup Capture continues while the flag is true and there is enough storage on the MCM800. There is enough memory
to store up to 40 files, but files can be off-loaded to the Data Server while the data is being captured. Delta RPM is
specified by means of ABB's Analyst diagnostic software and downloaded to each MCM800. While it is not normally
necessary, DCS logic can check the Run-up Data flag.
Rundown Capture
Same as Run-up Capture except speed must decrease by Delta RPM or more.
Event Active
The Event Waveform file contains up to 40 waveforms. The MCM800 will retain a configurable amount of waveforms
from the Current Data Buffer at a configurable Skip-over Factor prior to Event Active. The purpose is to store data from
before and after an event such as a Danger alarm or a machinery trip. Construction of the Event Waveform file starts
when Event Active becomes true. Construction continues until 40 waveforms, including pre-event captures, are stored
or Event Active becomes false, constituting a file. When a file is complete, the Event Data flag becomes true until the
waveforms are uploaded to the Data Server. If Event Active remains true, no additional Event Waveform files will be
constructed. The Skip-over Factor and Number of Pre-trigger Waveforms are specified by means of ABB's Analyst
diagnostic software and downloaded to each MCM800. While it is not normally necessary, DCS logic can check the
Event Data flag.

5.4 Functional Safety (SIL 2)

For systems that require IEC61508 Safety Integrity Level 2 (SIL 2) the following conditions must be met.
The Alert and Danger relays must be set to the same setpoint and set to de-energize to trip.
Both the Alert and Danger relays must be enabled.
Temperature shall be monitored by external means to guarantee the specified operations limits.
Use only probes with a DC offset and configure the DC offset accordingly to detect out of range failures.

5.5 Module Reset

If for some reason you wish to reset the MCM800, there is a reset pushbutton on the TBU850 near the ABB logo.
2VAA000341R6200 41
Preventive Maintenance MAINTENANCE

6. MAINTENANCE

6.1 Preventive Maintenance

Periodically (every six months) or during a plant shutdown, inspect modules and clean any dust accumulation with a
static safe vacuum cleaner.

6.2 Hardware Indicators

6.2.1 MPM810 I/O Module LEDs

LED Description

Health LED. If module is OK the LED is GREEN. On failure, the LED is either RED or OFF.
R/F
During startup this LED may flash GREEN and RED while going through diagnostics.

RxTxA Profibus Bus A communication. The LED is AMBER if the module is communicating over Bus A.
RxTxB Profibus Bus B communication. The LED is AMBER if the module is communicating over Bus B.

The LED is GREEN when running normally, completed diagnostics, or completed calibration. It is AMBER
STATUS during startup, running diagnostics or calibration. It is RED if the module failed startup, diagnostics or
calibration

Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH1 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 2 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH2 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 3 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH3 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 4 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH4 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 5 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH5 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 6 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH6 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.

Channel 7 status. GREEN means the channel is operational and not in alarm. Solid AMBER means the
CH7 channel is in Alert. Solid RED means channel is in Danger condition. Blinking AMBER means configuration
error. OFF means channel is not configured.
Table 6-1 MPM810 LEDs

42 2VAA000341R6200
MAINTENANCE Troubleshooting

6.3 Troubleshooting
Symptom Possible Causes Corrective Action
Module is not plugged in correctly. Re-adjust the module to fit properly.
Check Profibus Address Dipswitch.
Operating mode not set up correctly. Check Ethernet IP address.
Module does not initialize.
Check option Dipswitch.
Hardware failure. Replace the module.
Check +24 & -24 volt power supplies
No power to module.
and connector.
R/F LED is OFF.
Module is not plugged in correctly. Re-adjust the module to fit properly.
Hardware failure. Replace the module.
Re-adjust the module to fit properly.
Module is not plugged in correctly.
R/F LED is RED. TBU850 Power Failure.
Hardware failure. Replace the module.
Check Profibus master and
Profibus not communicating. configuration and addressing.
Check module Profibus address.
RxTxA & RxTxB OFF
Loose or disconnected. Check the cable for proper fitting.
Check Profibus termination Dipswitch
Profibus not properly terminated.
S3.
If LED does not turn green after
The module is on startup, calibration
STATUS LED is AMBER. several minutes the module may be
or diagnostic mode.
faulty. Replace module.
The LED will be red for about a
minute during startup. If it stays red
Module in startup.
from several minutes replace the
STATUS LED is RED.
module.
Module failed diagnostic. Replace MPM810 or TBU850.
Module failed calibration. Replace TBU850.
CHn LED is OFF. Channel not configured. Check configuration.
This is usually a normal condition.
However, it could be caused by a
Channel is in Alert condition.
CHn LED is AMBER noisy signal or an improper
configuration.
This is usually a normal condition.
However, it could be caused by a
Channel is in Danger condition.
CHn LED is RED noisy signal or an improper
configuration.
CHn LED is blinking AMBER There is a configuration error. Check configuration.
Configure channel using configuration
No configuration defined for channel.
Channel status indicates a Critical tool.
error, but no Configuration error. Re-configuration channel and set
Configuration not saved.
dipswitch to save parameters.
The possible corrective actions are
just as numerous, some are listed
There are numerous possible causes
below.
for incorrect values, some are listed
Check signal path.
below.
Check cable connections.
Signal noise.
Check cable shielding.
Poor connection.
Check sensitivity value.
Improper power and ground.
MCM800 reporting incorrect Check or adjust filter
Improper shielding.
values. settings.
Incorrect sensitivity.
Recalibrate TBU850.
Incorrect filter values.
Verify module with known
Improper calibration.
input signal.
Malfunctioning hardware.
Replace MPM810 or
TBU850.
Check cables for any faults. This
may be an infrequent occurrence that
Incorrect speed or phase Noise on Event Marker input signal.
cannot be easily identified and
corrected.
Hardware failure. Replace the module.

2VAA000341R6200 43
Diagnostics MAINTENANCE

Symptom Possible Causes Corrective Action

Check cables for any faults. This
Improper actuation of termination may be an infrequent occurrence that
Noise on input signal.
unit relays. cannot be easily identified and
corrected.
Hardware failure. Replace the module.

Note: When programming the MCM800 module, the programming jumper on the TBU850
must be set to the 2-3 position. If the MCM800 was programmed without moving the jumper
the firmware may behave unexpectedly. Many of the symptoms list in the table can be
corrected by reprogramming the module using the proper method.
For Profibus users: some Profibus repeaters use pin 4 on the connector. The MCM800
uses pins 2 and 4 to download firmware. Having a signal on pins 2 or 4 may cause noise
on the module that may result in higher than expected vibration readings. To avoid
creating this noise, do not have any signals on pins 2 or 4. It is preferred to only have
pins 3 and 8 connected for Profibus communication.

6.4 Diagnostics
The R/F LED will flash RED according to the table below if an error is detected. A Channel LED will light RED if the
corresponding component test fails.

Test R/F Status Channel Error Code

LED LED LED
TBU850 Test X Faulty Voltage(s) Solid RED
on TBU850
CPU access, instruction, register testing X Faulty CPU Repetitive RED
Flashes
Full DRAM Test X Faulty access or 2 Repetitive
data Flashes
Stack RAM X Faulty data 4 Repetitive
RED Flashes
FPGA Load X Faulty FPGA 5 Repetitive
RED Flashes
During any subsequent associated channel X Faulty Test Continuous
testing the Status LED may RED light if a test Flashing RED
fails. Following all testing the Status LED will
flash RED three times and the continually
flash RED if an error was discovered.
Non-initialized DRAM Test 1 Faulty access or Solid RED
data
Flash Test 2 Bad CRC Solid RED
Processor Test 3 Faulty CPU Solid RED
FPGA Test 4 Faulty Signature Solid RED
DSP Test 5 Faulty DSP Solid RED
NVRAM Test 6 Faulty Parameters Solid RED
Undefined 7 Program failure Solid RED

6.5 Module Replacement

6.5.1 General
All I/O modules are designed for long, trouble-free service. If it is determined that the module is faulty, replace it with a
new one. DO NOT try to repair the module as replacing components may adversely affect the module's performance
and void the warranty. If it becomes necessary to replace any parts, contact the ABB Customer Service Department.
All I/O modules can be exchanged on-line with the process power supply connected. However, it is important to
understand the consequences of a module exchange on-line and how it affects the process. Replacement of an I/O
module affects all channels on the module. It sometimes also indirectly affects the outputs, via some application
function, on another module.

44 2VAA000341R6200
MAINTENANCE Firmware Upgrade

6.5.2 Replacement
Replace faulty or suspect I/O modules in the following way:
Provide access to the module by loosening the module locking device.
Grip the module firmly and extract the module.
Store extracted modules in envelopes.
Insert the new module carefully and completely.
Ensure that the module contacts mate properly with the contacts in the TBU and activate the locking
mechanism in place.
Modules initialize automatically and will begin to execute in a few seconds.

6.5.3 Returning a Module

Note: most module failures are due to improper programming of the firmware. Before returning the module, please
consider reprogramming the module using the proper method. This will solve most failures.
When returning a module, first obtain a Return Material Authorization (RMA) number. Be sure to show this number
prominently on the outside of the shipping container, on the shipping label, and on the packing list.
Provide as much information as possible regarding the symptoms of the problem; include the part description, the part
number, and the serial number.

6.6 Firmware Upgrade

ABB recommends that all MCM800 modules be upgraded to the latest firmware in order to take advantage of the latest
enhancements and corrections.
For systems prior to the V5.1 release, it is recommended to upgrade to firmware V5.0.6.2.
For firmware revision prior to 6.2
Reprogramming the MCM800 requires serial communication with a specific cable pinout.
Contact your ABB service person for more information.
The procedure for upgrading the firmware requires using the proper process. Establish
communication with the module using the serial port on PA1 or PB2. Type UPGRADE. This
s Remove the MPM810, set the jumper J1 on the TBU850 to the
2-3 position, and replace the MPM810. To program the module
Send the firmware file using 1K Xmodem protocol. If the module times out after 30 seconds,
restart the process by typing DL. When complete, remove the MPM810, replace the jumper J1
to the 1-2 position, and replace the MPM810.
For firmware revision 6.2 or later
Remove the MPM810, set the programming jumper J1 on the TBU850 to the 2-3 position, and
replace the MPM810. This will generate a TU Failure, which can be ignored for programming.
Program the module using the latest firmware. When complete, remove the MPM810, replace
the jumper J1 to the 1-2 position, and replace the MPM810.
Note: not setting the programming jumper may cause the MCM800 to malfunction. Most MCM800
malfunctions can be corrected by reprogramming the module using the proper method.
For versions prior to 6.2 the firmware update should only be done using the serial interface. For versions
6.2 or later either the serial or Ethernet may be used.

2VAA000341R6200 45
MCM800 Product Specifications SPECIFICATIONS

7. SPECIFICATIONS

7.1 MCM800 Product Specifications

GENERAL

MCF5282 @ 64 MHz PLL

Microprocessors
MC56321 DSP @ 250 MHz PLL

Profibus DP V1
System Communications Modbus RTU (Output Only)
Ethernet 10/100 Base T, TCP/IP

I/O Module Mounting One slot in Modular Termination Unit (TBU850)

I/O Termination Termination Base Unit (TBU850)

TBU Cabinet Mounting Standard 35mm DIN Rail

24A/250V Compression: 0.14-1.5 / 0.14-1.5 / 28-16

TU Terminal Blocks
solid[mm 2] / stranded[mm2] / AWG
OPERATING

Positive Power +24 VDC current limited 30 mA each

Negative Power -24 VDC current limited 30 mA each

Constant Current 4.7 mA (for piezoelectric devices)

Digital Output (Alert / Danger) Dry Relay Contact (Form C) 2A @ 24 VDC

ELECTRICAL

Module Operating +24 / -24 VDC ±5% @ 300 mA each (typical)

Module Consumption 7.5 W each supply (typical)

Field I/O +24 / -24 VDC (fused @ 1/16 amp each)

46 2VAA000341R6200
REVISION HISTORY MCM800 Product Specifications

ENVIRONMENTAL

This product, when installed in a cabinet, was designed to comply with

the following Directives/Standards for CE Marking.
Emissions:
EN61000-6-2:2005
CE Mark
CIS 11:2003+A2:2006,EN55011:2007+A2:2007
EMC Directive
EN61000-3-2:2006,EN61000-3-3:1995+A1:2001+A2 :2005
2004/108/EC
Immunity:
EN61131-2 :2007,
EN61000-4-2 :1995+A1 :1999+A2 :2001, EN61000-4-3 :2006,
EN6111-4-4 :2004, EN61000-4-5 :2005,EN61000-4-6 :2007 ,
EN6100-4-8 :1993+A1 :2001, EN61000-4-11 :2004
EN61010-1 Safety Requirements for Electrical Equipment for
Safety Requirements Measurement, Control and Laboratory Use - Part 1: General
Requirements
Ambient Temperature 0° to 55° C (32° to 131° F)

5% to 90% RH (±5%) up to 55°C (non-condensing)

Humidity
5% to 40% RH (±5%) up to 70°C (non-condensing)
Atmospheric Pressure Sea level to 3 km (1.86 miles)

Air Quality Non-corrosive

Installation Category Category II per ANSI/ISA-S82.01-1994

8. REVISION HISTORY
Rev. Date / Initial
5.1 Updated for the Version 5.1 release 05/2010 KD
6.2 Updated for the Version 6.2 release 04/2014 KD

2VAA000341R6200 47
ABB Ltd. Notice

Document Number 2VAA000341R6200

The information in this document is subject to change
Business Unit Power Generation without notice and should not be construed as a
P.O. BOX 8131 commitment by ABB. ABB assumes no responsibility
8050 Zürich for any errors that may appear in this document.
SWITZERLAND In no event shall ABB be liable for direct, indirect,
special, incidental or consequential damages of any
Phone: +41 (0) 43 317-5380 nature or kind arising from the use of this document,
Fax: +41 (0) 43 317-5382 nor shall ABB be liable for incidental or consequential
www.abb.com/powergeneration damages arising from use of any software or hardware
described in this document.
This document and parts thereof must not be
reproduced or copied without written permission from
ABB, and the contents thereof must not be imparted to
a third party nor used for any unauthorized purpose.
The software or hardware described in this document
is furnished under a license and may be used, copied,
or disclosed only in accordance with the terms of such
license.
This product meets the requirements specified in EMC
Directive 89/336/EEC and in Low Voltage Directive
72/23/EEC.

Copyright © 2014 by ABB.

All rights reserved.
Release: April 2014

48 2VAA000341R6200_SPlus_MCM800 Product Guide.doc