Online System Installation

Reference Manual
RBMware Online System

Installation
Model 4500 RBMconsultant Manual
CSI Part # 97101 Rev. 3
Copyright
2002 by Computational Systems, Incorporated.
All rights reserved.
No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language in any form by any means
without the written permission of Computational
Systems, Incorporated (CSI).
Disclaimer
This manual is provided for informational purposes.
COMPUTATIONAL SYSTEMS, INCORPORATED MAKES NO
WARRANTY OF ANY KIND WITH REGARD TO THIS
MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. Computational
Systems, Incorporated shall not be liable for errors,
omissions, or inconsistencies that may be contained
herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of
this material. Information in this document is subject
to change without notice and does not represent a
commitment on the part of Computational Systems,
Incorporated. The information in this manual is not allinclusive and cannot cover all unique situations.
Product Support
Should you have any comments on this documentation or questions concerning the Agreement on the
following pages, please contact CSIs Product Support
Department.
Address:
Computational Systems, Incorporated
835 Innovation Drive
Knoxville, TN 37932 USA
Phone:
United States and Canada: 865-675-4274
FAX:
865-218-1416
Internet E-mail:
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Worldwide Web:
http://www.CSImeansReliablilty.com
ii
Reference Manual
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License Agreement
IMPORTANT: CAREFULLY READ ALL THE TERMS AND CONDITIONS OF THIS
AGREEMENT BEFORE OPENING THE PACKAGE OR PROCEEDING WITH INSTALLATION. OPENING THE PACKAGE OR COMPLETING THE INSTALLATION INDICATES YOUR ACCEPTANCE OF THE TERMS AND CONDITIONS CONTAINED IN
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IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS CONTAINED IN
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WITH DAMAGED OR MISSING COMPONENTS.
Definition of Software
As used herein, software refers to any computer program contained on
any medium. Software includes downloadable firmware for use in
devices such as analyzers or MotorSTATUS units and it includes
computer programs executable on computers or computer networks.
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You have the non-exclusive right to use this software on only one device
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updates to the software and made at the sole discretion of CSI. Should
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iii
Hardware Technical Help

1. Please have the number of the current version of
your firmware ready when you call. The version
of the firmware in CSIs Model 2100 series, Model
2400, and other analyzers appears on the powerup screen that is displayed when the analyzer is
turned on.
2. If you have a problem, explain the exact nature of
your problem. For example, what are the error
messages? When do they occur? Know what you
were doing when the problem occurred. For
example, what mode were you in? What steps did
you go through? Try to determine before you call
whether the problem is repeatable.
Hardware Repair
CSI repairs and updates its hardware products free for
one year from the date of purchase. This service
warranty includes hardware improvement, modification, correction, recalibration, update, and maintenance for normal wear. This service warranty excludes
repair of damage from misuse, abuse, neglect, carelessness, or modification performed by anyone other
than CSI.
After the one year service warranty expires, each
return of a CSI hardware product is subject to a
minimum service fee. If the cost of repair exceeds this
minimum fee, we will call you with an estimate before
performing any work. Contact CSIs Product Support
Department for information concerning the current
rates.
Obsolete Hardware
Although CSI will honor all contractual agreements
and will make every effort to ensure that its software
packages are backward compatible, to take advantage of advances in newer hardware platforms and to
keep our programs reasonably small, CSI reserves the
right to discontinue support for old or out-of-date
hardware items.
Software Technical Help

1. Please have the number of the current version of
your software ready when you call. The version
number for software operating under MS-DOS
appears at the top of every menu screen. The
version number for software operating under
Windows is displayed by selecting About under
the Help menu bar item.
2. If you have a problem, explain the exact nature of
your problem. For example, what are the error
messages? (If possible, make a printout of the error
message.) When do they occur? Know what you
were doing when the problem occurred. For
example, what mode were you in? What steps did
you go through? Try to determine before you call
whether the problem is repeatable.
3. Please be at your computer when you call. We can
serve you better when we can work through the
problem together.
Software Technical Support
CSI provides technical support through the following
for those under maintenance contracts:
Telephone assistance and communication via the
Internet.
Mass updates that are released during that time.
Interim updates upon request. Please contact CSI
Customer Services for more information.
Returning Items
1. Call Product Support (see page 2) to obtain a return
authorization number. Please write it clearly and
prominently on the outside of the shipping
container.
2. If returning for credit, return all accessories
originally shipped with the item(s). Include cables,
software diskettes, manuals, etc.
3. Enclose a note that describes the reason(s) you are
returning the item(s).
4. Insure your package for return shipment. Shipping
costs and any losses during shipment are your
responsibility. COD packages cannot be accepted
and will be returned unopened.
iv
Contents
Chapter 1 Introduction
Special Emphasis 1-2
How to Use 1-3
Plant Appointed Project Manager 1-3
Contractor 1-5
Supplemental Information 1-6
Where to Start 1-7
Chapter 2 Pre-Installation Review

Contractor Kickoff Meeting 2-2
Final Walk-Through 2-3
System Component Review 2-4
Chapter 3 System Documentation

System Overview Drawings 3-2
System Layout Drawings 3-5
Cable Administration Charts 3-6
Junction Box 3-7
4500R Enclosure 3-8
4500S Enclosure 3-11
Documentation Storage 3-13
Chapter 4 Install Instrumentation

Description and Handling Instructions 4-1
Required Tools & Parts 4-4
Surface Preparation 4-6
A0322 Mounting Stud Installation (Stud Mounting Only) 4-11
Sensor Mounting 4-12

A0322LC, A0322DS 4-15
Description & Handling Instructions 4-15
AO322LC Sensor Mounting (without Quick-Connect) 4-24
A0322LC with Quick-Connect Mounting Instructions 4-26
A0322RM 4-28
Description & Handling Instructions 4-28
A0322RM Mounting Stud Installation (Stud Mounting Only) 4-36
Sensor Mounting 4-37
V425 4-38
Description & Handling 4-38
Choosing Proper Actuator (Target) 4-40
Mounting Sensor Bracket 4-42
Mounting Sensor 4-43
Chapter 5 Enclosure Mounting

Description 5-1
Mounting Instructions 5-5
Mount 4500R and 4500S Data Collection Units 5-6
Description 5-6
Mounting Instructions 5-10
Prepare 4500R or 4500S Cable Access Plate 5-11
Description 5-11
Determine Hole Size & Location 5-12
Chapter 6 Cabling Requirements

Pull Instrumentation Wiring 6-5
vi
Installation 6-7
Pull A680 Bundled Cable from Junction Box/4500R or 4500S 6-9
Description 6-9
4500R or 4500S Enclosure 6-9
Guidelines for Dedicated 4500R or 4500S Network Segment 6-10
Description 6-10
4500R or 4500S Power Circuit Guidelines 6-11
Description 6-11
Chapter 7 Wire Terminations

Description 7-1
Terminate Instrumentation Wire 7-3
Terminate V680 Bundled Cable 7-5
Terminate 4500R Wiring 7-7
Description 7-7
Terminate Power 7-8
Appendix A 4500R or 4500S Default Network Addressing Schema

Appendix B Additional 4500R Connections
4500R Proximity Probe Interconnetion Diagram B-2
4500R 4-20ma Current Loop Interconnection B-3
Appendix C AC-DC Power Converter

Connecting and Maintaining the 4500R or 4500S unit C-2
Required Tools and Parts C-2
4500R (with duplex receptacle) C-3
4500R (without duplex receptacle) and 4500S C-3
Safe Operation of the 4500R or 4500S AC-DC Power ConverterC-3
Indicators C-4
vii
Power Output Connectors C-5

Auxiliary sensor output connections C-5
Fan output connections C-5
LED Indicators C-6
Appendix D Connection Parameters

Specifications for equipment that supplies and receives energy:D-2
Index
viii
Chapter
Introduction
Preface
Congratulations on your purchase of the CSI 4500R or 4500S online monitoring system. Along with your system hardware and software, you have
been provided several manuals to assist in installing, learning, and maintaining your system. This particular document is the RBMware Online System
Installation. The purpose of this document is to provide system installers
specific requirements and instructions for the correct installation of the CSI
4500R or 4500S online monitoring system and accessories.
This manual does not attempt to explain the operation or application of the
CSI 4500R or 4500S online system nor does it cover hardware or software
specifications.
Note
Normal installation for the Model 4500R or 4500S unit is in an

orientation such that the front panels are vertical.
1-1
Read This First

Special Emphasis
These conventions are used throughout this manual to call attention to the
adjacent text:
Note
A note indicates special comments or instructions.
Caution!
A caution indicates actions that may have a major impact on the

system integrity.
Warning!
The Warning paragraph warns you of actions that could

cause serious injury or death.
1-2
Introduction
How to Use
There are two intended audiences for this manual: the plant appointed
project manager, and the contractor. As such, it is important that each
understand how to make use of this document.
Warning!
All wiring should be installed by a trained and qualified

electrician. Wiring must conform to all applicable local
codes and regulations. Local codes and regulations
regarding wire type, wire size, color codes, insulation
voltage ratings, and any other standards must be followed.
Warning!
Power to the 4500R or 4500S AC-DC power converter

PCB must include a remote disconnect switch or circuit
breaker. The switch or circuit breaker must be in close
proximity to the equipment and within easy reach of the
operator.
Caution!
Use of the 4500R or 4500S AC-DC Power converter in a manner not

specified by CSI may impair protection offered by the equipment.
Plant Appointed Project Manager

The project manager will be involved in budgeting money for the installation work, setting schedules, procuring bids from contractors, and supervising the system install. Therefore, it is important that the project manager
understand the scope of work which is involved with an on-line system
installation which can be properly estimated by reviewing each section of
this manual. Furthermore, this manual is divided into sections:
How to Use
1-3
Pre-Installation Review
System Documentation
Install Instrumentation
Enclosure Mounting
Cabling Requirements
Wire Terminations.
These sections follow the natural progression of a system installation which
should make it easier for the project manager to estimate schedules and
budgets for the installation. Another important function of the project manager is to procure bids from contractors. Each contractor should receive a
copy of this manual and use that as a basis for their scope of work. Apart
from the installation manual, all the contractor should need is a copy of the
system proposal and any supplemental information for special purchases.
When reviewing bids from contractors it is very important that each contractors scope of work is based on this installation manual and all exceptions are noted.
Before the contractor begins work, the project manager will have the
important duty of performing an installation review and creating proper
system documentation. The installation review, which may include a Contractor Kickoff Meeting attended by a CSI online project manager, is
intended to educate everyone involved with the installation on requirements, deadlines, procedures, etc. The installation review also requires the
project manager to perform a final walk-through of the installation site and
determine if the purchased hardware is adequate and if any additional
hardware will be required.
System documentation is often neglected until an installation is completed.
The project manager must be in charge of creating proper system documentation for the contractor before the installation begins. This includes
assigning labels, creating system diagrams, and filling out cable administration charts. Having the proper system documentation will make the contractors job easier and reduce the number of mistakes made.
Finally the project manager should use this installation manual to validate
the work being performed by the contractor. Particular attention should be
paid to any Notes or Cautions within the document, which are the most
common causes of a poor installation.
1-4
Introduction
Contractor
The contractor will use this manual for two purposes: preparing a bid for
the system installation, and as a guide during the system installation.
When preparing a bid for the system installation, it is imperative that the
contractor reviews all parts of the manual that are specific to the installation
and list any exceptions to the manual within the bid. If the contractor takes
no exceptions, then it will be assumed that the bid covers the scope of work
as defined in the installation manual.
As an installation guide, it is not necessary that the installer be familiar with
the entire manual. The manual is written so a contractor when performing
a certain action, such as installing an AO322LC sensor, can turn to that particular section and have a complete instruction set without referencing any
other part of the manual. This should make it easier when many people are
involved with the installation, each performing a specific function.
How to Use
1-5
Supplemental Information
This installation manual covers the standard online system components.
For specific customer installations, there will be non-standard components
purchased with the online system. For each of these components, an installation guide supplement will be prepared by CSI and included with the
installation guide. If a purchased component cannot be found in the installation guide, please contact your CSI project manager and request an installation guide supplement.
1-6
Introduction
Where to Start
The chapters in this manual are intended to follow the natural progression
of a system installation. The plant assigned project manager needs to pay
particular attention to Chapter 2 Pre-Installation Review and Chapter 3
System Documentation. Contractors need to review Chapters 4-7 to fully
understand the scope of work involved in the online system installation.
The following is a brief summary of each chapter.
Chapter 2 Pre-Installation Review
The pre-installation review could also be called installation preparation.

This involves a contractor kickoff meeting, a final walkthrough of the
installation site, and examination of the delivered system components.
Chapter 3 System Documentation
System documentation is prepared before the system installation begins.

This involves assigning sensor names, wire tag designations, enclosure
names, preparing system layout diagrams, and filling out the cable administration charts.
Chapter 4 Install Instrumentation
The online system instrumentation includes the 322 family of accelerometers and the 425 tachometer. This chapter covers the handling requirements, required tools, and the installation procedures for each piece of
instrumentation.
Chapter 5 Enclosure Mounting
The online system will have two types of enclosures: junction boxes (701
family and the 745) and the 4500R or 4500S enclosure. This chapter covers
choosing proper enclosure mounting locations and mounting procedures as
well as preparing the 4500R or 4500S enclosure for conduit access.
Chapter 6 Cabling Requirements
This chapter covers conduit installation guidelines, network cabling guidelines, power line specifications, and pulling the online instrumentation
cabling as well as the 680 bundled (multi-pair) cable from junction boxes
to the 4500R or 4500S.
Where to Start
1-7
Chapter 7 Wire Terminations
Often the cause of most system failures, proper wire terminations within the
online system components is critical for a successful system startup. This
chapter covers routing, tagging, preparing, and terminating cables within
the V701, 702, 703, 745 junction boxes and 4500R or 4500S enclosures.
1-8
Introduction
Chapter
Description
The pre-installation review is a short but important phase in a successful
online system implementation. Consisting of a Contractor Kickoff
Meeting, final walk-through, and a system component review, it is the
responsibility of the plant assigned project manager with the assistance of
the CSI online project manager to ensure this phase of the system installation is completed successfully. The pre-installation review accomplishes the
following:
Identify and Educate all parties involved in the online system installation
Makes sure that the contractor fully understands the scope of work
Sets the system installation schedule
Confirms that system components fit customers application
Confirms that all necessary system components are on site and available.
Confirms location of system components is appropriate
It is not uncommon for plants to schedule the Contractor Kickoff
Meeting, final walk-through, and system component review all in one day.
This is especially beneficial when the CSI online project manager is
attending the Contractor Kickoff Meeting so that they may assist the plant
assigned project manager during the final walk-through and system component review. For this reason it is also recommended that the online system
has been shipped to the customer site before installation work begins.
2-1
Contractor Kickoff Meeting

Although referred to as the Contractor Kickoff Meeting, this meeting
brings together all parties involved with the online system installation. Typically, this will involve:
Plant Assigned Project Manager
CSI Online Project Manager
End User(s)
Contractor Representative(s)
Information Systems Representative(s).
The purpose of this meeting is to:
Assign Responsibilities
Review Scope of Work For Contractors
Answer Any Installation Related Questions
Review Customer Expectations of Installed System
Tentatively Set Schedules for Installation.
Although many contractors will be educated on the system installation
during the bid process by reviewing the installation manual and the system
documentation (see Chapter 3). It is important to confirm that they fully
understand the scope of work by reviewing each part of the installation
during this meeting. If the system documentation has not been submitted
to the contractors, this is the time to do so.
2-2
Final Walk-Through
The final walk-through is attended by the plant assigned project manager,
contractor representative(s), and the CSI online project manager. Using the
system documentation (see chapter 3) as reference, this is the opportunity
to physically walk-through each part of the installation with the contractors
representative(s) and the vendors representative (online project manager)
to review:
Sensor Mounting Locations
Cable Pulls
Conduit/Cable Tray Use
Enclosure Mounting Locations
Environmental Concerns
Hazardous Locations.
Final Walk-Through
2-3
System Component Review

The system component review confirms that the proper system components have been shipped and that nothing has been lost or damaged during
shipment. The review should be attended by the plant assigned project
manager, contractor representative(s), and the CSI online project manager.
It is the responsibility of the plant assigned project manager to gather
shipped components into an accessible area for the review process. The
review process simply consists of unpacking and inspecting system components to confirm all components are present. This is also the opportunity to
familiarize the plant assigned project manager and the contractor with the
different system components. In particular, the following items should be
confirmed during the review.
Any non-standard system components
Sensor mounting accessories (studs, mounting pads, quick-connects,
etc.)
Manuals
Junction box mounting tabs
4500R or 4500S board configurations
4500R or 4500S discrete input/output plug-in relays for correct configuration.
2-4
Chapter
Description
Often an overlooked part of the system installation, proper documentation
of a system installation will not only avoid problems during installation but
will also make system maintenance much more efficient. Unfortunately,
many system installations do not have documentation created until after an
installation is completed. A successful installation requires that proper
system documentation be created before a contractor begins working.
Proper documentation includes: system overview drawings showing the
on-line system layout within the plant; system layout drawings showing
sensor and enclosure mounting locations; and tags for all sensors, cables,
and enclosures documented in cable administration charts. This documentation must be given to a contractor before the installation begins and preferably as part of the bid package. When an installation is finished, it is
important that the documentation which has been maintained by the plant
assigned project manager is distributed to the proper plant personnel and
readily available for system maintenance and troubleshooting. The 4500R
or 4500S data collection unit and junction/switch box enclosures include
see-through pouches for storing the on-line system documentation.
3-1
System Overview Drawings

The system overview drawings illustrate how system components interconnect. These drawings are normally prepared by a CSI applications engineer and included in the online system proposal during the sales process. If
these drawings were not part of the proposal or if the system has changed
significantly from the time the proposal was created, it will be necessary for
the plant assigned project manager to create or update the drawings. The
following system drawings were taken from an on-line system proposal.
Example of System Overview Drawing (overall)
3-2
Example of System Overview Drawing (Machine Level)
As illustrated, the system overview drawings should consist of an overall

system diagram and then machine level diagrams showing sensor locations.
In general the following information should exist on each diagram.
Overall System Diagram:
4500R or 4500Ss
Junction/Switch Boxes
Cables
4500R or 4500S Network Segment Cables
Tags for each 4500R or 4500S, Junction/Switch box, and Cables
Machine Level Diagram:
Machine with Tag
Sensor Location with Tag
System Overview Drawings
3-3
Junction/Switch Boxes with Tag

Location on Plant Floor
3-4
System Layout Drawings

The system layout drawings illustrate exact locations for enclosure
mounting, conduit installation, cable pulls, and sensor mounting. These are
prepared by the plant assigned project manager utilizing facility blueprints.
The most common method for preparing these drawings is to copy blueprints of the plant floor/production line and mark the system installation
locations. Use color-coded highlights and symbols to mark the different
types of cable runs and enclosure mountings. The following is a recommended method of marking system layout drawings.
System Layout Marking Guidelines
System Layout Drawings
3-5
Cable Administration Charts

Cable administration charts are a convenient way to document wire terminations within system enclosures. Before the system installation begins and
preferably before bids are procured from contractors, the project manager
should work with the end user in the plant to determine sensor tags, enclosure tags, and cable tags. There is no recommended method for assigning
tags but the names should be consistent and represent physical locations or
machines. For instance, instead of naming a sensor, 23001, which represents nothing, a more meaningful name such as FAN1OV (fan number 1
outboard vertical) will make system maintenance and troubleshooting
much easier. After tags are assigned, it is important to document these in
cable administration charts. All enclosures for the CSI online system will
need to have cable administration charts created. For this reason, each
enclosure will include a special clear plastic pouch on the inside cover of
the enclosure to hold these cable administration charts for reference. There
are two types of cable administration charts for the online system: junction
box and 4500R.
3-6
Junction Box
The online system junction boxes each serve the same purpose: to provide
a junction between the instrumentation cable and the multi-pair bundled
cable which is pulled back to the 4500R. The cable administration chart for
a junction box simply documents the channel number, wire tag, sensor
type, and sensor location if the wire tag does not contain location information. The following is an example of the junction box cable administration
chart for a typical installation. These charts are shipped with the system and
can be found inside the online system junction boxes.
Junction Box Cable Administration Chart
3-7
4500R Enclosure
The 4500R enclosure has several types of cable terminations with specific
termination locations. The 4500R consists of removable boards to allow
several different configurations. These boards include mux 1&2, tach, I/O,
and the DCM. Each board has specific cable terminations which must be
documented in the cable administration charts. The cable administration
charts for the 4500R consist of two 8.5" x 11" pages. Templates are included
in the installation guide for the project manager to copy and fill out.
4500R Board Positions
3-8
3-9
3-10
4500S Enclosure
The 4500S enclosure has one cable termination card for the 8 sensors, 2
tachometers, and 2 discrete I/O. There is also a 10BaseT network termination and an AC power termination. These are to be documented on the
4500S cable administration chart. A template for this chart has been
included.
4500S Board Positions
3-11
3-12
Documentation Storage
After the system installation is complete, it is the project managers job to
review the system documentation and make any revisions such as rerouted
cables, misspelled wire tags, etc. and make the necessary revisions in the
system documentation. The last step is to create copies of the completed
system documentation and distribute to the appropriate plant personnel.
One copy should be sent to the CSI online project manager. This is also the
appropriate time to place the cable administration charts in the online
enclosures. Each enclosure contains a clear plastic pouch to allow easy reference by contractors and service personnel. In each 4500R enclosure, it is
recommended that a copy of the system overview and layout drawings be
placed in the pouch for quick reference.
Documentation Storage
3-13
3-14
Chapter
A0322RI, A0322RA, A0322DR

Description and Handling Instructions
A0322RI, A0322DR Image & Outline Drawing
4-1
A0322RA Image & Outline Drawing
4-2
Description
The A0322RI and A0322RA are general purpose accelerometers with 90degree integral cable connections. The A0322DR sensor is a general purpose accelerometer and temperature sensor with a 90-degree cable connection.These sensors are stud mounted or epoxy mounted to machinery
surfaces and transmit vibration data to the on-line monitoring system. The
integral cable connection joins the sensor housing at a 90-degree angle to
provide a low-profile installation. The A0322RI has a distinguishing bright
yellow polyurethane jacket for easy identification while the A0322DR has
a red polyurethane jacket. The A0322RA is contained in a steel housing
with an armored covered jacket.
Handling Instructions
General purpose accelerometers are susceptible to mechanical shock and

therefore it is very important for installers to take precaution when handling sensors. Do not drop, hammer, or impact the sensor housing before
during or after installation. Mechanical shock loads of over 5000 gs will
damage sensor and void manufacturers warranty.
Caution!
Do not drop, hammer, or impact sensor housing before, during, or after

installation.
When tightening down stud mounted accelerometers it is very important
not to exceed specified torque. Over-tightening of accelerometer will
damage sensing element and void manufacturers warranty.
Caution!
Do not exceed specified torque when tightening stud-mounted accelerometers.

Although the integral cable has built in strain relief, it is important that the
cable not be strained with excessive pulling force during cable pulls. No
more than 5-lbs. force should be exerted directly on sensor connection
during installation. It is recommended that cable be secured to machine
near the point of sensor installation if possible.
4-3
Caution!
Do not exert more than 5-lbs. pull force directly on sensor/cable connection during wire pulls.
If sensor mounting occurs before cable is pulled in conduit or raceway to
junction box it is important to leave cable bundled and secured to machine.
Sensor cable cannot be stepped on or severely kinked or permanent signal
degradation will occur. Also, cable bundle should not be placed in such a
manner that it will cause undue strain at the sensor/cable connection.
Required Tools & Parts

Below is a listing of the require tools and parts in order to install the
A0322RI and A0322RA accelerometers.
Spot Face and End Mill Tool
Suggested Vendor:
Industrial Monitoring Instrumentation (a division of PCB, Inc.)
3425 Walden Avenue, Depew, New York 14043, 1-800-959-4464. Web
sites: www.IMI-sensors.com or www.PCB.com.
IMI Part # 080A127
4-4
Description: the spot face tool attaches to a standard electric drill and provides a machined surface at least 1.1 times greater than the diameter of the
sensor. At the same time the tool drills a pilot hole which is then tapped for
the stud mounted sensor.
A901-1
A901-1 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Note
Contractor should confirm Material Data Sheet conforms to

plant safety regulations and substitute epoxy if necessary.
4-5
40-200 inch-lbs. Torque Wrench with 1/8" hex bit
Suggested Vendor:
Grainger Part # 4JW57
Description:
3/8" drive inch-lbs. torque wrench. Any torque wrench with a range of
40 to 70 inch-lbs. and less than 5 inch-lbs. increments can be substituted.
1/4"-28 taps & tap handle
9/16" open end wrench
Surface Preparation
There are several ways to mount your accelerometers. This section discusses those ways and what you need to do to successfully mount your
accelerometers.
Stud Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter.

If this is not possible, then an alternative mounting procedure
must be used. Do not proceed; contact project manager.
4-6
Note
Mounting location must provide a case thickness exceeding

.4". If this is not possible, then an alternative mounting procedure must be used. Do not proceed; contact project manager.
1 Prepare the spot face and end milling tool by setting the drill bit
depth to a minimum of .325".
2 Using wire brush and plant approved cleaner, clean and degrease
surface area.
3 Keeping spot face and end milling tool perpendicular to machine
surface, drill into mounting location until face has a minimum finish
of 63 micro inches. This will require the spot facing tool to remove
approximately .04" from the face. The surface should be smooth to
touch with no noticeable irregularities. The surface must be uniform
on all sides. If not, then the tool was not engaged perpendicular to
surface and the procedure must be repeated in a different location.
4-7
Note
If the spot face is not uniform on all sides this is an indication

that the spot face tool was not perpendicular to mounting surface and will not allow the sensor to be mounted properly.
4 Using 1/4"28 tap set, tap pilot hole a minimum depth of .25".
Spot Facing Tool
4-8
Proper (left) & Improper Spot Facing
4-9
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1/2" in diameter. If this is not possible, then an alternative mounting procedure must be used. Do not proceed; contact project manager.
1 If necessary, use spot facing tool to prepare flat surface.
mounting area.
4 Screw AO322 mounting stud into A901-1 mounting pad applying 78 ft.-lbs. of torque.
5 Using A92016 2-part epoxy, spray activator onto mounting surface.
Place a light coat of epoxy on surface of A0901-1 mounting pad and
hold firmly against surface for 1 minute.
6 If adhesive does not setup within 1 minute, this is an indication that
too much epoxy was applied or that the mounting surface was not
prepared properly. Repeat installation steps 1-5.
4-10
A0322 Mounting Stud Installation (Stud Mounting Only)

1 Using plant-approved degreaser, remove any lubricating fluid used
during the tapping process.
2 Using plant-approved epoxy, rub a small amount of epoxy onto spot
face.
3 Using 1/4" allen wrench loosely screw A0322 into mounting
location.
4 Using torque wrench with 1/4" hex bit, torque to 7-8 ft-lbs. If after
correct torquing, the A0322 mounting base is not seated against spot
face this is an indication that the tap was not deep enough. It will be
necessary remove V205 and tap hole deeper.
5 If sensor is not to be mounted immediately, it is necessary to cover
exposed quick connect threads to prevent contamination. Industrial
tape is recommended.
A0322 Quick Connect
4-11
Sensor Mounting
Note
If not ready to pull cables, it is recommended that sensors not

be mounted to machine. If it is necessary to mount a sensor,
then the bundled cable must be secured to the machine and
protected from damage.
1 If necessary, clean A0322 mounting stud threads using plant
approved degreaser/cleaner.
2 Apply a thin coating of Loc-Tite semi-permanent thread locker to
threads on sensor housing.
3 Place sensor onto A0322 and hold in desired position to create the
least amount of cable strain and cable exposure. Holding sensor,
hand-tighten 9/16" captive nut and use a torque wrench with 9/16"
open end to finish tightening to 50-60 in-lbs.
4 Secure sensor cable to machine approximately 4 to 5" from
mounting location using an appropriate size cable clamp. Do not
exceed bending radius of 2.8".
5 If not ready to perform cable pulls, it will be necessary to secure
bundled sensor cable to machine in such a manner that no strain is
placed on integral sensor/cable connector. Bundled cable must not
be left hanging from sensor nor should bundled cable be exposed to
damage such as on the plant floor, maintenance access footholds, etc.
4-12
Mounting Procedure
4-13
Proper Sensor Mounting with cable secured
4-14
A0322LC, A0322DS
Description & Handling Instructions
A0322LC, A0322DS Image & Outline Drawing
A0322LC, A0322DS
4-15
Description
The A0322LC is a general purpose accelerometer with a top exit integral

connection. The A0322DS is a general purpose accelerometer and temperature sensor with a top exit integral connection. This sensors are stud
mounted or epoxy mounted to machinery surfaces and transmit vibration
data to the on-line monitoring system. The integral cable connection enters
the top of the sensor housing. An optional quick release connection,
A0322LC-NT can be purchased to allow the A0322LC or A0322DS to be
easily removed from machine for maintenance.

Caution!

installation.
not to exceed specified torque. Over tightening of accelerometer will
Caution!

more than 5 lbs. force should be exerted directly on sensor connection
4-16
Caution!
manner that it will cause undue strain at the sensor/cable connection.

Below is a listing of the require tools and parts in order to install the
A0322LC and A0322DS accelerometers.
Suggested Vendor:
IMI Part # 080A127
A0322LC, A0322DS
4-17
Description:
the spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the
sensor. At the same time the tool drills a pilot hole which is then tapped
for the stud mounted sensor.
A212 Mounting Pad
A212 Mounting Pad
A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Note

4-18
A0322LC-NT Quick Release SS Nut & Threaded Base (Optional)
A0322LC-NT Quick Release
40-200 inch-lbs. Torque Wrench with 1/4" hex bit
Suggested Vendor:
Description:
A0322LC, A0322DS
4-19

Surface Preparation
There are several ways to mount your accelerometers. This section discusses those ways and what you need to do to successfully mount your
accelerometers
Stud Mounting
Note
Mounting location must provide a flat surface 1/2 in diameter.

Note

surface area.
4-20
Note

Spot Facing Tool
A0322LC, A0322DS
4-21
4-22
Epoxy Mounting
Note
Mounting location must provide a flat surface 1/2" in diameter.

mounting area.
4 Screw mounting stud into A212 mounting pad until stud is flush with
bottom of mounting pad. If using A0322LC-NT Quick-Connect then
screw threaded base into mounting pad and torque to 5 ft-lbs.
Place a light coat of epoxy on surface of A212 mounting pad and hold
firmly against machine spot face surface for 1 minute.
A0322LC, A0322DS
4-23
AO322LC Sensor Mounting (without Quick-Connect)

1 If necessary, clean mounting location threads using plant approved
degreaser/cleaner.
threads on mounting stud.
3 Screw mounting stud into sensor housing and hand tighten. Screw
sensor and mounting stud into mounting location and tighten with 9/
16" torque wrench to 5 ft-lbs.
4 Secure sensor cable to machine approximately 4 to 5" from mounting
location using an appropriate size cable clamp. Do not exceed
bending radius of 2.8".
damage such as on the plant floor, maintenance accesses, footholds,
etc.
4-24
Caution!
If not ready to pull cables, it is recommended that sensors not be

mounted to machine. If necessary to mount sensor, then bundled cable
must be secured to machine and protected from damage.
Caution!
Do not terminate or secure cable to machine before mounting sensor.
A0322LC, A0322DS
4-25
A0322LC with Quick-Connect Mounting Instructions

face.
3 Using 1/4" allen wrench loosely screw AO322LC-NT into mounting
location.
correct torquing, the A0322LC-NT Quick-Connect base is not seated
against spot face this is an indication that the tap was not deep
enough. It will be necessary remove quick-connect base and tap hole
deeper.
6 If necessary, clean A0322LC-NT Quick-Connect threads using plant
8 Place sensor onto A0322LC-NT and hold in desired position to
create the least amount of cable strain and cable exposure. Holding
sensor, hand-tighten 7/8" captive nut and use a torque wrench with
7/8" open end to finish tightening to 50-60 in-lbs.
9 Secure sensor cable to machine approximately 4 to 5" from mounting
location using an appropriate size cable clamp. Do not exceed
bending radius of 2.8".
damage such as on the plant floor, maintenance accesses, footholds,
etc.
4-26
Mounting Procedure
A0322LC, A0322DS
4-27
A0322RM
Description & Handling Instructions
A0322RM Image & Outline Drawing
4-28
Description
The A0322RM is a general purpose accelerometer with 90-degree MIL-2

pin connection. These sensors are stud mounted or epoxy mounted to
machinery surfaces and transmit vibration data to the on-line monitoring
system. The MIL-2 pin connection joins the sensor housing at a 90-degree
angle to provide a low-profile installation.

Caution!

installation.
not to exceed specified torque. Over tightening of accelerometer will
Caution!

more than 5-lbs. force should be exerted directly on sensor connection
Caution!
A0322RM
4-29

manner that it will cause undo strain at the sensor/cable connection.

Spot Face & End Mill Tool
Suggested Vendor:
IMI Part # 080A127
Description:
the spot face tool attaches to a standard electric drill and provides a
machined surface at least 1.1 times greater than the diameter of the
sensor. At the same time the tool drills a pilot hole which is then tapped
for the stud mounted sensor.
4-30
A212 Mounting Pad (Epoxy Mounting Only)
A212 Mounting Pad
A92106 Loctite Depend Mounting Pad Epoxy (Epoxy Mounting Only)

Note

40-200 inch-lbs Torque Wrench with 1/4" hex bit
Suggested Vendor:
Description:
Surface Preparation
There are several ways to mount your accelerators. This section discusses
those ways and what you need to do to successfully mount your accelerators
A0322RM
4-31
Stud Mounting
Note
Mounting location must provide a flat surface 1" in diameter.

Note

surface area.
4-32
Note

Spot Facing Tool
A0322RM
4-33
4-34
Epoxy Mounting
Note
Mounting Location must provide a flat surface 1" in diameter.

mounting area.
4 Screw mounting stud into A212 mounting pad applying 7-8 ft-lbs. of
torque.
Place a light coat of epoxy on surface of A212-1 mounting pad and
hold firmly against surface for 1 minute.
A0322RM
4-35
A0322RM Mounting Stud Installation (Stud Mounting Only)

face.
3 Using 1/4" allen wrench loosely screw mounting stud into mounting
location.
correct torquing, the A0322 Quick-Connect base is not seated against
spot face this is an indication that the tap was not deep enough. It will
be necessary remove mounting stud and tap hole deeper.
4-36
Sensor Mounting
1 If necessary, clean A0322RM Quick-Connect threads using plant
3 Place sensor onto mounting base and hold in desired position to
create the least amount of cable strain and cable exposure. Holding
sensor, hand-tighten 7/8" captive nut and use a torque wrench with
7/8" open end to finish tightening to 50-60 in-lbs.
4 If not ready to pull cables, cover exposed sensor connector threads
with supplied connector cover.
A0322RM
4-37
V425
Description & Handling
V425 Outline Drawing & Image
Description
The V425 Passive Magnetic Pickup is an industrial sensor used to measure

the rotational speed of machinery. The sensor is commonly used to sense
an actuator (target) on a rotating shaft giving a once per revolution trigger.
Handling
The V425 is unique in that it is the only piece of system instrumentation

which is installed near moving machinery (a rotating shaft typically).
Therefore, it is important to observe clearances between the sensor and the
target as well as observe cable clearances.
Caution!
The V425 can be damaged if proper clearance is not maintained

between sensor and actuator. It is important follow installation procedures to set proper clearance.
4-38

Mounting Bracket & Locking Nut (included)
A universal mounting bracket is included with sensor which will fit a variety
of applications. If the included bracket will not work, then the contractor
will have to fabricate a custom bracket.
V425 Mounting Bracket
V425
4-39
Choosing Proper Actuator (Target)

Actuator Dimensions
The V425 is designed to be used with a key meeting the following minimum specifications:
Key (Target) Dimensions
A > .15 inches

B > .5 inches
F > .3 inches
4-40
If the chosen actuator has a dimension (A) which is must greater than .5
inches it is necessary to round the edges of the actuator to allow sensor to
be as close as possible to actuator.
Modifying Large Actuators
Actuator Material
The actuator must be made of a metallic material with a high permeability.

Ideal actuators are soft iron, cold-rolled steel and #400 stainless steel.
V425
4-41
Mounting Sensor Bracket

1 Turn machinery shaft so that actuator is at mounting location.
2 Place sensor in mounting bracket and screw sensor into bracket
exposing equal amount of threads on back and front of mounting
bracket.
3 Place sensor/bracket assembly into mounting location and center
sensor pole piece over actuator with pole piece touching actuator.
Mark hole locations on bracket.
4 Drill and tap hole locations for appropriately sized bolt to fit .250 inch
opening on mounting bracket.
5 Secure bracket to mounting location and torque to bolt specifications
V425 Mounting
4-42
Mounting Sensor
1 Screw locking nut onto sensor and thread completely onto sensor.
2 Screw sensor into mounting bracket until sensor pole piece contacts
actuator.
3 Back sensor off 1 full turn and holding sensor in place thread locking
nut against mounting bracket. Torque to 15 ft.-lbs.
4 Slowly turn shaft and confirm that actuator is not contacting sensor.
If sensor is contacting shaft then repeat step (3) after loosening up lock
nut.
5 Run machinery at full speed and confirm that sensor is not contacting
actuator. Let machine reach normal operating temperature and run
through all operational speeds.
6 Observe machinery during coastdown and confirm that sensor is not
contacting actuator.
7 Cover exposed connector threads with included protective cap to
prevent contamination.
V425
4-43
4-44
Chapter
Enclosure Mounting
Mount V701, V702, V703, and V745 Junction Boxes

Description
The V701 series junction boxes are NEMA 4X rated enclosures used to terminate the online instrumentation wiring. The V701 series consist of 8, 12,
and 16 channel version in a fiberglass or stainless steel enclosure. Box consist of individual 3 lug terminal blocks mounted on a DIN rail. Sensor
cables are individually pulled into box through standard PGME07 cord
grips and exit the box through a 1.5" conduit connection.
The V745 junction/switch box serves the dual purpose of providing a junction between the instrumentation and the 4500R or 4500S online system as
well as allowing portable data collectors local data access. The V745 is a 12
channel box (fiberglass or stainless steel) with 3 terminal phoenix connections for both the inputs and outputs. Sensor cables are individually pulled
into box through standard PGME07 cord grips and exit the box through a
1.5" conduit connection.
Note
Normal installation for the Model 4500R or 4500S unit is in an

orientation such that the front panels are vertical.
5-1
V701 Outline Drawing
5-2
Enclosure Mounting
V745 Outline Drawing
5-3

Mounting Feet (supplied with enclosure)
Mounting Feet
5-4
Enclosure Mounting
Mounting Instructions
Caution!
Do not wire chassis to earth ground.

1 Ensure chosen mounting location allows proper clearance for
maintenance access. Location should be well lit and should be at
appropriate height off floor to allow service technician comfortable
access.
2 After choosing location, prepare mounting bracket using outline
drawing as a template for the mounting hole locations.
3 Attach mounting feet to back of enclosure using the 10-32x.375
machine screws included with mounting feet. Torque screws to 31 inlbs. Mounting feet should aligned vertically to box to insure proper
access for mounting.
4 Attach enclosure to mounting bracket, using bolts which will be
provided by the contractor.
Junction Box Access Requirements
5-5
Mount 4500R and 4500S Data Collection Units

Description
The 4500R and the 4500S are online data acquisition systems used for predictive maintenance of plant machinery. Low-voltage instrumentation is
terminated into the 4500R or the 4500S and is processed, analyzed, compressed, and output via an Ethernet connection to a database server. The
4500R or 4500S is enclosed in a stainless steel enclosure which is intended
to protect it from harsh industrial environments. The enclosure includes a
power supply (if powered by 110VAC), a duplex outlet receptacle for auxiliary power, a sub-panel for mounting accessories, a punch plate for pulling
wire through, and cable management pathways along the sides and top of
the enclosure.
5-6
Enclosure Mounting
4500R Outline Drawing
5-7
4500S Outline Drawing
5-8
Enclosure Mounting
4500R or 4500S Enclsoure Access Drawing (Top View)

Mounting hardware not included.
5-9
Mounting Instructions
Note
4500R or 4500S Enclosure must be grounded to earth. It is

acceptable to ground enclosure through conduit or mounting
structure if grounded to earth. Otherwise, a bonding wire must
be used to connect enclosure to earth ground
1 Ensure mounting location has proper access for installation and
maintenance. In particular, the door should be free to completely
open to the side and there should be enough room to run conduit into
the punch plate on the bottom of the box. Location should be well lit
and should be at appropriate height off floor to allow service
technician comfortable access.
2 If not using conduit into box, confirm that mounting location
provides a path to earth ground.
3 The preferred method of mounting the 4500R or 4500S is to use
mount the enclosure on two unistrut rails mounted on a vertical 24"
center. Attach all 4 mounting feet to rails and use hardened steel
bolts with lock washer torqued to 50 ft.-lbs.
5-10
Enclosure Mounting
Prepare 4500R or 4500S Cable Access Plate

Description
The 4500R or 4500S enclosure is designed to have all cables enter from the
bottom of the enclosure. For this reason, a removable cable access plate was
built into the bottom of the enclosure to allow contractors to remove the
plate and prepare the access holes. The stainless steel plate is mounted to
the box using 12 machine screws and a foam gasket to preserve a NEMA
4X rating.
Cable Access Plate

Stainless steel hole punch or drill.
Conduit fittings.
5-11
Determine Hole Size & Location

A680 Bundled Cable Pulls
1 A680 Cable pulls should be made on left side of access plate (facing
box) so that cables can be easily routed along left side of enclosure.
2 Conduit fittings must be sized according to the number of A680 pulls
coming from a junction box. An 8 channel junction box will use one
A680 cable pull while 16 channel boxes will require two A680 pulls.
The A680 cable is .5" in diameter and will require a 1.5" conduit run.
Two A680 cable pulls will require a 2" conduit run.
8-channel junction box ... 1 V680 cable ... 1.5" conduit
16-channel junction box ... 2 V680 cable ... 2.0" conduit
4500R or 4500S Power
1 Power line pull should be made to the far right corner of access plate
(facing box) so that power cable is routed along right rear of
enclosure.
2 The conduit should be sized according to plant code and NEC for
running power in the plant.
4500R or 4500S Ethernet Connection
1 4500R or 4500S Ethernet connection will be a 10BaseT Category 5

cable provided by the plant. The cable pull should be to the right
front of the cable access panel so that the CAT5 cable can be routed
as far from the 4500R or 4500S power supply as possible along the
right side of enclosure.
2 The Cat5 cable requires a minimum .5" conduit run.
4500R or 4500S Discrete Input/Outputs
1 The 4500R or 4500S Discrete input/output cable pulls should enter

the cable access plate on the right side (facing box) between the
power pull and the Ethernet connection.
2 The 4500R or 4500S Discrete input/output cable pulls will consist of
either:
a) A680 bundled cable pulls which will require 1.5" conduit for 1
cable and .5" extra for each additional cable in pull.
5-12
Enclosure Mounting
b) A672 single twisted pair cable, which will be .225 inches in

diameter and either run in conduit, or pulled through cable access
plate using 1/4" cord grips.
5-13
5-14
Enclosure Mounting
Chapter
Introduction
This chapter covers conduit installation guidelines, network cabling guidelines, power line specifications, and pulling the online instrumentation
cabling as well as the 680 bundled (multi-pair) cable from junction boxes
to the 4500R and 4500S.
Warning!

6-1
Jbox/4500R or 4500S Cable Recommendations

Table 1: Cable pulled in Steel Conduit
Belden #
Application
Description
9732
V701
9-pair, 24 AWG, Individual foil shield, PVC jacket
9734
V702, V745
12 pair, 24 AWG, Individual foil shield, PVC jacket
9736
V703
17-pair, 24 AWG, Individual foil shield, PVC jacket
Table 2: Cable pulled in Tray or Aluminum Conduit

Belden #
Application
Description
8168
V701
8-pair, 24 AWG, Individual foil shield, PVC jacket,

Overall Braid Shield
8175
V702, V745

8178
V703

Note
For cables with overall braided shield, the shield should be

grounded to 4500R or 4500S enclosure via the grounding stud
included on the 4500R or 4500S enclosures subpanel
assembly.
6-2
Conduit Installation Guidelines

Note
All conduit must be bonded to earth ground and adhere to

IEEE 1100 specifications for grounding.
1 The following cables must be pulled in Conduit:
a) Between junction boxes and 4500R or 4500S
b) Any 4500R or 4500S dedicated network segment cables not
pulled in existing plant network infrastructure.
c) Power cables for the 4500R or 4500S
d) Any instrumentation cabling exceeding 50 feet.
2 The conduit must be sized to not exceed a 40 percent fill.
3 Steel Conduit must be used. If plant codes will not allow the use of
steel conduit then please contact project manager.
4 Effort should be made to route conduit away from power trays using
the following guidelines:
6" ... 110VAC
12" ... 220VAC
2 ... 440VAC
6-3
5 Conduit must enter 4500R or 4500S and junction boxes from bottom
of enclosures.
Conduit Access from Bottom
6-4
Pull Instrumentation Wiring

Description
The on-line instrumentation wiring is a polyurethane jacketed, twisted pair,

shielded, instrumentation cable used to transmit millivolt level instrumentation signals to the online system. The cable is designed to provide noise
shielding and protection within harsh industrial environments. The instrumentation wire is pulled to the junction/switch boxes where it is joined to
bundled, multi-pair cabling ran back to the 4500R or 4500S. Because the
instrumentation to junction box pull is relatively short (<50 feet) and close
to the machinery, it is not normally enclosed in conduit although conduit
will be required for specific applications. Care must be taken to ensure that
exposed cabling is secured to machinery and plant infrastructure so as to
not interfere with maintenance or cause safety hazards.
6-5
Cable Variations
There are four variations of instrumentation cable which are used in the online system:
A. 2 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
Sensor
B. 2 Conductor, Single Twisted-Pair Armored Cable Integrated into
Sensor
C. 4 Conductor, Single Twisted-Pair Polyurethane Cable Integrated into
V325 Sensor
D. 2 Conductor, Single Twisted-Pair Polyurethane Cable With 2-Pin Mil
Splash Proof Connector.
Instrumentation Cables
6-6

cable tie downs
wire labels
dielectric grease
Installation
Caution!
If pulling in conduit cable pull force should not exceed 25 lbs. Excessive
force will deform twisted pair and degrade performance of cable.
Note
Wire labels must be placed on each end of cable and have the
same designation. Wire label designations must be documented on SENSOR LOCATION CARD chart included
on inside of junction/switch boxes.
Caution!
Cables must be secured to plant infrastructure in such a manner that

no safety hazards are created from plant personnel tripping on or
catching slack cable on clothing or tool belt, etc.
1 If using the A612-I-30 cable, apply a thin coating of dielectric grease
to connector and screw into sensor housing using hand force only.
2 Label cable on both ends using plant approved wire labels. Wire label
designation must be the same on both ends of cable.
3 Choose a physical path for the sensor cable pull using the following
guidelines:
a) Remain 12" from 110VAC, 2 from 220VAC and 440VAC
power lines.
6-7
b) Do not pull cable across machinery maintenance access areas:

guards, shields, access panels.
c) Do not pull cable in machinery control/starting cable trays.
d) Do not run any cable on floor.
e) Do not run cable near pathways where it will be exposed to
damage from moving machinery.
4 Starting at sensor housing, secure cable in 2-foot intervals to
machinery and plant infrastructure using cable tie downs.
5 At junction/switch box cable should be pulled through an existing
PGME07 cord grip. Tighten cord grip with 9/16 wrench until cable
is secure. (Do not overtighten) Blunt cut cable leaving approximately
2 feet in box and relabel wire if necessary. If using armored cable,
remove armor before pulling through box by snipping the end of the
armor with a pair of wire cutters and unraveling the length to be
removed. Cut armor off with wire cutters and use heat shrink to seal
end of armor.
6-8
Pull A680 Bundled Cable from Junction Box/4500R or 4500S

Description
The A680 bundled cable is a nine twisted pair instrumentation grade cable
with individual foil shielding on each pair. The twisted pair is 24 gauge and
individually color-coded. The A680 is used to extend the on-line instrumentation wiring from the V701 and V745 junction boxes to the 4500R or
4500S data collection unit.
A680

wire labels
4500R or 4500S Enclosure

Installation
1 Starting at junction box, pull cable through conduit run. At 4500R or

4500S enclosure, blunt cut cable leaving 4 feet inside box for routing.
2 Label wire according to project specifications and place label within
6 inches of cable access plate with label facing toward front of
enclosure.
3 Blunt cut cable at junction box leaving 2 feet inside box for routing.
Pull A680 Bundled Cable from Junction Box/4500R or 4500S
6-9
Guidelines for Dedicated 4500R or 4500S Network Segment

Description
The 4500R or 4500S Data Collection Unit communicates with a database
server via a 10BaseT-network connection adhering to the IEEE 802.3
Ethernet protocol. It is recommended that customers run a dedicated physical network segment between the database server and 4500R or 4500S.
Although it is ultimately the responsibility of the plant to install and maintain the network, the following guidelines are recommended:
1 Handling & Care Guidelines per EIA/TIA 568/569.
Note
Although EIA/TIA 568/569 only requires CAT5 cabling, it is

recommended that customers run at least CAT5e to be compatible with future upgrades.
2 Pathways & Cable Trays per EIA/TIA 569.
Note
Network Cabling to 4500R or 4500S should be in steel conduit.
6-10
4500R or 4500S Power Circuit Guidelines

Description
The 4500R or 4500S Data Collection Unit is a laboratory grade instrument
measuring millivolt level instrument signals. Therefore, the quality of the
power provided to the 4500R or 4500S is very important. Although the
4500R or 4500S contains input protection and some degree of line conditioning, it is important for the plant to follow specific guidelines when running power to the 4500R or 4500S enclosure.
Note
Contractors should adhere to the IEEE 1100 specification for

powering and grounding electronic equipment.
Note
Power circuit should contain an isolated ground.

The 4500R or 4500S was designed to be powered by a DC supply to make
use of existing plant process control power. An optional AC power supply
can be purchased if 110 VAC is available.
DC Power Specifications:
Nominal input voltage range:12v to 24v DC

Absolute input voltage range:10v to 36v DC
Maximum Current Draw3.5 Amps
Nominal Current Draw1.5 Amps
Minimum wire gauge:16AWG
Cable:shielded twisted pair.
AC Power Specifications:
Nominal voltage:110VAC
Circuit Breaker:10 Amps (with duplex receptacle)
4500R or 4500S Power Circuit Guidelines
6-11
Power ground:Isolated (from production equipment)
6-12
Chapter
Wire Terminations
Terminate V701, 702, 703, and 745 Wiring

Description
The V701 and V745 series junction boxes will have single twisted pair
instrumentation wire pulled through cable grips on the left side of box and
one or more V680 bundled 9 twisted pair cable pulled through a 1.5" conduit fitting on the right side of the box. The cables will be routed through
the box leaving a service loop and terminated to 3-lug terminal blocks on
the V701 series or industry standard Phoenix connectors on the V745.
Junction Box Routing
7-1

wire labels
24 AWG wire strippers
cable tie down
7-2
Wire Terminations
Terminate Instrumentation Wire

Caution!
Use correct gauge strippers on individual conductors. Do not strip more

than a 1/4" off conductor. Do not overtighten connector. Turn terminal
screw clockwise until contact with wire is made then 1/4 turn additional.
Note
Shield connections pass through junction boxes and are not

grounded at the box!
1 Starting at cord grip pull wire to top of box on left side. Pull service
loop as shown in diagram.
2 Strip 1" of polyurethane jacket from cable.
3 Carefully pull twisted pair conductors out of braided shield. Do not
remove braided shield.
Twisted Pair Prepared
4 Strip 1/4" from each conductor and twist braided shield at end.
5 Terminate the wire into the proper terminal block as follows:
a) Connect white wire (sensor positive input) to upper level of the
terminal block.
b) Connect black wire (sensor negative input) to middle level of the
terminal block.
c) Connect braided shield to lower level of the terminal block.
7-3
Terminal Connections
6 Relabel wire at phoenix connector

7 After all cables are terminated, bundle cables and secure against side
of junction box using only one cable tie down.
7-4
Wire Terminations
Terminate V680 Bundled Cable

Caution!
Use 24 AWG gauge strippers on individual conductors. Do not strip

more than a 1/4" off conductor. Do not overtighten connector. Turn terminal screw clockwise until contact with wire is made then 1/4 turn
additional.
1 Starting at cord grip, strip cable jacket and braided shield off cable.
2 Use the following pair sequence from top to bottom beginning at first
terminal block:
Positive
Conductor
Terminal Block
Negative
Conductor
Foil Shield
Yellow
Black
Black
Blue
Black
Blue
Brown
Black
Blue
Orange
Black
Blue
White
Black
Red
Red
Black
Red
Green
Black
Green
Red
White
Blue
7-5
Note
For 16 channel box, start sequence over on terminal block #9.

3 Pull individual twisted pair (with foil shield in place) to top of box on
right side. Pull service loop as shown in diagram.
4 Pull to terminal block and blunt cut any extra wire.
5 Remove 1" of foil shield from twisted pair and seal foil shield using
heat shrink or electrical tape.
6 Strip 1/4" from each conductor and terminate to terminal block as
follows:
a) Positive Conductor on upper level of terminal block.
b) Negative Conductor on middle level of terminal block.
c) Shield Drain on lower level of terminal block.
V680 Cable Preparation
7-6
Wire Terminations
Terminate 4500R Wiring

Description
The 4500R enclosure was designed to have cables enter from the bottom
through a stainless steel removable access plate. The access plate will have
conduit fittings/cord grips for instrumentation wiring, control wiring (discrete input/outputs), power, and a network connection. Instrumentation
wiring is routed along the left side of the enclosure while control, power,
and the network connection is routed along the right side of the enclosure.
The 4500R enclosure also includes a 110V duplex receptacle for auxiliary
power.
4500R Cable Routing
7-7

Velcro cable tie downs
5 AMP fuse block (required for auxiliary 110V AC power)
RJ45 CAT5 connector and tools
Terminate Power
DC (with Fan Tray)
1) Route Cable along right rear of box and up right side pulling service
2) Pull wire to phoenix connector located next to the On/Off switch and
blunt cut excess wire.
3) Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connection as follows:
a) + DC ... + (right-most terminal)
b) DC ... (middle terminal)
c) shield ... (left terminal)\
4) Secure power cable to side of enclosure using only one cable tie down.
Fan Tray Termination
7-8
Wire Terminations
DC (without Fan Tray)
1 Route Cable along right rear of box and up right side pulling service
2 Pull wire to Phoenix connector labeled input on the 4500R Power
Supply card and blunt cut excess wire.
3 Remove 1" of cable jacket and strip conductors 1/4" and terminate
to Phoenix connection as follows:
d) + DC ... + (left most terminal)
e) DC ... (middle terminal)
f) shield ... (right terminal)
7-9
4 Secure power cable to side of enclosure using only one cable tie
down.
4500R Power Supply Termination
7-10
Wire Terminations
AC Power (with duplex receptacle)
1 Route power cable from right rear of enclosure into the 4500R
external power supply AC input connection.
2 Terminate power cables line, neutral, and ground according to AC
input connector labels.
3 Splice 16 gauge wire from AC input connector to duplex receptacle.
4 Install 5 amp in-line fuse on hot conductor running to duplex
receptacle
5 Terminate wire inside receptacle.
Phoenix Connection
7-11
AC Power (without Duplex Receptacle)
1 Route power cable from right rear of enclosure into the 4500R
external power supply AC input connection.
2 Terminate power cord line, neutral, and ground according to phoenix
connection labels.
Terminate Discrete Input/Outputs
Caution!
Use correct gauge strippers on individual conductors. Do not strip more

than a 1/4" off conductor. Do not overtighten connector. Turn terminal
screw clockwise until contact with wire is made then 1/4 turn additional.
1 Pull cable up right side of enclosure (in front of AC power supply if
present) and over the top of 4500R unit. Pull cable down to discrete
input/output channel.
2 Blunt cut excess wire. Strip 1" from cable jacket and 1/4" from each
conductor.
3 Terminate in phoenix connector as follows:
a) Relay Excitation Voltage ... (+)
b) Voltage Return ... ()
c) Shield Drain ... (GND)
7-12
Wire Terminations
4 Relabel wire at connector.

5 After all wires are pulled, bundle wires with Velcro cable wrap on
right side of enclosure and on top of 4500R. Secure bundle to right
side of enclosure in only one location.
6 Document discrete input/output name, wire label name, and 4500R
channel number on cable administration chart.
Discrete I/O Cable Routing
7-13
Terminate Network Connection
1 Pull network cable up right side of enclosure (in front of AC power

supply if present) and along side of 4500R unit.
2 Bring cable across 4500R power supply card and to 10BaseT RJ45
connection point.
3 Blunt cut excess wire and attach RJ45 CAT5 connector using plant
specified pintout for 10BaseT.
4 Secure network connection to right side of enclosure using cable tie
down.
Network Connection Training
7-14
Wire Terminations
Terminate A680 Bundled Cable Instrumentation Wiring

Caution!
Use 24 AWG gauge strippers on individual conductors. Do not strip

more than a 1/4" off conductor. Do not overtighten connector. Turn terminal screw clockwise until contact with wire is made then1/4 turn
additional.
Instrumentation Cable Routing
1 Pull cable up left side of enclosure and over top of 4500R.

2 Secure cable to left side of enclosure with cable tie down.
3 Remove cable jacket beginning where cable crosses over top of
4500R.
4 Pull individual pairs down to proper channel on 4500R unit.
5 Blunt cut excess wire.
7-15
6 Remove 1" of foil shield and place wire label around end of foil
shield. Wire label must match sensor wire label in junction box.
7 Strip 1/4" from each conductor and terminate into phoenix connector
as follows:
a) Positive Conductor from Junction Box ... (+)
b) Negative Conductor from Junction Box ... ()
c) Shield Drain ... GND
8 Document sensor name, wire label name, and 4500R channel
number on 4500R cable administration chart.
7-16
Wire Terminations
Appendix
4500R or 4500S Default Network Addressing Schema

1
A-1
A-2
4500R or 4500S Default Network Addressing Schema
Appendix
Additional 4500R Connections
Introduction
On the following pages are additional connections that may help you in setting up the 4500R.
B-1
4500R Proximity Probe Interconnetion Diagram
B-2
4500R 4-20ma Current Loop Interconnection

2
4500R 4-20ma Current Loop Interconnection
B-3
B-4
Appendix
AC-DC Power Converter
Introduction
The AC-DC Converter is the power center of the 4500R or 4500S unit. If
it is not installed and maintained properly, the 4500R unit may not function
properly or in the manner desired.
Warning!

Warning!
Power to the 4500R or 4500S AC-DC power converter

PCB must include a remote disconnect switch or circuit
breaker. The switch or circuit breaker must be in close
proximity to the equipment and within easy reach of the
operator.
Caution!
Installation and use of the Model 4500R or 4500S AC-DC Power

Converter in a manner not specified by CSI may impair protection
offered by the equipment.
C-1
Connecting and Maintaining the 4500R or 4500S unit

General points to remember when installing the 4500R or 4500S unit and
connecting power to it:
The Model 4500R or 4500S AC-DC Power converter PCB is connected to the mains supply through the AC Power Input terminal
block located near the bottom of the panel.
All wiring should be installed by a trained and qualified electrician.
Wiring must conform to all applicable local codes and regulations.
Normal installation of the Model 4500R or 4500S unit is in an orientation such that the front panels are vertical.
Operators should use normal caution when cleaning surfaces of the
Model 4500R or 4500S front panels. Abrasive cleaners or instruments should not be used. Wipe off with a clan damp cloth.
Replacement fuses should be 1.6A 250V Slo-Blow type (250V 1.6A
T).
Fuses should be replaced by qualified personnel only.
Required Tools and Parts

Velcro cable tie downs
Remote disconnect switch or circuit breaker
5 AMP fuse block (required for auxiliary 110V AC power)
# 8 ring terminals
16 GA wire strippers
Crimp tool for ring terminal
Flat tip screwdriver
C-2
4500R (with duplex receptacle)

1. Route power cable from right rear of enclosure into the 4500 AC-DC
power converter AC input connection.
2. Terminate power cables line, neutral, and ground according to AC
3. Splice 16 gauge wire from AC input connector to duplex receptacle.
4. Install 5 amp in-line fuse on hot conductor running to duplex
receptacle.
5. Terminate wire inside receptacle.
4500R (without duplex receptacle) and 4500S

1. Route power cable from right rear of enclosure into the 4500 AC-DC
power converter AC input connection.
2. Terminate power cables line, neutral, and ground according to AC
Safe Operation of the 4500R or 4500S AC-DC Power Converter

The Model 4500R or 4500S AC-DC Power Converter PCB is suitable for
safe operation in:
Intended for indoor use.
Overvoltage Category II (Installation Category II), Pollution Degree
2 environments.
Intended temperature ranges 5C (41F) to 50C (122F).
Relative humidity: 0 to 95% non-condensing.
Altitude up to 2000m.
Power input ranges of 100 - 240 Volts, 50 - 60 hertz, 2 Amperes (maximum) and will dissipate approximately 35 Watts of power.
Note
No configuration setup of the unit is required to change operating voltage.
Connecting and Maintaining the 4500R or 4500S unit
C-3
Indicators
There are several indicators on the AC-DC Converter panel. These include
two power outputs and eleven LEDs. Below is a brief description of the
indicators.
AC-DC Converter panel
C-4
Power Output Connectors

Two power outputs provide optional power to auxiliary external sensors
(such as proximity probes) and an external cooling fan. Both are stenciled
to indicate the maximum output voltage and current from the terminals.
Auxiliary sensor output connections

1. Route cable along right rear of box and up the right side pulling a
service loop.
2. Pull wire to the phoenix connector located just below the power
status indicators and blunt cut excess wire.
3. Remove 1" of cable jacket and strip conductors 1/4" and terminate
to Phoenix connector as follows:
a) +DC + ( top terminal)
b) DC (middle terminal)
c) shield Gnd (bottom terminal)
The auxiliary sensor output connector is labeled:
AUX+/24V
25V, 0.6A
Fan output connections

1. Route cable along right rear of box and up the right side pulling a
service loop.
2. Pull wire to the phoenix connector located just above the power
switch and blunt cut excess wire.
3. Remove 1" of cable jacket and strip conductors 1/4" and terminate to
Phoenix connector as follows:
a) +DC + ( top terminal)
b) DC (middle terminal)
c) shield Gnd (bottom terminal)
Power Output Connectors
C-5
The fan output connector is labeled:
FAN24
25V. 0.3A
LED Indicators
Eleven individual LEDs indicate the condition of internal and external
voltage signals. Ten are green and when on (illuminated) indicate
that the corresponding voltage signal is at is active level. One LED
is red and when on (illuminated) indicates that power has failed. The
LEDs are listed in the following table:
Front Panel Label
C-6
Color
Fail
Red
3.3V
Green
5V
Green
+12V
Green
12V
Green
+24V
Green
AUI
Green
AUX24V
Green
Fan24
Green
Power On
Green
AC Power
Green
Appendix
Connection Parameters
Uses and Specifications

Note
This equipment is only suitable to use in Class I, Division 2,

Groups C and D or non-hazardous locations.
Warning!
Explosion Hazard. Do not remove or replace lamps or

fuses unless you have disconnected the power or you are
in a non-hazardous area.
Warning!
Explosion Hazard. Do not disconnect equipment unless

you are in a non-hazardous area.
D-1
Specifications for equipment that supplies and receives energy:

Mux Board:
Vt = 24VDC
Vmax = +/- 24 VDC
It = 5mA
Imax = 50uA
Ca = 1-uf
Ci = 1.5uf
La = 100mH
Li = 100mH
Tach Board:
Vmax = +/- 24VDC
Imax = 100uA
Ci = 1.5uf
Li = 100mH
I/O Board:
D-2
Vt = 24VDC
Vmax = 10VDC
It = 500mA
Imax = 500mA
Ca = 10uf
Ci = 1500uf
La = 1mH
Li = 1mH
Connection Parameters
Index
Numerics
1/4"-28 taps & tap handle 4-6, 4-20, 4-31
10BaseT RJ45 7-14
110AC 6-3
220AC 6-3, 6-7
24 AWG gauge strippers 7-5
24 AWG wire strippers 7-2
440AC 6-3, 6-7
4500 4-20ma Current Loop
Interconnection B-3
4500 Enclosure 3-7, 6-9
4500 Proximity Probe Interconnetion
Diagram B-2
4500S Enclosure 3-11
5 AMP fuse block 7-8
9/16" open end wrench 4-6, 4-20, 4-31
A
A0322 4-11
A0322 Quick-Connect 4-11, 4-12, 4-36
A0322DR 4-1
A0322DS 4-15
A0322LC 4-15
A0322LC with Quick-Connect 4-26
A0322LC-NT 4-16
A0322LC-NT Quick Release SS Nut &
Threaded Base 4-19
A0322LC-NT Quick-Connect 4-23, 4-26
A0322RA 4-1
A0322RI 4-1
A0322RM 4-28, 4-36
A0322RM Quick-Connect 4-37
A212 Mounting Pad 4-18, 4-31
A212 mounting pad 4-23
A612-I-30 cable 6-7
A680 Bundled Cable 7-15
A680 Bundled Cable Pulls 5-12

A901-1 mounting pad 4-10
A92016 2-part epoxy 4-10, 4-23, 4-35
A92106 4-5, 4-18
A92106 Loctite Depend Mounting Pad
Epoxy (Epoxy Mounting Only)
4-31
AC Power (with duplex receptacle) 7-11
AC Power (without Duplex Receptacle
7-12
AC Power Specifications
6-11
AC-DC Power Converter C-1
safe operation C-3
Actuator Dimensions 4-40
Actuator Material 4-41
AO322 Quick-Connect 4-10
AO322LC Sensor Mounting 4-24
C
cable tie down 7-2
cable tie downs 6-7
Cable Variations 6-6
Chapter 2 Pre-Installation Review 1-7
Chapter 3 System Documentation 1-7
Chapter 4 Instrumentation Installation 1-7
Chapter 5 Enclosure Mounting 1-7
Chapter 6 Cabling Requirements 1-7
Chapter 7 Wire Terminations 1-8
conduit
steel 6-2
tray or aluminum 6-2
Connecting and Maintaining the 4500R or
4500S unit C-2
Connection Parameters D-1
Contractor Kickoff Meeting 2-2
I-1
DC (with Fan Tray) 7-8

DC (without Fan Tray) 7-9
DC Power Specifications
6-11
Dedicated V4500 Network Segment 6-10
Description 4-3, 4-16, 4-29
dielectric grease 6-7
Documentation Storage 3-13
Machine Level Diagram

3-3
Mount V4500 and 4500S Data Collection
Units 5-6
Mounting Bracket & Locking Nut 4-39
Mounting Sensor 4-43
Mounting Sensor Bracket 4-42
Mux Board D-2
EIA/TIA 568/569 6-10

Epoxy Mounting 4-10, 4-23, 4-35
Equipment
warnings, uses and specifications D-1
Negative Conductor 7-5
Final Walk-Through 2-3

Foil Shield 7-5
output connections
auxiliary sensor C-5
fan C-5
Overall System Diagram
3-3
Handling Instructions 4-3, 4-16, 4-29
PGME07 cord grip 6-8

phoenix connector 7-8, 7-12
Positive Conductor 7-5
Prepare V4500 Cable Access Plate 5-11
Project Manager 1-3
Pull Instrumentation Wiring 6-5
I
I/O Board D-2
Indicators C-4
LED C-6
Power Output Connectors C-5
auxillary sensor C-5
fan output C-6
Installation 6-7
J
Jbox 6-2
Junction Box 7-16
I-2
R
RJ45 CAT5 connector 7-8, 7-14
S
SENSOR LOCATION CARD 6-7
Sensor Mounting 4-12, 4-37
Special 1-2
Spot Face & End Mill Tool 4-30
Spot Face and End Mill Tool 4-4, 4-17

Stud Mounting 4-6, 4-20, 4-32
Surface Preparation 4-6, 4-20, 4-31
System Component Review 2-4
T
Tach Board D-2
terminal block 7-3
7-5
Terminate Discrete Input/Outputs 7-12
Terminate Network Connection 7-14
Torque Wrench 4-6, 4-19, 4-31
V
V425 4-38
V425 Passive Magnetic Pickup 4-38
V4500 and junction boxes 6-4
V4500 dedicated network segment cables
6-3
V4500 Discrete Input/Outputs 5-12
V4500 Ethernet Connection 5-12
V4500 Power 5-12
V4500 Power Circuit Guidelines 6-11
V4500 Power Supply 7-9
V4500 power supply card 7-14
V4500 Wiring 7-7
V680 Bundled Cable 7-5
V701 and V745 series junction 7-1
V701 series junction boxes 5-1
V745 junction/switch box 5-1
Velcro cable tie downs 7-8
W
wire labels 6-7, 6-9, 7-2
I-3
I-4

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Reference Manual

RBMware Online System

CSI Part # 97101 Rev. 3

Hardware Technical Help

Software Technical Help

Chapter 2 Pre-Installation Review

Chapter 3 System Documentation

Chapter 4 Install Instrumentation

Sensor Mounting 4-12

Chapter 5 Enclosure Mounting

Chapter 6 Cabling Requirements

Chapter 7 Wire Terminations

Appendix A 4500R or 4500S Default Network Addressing Schema

Appendix C AC-DC Power Converter

Power Output Connectors C-5

Appendix D Connection Parameters

Normal installation for the Model 4500R or 4500S unit is in an

Read This First

A note indicates special comments or instructions.

A caution indicates actions that may have a major impact on the

The Warning paragraph warns you of actions that could

All wiring should be installed by a trained and qualified

Power to the 4500R or 4500S AC-DC power converter

Use of the 4500R or 4500S AC-DC Power converter in a manner not

Plant Appointed Project Manager

The pre-installation review could also be called installation preparation.

System documentation is prepared before the system installation begins.

Chapter 7 Wire Terminations

Contractor Kickoff Meeting

System Component Review

System Overview Drawings

Example of System Overview Drawing (overall)

Example of System Overview Drawing (Machine Level)

As illustrated, the system overview drawings should consist of an overall

System Overview Drawings

Junction/Switch Boxes with Tag

System Layout Drawings

System Layout Marking Guidelines

System Layout Drawings

Cable Administration Charts

Junction Box Cable Administration Chart

Cable Administration Charts

4500R Board Positions

Cable Administration Charts

4500S Board Positions

Cable Administration Charts

A0322RI, A0322RA, A0322DR

A0322RI, A0322DR Image & Outline Drawing

A0322RA Image & Outline Drawing

General purpose accelerometers are susceptible to mechanical shock and

Do not drop, hammer, or impact sensor housing before, during, or after

Do not exceed specified torque when tightening stud-mounted accelerometers.

Required Tools & Parts

Spot Face and End Mill Tool

A901-1 Mounting Pad

A92106 Loctite Depend mounting pad epoxy (epoxy mounting only)

Contractor should confirm Material Data Sheet conforms to

40-200 inch-lbs. Torque Wrench with 1/8" hex bit

Mounting location must provide a flat surface 1/2" in diameter.

Mounting location must provide a case thickness exceeding

If the spot face is not uniform on all sides this is an indication

Spot Facing Tool

Proper (left) & Improper Spot Facing

A0322 Mounting Stud Installation (Stud Mounting Only)