S+ Turbine: Machinery Condition Monitoring MCM800: Product Guide

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 2010 by ABB.
All rights reserved.
Release: Dec 2010
Document number: 2VAA000341
TRADEMARKS
All rights to other trademarks reside with their respective owners.
0BABOUT THIS BOOK
8BOverview
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......................................................................................... 15
4.1
Before You Start ................................................................................................15
2VAA000341
8BOverview
4.2
0BABOUT THIS BOOK
Termination Base Units ....................................................................................15
4.2.1 Signal Input Configuration ..............................................................................17

4.2.2 Relay Output Configuration ............................................................................18
4.2.3 Event Marker Input Configuration...................................................................19
4.3
DIP Switch Configuration .................................................................................20
4.3.1 Profibus/Modbus Dipswitch ............................................................................20

4.3.2 Profibus/Modbus Address ..............................................................................21
4.3.3 Option Dipswitch ............................................................................................21
4.3.4 Profibus Termination Dipswitch (S3) ..............................................................22
4.3.5 MPM810.........................................................................................................22
4.4
MCM800 Configuration via Profibus & Ethernet .............................................23
4.4.1 Module Specific Parameters sent to MCM800 ...............................................23

4.4.2 Channel Specific Parameters sent to MCM800..............................................24
4.4.3 Active Data Sent To the MCM800..................................................................26
4.4.4 Active Data Reported By the MCM800 ..........................................................28
5.
OPERATION.................................................................................................. 33
5.1
General Description ..........................................................................................33
5.2
I/O Conditioning Functions ..............................................................................33
5.2.1 Signal Inputs ..................................................................................................33

5.2.2 Event Marker Inputs .......................................................................................33
5.2.3 Relay Outputs ................................................................................................34
5.3
Functions ...........................................................................................................35
5.3.1 Vibration .........................................................................................................35

5.3.2 Eccentricity.....................................................................................................36
5.3.3 Thrust (Rotor) Position ...................................................................................36
5.3.4 Differential Expansion ....................................................................................37
5.3.5 Case Expansion .............................................................................................38
5.3.6 Dual Probe .....................................................................................................38
6
2VAA000341
0BABOUT THIS BOOK
8BOverview
5.3.7 SMAX .............................................................................................................39

5.3.8 Complementary Position ................................................................................39
5.3.9 Waveform Capture Settings ...........................................................................40
6.
MAINTENANCE............................................................................................. 41
6.1
Preventive Maintenance....................................................................................41
6.2
Hardware Indicators ..........................................................................................41
6.2.1 MPM810 I/O Module LEDs.............................................................................41

6.3
Troubleshooting ................................................................................................42
6.4
Diagnostics ........................................................................................................43
6.5
Module Replacement.........................................................................................43
6.5.1 General ..........................................................................................................43

6.5.2 Replacement ..................................................................................................43
6.5.3 Returning a Module ........................................................................................44
6.6
7.
SPECIFICATIONS ......................................................................................... 45
7.1
8.
Firmware Upgrade .............................................................................................44
MCM800 Product Specifications ......................................................................45
REVISION HISTORY ..................................................................................... 46
2VAA000341
8BOverview
0BABOUT 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.
2VAA000341
0BABOUT THIS BOOK

K
9BUse 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
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
2VAA000341
12BProduct Overview
1BINTRODUCTION
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
2VAA000341
1BINTRODUCTION
2.4
15BProduct Features
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 to -20 volts AC or DC.
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)
Danger
Dry Contact (Form C)
2A @ 24 VDC / VAC (resistive load)

Normally de-energized/energized
selectable
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
Note: a special cable is required.
2VAA000341
Debugging and Firmware Upgrades.
11
16BCabinet Installation
on
2BINSTALLATION
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
2VAA000341
2BINSTALLATION
3.5
20BModule Interconnection
Module Interconnection
On each side of the TBU are two DSBU9 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
+24VDC Power (in)
Power Common (in)
-24VDC Power (in)
+24VDC Power (out)
Power Common (out)
-24VDC Power (out)

Table 3-1 TBU850 Power Terminals
Figure 3-3 Typical Power Connection

2VAA000341
13
22BRedundant Power Supply Configuration
3.7
2BINSTALLATION
Redundant Power Supply Configuration

To configure the power supplies for redundancy, two voting units are required.
Note: There is a positive and a negative voting unit one for +24VDC and the other 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 monitors
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. Care must be taken such that the -24VDC is not connected to the
Common.
Figure 3-5 Power Distribution and Grounding

14
2VAA000341
3BCONFIGURATION
FIGURATION
24BBefore You Start
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.
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
Transducer Power (+24) (out)
Constant Current (4.7mA)
Transducer Common
Transducer Signal
Transducer Power (-24) (out)
Earth Ground (Shield)
Table 4-1 TBU850 Signal Terminals Channels 1- 4
2VAA000341
15
25BTermination Base
e Units
3BCONFIGURATION
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 can not handle proximity probe inputs.
Terminal
Description
EM Out (+) TTL
EM Out (-) TTL
Transducer Common
EM Signal (out)
EM Common (out)
EM Signal (in)
EM Common (in)
Transducer Power (-) (out)
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 are not intended to drive high voltage, high current or
inductive loads, so an interposing relay may be required for these
applications.
Terminal
Description
Alert Normally Closed
Alert Common
Alert Normally Open
Danger Normally Closed
Danger Common
Danger Normally Open

Table 4-3 TBU850 Relay Contacts
16
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3BCONFIGURATION
25BTermination Base Units
4.2.1 Signal Input Configuration

The MCM800 signal input terminals are designed to interface to a variety of sensors. Figures 3-2 through 3-5 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
2VAA000341
17
3BCONFIGURATION
Figure 4-5 DC LVDTs
4.2.2 Relay Output Configuration

The MCM800 relay output terminals are designed to interface directly to low power switching configurations or high
power switching devices using interposing relays. Figure 3-6 shows the TBU850 configuration for the on-board relay
contacts.
Figure 4-6 Relay Terminal Connections
18
2VAA000341
3BCONFIGURATION
4.2.3 Event Marker Input Configuration

The TBU850 has an Event Marker input which typically is used to interface to an eddy current probe. Figures 3-7 and
3-8 show the TBU850 wiring configurations associated with these probes.
Figure 4-7 Event Marker with single TBU850
Figure 4-8 Event Marker with multiple TBU850s
2VAA000341
19
26BDIP Switch Configuration
4.3
3BCONFIGURATION
DIP Switch Configuration

The TBU850 requires proper Dipswitch setting prior to operation.
4.3.1 Profibus/Modbus 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
2345678
Profibus
Address
Switch
2345678
Profibus
Address
Switch
2345678
Profibus
Address
Switch
2345678
Profibus
Address
0000000
0010000
16
0100000
32
0110000
48
0000001
0010001
17
0100001
33
0110001
49
0000010
0010010
18
0100010
34
0110010
50
0000011
0010011
19
0100011
35
0110011
51
0000100
0010100
20
0100100
36
0110100
52
0000101
0010101
21
0100101
37
0110101
53
0000110
0010110
22
0100110
38
0110110
54
0000111
0010111
23
0100111
39
0110111
55
0001000
0011000
24
0101000
40
0111000
56
0001001
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
20
2VAA000341
3BCONFIGURATION
URATION
4.3.2 Profibus/Modbus Address

Switch 1 of Dipswitch S1 is used to determine the Profibus redundancy format used by the MCM800.
Setting Description
0
System Redundancy Disabled
System Redundancy Enabled
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
Normal Mode
Diagnostic Mode
Low Speed Mode
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.
The MCM800 has a level of Ethernet security that reduces the risk of unauthorized
access to the module. The security may make it more difficult to troubleshoot the
Ethernet connection. To lower the Ethernet security for troubleshooting, set the
option dipswitch to Diagnostic 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.
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).
2VAA000341
21
3BCONFIGURATION
Module Communication Protocol

Switch 4 determines the communication protocol for ports PA 1 & 2 and PB 1 & 2.
0
Modbus RTU protocol.
Profibus DP-V1 protocol.
Modbus Baud Rate Selection

When the Modbus Protocol is selected (Switch 4 of S2 = 0), switch 1 of S1 determines the baud rate.
0
38400 Baud
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.
22
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3BCONFIGURATION
4.4
27BMCM800 Configuration via Profibus & Ethernet
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.
4.4.1 Module Specific Parameters sent to MCM800

Description
Range
Units
Type
IP Address NNN.xxx.xxx.xxx
0 to 255
None
IP Address xxx.NNN.xxx.xxx
0 to 255
None
IP Address xxx.xxx.NNN.xxx
0 to 255
None
IP Address xxx.xxx. xxx.NNN
0 to 255
None
Subnet Mask NNN.xxx.xxx.xxx
0 to 255
None
Subnet Mask xxx.NNN.xxx.xxx
0 to 255
None
Subnet Mask xxx.xxx.NNN.xxx
0 to 255
None
Subnet Mask xxx.xxx. xxx.NNN
0 to 255
None
English/Metric EU
0, 1
None
Angular Position of Event Marker

probe
-360 to 360
Degrees
Event Marker Detect Voltage
0 to 15
Volts
Normal Alert relay state
0,1
None
Normal Danger relay state
0,1
None
IP Address and Subnet Mask The IP Address and Subnet Mask is 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 0if 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.
2VAA000341
23
3BCONFIGURATION
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).
4.4.2 Channel Specific Parameters sent to MCM800
24
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
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).
0 to 10
None
Block output select

Value of the output (valid for all channels).
0 = Peak-to-Peak.
1 = Peak.
2 = RMS.
3 = Average.
4 = Calculated Peak-to-Peak.
5 = Calculated Peak.
0 to 5
None
Probe type
Type of probe (valid for channels 1 - 4 only).
0 = None.
1 = Proximity Probe.
2 = DC LVDT.
3 = Accelerometer.
4 = Moving Element velocity probe.
5 = Piezoelectric velocity probe.
0 to 8
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Probe Sensitivity
Sensitivity of the probe in mv/EU (valid for channels 1 - 4 only)
Full
mv/EU
Integration
Sets the type of integration (valid for channels 1-4 only).
0 = None.
1 = Velocity to displacement (velocity probes only).
2 = Acceleration to velocity (accelerometers only).
0 to 2
None
Angular Position of Probe (see note pg 26)
-360 to 360
Degrees
Ramp Angle (see note pg 26)
0 to 90
Degrees
Probe DC Voltage High Failure Threshold (see note pg 26)
-24 to +24
Volts
Probe DC Voltage Low Failure Threshold (see note pg 26)
-24 to +24
Volts
N for Nth Order

User defined order calculation from 3 to 10
3 to 10
None
Dual Vote Enable
0,1
None
6 = Complementary proximity probe.

7 = Ramped proximity probe.
8 = Ramped complementary proximity probe.
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.
2VAA000341
25
3BCONFIGURATION
Note: Non-Linear Correction X1-X5, Y1-Y5 are pairs of values are used to correct for non-linearity effects of probes are
for Future Use.
4.4.3 Active Data Sent To the MCM800
26
Description
Range
Units
Type
Shaft Rotational Direction

Indicates the rotation of the shaft.
0 = Clockwise.
1 = Counter-clockwise.
0,1
None
Set Alert Relay

Forces the relay to the active state.
0 = Normal operation.
1 = Force relay active.
0,1
None
Set Danger Relay

Forces the relay to the active state.
1 = Force relay active.
0,1
None
Reset Diagnostic Function

A transition from 0 to 1 forces a reset of the Ethernet
communication interface.
0 = Normal Operation.
1 = Forces Ethernet Network close and restart.
0,1
None
High Danger Threshold

The values determine the point above which the corresponding
action will occur. (Valid for all channels).
Full
EU
High Alert Threshold

The values determine the point above which the corresponding
Full
EU
Low Alert Threshold

The values determine the point below which the corresponding
Full
EU
Low Danger Threshold

The values determine the point below which the corresponding
Full
EU
Alert Delay
Determines the delay in seconds the condition must exist before
activating Alert status. Note: If the value exceeds the Danger set
point before the Alert delay expires, the module will immediately
set the Alert status. (Valid for all channels).
0.1 to 300
Seconds
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Danger Delay
Determines the delay in seconds the condition must exist before
activating Danger status. Note: If the value exceeds the Danger
set point before the Alert delay expires, the module will
immediately set the Alert status. (Valid for all channels).
0.1 to 300
Seconds
Alert Enable
Enables the alert action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.
0,1
None
Danger Enable
Enables the danger action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.
0,1
None
Filter Low Cutoff Frequency

Sets the cutoff frequency below which the signal is attenuated.
The value specified is the -3dB point of a 4-pole Butterworth filter.
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types).
1 to 1,000
Hz
Filter High Cutoff Frequency

Sets the cutoff frequency above the signal is attenuated. The
value specified is the -3dB point of a 4-pole Butterworth filter.
(Valid for channels 1 - 4, Vibration, Relative, or Seismic channel
types).
30 to
15,000
Hz
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
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).
Full
EU
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
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).
-24 to +24
Volts
0,1
None
Waveform Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
0,1
None
Run-up Capture
0,1
None
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
values to determine position.)
1 = Set Null Position.
2VAA000341
27
3BCONFIGURATION
Description
Range
Units
Type
Rundown Capture
0,1
None
Event Capture
0,1
None
4.4.4 Active Data Reported By the MCM800
28
Description
Range
Units
Type
Module Alert
Indicates the Alert alarm status.
0 = Normal.
1 = Alert / Danger Active.
0,1
None
Module Danger
Indicates the Danger alarm status.
0 = Normal.
1 = Alert / Danger Active.
0,1
None
Dual Vote Alert Ch 1&2

Indicates if both channels are active when Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).
0,1
None
Dual Vote Danger Ch 1&2

0 = Normal.
0,1
None
Dual Vote Alert Ch 3&4

0 = Normal.
0,1
None
Dual Vote Danger Ch 3&4

0 = Normal.
0,1
None
Dual Vote Alert Ch 5&6 Indicates if both channels are active when
Dual Voting is enabled.
0 = Normal.
0,1
None
Dual Vote Danger Ch5&6

0 = Normal
0,1
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
MCM Mode
Reflects the operational mode of the MCM800 based on Dipswitch
S2.
0 = Normal.
1 = Low Speed.
0,1
None
Calibration Active
Calibration status.
0 = Not calibrating (Normal).
1 = Module is calibrating.
0,1
None
Diagnostic Error
Indicates the diagnostic status.
0 = Diagnostics successfully passed.
1 = Diagnostics failed.
0,1
None
Orders Active
Orders are being calculated.
0 = Orders are not being calculated.
1 = Orders are being calculated.
0,1
None
Event Marker Status

Indicates Event Marker Status.
0 = Event Marker Failed.
1 = Event Marker OK.
0,1
None
Zero Speed Indicator

Indicates if shaft has stopped.
0 = Speed is >= 1 RPM or bad quality (Event Marker Status = 0).
1 = Speed is < 1 RPM and good quality (Event Marker Status = 1).
0,1
None
Invalid IP Address
Indicates if the IP address or subnet mask is invalid.
0 = IP Address and Subnet mask are valid.
1 = IP Address or Subnet mask is invalid.
0,1
None
Profibus Active
Indicates a Profibus Master is communicating.
0 = Profibus not communicating.
1 = Profibus is communicating.
0,1
None
Software Version Major

Indicates the software major version.
0 to 255
None
Software Version Minor

Indicates the software minor version.
0 to 255
None
Software Version Revision

Indicates the software version revision.
0 to 255
None
Software Version Pre-Release

Indicates the software version pre-release.
0 to 255
None
Speed
The current speed in RPM.
0 to 30,000
RPM
Overall Output
The overall movement or position in Engineering Units according
to channel type. (Valid for all channels).
Full
EU
2VAA000341
29
30
3BCONFIGURATION
Description
Range
Units
Type
DC Voltage
The current DC component of the output value in Volts. (Valid for
channels 1 - 4).
-24 to +24
Volts
DC Relative Gap
The current DC component of the output value in Engineering
Units according to channel type. (Valid for channels 1 4,
Ethernet Only).
Full
EU
Order 0.5x Amplitude

Half Order Vibration component in Engineering Units. (Valid for
channels 1 6, Vibration only).
Full
EU
Order 0.5x Phase

Half Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order 1x Amplitude
First Order Vibration component in Engineering Units. (Valid for
channels 1 6, Vibration only).
Full
EU
Order 1x Phase
First Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order 2x Amplitude
Second Order Vibration component in Engineering Units. (Valid
for channels 1 6, Vibration only).
Full
EU
Order 2x Phase
Second Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order Nx Amplitude
Indicates the Nth Order Vibration component in Engineering Units.
(Valid for channels 1 6, Vibration only).
Full
EU
Order Nx Phase
The Nth Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order Not1x Amplitude

Not First Order Vibration components in Engineering Units. (Valid
for channels 1 6, Vibration only).
Full
EU
N for Nth Order

The Nth Order phase angle in degrees. (Valid for channels 1-6,
Vibration only).
0 to 359
Degrees
Critical Error
Any module error detected by the system.
0 = Normal.
1 = Error.
0,1
None
Configuration Error
A channel is configured improperly.
0 = Normal.
1 = Error.
0,1
None
Probe Voltage Error

The channels DC voltage is out of limits.
0 = Normal.
1 = Error.
0,1
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Bad Data
The overall value is out of the specified limits.
0 = Normal.
1 = Bad Quality.
0,1
None
Suspect Data
The Overall value is within 5% of the specified limit.
0 = Normal.
1 = Suspect Quality.
0,1
None
Alert Active
The Overall value has exceeded the specified range.
0 = Normal.
1 = Alert.
0,1
None
Alert Low Active

0 = Normal.
1 = Alert.
0,1
None
Alert High Active

0 = Normal.
1 = Alert.
0,1
None
Danger Active
0 = Normal.
1 = Danger.
0,1
None
Danger Low Active

0 = Normal.
1 = Danger.
0,1
None
Danger High Active

0 = Normal.
1 = Danger.
0,1
None
Time Waveform Buffer Full

Indicates Capture buffer is full.
0 = Normal.
1 = Buffer Full.
0,1
None
Time Waveform Capture Complete

Indicates a single capture has completed.
0 = Normal.
1 = Complete.
0,1
None
0,1
None
Time Waveform Run-up Active

The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.
2VAA000341
31
Description
Time Waveform Rundown Active
0 = Normal.
1 = Active.
Time Waveform Event Log Active
0 = Normal.
1 = Active.
32
3BCONFIGURATION
Range
Units
Type
0,1
None
0,1
None
2VAA000341
4BOPERATION
28BGeneral Description
5. OPERATION
5.1
General Description
The MCM800 system is part of ABBs 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 builtin 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 is comprised of 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 is then transferred to the microcontroller 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 DC signal is filtered to remove the AC component providing a steady output 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 sec (larger signals are preferred). The Event Marker has two functions:
Shaft speed (in RPMs).
Orders calculations.
Speed is measured between 1 RPM and over 20,000 RPMs. When the speed goes below 1 RPM, the module
interprets this as zero speed. If the speed is suddenly lost above 20 RPMs the speed output is set to bad quality.
For orders calculations, the event marker is used 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
2VAA000341
33
29BI/O Conditioning Functions

nctions
4BOPERATION
NX.
5.2.3 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 a Normally Open (NO) and Normally Closed (NC) contact. 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.
34
2VAA000341
4BOPERATION
5.3
30BFunctions
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
Output Select
Probe Type
Probe Sensitivity
Integration
1 = Vibration
0 = Peak-to-Peak
1 = Peak
2 = RMS
3 = Average
4 = Calculated Peak-to-Peak
5 = Calculated peak
1 = Proximity Probe
3 = Accelerometer
4 = Moving Element velocity probe
5 = Piezoelectric velocity probe
Millivolts / EU
0 = None
1 = Velocity to displacement (velocity probes only)
2 = Acceleration to velocity (accelerometers only)
Angular Position
of Probe
High Failure
Threshold
Low Failure
Threshold
N for Nth Order

Filter Low Cutoff
Frequency
2VAA000341
Typical settings
Proximity Probe = -0.5
Accelerometer = 20.0
Moving Element velocity probe = 20.0
Piezoelectric velocity probe = 20.0
Typical settings
Accelerometer = 0.5
Moving Element velocity probe = -20.0
Piezoelectric velocity probe =0.5
3 10 (User specified)
User defined (recommendations listed below)
Proximity Probe = 1
Accelerometer = 10
Moving Element velocity probe = 10
Piezoelectric velocity probe = 10
Integrated signals with low frequency noise = 40
35
30BFunctions
4BOPERATION
Filter High Cutoff

Frequency
Shaft Rotation
Direction
User defined (recommendations listed below)

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
Shaft rotation is determined looking axially from the
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
Output Select
Probe Type
Probe Sensitivity
2 = Eccentricity
0 = Peak-to-Peak
1 = Proximity Probe
Millivolts / EU
Angular Position
of Probe
High Failure
Threshold
Low Failure
Threshold

5.3.3 Thrust (Rotor) Position

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

Channel Type
Probe Type
Probe Sensitivity
36
3 = Thrust
1 = Proximity Probe
6 = Complementary proximity probe
Millivolts / EU
2VAA000341
4BOPERATION
30BFunctions
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage

User defined.
Set by user.
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
Probe Type
Probe Sensitivity
Ramp Angle
4 = Differential Expansion
1 = Proximity Probe
2 = DC LVDT
6 = Complementary proximity probe
7 = Ramped Complementary proximity probe
Millivolts / EU
(for probe type 7 only)
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage
Non-linear
Correction

DC LVDT = probe dependent
User defined.
Set by user.
User defined. This is intended to extend the usable
range of a probe. (For Future Use Only)
100
90
80
70
60
50
40
30
20
10
0
0
2VAA000341
10
15
20
37
30BFunctions
4BOPERATION
5.3.5 Case Expansion

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

Channel Type
Probe Type
Probe Sensitivity
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage
5 = Case Expansion
1 = Proximity Probe
2 = DC LVDT
Millivolts / EU
User defined.
Set by user.
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
Channel Type
Output Select
Probe Type
Probe
Sensitivity
Integration
Seismic (2/4)
Absolute (5/6)
6 = Relative
0 = Peak-to-Peak
1 = Proximity Probe
7 = Seismic
0 = Peak-to-Peak
4 = Moving Element
velocity probe
5 = Piezoelectric
velocity probe
Millivolts / EU
8 = Absolute
0 = Peak-to-Peak
N/A
Millivolts / EU
N/A
0 = None
1 = Velocity to
displacement
N/A
Angular
Position of
Probe
High Failure
Threshold
Low Failure
Threshold
45
-45
N/A
velocity probe = 20.0
N/A
N for Nth
Order
Filter Low
Cutoff
Frequency
3 10 (User specified)
Moving Element velocity

probe = -20.0
Piezoelectric velocity
probe =0.5
Same as relative
Same as relative
Filter High
Cutoff
Frequency
38
Relative (1/3)
User defined
(recommendations
listed below)
1 to 10 Hz
User defined
(recommendations
listed below)
Low Speed (< 1000
User defined
(recommendations
listed below)
5 to 10 Hz
Same as relative
N/A
N/A
2VAA000341
4BOPERATION
30BFunctions
RPM) = 200
Medium Speed (10005000 RPM) = 300 to
1000
High Speed (> 5000
RPM) = up to 2000
Highest speed of
interest in Hertz times
10
5.3.7 SMAX
This function measures shaft vibration using two probes in an X/Y configuration.
displacement of the shaft by trigonometrically combining the two signals.
It determines the maximum
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
Output Select
9 = SMAX
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
2VAA000341
39
30BFunctions
4BOPERATION
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.
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.
40
2VAA000341
5BMAINTENANCE
31BPreventive 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
R/F
Health LED. If module is OK the LED is GREEN. On failure, the LED is either RED or OFF.
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
STATUS is AMBER during startup, running diagnostics or calibration. It is RED if the module failed
startup, diagnostics or calibration
CH1
Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH2
CH3
CH4
CH5
CH6
CH7
Table 6-1 MPM810 LEDs
2VAA000341
41
33BTroubleshooting
6.3
5BMAINTENANCE
Troubleshooting
Symptom
Possible Causes
Module is not plugged in correctly.
Module does not initialize.
Operating mode not set up correctly.

Hardware failure.
No power to module.
R/F LED is OFF.
R/F LED is RED.

Hardware failure.
Hardware failure.
Profibus not communicating.
RxTxA & RxTxB LEDs are OFF
Loose or disconnected.
Profibus not properly terminated.
STATUS LED is AMBER.

STATUS LED is RED.
CHn LED is OFF.
CHn LED is AMBER
CHn LED is RED

CHn LED is blinking AMBER
Channel status indicates a Critical
error, but no Configuration error.
MCM800 reporting incorrect

values.
Incorrect speed or phase
The module is on startup, calibration

or diagnostic mode.
Module failed startup.
Module failed diagnostic.
Module failed calibration.
Channel not configured.
Channel is in Alert condition.
Channel is in Danger condition.

There is a configuration error.
No configuration defined for channel.
Configuration not saved.
There are numerous possible causes

for incorrect values, some are listed
below.
Signal noise.
Poor connection.
Improper power and ground.
Improper shielding.
Incorrect sensitivity.
Incorrect filter values.
Improper calibration.
Malfunctioning hardware.
Noise on Event Marker input signal.

Hardware failure.
Improper actuation of termination

unit relays.
Noise on input signal.

Hardware failure.
42
Corrective Action
Re-adjust the module to fit properly.
Check Profibus Address Dipswitch.
Check Ethernet IP address.
Check option Dipswitch.
Replace the module.
Check +24 & -24 volt power supplies
and connector.
Replace the module.
TBU850 Power Failure.
Replace the module.
Check Profibus master and
configuration and addressing.
Check module Profibus address.
Check the cable for proper fitting.
Check Profibus termination Dipswitch
S3.
If LED does not turn green after
several minutes the module may be
faulty. Replace module.
Replace MPM810.
Replace MPM810 or TBU850.
Replace TBU850.
Check configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
Check configuration.
Configure channel using configuration
tool.
Re-configuration channel and set
dipswitch to save parameters.
The possible corrective actions are
just as numerous, some are listed
below.
Check signal path.
Check cable connections.
Check cable shielding.
Check sensitivity value.
Check or adjust filter

settings.
Recalibrate TBU850.
Verify module with known

input signal.
Replace MPM810 or
TBU850.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
2VAA000341
5BMAINTENANCE
6.4
34BDiagnostics
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
TBU850 Test
R/F
LED
X
Channel
LED
Error
Code
Faulty Voltage(s)
on TBU850
Faulty CPU
Solid RED
CPU access, instruction, register testing
Full DRAM Test
Stack RAM
Faulty access or
data
Faulty data
FPGA Load
Faulty FPGA
During any subsequent associated channel

testing the Status LED may RED light if a test
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
6.5
Status
LED
Faulty Test
Repetitive RED
Flashes
2 Repetitive
Flashes
4 Repetitive
RED Flashes
5 Repetitive
RED Flashes
Continuous
Flashing RED
Flash Test
Faulty access or
data
Bad CRC
Solid RED
Processor Test
Faulty CPU
Solid RED
FPGA Test
Faulty Signature
Solid RED
DSP Test
Faulty DSP
Solid RED
NVRAM Test
Faulty Parameters
Solid RED
Undefined
Program failure
Solid RED
Solid RED
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.
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.
2VAA000341
43
36BFirmware Upgrade
5BMAINTENANCE
6.5.3 Returning a Module

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
Occasionally firmware upgrades of the MCM800 will be available at which time an upgrade procedure will be available
with the firmware release.
44
2VAA000341
6BSPECIFICATIONS
37BMCM800 Product Specifications
7. SPECIFICATIONS
7.1
MCM800 Product Specifications

GENERAL
Microprocessors
MCF5282 @ 64 MHz PLL

MC56321 DSP @ 250 MHz PLL
System Communications
Profibus DP V1
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
TU Terminal Blocks
24A/250V
Compression: 0.14-1.5 / 0.14-1.5 / 28-16

solid[mm2] / 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)
2VAA000341
45
37BMCM800 Product Specifications
7BREVISION HISTORY
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
CIS 11:2003+A2:2006,EN55011:2007+A2:2007
EN61000-3-2:2006,EN61000-3-3:1995+A1:2001+A2 :2005
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
CE Mark
EMC Directive
2004/108/EC
Safety Requirements
EN61010-1 Safety Requirements for Electrical Equipment for

Measurement, Control and Laboratory Use - Part 1: General
Requirements
Ambient Temperature
0 to 55 C (32 to 131 F)
Humidity
5% to 90% RH (5%) up to 55C (non-condensing)

5% to 40% RH (5%) up to 70C (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.
5.1
46
Date / Initial
Updated for the Version 5.1 release
05/2010 KD
2VAA000341
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 2010 by ABB.
All rights reserved.
Release: June 2010
47
2VAA000341A5100_SPlus_MCM800 Product Guide.doc
Document Number 2VAA000341
ABB Ltd.
Business Unit Power Generation
P.O. BOX 8131
8050 Zrich
SWITZERLAND
Phone: +41 (0) 43 317-5380
Fax:
+41 (0) 43 317-5382
www.abb.com/powergeneration

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S+ Turbine: Machinery Condition Monitoring MCM800

0BABOUT THIS BOOK

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Before You Start ................................................................................................15

0BABOUT THIS BOOK

Termination Base Units ....................................................................................15

4.2.1 Signal Input Configuration ..............................................................................17

DIP Switch Configuration .................................................................................20

4.3.1 Profibus/Modbus Dipswitch ............................................................................20

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

4.4.1 Module Specific Parameters sent to MCM800 ...............................................23

General Description ..........................................................................................33

I/O Conditioning Functions ..............................................................................33

5.2.1 Signal Inputs ..................................................................................................33

5.3.1 Vibration .........................................................................................................35

0BABOUT THIS BOOK

5.3.7 SMAX .............................................................................................................39

Hardware Indicators ..........................................................................................41

6.2.1 MPM810 I/O Module LEDs.............................................................................41

6.5.1 General ..........................................................................................................43

Firmware Upgrade .............................................................................................44

MCM800 Product Specifications ......................................................................45

REVISION HISTORY ..................................................................................... 46

0BABOUT THIS BOOK

ABOUT THIS BOOK

Design considerations and guidelines.

0BABOUT THIS BOOK

9BUse of Warnings, Caution, Information, and Tip Icons

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

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

A caution icon indicates important information or a warning related to

MCM Processor Module for the MCM800

Terminal Base Unit for the MPM810

Alternating Current Voltage (value is rms unless otherwise stated)

Direct Current Voltage

1.4 Related Documentation

3BUA000258R5 ABB Site Planning Guide

2.1.1 MPM810 Overview

Executes the selected functions of the MCM800 system.

Communicates to the control system via Profibus DP or Modbus RTU.

2.1.2 TBU850 Overview

2.2.1 MPM810 Module

2.2.2 Termination Base Unit (TBU850)

Prerequisites and Requirements