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DynAmp RCEM Installation, Operation And Service Manual

Portable flexible version rectifier monitoring system
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PORTABLE FLEXIBLE VERSION
RECTIFIER MONITORING SYSTEM
Installation, Operation and Service Manual
DynAmp, LLC
MODEL RCEM
Manual Item No. 043756
3735 Gantz Road
Grove City, Ohio 43123 USA
Rev. G
Phone +1 614.871.6900
Fax +1 614.871.6910
www.dynamp.com
help@dynamp.com

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  • Page 1 MODEL RCEM PORTABLE FLEXIBLE VERSION RECTIFIER MONITORING SYSTEM Installation, Operation and Service Manual Manual Item No. 043756 Rev. G DynAmp, LLC 3735 Gantz Road Phone +1 614.871.6900 www.dynamp.com Grove City, Ohio 43123 USA Fax +1 614.871.6910 help@dynamp.com...
  • Page 2 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page ii 43756 G...
  • Page 3 Items and components not manufactured and resold by Seller are warranted by their manufacturer. Warranty repair shall be, at DynAmp's option, in the form of repair or replacement of the defective items or components. Concerning warranty repairs, DynAmp will be responsible for DynAmp provided time, material and transportation costs (shipping or travel).
  • Page 4 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page iv 43756 G...
  • Page 5 Disconnect power to the system before servicing or replacing fuses. Use of the equipment in a manner not specified by the manufacturer can impair the protection provided within. DynAmp does not assume liability for the customer’s failure to comply with the GENERAL rules and requirements provided in this manual.
  • Page 6 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page vi 43756 G...
  • Page 7 Installation, Operation and Service Manual RCEM DynAmp, LLC Customer Support For further assistance, contact DynAmp Customer Support at: Americas: Telephone: +1 614.871.6900 Fax: +1 614.871.6910 8:00 AM to 5:00 PM USA Eastern Time From first Sunday in November to second Sunday in March – 13:00 GMT to 22:00 GMT From second Sunday in March to first Sunday in November –...
  • Page 8 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page viii 43756 G...
  • Page 9 Computer 45-54 ECO-3099 - Revise Appendix B: Add Devices/Leg 08/04 Command Button 45-54 Update to DynAmp, LLC, ECO-3102 – Revise Appendix B: 12/04 Add ANSI Rectifier Circuit select v, 1, 27, Update fuse precautions per ECR 1304 07/06 PAR 10245 – Handling & Storage, ECR 1440- Calibration...
  • Page 10 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page x 43756 G...

  • Page 11: Table Of Contents

    ) ................30 ENSOR ESTING ONTINUITY ETHOD 7.10 S ............31 ENSOR IELECTRIC ESTING INDINGS TO URFACE 7.11 C ) .............. 32 ONNECTOR ONTAMINATION NTEGRATOR CARDS 7.12 R ................33 ESET RROR OR NCORRECT © 2012 DynAmp, LLC Page xi 43756 G...
  • Page 12 Figure A.6 ANSI Rectifier Circuit 32 ..................41 Figure A.7 ANSI Rectifier Circuit 45 ..................42 Figure A.8 ANSI Rectifier Circuit 46 ..................42 Figure A.9 ANSI Rectifier Circuit 52 ..................43 Figure B.1 6Leg120Ch Spreadsheet ..................52 © 2012 DynAmp, LLC Page xii 43756 G...
  • Page 13 Table 6.6 Transducer Connections, 12-Leg Rectifier (20 Diodes Max.) ......... 24 Table 6.7 Transducer Connections, 1-Leg of a Multi-Leg Rectifier ......... 25 Table 8.1 Spare Parts List ..................... 36 Table 9.1 Drawing List ......................37 © 2012 DynAmp, LLC Page xiii 43756 G...
  • Page 14 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page xiv 43756 G...

  • Page 15: Safety

    Use of the equipment in a manner not specified by the manufacturer can impair the • protection provided. DynAmp does not assume liability for the customer’s failure to comply with the rules and requirements provided in this manual. © 2012 DynAmp, LLC...
  • Page 16 Installation, Operation and Service Manual RCEM This Page is Intentionally Blank © 2012 DynAmp, LLC Page 2 43756 G...

  • Page 17: Handling And Storage

    -40 to 70°C -40 to 158°F Storage Humidity: 85%, non-condensing DynAmp, LLC does not assume liability for the customer’s failure to comply with handling and storage requirements. For further assistance, contact DynAmp customer support. © 2012 DynAmp, LLC Page 3...
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  • Page 19: Description

    The DynAmp RECTIFIER MONITORING SYSTEM Model RCEM is designed for isolated measurement of device currents in multiple path power rectifiers. Model RCEM is a monitoring system composed of a 120 Channel Data Acquisition Unit, a laptop computer, Flexible Current Sensors, and the interconnection cables.

  • Page 20: Laptop Computer

    FLEXIBLE CURRENT SENSORS The 3.625 ID Flexible Current Sensor is the standard sensor supplied with the RCEM. Other Flexible Current Sensor sizes are available from DynAmp, if required. Presently they include inside diameter (I.D.) sizes of 1.000", 1.500", 2.750", 4.250", and 2.875” x 5.500”...

  • Page 21: Specifications

    Environmental Temperature Comments: Data Acquisition Unit ° ° C to 50 Flexible Current Sensor ° ° C to +150 Humidity Data Acquisition Unit 85% RH non-condensing Flexible Current Sensor 85% RH non-condensing © 2012 DynAmp, LLC Page 7 43756 G...

  • Page 22: Table 4.1 Rectifier Condition Evaluation Monitor Specifications (Continued)

    Visual Indicators Comments: Data Acquisition Unit +24V LED MUX A0 – MUX A2 LEDs TEST MODE LED TEST A0 – TEST A1 LEDs Personal Daq/56 Update Rate 4 seconds for 120 channels © 2012 DynAmp, LLC Page 8 43756 G...

  • Page 23: Technical Description

    See Figure 5.1. DAU Data I/O Connector Variations DAU Version Data Port USB Port 120 Channel Installed 240 Channel DAU #1 Installed USB “A” 240 Channel DAU #2 USB “B” © 2012 DynAmp, LLC Page 9 43756 G...

  • Page 24: Backplane

    The power circuits in the Data Acquisition Unit consist of the ac power input circuit, the regulated quad output power supply, the +12V power supply, the + 5V power supply, and the dc power input circuits. © 2012 DynAmp, LLC Page 10 43756 G...

  • Page 25: Analog Input Connectors

    CMOS analog switch to reset the integrating capacitor. Integrator reset pulses are buffered by CMOS digital buffers. Integrator resets are synchronized to the ac line supplying power to the DAU. Reset synchronization is established by the Reset Sync Cards during its © 2012 DynAmp, LLC Page 11 43756 G...

  • Page 26: Reset Sync Cards

    Installation, Operation and Service Manual RCEM initialization sequence upon power-up. A “RCEM RESET” command from the spreadsheet program will also cause the integrator resets to synchronize to the ac line. To work properly, each integrator must be reset when the associated rectifier device is not conducting current during the commutation cycle.

  • Page 27: Test Signal Generator

    U11 and U14, analog switch U9, and a reference voltage produced by U12. The test signal waveform for the 571A test signal is shown in Figure 5.4. © 2012 DynAmp, LLC Page 13 43756 G...

  • Page 28: Personal Daq/56

    The Personal Daq/56 is a self-contained USB data acquisition module with twenty analog input channels and 16 digital I/O channels. The Personal Daq/56 is located on the top end panel of the Data Acquisition Unit. See Figure 5.5. Figure 5.5 Personal Daq/56 © 2012 DynAmp, LLC Page 14 43756 G...

  • Page 29: Usb Extender Receiver

    24V digital inputs required by the backplane. This module consists of an input terminal strip, an interface integrated circuit, and an output terminal strip. The module is located adjacent to the Personal Daq/56 Data Acquisition Module. See Figure 5.7. Figure 5.7 Digital Interface Module © 2012 DynAmp, LLC Page 15 43756 G...
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  • Page 31: Preparation For Use

    Section 6 describes how to check for such paths. The Flexible Current Sensors are factory calibrated to DynAmp’s standard Flexible Current Sensor circuit. All Flexible Current Sensors are interchangeable regardless of the physical size.

  • Page 32: Figure 6.1 Flexible Current Sensor Installation Detail

    Turn ON the Data Acquisition Unit using the power switch located on the I/O Panel. f.) Put the rectifier back on-line and bring it up to load. The RCEM may be tested, using its built-in test signal generator, during rectifier testing. Use the procedure in Appendix B.9 whenever the RCEM measurements indicate a problem in a rectifier, before taking the rectifier off-line.

  • Page 33: Table 6.1 Transducer Connections, 6-Leg Rectifier (20 Diodes Max.)

     4B-10 5B-10 6B-10 Notes: 1) This chart applies to a 120 Channel RCEM 2) 1A-1 = Leg cable “1A”, Current Transducer connector “1” 3) Cables 1A through 6B connect to Data Acquisition Unit connectors 1A through 6B © 2012 DynAmp, LLC...

  • Page 34: Table 6.2 Transducer Connections, 6-Leg Rectifier (40 Diodes Max.)

    5D-10 6D-10 Notes: This chart applies to a 240 Channel RCEM 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6B connect to Data Acquisition Unit #1 connectors 1A through 6B Cables 1C through 6D connect to Data Acquisition Unit #2 connectors 1A through 6B ©...

  • Page 35: Table 6.3 Transducer Connections, Parallel 6-Leg Rectifier (10 Diodes Max)

    4B-10 5B-10 6B-10 Notes: This chart applies to a 120 Channel RCEM 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6B connect to Data Acquisition Unit connectors 1A through 6B © 2012 DynAmp, LLC Page 21...

  • Page 36: Table 6.4 Transducer Connections, Parallel 6-Leg Rectifier (20 Diodes Max)

    5D-10 6D-10 Notes: This chart applies to a 240 Channel RCEM 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6B connect to Data Acquisition Unit #1 connectors 1A through 6B Cables 1C through 6D connect to Data Acquisition Unit #2 connectors 1A through 6B ©...

  • Page 37: Table 6.5 Transducer Connections, 12-Leg Rectifier (10 Diodes Max.)

    4B-10 5B-10 6B-10 Notes: This chart applies to a 120 Channel RCEM 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6B connects to Data Acquisition Unit connectors 1A through 6B © 2012 DynAmp, LLC Page 23...

  • Page 38: Table 6.6 Transducer Connections, 12-Leg Rectifier (20 Diodes Max.)

    5D-10 6D-10 Notes: This chart applies to a 240 Channel RCEM 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6B connects to Data Acquisition Unit #1 connectors 1A through 6B Cables 1C through 6D connects to Data Acquisition Unit #2 connectors 1A through 6B ©...

  • Page 39: Table 6.7 Transducer Connections, 1-Leg Of A Multi-Leg Rectifier

    Rectifier must have at least 3 legs This table shows connections for 30 diodes/leg 1A-1 = Leg cable “1A”, Current Transducer connector “1” Cables 1A through 6A connects to Data Acquisition Unit connectors 1A through 6A © 2012 DynAmp, LLC Page 25 43756 G...
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  • Page 41: Maintenance And Troubleshooting

    This section contains some specialized tests of the electronics and current sensors of the RCEM, as well as some preventive maintenance procedures. The output of the built-in signal generator provides a test signal for testing the overall operation of the RCEM as well as its accuracy.

  • Page 42: Fuse Replacement

    Keep plastic, vinyl, Styrofoam and other non-conductive materials away from printed circuit boards. They are good static generators that do not give up their charge easily. Return goods to DynAmp in static safe packaging. This will limit further component damage from ESD. CAUTION Do not touch any printed circuit board unless you are wearing a grounded wrist strap, as circuit damage may occur.

  • Page 43: Verifying Proper Integrator Reset Synchronization

    Make sure that all integrator cards are properly seated in the card rack. Connect the oscilloscope to the questionable waveform test points. See Figure 7.2. With the laptop computer connected to the Personal Daq/56, click on the “RCEM RESET” button on the spreadsheet.

  • Page 44: Adjusting The Integrator Pc Boards

    20). SENSOR TESTING (CONTINUITY METHOD) The current sensor continuity test (described below) is made when the RCEM is first installed and will also prove useful in troubleshooting. The dielectric test, paragraph 7.9, is another useful preventive maintenance and diagnostic tool.

  • Page 45: Sensor Dielectric Testing - Windings To Surface

    Replace any defective current sensor(s) and repeat the test. 7.10 SENSOR DIELECTRIC TESTING - WINDINGS TO SURFACE Dielectric withstand-voltage tests of the current sensors can be useful in preventive maintenance and troubleshooting of the RCEM. WARNING DANGER HIGH VOLTAGE exists while performing Hipot tests.

  • Page 46: Connector Contamination (Integrator Cards)

    In the process of daily operation or during vibration in shipment, the DAU integrator card connectors may get contaminated. This may also happen from airborne contaminants that may enter the DAU from normal factory use. This action may cause abnormal operation of the RCEM. © 2012 DynAmp, LLC Page 32 43756 G...

  • Page 47: Reset Sync Error Or Incorrect Data

    The “RCEM RESET” command button will also cause the Data Acquisition Unit to synchronize to the rectifier. This may be accomplished by turning the DAU power off then on, or by clicking on the “RCEM RESET” command button located on the laptop computer spreadsheet.
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  • Page 49: Service, Parts, And Documentation

    Installation, Operation and Service Manual RCEM 8. SERVICE, PARTS, AND DOCUMENTATION SERVICE ASSISTANCE For further assistance, contact DynAmp Customer Support at: Americas: Telephone: +1 614.871.6900 Fax: +1 614.871.6910 8:00 AM to 5:00 PM USA Eastern Time From first Sunday in November to second Sunday in March – 13:00 GMT to 22:00 GMT From second Sunday in March to first Sunday in November –...

  • Page 50: Spare Parts Orders - Routine Or Emergency

    Requests for spare parts, either in an emergency or for a routine order, should be directed to "Inside Sales" at DynAmp during normal hours, if possible, or via any method shown above for off-hours. When contacting us, please present as much information as possible - the related equipment Model Number and Serial Number;...

  • Page 51: Drawing List

    Drawings should be kept with the manual at all times. TABLE 9.1 DRAWING LIST DRAWING TITLE NUMBER Interconnection Diagram: RCEM 120 Channel COP (6-Pulse) 02D108554 Interconnection Diagram: RCEM 120 Channel COP (12-Pulse) 02D108555 Outline and Mounting: RCEM DAU 120 Channel 02D108504 Outline and Mounting: COP 3.625 ID Flexible...
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  • Page 53: Appendix A: Ansi Rectifier Circuits

    Installation, Operation and Service Manual RCEM APPENDIX A: ANSI RECTIFIER CIRCUITS Figure A.1 ANSI Rectifier Circuit 23 Figure A.2 ANSI Rectifier Circuit 24 © 2012 DynAmp, LLC Page 39 43756 G...

  • Page 54: Figure A.3 Ansi Rectifier Circuit 25

    Installation, Operation and Service Manual RCEM Figure A.3 ANSI Rectifier Circuit 25 Figure A.4 ANSI Rectifier Circuit 26 © 2012 DynAmp, LLC Page 40 43756 G...

  • Page 55: Figure A.5 Ansi Rectifier Circuit 31

    Installation, Operation and Service Manual RCEM Figure A.5 ANSI Rectifier Circuit 31 Figure A.6 ANSI Rectifier Circuit 32 © 2012 DynAmp, LLC Page 41 43756 G...

  • Page 56: Figure A.7 Ansi Rectifier Circuit 45

    Installation, Operation and Service Manual RCEM Figure A.7 ANSI Rectifier Circuit 45 Figure A.8 ANSI Rectifier Circuit 46 © 2012 DynAmp, LLC Page 42 43756 G...

  • Page 57: Figure A.9 Ansi Rectifier Circuit 52

    Installation, Operation and Service Manual RCEM Figure A.9 ANSI Rectifier Circuit 52 © 2012 DynAmp, LLC Page 43 43756 G...
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  • Page 59: Appendix B: Software

    RCEM APPENDIX B: SOFTWARE PROVIDED SOFTWARE All software and drivers associated with this product are supplied on CD-ROMs. The contents of the DynAmp CD-ROM are as follows: DynAmp spreadsheet(s) • Personal Daq/56 configuration file: “RCEM.cfg” • A copy of this manual “043526x.pdf” (x = manual revision) •...

  • Page 60: Starting The Data Acquisition Program

    The pDaqView drivers communicate with the Personal Daq/56 via the laptop’s USB port. The customized spreadsheet file(s) provided on the DynAmp CD-ROM should be copied to the “Program Files\pDaqView” directory and the “RCEM.cfg” file should be copied to the “Program Files\pDaqView\Applications” directory. Finally, a shortcut to each spreadsheet should be created on the “Desktop”...

  • Page 61: Spreadsheet Description

    The spreadsheet allows the monitoring of the diode currents, and provides visual indicators of all the alarm conditions. It also allows the RCEM system to be operated in test mode to assist in troubleshooting problems with the system.

  • Page 62: Programming The Numer Of Devices/Leg

    20.) DEVICES/LEG: Command button used to enter the number of rectifying devices/leg. Note: This command button may not be preset on some RCEM spreadsheets. 21.) ANSI RECTIFIER CIRCUIT: Selection box used to select the appropriate ANSI Rectifier Circuit Number.

  • Page 63: Acquiring A Rectifier Data Set

    Enter the waveform factor in the “Waveform Factor:” field. See Appendix A for the correct waveform factor to use. This value varies with the ANSI rectifier circuit number but regardless of the waveform factor used, the diode currents will be correct. © 2012 DynAmp, LLC Page 49 43756 G...

  • Page 64: Stopping The Scan Mode Of Operation

    CAUTION Do not turn RCEM DAU power off when SCAN mode is active. The computer may lose communications with the RCEM DAU. See “Recovering from DAQ Errors” below to correct problem.

  • Page 65: Calibrate Worksheet

    B.15 CALIBRATE WORKSHEET A special worksheet is provided for use in calibrating the RCEM. See Figure B.6. The diode data are displayed in rows and the legs in columns. Each row corresponds to an Integrator PC Board. The average of the diode currents in each row is calculated and displayed.

  • Page 66: Figure B.1 6Leg120Ch Spreadsheet

    Installation, Operation and Service Manual RCEM Figure B.1 6Leg120Ch Spreadsheet Figure B.2 M6Leg120Ch Spreadsheet © 2012 DynAmp, LLC Page 52 43756 G...

  • Page 67: Figure B.3 12Leg120Ch Spreadsheet

    Installation, Operation and Service Manual RCEM Figure B.3 12Leg120Ch Spreadsheet Figure B.4 1Leg-20ch Spreadsheet © 2012 DynAmp, LLC Page 53 43756 G...

  • Page 68: Figure B.5 Leg 1 Bar Chart

    Installation, Operation and Service Manual RCEM LEG 1 1300.0 1250.0 1200.0 1150.0 1100.0 1050.0 1000.0 DIODE Figure B.5 Leg 1 Bar Chart Figure B.6. Calibrate Worksheet © 2012 DynAmp, LLC Page 54 43756 G...

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