Emerson Machinery Health A6500-RC Operating Manual
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Emerson Machinery Health A6500-RC Operating Manual

Emerson Machinery Health A6500-RC Operating Manual

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Operating Manual
MHM-97876 , Rev 5.06
June 2023
™
Machinery Health
System
A6500-RC Relay Card

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Summary of Contents for Emerson Machinery Health A6500-RC

  • Page 1 Operating Manual MHM-97876 , Rev 5.06 June 2023 ™ Machinery Health System A6500-RC Relay Card...
  • Page 2 Information in this document is subject to change without notice and does not represent a commitment on the part of Emerson. The information in this manual is not all-inclusive and cannot cover all unique situations.
  • Page 3 Opmerking m.b.t. installatie van elektrische meet circuits in explosiegevaarlijke omgeving Dient de installatie van elektrische meet circuits in een explosiegevaarlijke omgeving te geschieden, moet men toezien dat de in de gebruikshandleiding opgenomen installatieinstructies worden nageleefd. Bij taalkundige problemen gelieve contact op te nemen met de fabrikant, deze zal u vervolgens een vertaling in de taal van het gebruiksland doen toekomen.
  • Page 4 Piezīme par mērīšanas ķēžu instalēšanu sprādziena bīstamās zonās. Ja mērīšanas ķēde jāuzstāda sprādzienbīstamā zonâ, ir jāievēro lietošanas instrukcijā dotie instalēšanas norādījumi. Ja rodas kādas valodas grūtības, lūdzu griezieties pie izgatavotāja firmas, kas Jums nosūtīs nozīmīgâko nodaļu tulkojumus lietotāja valsts valodā. Emerson epro GmbH Jöbkesweg 3 48599 Gronau...

  • Page 5: Table Of Contents

    Operating Manual Contents MHM-97876 June 2023 Contents Chapter 1 General.......................... 7 1.1 Using this manual..........................7 1.2 Symbols............................7 1.3 Liability and guarantee........................8 1.4 Incoming goods inspection......................8 1.5 Technical support..........................8 1.6 Storage and transport........................9 1.7 Disposal of the device........................9 1.8 China RoHS Compliance........................
  • Page 6 Contents Operating Manual June 2023 MHM-97876 7.1 Overview............................60 7.2 Details............................62 7.3 Online commands.......................... 63 Chapter 8 Functional check and maintenance................65 8.1 Functional check..........................65 8.1.1 Simulation by using a F48 extension card..................65 8.1.2 Simulation by using the installed cards..................67 8.2 Maintenance..........................

  • Page 7: Chapter 1 General

    Operating Manual General MHM-97876 June 2023 General Using this manual This manual contains information concerning the use of the device. Read the operating manual completely prior to starting installation and operating the device. Comply with all safety instructions. This operating manual applies for A6500-RC Relay Cards with hardware revisions and software versions listed in Table 1-1.

  • Page 8: Liability And Guarantee

    Liability and guarantee Emerson is not liable for damages that occur due to improper use. Proper use also includes the knowledge of, and compliance with, this document. Customer changes to the device that have not been expressly approved by Emerson will result in the loss of guarantee.

  • Page 9: Storage And Transport

    Operating Manual General MHM-97876 June 2023 To search for documentation, visit http://www.emerson.com. To view toll free numbers for specific countries, visit http://www.emersonprocess.com/ technicalsupport. Note If the equipment has been exposed to a hazardous substance, a Material Safety Data Sheet (MSDS) must be included with the returned materials. An MSDS is required by law to be available to people exposed to specific hazardous substances.

  • Page 10: Ccc Certification - Ams 6500 Atg

    General Operating Manual June 2023 MHM-97876 Circling arrow symbol with "e": The product contains no hazardous substances over the Maximum Concentration Value and it has an indefinite Environmental Friendly Use Period. Circling arrow symbol with a number: This product contains certain hazardous substances over the Maximum Concentration Value and it can be used safely under normal operating conditions for the number of years indicated in the symbol.

  • Page 11: Chapter 2 Safety Instructions

    Operating Manual Safety instructions MHM-97876 June 2023 Safety instructions To ensure safe operation, carefully observe all instructions in this manual. The correct and safe use of this device requires that operating and service personnel both understand and comply with general safety guidelines and observe the special safety comments listed in this manual.

  • Page 12: Radio Interference

    Safety instructions Operating Manual June 2023 MHM-97876 Radio interference The device is carefully shielded and tested to be technically immune to radio interference and complies with current standards. However, if you operate this device together with other peripheral devices that are not properly shielded against radio interference, disturbances and radio interferences may occur.

  • Page 13: Application And Design

    Operating Manual Application and design MHM-97876 June 2023 Application and design Application The A6500-RC Relay Card is a component of the AMS 6500 ATG machine protection system. It is a freely programmable microprocessor-controlled module that can be used to do logical combination of binary signals within a AMS 6500 ATG system. When connected to an A6500-xR System Rack, the measurement cards provide and connect their logical outputs (COK, Alert, and Danger) automatically to the A6500-RC inputs through the backplane of the System Rack.
  • Page 14 Application and design Operating Manual June 2023 MHM-97876 Figure 3-1: Side view A. Handle for pulling the monitor from the rack with a small sticker with the serial number on it. B. Mounting screws C. Connector with type plate with designation (PN), serial number (SN), and hardware revision (Rev.).
  • Page 15 Operating Manual Application and design MHM-97876 June 2023 Figure 3-2: Front view A. Handle B. Mounting screws C. green LED: Supply voltage OK indication orange LEDs: Status of the 16 relay outputs MHM-97876, Rev. 5.06...
  • Page 16 Application and design Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 17: Chapter 4 Installation

    Operating Manual Installation MHM-97876 June 2023 Installation For installation and mounting of the A6500-RC into an A6500-xR System Rack the relay output terminals and wiring are described in the operation manual of the A6500-xR System Racks. The Relay Card can be only installed in the double slot 12 (12.1 and 12.2) of the A6500-SR System Rack or in the double slots 10 (10.1 and 10.2) and 11 (11.1 and 11.2) of the A6500-RR System Rack.
  • Page 18 Installation Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 19: Hazardous Location Installation

    Operating Manual Hazardous location installation MHM-97876 June 2023 Hazardous location installation The ex-approval of the A6500-RC Relay Card is only valid if the Relay Card is installed in an A6500-xR System Rack. See chapter "Hazardous location installation" of the A6500-xR System Racks operating manual (MHM-97877) for details.
  • Page 20 Hazardous location installation Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 21: Chapter 6 Configuration

    Operating Manual Configuration MHM-97876 June 2023 Configuration General configuration procedure The configuration can be performed offline, that means without connection to the card or online with a connection to the card. In any case, the configuration has to be loaded into the card.

  • Page 22: Online Configuration

    Configuration Operating Manual June 2023 MHM-97876 6.1.2 Online configuration Procedure 1. Switch on the power supply of the system if not already on. 2. Connect the laptop to the Com Card of the system by using the UBS or Ethernet connection.
  • Page 23 Operating Manual Configuration MHM-97876 June 2023 Figure 6-2: Device selection The Relay Card will be added to the list below Workspace. 3. Select Relay/Logic Card (A6500-RC) from the device list and click Configure (see Figure 6-3). Figure 6-3: Open editor A.

  • Page 24: Start Of An Online Card Configuration

    Configuration Operating Manual June 2023 MHM-97876 Start of an online card configuration Procedure 1. Select the A6500-RC card from the Network list in the left part of the Home window, then click Configure (see Figure 6-4). Figure 6-4: Select Relay Card for online configuration A.

  • Page 25: Configuration Editor And Parameters

    Operating Manual Configuration MHM-97876 June 2023 Configuration editor and parameters Figure 6-5 shows an overview of the general configuration editor Configuration. Figure 6-5: Configuration editor A. Ribbon command bar B. Card name and position within the rack (only visible at connected racks, for example: R1 = Rack 1;S12 = Slot 12) C.
  • Page 26 Configuration Operating Manual June 2023 MHM-97876 Figure 6-7: Button "Send & close" Click Send & close to send the configuration to the Relay Card. The configuration editor automatically closes after the sending process. This command requires an online connection to the card. See Send a configuration.
  • Page 27 Operating Manual Configuration MHM-97876 June 2023 Figure 6-11: Button "Compare" Click Compare to show differences between the configuration on the card and in the memory of the used Laptop or PC. Report Figure 6-12: Button "Report" Click Report to open the report viewer. This report shows all configured parameters and some additional information as, for example, serial number and user information.
  • Page 28 Configuration Operating Manual June 2023 MHM-97876 Figure 6-13: General settings Show History/Drafts Figure 6-14: Button "Shows History/Drafts" Click Show History/Drafts to open the History (see Figure 6-15). MHM-97876, Rev. 5.06...
  • Page 29 Operating Manual Configuration MHM-97876 June 2023 Figure 6-15: History The right part of Figure 6-15 lists the configuration history. The individual files are marked with date and time and type: • Draft Config A saved preliminary configuration file which has not yet send to the card. •...

  • Page 30: Basic

    Configuration Operating Manual June 2023 MHM-97876 Figure 6-17: Button "Close configuration" Click Close configuration to leave the configuration editor. Changes are automatically saved as a draft configuration. A saved draft can be opened in the history view. 6.5.2 Basic Enter the basic settings of the configuration (see Figure 6-18).

  • Page 31: Module 1 To Module 32

    Operating Manual Configuration MHM-97876 June 2023 Enable marker Place a checkmark in the box to add events caused by markers to events the event list. The amount of events caused by markers depends on the configuration of the Relay Card and can be enormous. Note The A6500-RC card is able to process 32 events per second.
  • Page 32 Configuration Operating Manual June 2023 MHM-97876 Note All elements can be placed within the configuration window by drag and drop. Logic elements that are configured incorrectly are marked red. Observe the following limitations for a logic configuration: • Maximum of 32 logic modules. •...
  • Page 33 Operating Manual Configuration MHM-97876 June 2023 Table 6-1: Standard logic gates (continued) Logic gate Description SR-Latch; R (reset) has priority There are two inputs: S (set) and R (reset). A logical 1 at input S sets the output to 1. A logical 1 at input R sets the output to 0. A logical 1 at both inputs sets the output to 0.
  • Page 34 Configuration Operating Manual June 2023 MHM-97876 Figure 6-21: Place the first logic gate 1. Click and hold a logic gate (A, Figure 6-21). 2. Move the selected gate into the configuration area (B, Figure 6-21). 3. Release the mouse button to place the gate into the area (C, Figure 6-21).
  • Page 35 Operating Manual Configuration MHM-97876 June 2023 Figure 6-22: Add a logic gate 1. Click and hold a logic gate (A, Figure 6-22). 2. Move the selected gate into the configuration area (B, Figure 6-22). The selected gate can be connected either to an input or an output of an already placed logic gate.
  • Page 36 Configuration Operating Manual June 2023 MHM-97876 Note Not connected gate inputs are ignored in the logic. To delete a logic gate, click it with the left mouse button. The frame becomes blue and a delete icon appears (see Figure 6-24). Click the icon or press the delete key to remove the logic gate.
  • Page 37 Operating Manual Configuration MHM-97876 June 2023 Table 6-2: Assignment of digital outputs to Relay Card inputs (continued) Slot Digital Input Slot Digital Input Slot Digital Input output Relay output Relay output Relay Card Card Card DOUT2 DIN14 DOUT6 DIN36 DOUT4 DIN58 DOUT3 DIN15...
  • Page 38 Configuration Operating Manual June 2023 MHM-97876 The selected input can be connected to available inputs of a logic gate. If all visible inputs are occupied, add a new input to the logic gate (32 inputs at maximum). 3. Place the selected input so that the connection point of the input and the input of the logic gate are blue framed (see Figure 6-23).
  • Page 39 Operating Manual Configuration MHM-97876 June 2023 Figure 6-29: Properties - digital input A. Rename icon B. Delete icon If you do not want to make any changes, click somewhere on the configuration area to reset the selection of the digital input. Software inputs Up to 16 software inputs can be used to build up logical conjunctions.
  • Page 40 Configuration Operating Manual June 2023 MHM-97876 Figure 6-30: Add a software input 1. Click and hold a software input (A, Figure 6-30). 2. Move the selected software input into the configuration area (B, Figure 6-30). The selected input can be connected to available inputs of a logic gate. If all visible inputs are occupied, add a new input to the logic gate (32 inputs at maximum).
  • Page 41 Operating Manual Configuration MHM-97876 June 2023 Figure 6-32: Add a new port for a software input 4. Release the mouse button. The input is added to the logic gate. The inputs are connected to the logic gate in the same sequence as they are added. To negate an input, click on the input line (see Figure 6-33).
  • Page 42 Configuration Operating Manual June 2023 MHM-97876 Replace an input Each input can be replaced by another input without deleting the prior input. 1. Select an input from the available elements. This can be a digital input, a software input, a marker, or a digital output. 2.
  • Page 43 Operating Manual Configuration MHM-97876 June 2023 1. Click and hold a marker (A, Figure 6-36). 2. Move the selected marker close to the output of a logic gate (B, Figure 6-36). Place the selected marker so that the connection point of the marker and the output of the logic gate are blue framed (see Figure 6-37).
  • Page 44 Configuration Operating Manual June 2023 MHM-97876 Figure 6-39: Add a marker as a digital input 1. Click and hold a marker (A, Figure 6-39). 2. Move the selected marker close to the input of the logic gate where to add it (B, Figure 6-39).
  • Page 45 Operating Manual Configuration MHM-97876 June 2023 Figure 6-41: Add a new port for a marker 3. Release the mouse button (C, Figure 6-39). The marker is added to the logic gate. The markers are connected to the logic gate in the same sequence as they are added. To negate a marker input, click the input line (see Figure 6-42).
  • Page 46 Configuration Operating Manual June 2023 MHM-97876 Timer This list contains different timers (see Table 6-3). Use the timers to add, for example, turn- on delays to logical gate outputs. Table 6-3: Timer Timer Description Timer off Delay (switch off delay) This timer has a trigger input (T), a reset input (R) and a configurable switch off delay time (Time[s]).
  • Page 47 Operating Manual Configuration MHM-97876 June 2023 Table 6-3: Timer (continued) Timer Description Timer Enlarged Impulse This timer has a trigger input (T), a reset input (R), and a configurable impulse time (Time[s]). At a transition from logical 0 to 1 at the trigger input (T) the output is set to logical 1 and the time starts to elapse from the configured time.
  • Page 48 Configuration Operating Manual June 2023 MHM-97876 Figure 6-45: Connection of a timer to an output of logic gate To connect the timer to an input of a logic gate, place the timer so that the output of the timer (out) and the input of the logic gate are blue framed (see Figure 6-46).
  • Page 49 Operating Manual Configuration MHM-97876 June 2023 Figure 6-47: Negate timer inputs To delete a timer, click it with the left mouse button. The frame becomes blue and a delete icon appears (see Figure 6-48). Click the icon or press the delete key to remove the timer. Figure 6-48: Delete a timer Note If the timer has more than one connected input, all connected inputs are deleted.
  • Page 50 Configuration Operating Manual June 2023 MHM-97876 Figure 6-49: Add a digital output 1. Click and hold a digital output (A, Figure 6-49). 2. Move the selected digital output close to the output of a logic gate or timer (B, Figure 6-49).
  • Page 51 Operating Manual Configuration MHM-97876 June 2023 Figure 6-51: Properties – digital output A. Delete icon B. Rename icon If you do not want to delete the digital output, click somewhere on the configuration area to reset the selection of the digital output. To rename the digital output, click it with the left mouse button.
  • Page 52 Configuration Operating Manual June 2023 MHM-97876 Figure 6-52: Add a digital output as a digital input 1. Click and hold a digital output (A, Figure 6-52). 2. Move the selected digital output close to the input of a logic gate or timer where to add it (B, Figure 6-52).
  • Page 53 Operating Manual Configuration MHM-97876 June 2023 Figure 6-54: Add a new port for a digital output 3. Release the mouse button to connect the selected digital output to the input (C, Figure 6-52). The digital output is connected to the input of the logic gate or timer. To negate an input click on the respective input line (see Figure 6-55).
  • Page 54 Configuration Operating Manual June 2023 MHM-97876 Figure 6-56: Pop-up menu – digital output as input A. Rename icon B. Delete icon If you do not want to make any changes, click somewhere on the configuration area to reset the selection of the digital output. Special functions Table 6-4 lists the available functions.
  • Page 55 Operating Manual Configuration MHM-97876 June 2023 Figure 6-57 how to add a special function. Figure 6-57: Add a special function 1. Click and hold a special function (A, Figure 6-57). 2. Move the selected special function close to the input of a logic gate or timer where to add it (B, Figure 6-57).

  • Page 56: Send And Reload A Configuration

    Configuration Operating Manual June 2023 MHM-97876 Figure 6-59: Add a new port for a special function 3. Release the mouse button to connect the special function to the input (C, Figure 6-57). The special function is connected to the input of the logic gate or the timer. To negate a special function click on the respective input line (see Figure 6-60).
  • Page 57 Operating Manual Configuration MHM-97876 June 2023 Note Modbus requests are answered with Server Device Busy (0x06) when sending a configuration. Whether or not a reboot is required will depend on the changes to the configuration. The changes of names or text field entries do not require a reboot of the card. Procedure 1.

  • Page 58: Reload A Configuration

    Configuration Operating Manual June 2023 MHM-97876 successful update is also indicated by a message in the upper right corner (see Figure Figure 6-64: Modbus synchronization The card is ready to use when the "OK" LED on the card front shows a green steady light.

  • Page 59: Chapter 7 Online View

    Operating Manual Online View MHM-97876 June 2023 Online View After connection to an A6500-xR System Rack the Online View of the connected rack appears on the main page of AMS Machine Studio. Figure 7-1 shows this view. Figure 7-1: Overview Online View A.

  • Page 60: Overview

    Online View Operating Manual June 2023 MHM-97876 1. Click the Relay Card not in sync in the listed of connected devices below Network to select the card. The row will be colored blue. 2. Click Configure in the ribbon command bar to open the editor. 3.
  • Page 61 Operating Manual Online View MHM-97876 June 2023 Figure 7-4: Overview A. State digital inputs and software inputs B. State relay outputs C. Card health State of the digital inputs These graphic objects display the state of the digital inputs. For each slot of the A6500-xR System Racks, one graphical object is available.

  • Page 62: Details

    Online View Operating Manual June 2023 MHM-97876 Table 7-1: Card health temperature flag Icon Meaning Action No over temperature The temperature, measured by Take appropriate measures to the internal temperature reduce the environmental sensor has exceeded the alert temperature. limit of 70°C. The temperature, measured by We recommend to replace the the internal temperature...

  • Page 63: Online Commands

    Operating Manual Online View MHM-97876 June 2023 Service data This graphical object contains some statistical values and temperature information. • Up time Days in operation since the last power on. This counter is reset at each power on. • Operation time Days in operation since the first power on.
  • Page 64 Online View Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 65: Functional Check And Maintenance

    Operating Manual Functional check and maintenance MHM-97876 June 2023 Functional check and maintenance Functional check CAUTION Any work at the system may impair machine protection. Check the A6500-RC Relay Card and its logic configuration by simulating the digital input signals. Check the configured logic results by checking the LED statuses at the A6500-RC front plate or checking the respective output relay statuses.
  • Page 66 Functional check and maintenance Operating Manual June 2023 MHM-97876 Table 8-1: Extension card - terminal assignment Terminals F48 Slot output A6500-UM A6500-TP extension card (wire switch board) +24 V +24 V Digital output 1 Danger alarm Channel 1 Output 1 Digital output 2 Alert alarm Output 2 Digital output 3 Channel OK...

  • Page 67: Simulation By Using The Installed Cards

    Operating Manual Functional check and maintenance MHM-97876 June 2023 8.1.2 Simulation by using the installed cards Use the installed A6500-UM and A6500-TP cards to simulate digital output signals. Procedure 1. Force the installed cards to generate messages by simulating measurement signals higher than the configured alarm limits.
  • Page 68 Functional check and maintenance Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 69: Chapter 9 Card Replacement

    Operating Manual Card replacement MHM-97876 June 2023 Card replacement Follow the steps listed below if a A6500-RC Relay Card needs to be replaced, for example, due to a defect. CAUTION Any work at the system may impair machine protection. Procedure 1.
  • Page 70 Card replacement Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 71: Chapter 10 Technical Data

    Operating Manual Technical data MHM-97876 June 2023 Technical data Only specifications with indicated tolerances or limit values are obligatory. Data without tolerances or without error limits are informative data and not guaranteed. Technical modification, especially of the software, are subject to changes without notice. If not specified otherwise, all data are referred to an environmental temperature of +25°C.

  • Page 72: Data Interface

    Technical data Operating Manual June 2023 MHM-97876 10.4 Data interface Communication bus RS 485 according to EIA485 standard Bus termination exterior bus termination according to EIA485 can be provided externally 10.5 Mechanical design and environmental conditions Mechanical design Rack slot 3RU/10HP Material front panel aluminum, clear anodized...
  • Page 73 Operating Manual Technical data MHM-97876 June 2023 Environmental conditions Vibration 0.15 mm 10 to 55 Hz 20 m/s² 55 to 150 Hz according to IEC 60068-2-6, float sinus, three axis Operating altitude <2000 m above see level Environmental area Indoor use only External devices in case of a single failure, externally connected devices...
  • Page 74 Technical data Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 75: Chapter 11 Certificates

    Operating Manual Certificates MHM-97876 June 2023 Certificates MHM-97876, Rev. 5.06...
  • Page 76 Certificates Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...
  • Page 77 Operating Manual Certificates MHM-97876 June 2023 MHM-97876, Rev. 5.06...
  • Page 78 Certificates Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...

  • Page 79: Appendix A Card Related System Events

    Operating Manual Card related system events MHM-97876 June 2023 Card related system events The possible system events provided by the A6500-RC card are listed in Table A-1. See column Cross reference / Note for further event related information. See Machine Studio –...
  • Page 80 Card related system events Operating Manual June 2023 MHM-97876 Table A-1: Card events (continued) Event Cross reference / Note Software input x Software inputs Software input x x = 1 to 16 x = 1 to 64 x = 1 to 16 MHM-97876, Rev.

  • Page 81: Index

    Operating Manual Index MHM-97876 June 2023 Index Basic Properties Card replacement Reload 26, CCC Certification Rename 38, 41, 45, Close configuration Report Compare Reset to factory default Configuration Ribbon command bar Delete 38, 41, 43, 45, 49, 50, 53, Send Digital input Send &...
  • Page 82 Index Operating Manual June 2023 MHM-97876 MHM-97876, Rev. 5.06...
  • Page 83 Operating Manual MHM-97876 June 2023 MHM-97876, Rev. 5.06...
  • Page 84 The Emerson logo is a trademark and service mark of Emerson Electric Co. The AMS logo is a mark of one of the Emerson family of companies. All other marks are the property of their respective owners.

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