Emerson Machinery Health A6500 R Series Operating Manual
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Emerson Machinery Health A6500 R Series Operating Manual

Emerson Machinery Health A6500 R Series Operating Manual

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Operating Manual
MHM-97877, Rev 5.07
June 2023
™
Machinery Health
System
A6500-xR System Racks

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Summary of Contents for Emerson Machinery Health A6500 R Series

  • Page 1 Operating Manual MHM-97877, Rev 5.07 June 2023 ™ Machinery Health System A6500-xR System Racks...
  • 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-97877 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-97877 4.7.1 Digital inputs..........................69 4.7.2 Key-signal............................71 4.8 Communication..........................75 4.8.1 Bus line interconnection of two System Racks................76 4.8.2 A6500-FR – Ethernet connection....................77 4.9 Sensor raw signal..........................78 4.10 Connection of current outputs..................... 83 4.11 Digital outputs and Relay Card......................83 4.12 A6500-RR - external inputs......................

  • Page 7: Chapter 1 General

    Operating Manual General MHM-97877 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-xR System Racks with hardware revision 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

    General MHM-97877 June 2023 Guardian.GSC@Emerson.com Email http://www.emerson.com/en-us/contact-us 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.

  • Page 10: Ccc Certification - Ams 6500 Atg

    General Operating Manual June 2023 MHM-97877 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-97877 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-97877 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-97877 June 2023 Application and Design Application Different System Racks are part of the AMS 6500 ATG system. See Table 3-1. Table 3-1: System Racks System Rack Description A6500-SR 11 slots for A6500-UM Universal Measurement Cards or A6500-TP Temperature Process Cards One slot for an A6500-RC Relay Card Two slots for A6500-CC Com Cards...

  • Page 14: A6500-Rr System Rack For Redundant Relay Cards

    Application and Design Operating Manual June 2023 MHM-97877 You can extend the system with a second System Rack to a 6RU system. In this case, the Com Card(s) of the first rack are used for both System Racks. 3.1.2 A6500-RR System Rack for redundant Relay Cards The A6500-RR System Rack for redundant Relay Cards allows you to install two A6500-RC Relay Cards.
  • Page 15 Operating Manual Application and Design MHM-97877 June 2023 Table 3-2: System Racks - overview differences (continued) Functions / connections A6500-SR A6500-RR A6500-FR Dimensions 3RU/84HP 3RU/84HP 6RU/50HP MHM-97877, Rev. 5.07...

  • Page 16: Design

    Application and Design Operating Manual June 2023 MHM-97877 Design 3.2.1 A6500-SR System Rack Figure 3-1 Figure 3-2 show the structure of the A6500-SR System Rack backplane. Figure 3-1: A6500-SR front view A. Slots 1 to 11 for Universal Measurement Cards and Temperature Process Cards B.
  • Page 17 Operating Manual Application and Design MHM-97877 June 2023 Figure 3-2: A6500-SR rear view A. Redundant power supply (+24 V DC). B. Slide switches for slots 1 to 11 to assign digital inputs and activate the pulse pull-up voltage. C. D-Sub connectors for the sensor raw signals. One connector for four raw signals (two cards with two channels each).

  • Page 18: A6500-Rr System Rack For Redundant Relay Cards

    Application and Design Operating Manual June 2023 MHM-97877 3.2.2 A6500-RR System Rack for redundant Relay Cards Figure 3-3 Figure 3-4 show the structure of the backplane with redundant relays. Figure 3-3: A6500-RR front view A. Slots 1 to 9 for Universal Measurement Cards and Temperature Process Cards B.
  • Page 19 Operating Manual Application and Design MHM-97877 June 2023 Figure 3-4: A6500-RR rear view A. Redundant power supply (+24 V DC). B. Screw terminal connectors to connect external signals to the Relay Card. C. Slide switches for slots 1 to 9 to assign digital inputs and activate the pulse pull-up voltage.

  • Page 20: A6500-Fr System Rack With Front Terminal Connectors

    Application and Design Operating Manual June 2023 MHM-97877 3.2.3 A6500-FR System Rack with front terminal connectors Figure 3-5 Figure 3-6 show the structure of the backplane with front terminal connectors. MHM-97877, Rev. 5.07...
  • Page 21 Operating Manual Application and Design MHM-97877 June 2023 Figure 3-5: A6500-FR front view A. Slots 1 to 6 for Universal Measurement Cards and Temperature Process Cards B. Slot for Relay Card C. Slot for Com Card with cut-out opening for the Ethernet cable. The Ethernet cable connect to the Com Card passes through this cut-out opening and connects to the RJ45 socket on the rear.
  • Page 22 Application and Design Operating Manual June 2023 MHM-97877 J. Screw terminal connectors to connect the 16 output relays of the Relay Card. K. RJ45 connector to connect an Ethernet to the Com Card. This connector allows you to access the Ethernet signal of the Com Card. Figure 3-6: A6500-FR rear view A.
  • Page 23 Operating Manual Application and Design MHM-97877 June 2023 Figure 3-7: Front view of the complete A6500-FR System Rack MHM-97877, Rev. 5.07...
  • Page 24 Application and Design Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...

  • Page 25: Installation And Mounting

    Operating Manual Installation and Mounting MHM-97877 June 2023 Installation and Mounting CSA - General safety Conditions of acceptability Observe the listed conditions to built-up a system in accordance with the CSA approval: • A disconnecting device – required by clause 6.11 of IEC 61010-1:2010 – has to be provided, the power supply disconnecting device or interrupt facility may be used.

  • Page 26: Mount The System Rack - A6500-Sr And A6500-Rr

    Installation and Mounting Operating Manual June 2023 MHM-97877 volume of at least 300 m /h is mounted directly on the top side of the rack. • The installation of the AMS 6500 ATG Fan Kit must be verified according to the country-specific regulations. Mount the System Rack –...

  • Page 27: Ams 6500 Atg Fan Kit For A6500-Sr

    Operating Manual Installation and Mounting MHM-97877 June 2023 • Suitable Phillips screwdriver for mounting the System Rack with the cage nuts into the cabinet • Suitable screwdriver for the screw terminal connectors Recommendation: Screwdriver 0.4 x 2.5 x 80 mm (Phoenix Contact SZS 0.4X2.5 VDE - 1205037) for the 6-, and 8-pole screw terminal connectors Screwdriver 0.6 x 3.5 x 100 mm (Phoenix Contact SZS 0.6X3.5 VDE - 1212602) for the 5-pole screw terminal connector...

  • Page 28: Mount The System Rack - A6500-Fr

    Installation and Mounting Operating Manual June 2023 MHM-97877 Mounting Prerequisites • Suitable screw driver for the M5x12 screws. • Suitable screw driver for the push-in spring cage terminal block. Procedure 1. Place the fan tray at the bottom of the A6500-SR or A6500-RR System Rack. The fan tray fits only in one position.
  • Page 29 Operating Manual Installation and Mounting MHM-97877 June 2023 The minimum recommended cabinet size to use with the A6500-FR is 406.4 mm x 406.4 mm x 304.8 mm (16"x16"x12") assuming external power supplies are used and only A6500-FR is installed inside. A larger cabinet will be needed if power supplies or other equipment are included inside the cabinet.
  • Page 30 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-4: Dimensions A. 88.2 mm B. 153.5 mm C. 133.9 mm D. 268.0 mm E. 132.5 mm Prerequisites Before mounting the System Rack connect the included Ethernet cable. See A6500-FR – Ethernet connection.

  • Page 31: Ams 6500 Atg Fan Kit For A6500-Fr

    Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-5: Assembly brackets A. Assembly brackets on the left and right side of the rack. B. 190 mm C. 26.2 mm D. 12.9 mm E. 6.3 mm F. 37.6 mm G. 292.2 mm H.
  • Page 32 Installation and Mounting Operating Manual June 2023 MHM-97877 • Tray with two fans. • Push-in spring cage terminal block for connecting the fan supply voltage. • Two 3x10 A2 screws for the terminal block mounting. • Two ferrules. • Six M5x12 screws for mounting the tray at to top of the A6500-FR (self-cutting screws). •...

  • Page 33: Required Installation Space Including Cables And Ventilation

    Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-7: Screw hole location and fan tray height A. Location of the screw hole for the M4x16 screw. One on each side of the rack. B. Location of the screw holes for the M5x12 screws. Three on each side of the rack. C.

  • Page 34: Emc-Compliant Installation And Grounding Example

    Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-8: 19" System Rack mounting space The following requirements apply to all System Racks: You must provide an adequate ventilation space so that heat does not build up. The ventilation space must be at least 1RU (1.75 inch; 44.45 mm) in all directions. If the ambient temperature of the rack rises above 55°C, cool this instrument with a forced air fan, cooler, or something similar.

  • Page 35: Connect I/O Signals

    By grounding as shown, field shields are connected at the cabinet inlet, so that disturbances do not affect the entire cabinet. When connecting sensor signals, Emerson recommends LiYCY-CY cables. Connect I/O signals The connections of the input and output signals as well as the voltage supply is made by 5-, 6-, and 8-pole screw terminal connectors.
  • Page 36 Installation and Mounting Operating Manual June 2023 MHM-97877 Table 4-1: 5-pole supply voltage screw terminal connectors Wire description Wire cross-section Minimum Maximum Conductor cross section solid 0.34 mm² 2.5 mm² Conductor cross section stranded 0.2 mm² 2.5 mm² Conductor cross section stranded, with ferrule 0.25 mm²...
  • Page 37 Operating Manual Installation and Mounting MHM-97877 June 2023 Table 4-3: 6- and 8-pole screw terminal connectors Wire description Wire cross-section Minimum Maximum Conductor cross section solid and stranded 0.14 mm² 1.5 mm² Conductor cross section stranded, with ferrule 0.25 mm² 1.5 mm²...
  • Page 38 Installation and Mounting Operating Manual June 2023 MHM-97877 Pin assignment The following figures show an overview of the connection terminals of the System Racks. Note The position of the connectors depends on the System Rack used. The pin assignment of the connectors is identical for all System Racks.
  • Page 39 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-11: A6500-F front connectors counting direction: left to right Pin assignment card slot Figure 4-12 Figure 4-13 show the pin assignment of the protection card slots if you use a two-channel Universal Measurement Card. Figure 4-14 Figure 4-15 show pin...
  • Page 40 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-12: A6500-SR and A6500-RR – Pin assignment slot with Universal Measurement Card A6500-SR: Slots 1 to 11 A6500-RR: Slots 1 to 9 MHM-97877, Rev. 5.07...
  • Page 41 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-13: A6500-FR – pin assignment slot with Universal Measurement Card A6500-FR: Slots 1 to 6 MHM-97877, Rev. 5.07...
  • Page 42 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-14: A6500-SR and A6500-RR – pin assignment slot with Temperature Process Card A6500-SR: Slots 1 to 11 A6500-RR: Slots 1 to 9 MHM-97877, Rev. 5.07...
  • Page 43 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-15: A6500-FR – pin assignment slot with Temperature Process Card A6500-FR: Slots 1 to 6 Pin assignment Relay Card slot Figure 4-16 shows the pin assignment of the Relay Card slot. Each slot has six 8-pole screw terminal connectors.
  • Page 44 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-16: Pin assignment Relay Card x = slot number 10 (A6500-RR, first Relay Card), 11 (A6500-RR, second Relay Card), or 12 (A6500-SR and A6500-FR) Pin assignment Com Card slot Figure 4-17 Figure 4-18 show the pin assignment of the 6-pole screw terminal connector for the Modbus RTU connection.

  • Page 45: Power Supply

    Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-18: Pin assignment Com Card slot A6500-FR (1) Modbus GND is galvanically separated from the system GND. x = 13 Pin Assignment supply voltage connection Figure 4-19 shows the pin assignment of both 5-pole screw terminal connectors XR1 and XR2 of the redundant supply voltage connection.
  • Page 46 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-20: Voltage supply option - one supply One supply for card slots (Slots) and digital outputs (Out). Figure 4-21: Voltage supply option - two supplies, separate Two power supplies for separate supply of card slots (Slots) and digital outputs (Out). Figure 4-22: Voltage supply option - two supplies, redundant supply Two power supplies for redundant supply of card slots (Slots) and digital outputs (Out) without supply separation of slots and outputs.
  • Page 47 UN+ (Slot), UN+ (Out), UB+ (Slot), and UB+ (Out). According to IEC 61010-1, the total current of each supply terminal shall never exceed I = 200 W/U after 120 seconds. Emerson recommends using fuses with ON/OFF functionality to provide a switchable energy source. How to define a suitable pre-fuse The procedure is described with a supply voltage of 24.0 V and the circuit breaker family...

  • Page 48: Connecting Sensors To The System Rack

    Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-24: Rated current diagram 3. Calculate the required rated current by dividing the maximum allowed current by the multiple of the rated current. / multiple = 8.33 A / 1.6 = 5.2 A rated This example shows that all 1180-01 (E-T-A) circuit breakers with a rated current up to 5.0 A can be considered as feasible pre-fuses for a supply voltage of 24 V.
  • Page 49 Operating Manual Installation and Mounting MHM-97877 June 2023 • Linear displacement transducers (for example PR 9350) – Connect linear displacement transducers • Speed sensors (for example PR 9376, Hall-effect sensor) – Connect Hall-effect sensors • Variable reluctance sensors (VR sensors) – Connect VR sensors •...
  • Page 50 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-25: Connection example for eddy current measuring chains x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) Connect 3-wire eddy current measuring chains Use eddy current measuring chains for measuring tasks listed in Connect eddy current measuring...
  • Page 51 Operating Manual Installation and Mounting MHM-97877 June 2023 For further information about the used eddy current measuring chains see the related operating manual. For information about grounding and connection of cable shields see EMC-compliant installation and grounding example. Figure 4-26: 3-wire connection example of an eddy current sensors Connect piezoelectric sensors Piezoelectric sensors like PR 9270-Ex (acceleration) or PR 9270V-Ex (velocity) are generally used to measure bearing vibration.
  • Page 52 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-27: Connection example for piezoelectric sensors x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) Connect 3-wire piezoelectric sensors Piezoelectric sensors are generally used to measure bearing vibration. Figure 4-28 shows the connection of -24 V DC powered 3-wire piezoelectric sensors such as GE 330400 and GE 330425.
  • Page 53 Operating Manual Installation and Mounting MHM-97877 June 2023 Further information regarding 3-wire piezoelectric sensors can be found in their respective operating manuals. For information regarding grounding and connection of cable screens, EMC-compliant installation and grounding example. Figure 4-28: Connection example for 3-wire piezoelectric sensors x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) Connect dynamic pressure sensor chains Dynamic pressure is often measured with sensor chains consisting of a piezoelectric...
  • Page 54 Installation and Mounting Operating Manual June 2023 MHM-97877 For further information on dynamic pressure sensors, see their respective operating manuals. For information about grounding and connection of cable shields, see EMC- compliant installation and grounding example. For connection of 2-wire dynamic pressure sensors with integrated charge amplifier, see Connect piezoelectric sensors.
  • Page 55 Operating Manual Installation and Mounting MHM-97877 June 2023 Connect static pressure sensors – Bently Nevada 165855 Static pressure sensors are used to measure different kinds of quantities such as suction pressure, discharge pressure, or peak rod compression at reciprocating compressors. Figure 4-30 for an example for connection of a static pressure sensor.
  • Page 56 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-30: Connection example for static pressure sensors – Bently Nevada 165855 A. Power supply + B. Common C. Signal D. Static pressure sensor E. Additional 20 kΩ resistor for channel OK detection if using Bently Nevada 165855 sensors x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) Open circuit detection...
  • Page 57 Operating Manual Installation and Mounting MHM-97877 June 2023 Recommendations • Twisted pair and double screened cables, such as LiYCY-CY. Connections • Channel 1: Connect the sensor terminal 3 to XRx1.2 and terminal 2 to XRx1.1 (only if sinking is required, otherwise connect the sensor as shown for channel 2). •...
  • Page 58 Installation and Mounting Operating Manual June 2023 MHM-97877 Connections • Channel 1 sensor signal: Connect the sensor terminal 1 (Signal +) to XRx1.1 and terminal 2 (Signal GND) to XRx1.2. • Channel 1 sensor supply: Connect the sensor terminal 4 (Power +) to XRx1.3, terminal 5 (Power -) to XRx1.4, and terminal 3 (Power GND) to XRx1.5.
  • Page 59 Operating Manual Installation and Mounting MHM-97877 June 2023 Connect linear displacement transducers The A6500-LC converter is necessary for connecting linear displacement transducers. Figure 4-33 shows the connection of an A6500-LC to the System Rack. Recommendations • Twisted pair and double screened cables, such as LiYCY-CY. •...
  • Page 60 Installation and Mounting Operating Manual June 2023 MHM-97877 Connect Hall-effect sensors The PR 9376 Hall-effect sensor is used to measure speed or to generate key pulses (for example, for analytical purposes). Figure 4-34 shows the connection of Hall-effect sensors of type PR 9376. Recommendations •...
  • Page 61 30 V of the A6500-UM card. Ensure that the voltage at the signal input does not exceed 30 V. Emerson recommends the use of a Zener barrier to limit the output voltage of the connected VR sensor to avoid damaging the card.
  • Page 62 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-35: Connection example for VR sensors A. Barrier for signal voltage limitation. B. Pin A of the sensor connector C. Pin B of the sensor connector D. VR sensor Connect temperature sensors CAUTION Ensure that the thermocouples are always connected with the correct polarity.
  • Page 63 Operating Manual Installation and Mounting MHM-97877 June 2023 Thermocouple types and the polarities of thermocouple wires are identified with colors. The different coloring of thermocouple sheaths and wires are subject to various national standards. Figure 4-37 Figure 4-41 show the colors of thermocouple sheaths, wires and their polarity that comply with the European standard IEC 584-3.
  • Page 64 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-40: Thermocouple - Type N Figure 4-41: Thermocouple - Type T To avoid errors in temperature measurements due to incorrectly connected thermocouples, observe the information provided by thermocouple supplier. Shielding of thermocouple cables Thermocouple cables consist of two thermocouple conductors, insulation material, cable shield and a metal protection sheath around the conductors.
  • Page 65 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-42: Design of insulated thermocouple versions A. Insulated material B. Welding point (hot junction point) C. Thermocouple sheath interconnected with cable screen Figure 4-43: Design of uninsulated thermocouple versions A. Insulated material B.
  • Page 66 Installation and Mounting Operating Manual June 2023 MHM-97877 Table 4-6: A6500-TP connection types Type Temperature Basic resistance Temperature Sensor sensor range connection Pt 100 Platin 100 Ω / 0°C -200… +850°C 2-wire, 3-wire, 4- wire RTDs Ni 100 Nickel 100 Ω / 0°C -60…...
  • Page 67 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-44: Sensor connection x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) You can mix temperature input signals and process input signals channel-by-channel. For example, you can connect a voltage signal to channel 1 and a 3-wire RTD to channel 2 of the Temperature Process Card.

  • Page 68: Slide Switch Settings - Digital Inputs And Key-Signals

    Installation and Mounting Operating Manual June 2023 MHM-97877 Table 4-8: Signal connections (continued) Signal Channel 1 Channel 2 Channel 3 Channel 4 I (Current) XRx1.1 XRx2.1 XRx3.1 XRx4.1 XRx1.3 XRx2.3 XRx3.3 XRx4.3 x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) Figure 4-45: Connection of process signals x = slot number 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR) You can mix temperature input signals and process input signals channel-by-channel.

  • Page 69: Digital Inputs

    Operating Manual Installation and Mounting MHM-97877 June 2023 The slide switches for each slot configure the digital inputs and key-signals. Slide switches 1 to 5 configure the digital inputs, and slide switch 6 supplies the key-signal function. For location of the slide switches, see Figure 3-2 (A6500-SR), Figure 3-4...
  • Page 70 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-46: Digital input general wiring diagram The function of the digital inputs depends on the configuration of the card installed in the appropriate slot. You can use these digital inputs for functions such as resetting of latched alarms, limit level multiplier, and bypass.

  • Page 71: Key-Signal

    Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-47: Digital input example diagram 4.7.2 Key-signal This section describes the System Rack configuration for providing key-signals. Each Universal Measurement Card can work as a two-channel key card. Universal Measurement Cards in key mode can be installed in slots 1 to 6 (A6500-FR), 1 to 9 (A6500-RR), or 1 to 11 (A6500-SR).
  • Page 72 Installation and Mounting Operating Manual June 2023 MHM-97877 Postrequisites Note Only digital input 1 and digital input 2 can be used for forwarding key-signals to other slots. The following items describe the configuration of an arbitrary slot for key-signal input. •...
  • Page 73 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-49 explains the connection of a key-signal to a second rack. In this example, slot 1 of the first A6500-SR System Rack is configured to generate a key-signal (Key 1) with channel 1 of an installed A6500-UM card: •...
  • Page 74 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-49: Example for a connection of a key-signal to a second rack A. First A6500-SR System Rack B. Second A6500-SR System Rack Prerequisites • Short wire jumper for connecting the key-signal to the digital input, wire cross section in accordance to Table 4-3 (6- and 8-pole screw terminal connectors) or...

  • Page 75: Communication

    Flat head screwdriver for the screw terminal connectors. • Ensure that both A6500-xR System Racks are connected to the same ground (GND). Emerson recommends to use the same power supply connection option (see Power supply) for both System Racks. •...

  • Page 76: Bus Line Interconnection Of Two System Racks

    Install an additional Com Card in the remaining communication slot if you require redundant communication. Note Emerson recommends using the left slot (A6500-RR: slot CD12, A6500-SR: slot CD13) for single Com Card installations and for the primary Com Card in redundant MHM-97877, Rev. 5.07...

  • Page 77: A6500-Fr - Ethernet Connection

    Operating Manual Installation and Mounting MHM-97877 June 2023 systems, and the right slot (A6500-RR: slot CD13, A6500-SR: slot CD14) for the secondary Com Card in redundant systems. 2. Use the 9-pole male and female D-Sub 1 m cable to connect the bus lines. a) Connect the female connector of the cable to the 9-pole D-Sub socket OUT (CD32) of the first System Rack with the installed Com Card(s).

  • Page 78: Sensor Raw Signal

    Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-52: Rear view A6500-FR with Ethernet cable Sensor raw signal The backplane of the System Racks is equipped with 9-pole D-Sub connectors that connect the sensor raw signals of each A6500-UM Universal Measurement Card installed to a prediction system.
  • Page 79 Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-53: Female 9-pole D-Sub connector Table 4-9 lists the pin assignment of the 9-pole connectors. CAUTION Ensure that the shielding of the used connection cables is not connected to the System Rack and the prediction system.
  • Page 80 Installation and Mounting Operating Manual June 2023 MHM-97877 Table 4-9: Pin assignment sensor raw signal connectors (continued) 9-pole connector Slot Signal Sensor raw signal 2 CD24 Sensor raw signal 1 Sensor raw signal 2 Sensor raw signal 1 Sensor raw signal 2 CD25 Sensor raw signal 1 Sensor raw signal 2...
  • Page 81 Operating Manual Installation and Mounting MHM-97877 June 2023 Use these outputs for connecting sensor raw signals to prediction systems. The wiring example in Figure 4-54 shows the connection of the sensor raw signals of the first two slots to four inputs of the AMS 6500 prediction system. MHM-97877, Rev.
  • Page 82 Installation and Mounting Operating Manual June 2023 MHM-97877 Figure 4-54: Sensor raw signal - connection example CD21.2: Sensor raw signal slot 1, channel 1 CD21.3: GND slot 1, channel 1 CD21.4: Sensor raw signal slot 1, channel 2 CD21.5: GND slot 1, channel 2 CD21.6: Sensor raw signal slot 2, channel 1 CD21.7: GND slot 2, channel 1 CD21.8: Sensor raw signal slot 2, channel 2...

  • Page 83: Connection Of Current Outputs

    Operating Manual Installation and Mounting MHM-97877 June 2023 Available accessory for raw signal connection to a prediction system: • Connection cable to 6500 Prediction: D25676 (9-pole male to blunt cut wire) 4.10 Connection of current outputs Table 4-10 lists the terminal assignment of the two current outputs of the Universal Measurement Card and the four current outputs of the Temperature Process Card.
  • Page 84 Installation and Mounting Operating Manual June 2023 MHM-97877 Table 4-11: 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 DOUT6 IN06 DOUT4 IN28 DOUT2 IN50...

  • Page 85: A6500-Rr - External Inputs

    Operating Manual Installation and Mounting MHM-97877 June 2023 Figure 4-55: Digital outputs connection example 4.12 A6500-RR - external inputs Because of the reduced number of protection card slots, 9 instead of 11, up to 12 external digital signals can be connected in parallel to both Relay Cards. Figure 4-56 shows the pin assignment of the 6-pole screw terminal connectors XR107 and XR108.

  • Page 86: A6500-Fr - External Inputs

    Installation and Mounting Operating Manual June 2023 MHM-97877 4.13 A6500-FR - external inputs Up to six external digital signals can be connected to the Relay Card. Figure 4-57 shows the pin assignment of the 6-pole screw terminal connector XR131. See A6500-RC Relay Card operating manual (MHM-97876) for technical data of these digital inputs.

  • Page 87: Hazardous Location Installation

    Operating Manual Hazardous location installation MHM-97877 June 2023 Hazardous location installation Version 1.10 General installation requirements The A6500-SR, A6500-RR, and A6500-FR System Racks must be solely connected to SELV/ PELV electrical circuits to meet the requirements for explosion protection. This also applies to all devices connected to the System Racks.
  • Page 88 Hazardous location installation Operating Manual June 2023 MHM-97877 Figure 5-1: Dimension terminal compartment – A6500-SR and A6500-RR Figure 5-2: Dimensions terminal compartment – A6500-FR A. 153.5 mm B. 268.0 mm C. 132.5 mm The cable glands must match the diameter of the used cables. The cable diameters are variable and must be considered.

  • Page 89: Connection Requirements

    Operating Manual Hazardous location installation MHM-97877 June 2023 Ensure a transition resistance of <10 Ω between frame of the system rack and potential equalization. Connection requirements The wire cross section of the used cables must be within the range of 0.34 < F < 2.5 mm Use ferrules at stranded conductors.

  • Page 90: Technical Data, Explosion Protection

    Hazardous location installation Operating Manual June 2023 MHM-97877 Ambient The ambient temperature within the end use enclosure shall temperature – not exceed 55 °C. A6500-FR The ambient temperature within the end use enclosure shall not exceed 70 °C if a fan tray with two fans and a minimum airflow volume of at least 300 m /h is mounted directly on the top side of the rack.
  • Page 91 Operating Manual Hazardous location installation MHM-97877 June 2023 IECEx/ATEX/CSA CAN/CSA-C22.2 N0. 0-10 CAN/CSA-C22.2 N0. 61010-1-12 CAN/CSA-22.2 No. 60079-0:15 CAN/CSA-22.2 No. 60079-7 IEC 60529:2013 + COR2:2015 UL 61010-1:12 UL 60079-0:13 UL 60079-7 IECEx approval number IECEx BVS 16.0012U ATEX approval number BVS 16 ATEX E 016 U CSA approval number CSA 16.70052580...

  • Page 92: Control Drawing - A6500-Sr And A6500-Rr

    Hazardous location installation Operating Manual June 2023 MHM-97877 Control drawing – A6500-SR and A6500-RR MHM-97877, Rev. 5.07...
  • Page 93 Operating Manual Hazardous location installation MHM-97877 June 2023 MHM-97877, Rev. 5.07...
  • Page 94 Hazardous location installation Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...
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  • Page 96 Hazardous location installation Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...

  • Page 97: Control Drawing - A6500-Fr

    Operating Manual Hazardous location installation MHM-97877 June 2023 Control drawing – A6500-FR MHM-97877, Rev. 5.07...
  • Page 98 Hazardous location installation Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...
  • Page 99 Operating Manual Hazardous location installation MHM-97877 June 2023 MHM-97877, Rev. 5.07...
  • Page 100 Hazardous location installation Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...
  • Page 101 Operating Manual Hazardous location installation MHM-97877 June 2023 MHM-97877, Rev. 5.07...

  • Page 102: Revision History

    Hazardous location installation Operating Manual June 2023 MHM-97877 Revision history Version Date Remarks/Changes 06. August 2015 Initial version 24. February 2016 Correction of chapter "Connection requirements" 09. May 2016 CSA parts added 18. May 2016 Warning notes 13. June 2017 Added A6500-RR System Rack and Control Drawing update 05.

  • Page 103: Chapter 6 Maintenance

    Operating Manual Maintenance MHM-97877 June 2023 Maintenance The A6500-FR, A6500-RR, and A6500-SR System Racks do not require any maintenance during normal operation. MHM-97877, Rev. 5.07...
  • Page 104 Maintenance Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...

  • Page 105: Replace The System Rack

    Operating Manual Replace the System Rack MHM-97877 June 2023 Replace the System Rack Follow the steps listed below if the System Rack needs to be replaced. For example, as a result of a defect. CAUTION Any work at the system may impair machine protection. Procedure 1.
  • Page 106 Replace the System Rack Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...

  • Page 107: Chapter 8 Technical Data

    Operating Manual Technical data MHM-97877 June 2023 Technical data Only specifications with indicated tolerances or limit values are required. Data without tolerances or without error limits are informative data and not guaranteed. Technology is under constant development, and specifications are subject to change without notice. If not specified otherwise, all data are referred to an environmental temperature of +25°C.
  • Page 108 Technical data Operating Manual June 2023 MHM-97877 Table 8-3: Mechanical Design Specifications (continued) 6RU/50HP (A6500-FR) Board coating Airborne contaminants ISA-S71.04-1985 airborne resistance contaminants class G3, Conformal Coating ® Material: HumiSeal 1B31 EPA according to IPC-CC-830B and IPC-A 610 Connector measurement card type F48 female according to IEC 60603-2 slot...
  • Page 109 Operating Manual Technical data MHM-97877 June 2023 Table 8-4: Environmental Conditions Specifications (continued) External devices in case of a single failure, externally connected devices must not exceed the level of IEC 60204-1 or IEC 61131-2 An airflow of ≥440 m /h is required.
  • Page 110 Technical data Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...

  • Page 111: Chapter 9 Certificates

    Operating Manual Certificates MHM-97877 June 2023 Certificates MHM-97877, Rev. 5.07...
  • Page 112 Certificates Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...
  • Page 113 Operating Manual Certificates MHM-97877 June 2023 MHM-97877, Rev. 5.07...
  • Page 114 Certificates Operating Manual June 2023 MHM-97877 MHM-97877, Rev. 5.07...
  • Page 115 Operating Manual MHM-97877 June 2023 MHM-97877, Rev. 5.07...
  • Page 116 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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