2291B1 3500 33 16

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Operation and Maintenance Manual

3500/33 16-Channel Relay Module

Part Number 162291-01 Part Number 162291-01

Rev. B Rev. B (02/08)(02/08)

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3500/33 16 Channel Relay Module Operation and Maintenance Manual 3500/33 16 Channel Relay Module Operation and Maintenance Manual

Copyright 2002. Bently Nevada LLC.

All rights reserved.

The information contained in this document is subject to change without notice. The information contained in this document is subject to change without notice.

The following are trademarks of General Electric Company in the United States and other The following are trademarks of General Electric Company in the United States and other countries:

countries: Bently Nevada Bently Nevada

The following are trademarks of the legal entities cited: The following are trademarks of the legal entities cited: Velostat is a trademark of 3M Company.

Velostat is a trademark of 3M Company.

Contact Information

The following contact information is provided for those times when you cannot contact The following contact information is provided for those times when you cannot contact your local representative:

your local representative: Mailing

Mailing Address Address 1631 1631 Bently Bently Parkway Parkway SouthSouth Minden,

Minden, Nevada Nevada USA USA 8942389423 USA USA Telephone 1.775.782.3611 Telephone 1.775.782.3611 1.800.227.5514 1.800.227.5514 Fax 1.775.215.2873 Fax 1.775.215.2873 Internet

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Copyright 2002. Bently Nevada LLC.

All rights reserved.

The information contained in this document is subject to change without notice. The information contained in this document is subject to change without notice.

The following are trademarks of General Electric Company in the United States and other The following are trademarks of General Electric Company in the United States and other countries:

countries: Bently Nevada Bently Nevada

The following are trademarks of the legal entities cited: The following are trademarks of the legal entities cited: Velostat is a trademark of 3M Company.

Velostat is a trademark of 3M Company.

Contact Information

The following contact information is provided for those times when you cannot contact The following contact information is provided for those times when you cannot contact your local representative:

your local representative: Mailing

Mailing Address Address 1631 1631 Bently Bently Parkway Parkway SouthSouth Minden,

Minden, Nevada Nevada USA USA 8942389423 USA USA Telephone 1.775.782.3611 Telephone 1.775.782.3611 1.800.227.5514 1.800.227.5514 Fax 1.775.215.2873 Fax 1.775.215.2873 Internet

Internet www.ge-energy.com/bentlywww.ge-energy.com/bently

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Additional Information

Notice:

This manual does not contain all the information required

This manual does not contain all the information required to operate and maintainto operate and maintain the product.

the product. Refer to the foRefer to the following manuals for other llowing manuals for other required information.required information.

3500 Monitoring System Rack Installation and Maintenance Manual

3500 Monitoring System Rack Installation and Maintenance Manual (Part

(Part

Number 129766-01)

•

• General description of a standard system.General description of a standard system. •

• Instructions for installing and removing the module from a 3500 rack.Instructions for installing and removing the module from a 3500 rack. •

• Drawings for all cables used in the 3500 Monitoring System.Drawings for all cables used in the 3500 Monitoring System.

3500 Monitoring System Rack Configuration and Utilities

3500 Monitoring System Rack Configuration and Utilities Guide (Part

Guide (Part

Number 129777-01)

•

• Guidelines for using the 3500 Rack Configuration software for setting theGuidelines for using the 3500 Rack Configuration software for setting the

operating parameters of the module. operating parameters of the module.

•

• Guidelines for using the 3500 test utilities to verify that the input and outputGuidelines for using the 3500 test utilities to verify that the input and output

terminals on the module are operating properly. terminals on the module are operating properly.

3500 Monitoring System Computer Hardware and Software Manual

3500 Monitoring System Computer Hardware and Software Manual (Part

(Part

Number 128158-01)

•

• Instructions for connecting the rack to 3500 host computer.Instructions for connecting the rack to 3500 host computer. •

• Procedures for verifying communication.Procedures for verifying communication. •

• Procedures for installing software.Procedures for installing software. •

• Guidelines for using Data Acquisition / DDE Server and Operator Display Software.Guidelines for using Data Acquisition / DDE Server and Operator Display Software. •

• Procedures and diagrams for setting up network and remote communications.Procedures and diagrams for setting up network and remote communications.

3500 Field Wiring Diagram Package (Part Number 130432-01)

•

• Diagrams that show how to hook up a particular transducer.Diagrams that show how to hook up a particular transducer. •

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Product Disposal Statement Product Disposal Statement

Customers and third parties, who are not member states of the European Union, who are Customers and third parties, who are not member states of the European Union, who are in control of the product at the end of its life or at the end of its use, are solely

in control of the product at the end of its life or at the end of its use, are solely responsible for the proper disposal of the product. No person, firm, corporation, responsible for the proper disposal of the product. No person, firm, corporation,

association or agency that is in control of product shall dispose of it in a manner that is association or agency that is in control of product shall dispose of it in a manner that is in violation of any appli

in violation of any applicable federal, state, local cable federal, state, local or international law. or international law. Bently Nevada LLCBently Nevada LLC is not responsible for the disposal of the product at the end of its life or at the end of its is not responsible for the disposal of the product at the end of its life or at the end of its use.

use.

iv iv

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1.

1. Receiving

Receiving and

and Handling

Handling Instructions

Instructions ...

...

... 1

1

1.1

1.1 ReceivReceiving ing InspecInspection...tion... 11 1.2

1.2 HandliHandling ng and and StorinStoring g ConsidConsiderationerationss... 11

2.

2. General

General Information

Information ...

...

... 3

3

2.1

2.1 The The 16-Chan16-Channel Relay nel Relay ModuleModule ... 33 2.2

2.2 Statuses...Statuses... 77 2.2.1

2.2.1 Module Module StatusStatuseses ... 77 2.2.2

2.2.2 Channel Channel StatusStatus ... 88 2.3

2.3 LED LED DescrDescriptions...iptions... 99

3.

3. Configuration

Configuration Information

Information ...

...

... 11

11

3.1

3.1 Hardware Hardware ConsideConsiderationsrations ...11...11 3.2

3.2 EnteriEntering ng Alarm Alarm Drive Drive Logic...Logic...11...11 3.2.1

3.2.1 Relay Relay Module Module ConfiguConfiguration ration ConsideConsiderationsrations ...12...12 3.2.2

3.2.2 Relay Relay Module Module ConfiguConfiguration ration Options...Options...12...12 3.3

3.3 Software Software SwitcSwitcheshes ...14...14 3.3.1

3.3.1 ConfiguConfiguration ration ModeMode ...15...15 3.3.2

3.3.2 Bypass...Bypass...15...15

4.

4. Output Module

Output Module Description

Description...

...

... 17

17

4.1

4.1 16-Chan16-Channel nel Relay Relay Output Output Module.Module...17...17 4.2

4.2 Wiring Wiring Euro Euro Style Style ConnectorConnectorss ...19...19

5.

5. Maintenance

Maintenance ...

...

... 21

21

5.1

5.1 VerifyVerifying a ing a 3500 Rack 3500 Rack - - Relay ModuleRelay Module ...21...21 5.1.1

5.1.1 ChoosinChoosing g a a MainteMaintenance nance Interval...Interval...21....21 5.1.2

5.1.2 RequirRequired ed Test Test EquipmEquipment...ent...22...22 5.1.3

5.1.3 TypicTypical al VerifiVerification cation test test setupsetup ...22...22 5.1.4

5.1.4 Using Using the the Rack Rack ConfiguConfiguration ration Software...Software...23....23 5.1.5

5.1.5 Standard Standard Relay Relay ChannelChannelss ...24...24 5.1.6

5.1.6 If If a a Channel Fails Channel Fails a a VerifiVerification Test...cation Test...26...26 5.2

5.2 16-Chan16-Channel nel Relay Firmware Relay Firmware Upgrade ProcedureUpgrade Procedure ...26...26

6.

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3500/33 16 Channel Relay Module Operation and Maintenance Manual

6.1 Self-test...28

6.2 LED Fault Conditions...29

6.3 System Event List Messages ...30

6.4 Alarm Event List Messages ...41

7. Ordering Information...42

7.1 16-Channel Relay Module ...42

7.2 Spares...42

8. Specifications...43

8.1 Relays ...43 8.2 Environmental Limits...44 8.3 Mechanical...44 8.4 Electromagnetic Compatibility...44 8.5 Approvals ...45 8.6 Physical...46 8.6.1 Main Module...46 8.6.2 Output Module...46

8.7 Rack Space Requirements ...46

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Section 1 - Receiving and Handling Instructions

1. Receiving and Handling Instructions

1.1 Receiving Inspection

Visually inspect the module for obvious shipping damage. If shipping damage is apparent, file a claim with the carrier and submit a copy to Bently Nevada LLC.

1.2 Handling and Storing Considerations

Circuit boards contain devices that are susceptible to damage when exposed to electrostatic charges. Damage caused by obvious mishandling of the board will void the warranty. To avoid damage, observe the following precautions in the order given.

Application Advisory

Machinery protection will be lost when this module is removed from the rack.

• Do not discharge static electricity onto the circuit board. Avoid tools or

procedures that would subject the circuit board to static damage. Some possible causes include ungrounded soldering irons, nonconductive plastics, and similar materials.

• Personnel must be grounded with a suitable grounding strap (such as 3M

Velostat®_{No. 2060) before handling or maintaining a printed circuit board.}

• Transport and store circuit boards in electrically conductive bags or foil. • Use extra caution during dry weather. Relative humidity less than 30%

tends to multiply the accumulation of static charges on any surface.

• When performed properly, you may install this module into or remove it

from the rack while power is applied to the rack. Refer to the Rack Installation and Maintenance Manual (part number 129766-01) for the proper procedure.

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Section 2 - General Information

2. General Information

You can use the 16-Channel Relay Module for most monitoring applications. The module uses a single relay to drive the output for each channel. See Section 2.1 for additional information on the 16-Channel Relay Module.

4 5 6 7 1 2 3 NE NDE RELAY MODE NDE NE 1. Relay module

2. I/O module (front view) 3. I/O module (left side view)

4. LEDs indicating the module status.

5. LEDs indicating the status of the Relay Channels.

6. Terminals for connecting relay contacts to external devices. 7. Switches that control how the relay contacts work.

Figure 2-1: Views of 16-Channel Relay Module

2.1 The 16-Channel Relay Module

The 3500/33 16-Channel Relay Module is a full-height module that provides 16 relay outputs. You can place any number of these relay modules in any of the slots to the right of the Rack Interface Module (RIM).

You can use AND and OR voting to fully program each relay output. The Alarm Drive Logic for each relay channel can use alarming inputs (Alert, Danger, Not OK, and individual channel parameters) from any monitor channel in the rack. You program this Alarm Drive Logic using the Rack Configuration Software.

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3500/33 16 Channel Relay Module Operation and Maintenance Manual The three common configuration types of Alarm Drive Logic are:

1) Bussed relays. Bussed relays use an Alarm Drive Logic that ORs the Alerts or Dangers for all channels in the rack to drive a single relay. 2) Individual relays. Individual relays use Alarm Drive Logic that ORs the

Alerts or Dangers for channel pairs (channel 1 and channel 2 or channel 3 and channel 4) in a monitor to drive a single relay.

3) Independent relays. Independent relays use Alarm Drive Logic that cause each alarm level (Alert and Danger) from a channel to drive a separate relay channel.

The following examples show the drive logic for these three types of logic .

S = Monitor Slot A1 = Alert/Alarm 1

C = Channel A2 = Danger/Alarm 2

Example 1: Bussed Relays (Alert and Danger)

##A1 = Any Active Alert ##A2 = Any Active Danger

((S02C##A1) OR (S03C##A1) OR ... OR (S15C##A1))  Trip Relay Channel 1 ((S02C##A2) OR (S03C##A2) OR … OR (S15C##A2))  Trip Relay Channel 2

Figure 2-2: Bussed Relays Example

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Section 2 - General Information Example 2: Individual Relays (Alert and Danger)

(S02C01A1) OR (S02C02A1)  Trip Relay Channel 1 (Alert Relay) (S02C01A2) OR (S02C02A2)  Trip Relay Channel 2 (Danger Relay) (S02C03A1) OR (S02C04A1)  Trip Relay Channel 3 (Alert Relay) (S02C03A2) OR (S02C04A2)  Trip Relay Channel 4 (Danger Relay)

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Example 3: Independent Relays (Alert and Danger)

(S02C01A1)  Trip Relay Module in slot 2 Channel 1 (Alert Relay) (S02C02A1)  Trip Relay Module in slot 2 Channel 2 (Alert Relay) (S02C03A1)  Trip Relay Module in slot 2 Channel 3 (Alert Relay) (S02C04A1)  Trip Relay Module in slot 2 Channel 4 (Alert Relay) (S02C01A2)  Trip Relay Module in slot 2 Channel 5 (Danger Relay) (S02C02A2)  Trip Relay Module in slot 2 Channel 6 (Danger Relay) (S02C03A2)  Trip Relay Module in slot 2 Channel 7 (Danger Relay) (S02C04A2)  Trip Relay Module in slot 2 Channel 8 (Danger Relay)

Independent relays require one 16-Channel Relay Modules for each monitor module.

Figure 2-4: Independent Relays Example

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Section 2 - General Information

2.2 Statuses

The 16-Channel Relay Module will return both module and channel statuses. This section describes the available statuses and where you can find them.

2.2.1 Module Statuses

OK

This indicates if the 16-Channel Relay Module is functioning correctly. The module returns a Not OK status under any of the following conditions:

• Hardware Failure in the module • Node Voltage Failure

• Configuration Failure • Slot ID Failure

If the Module OK status goes Not OK, then the module will drive the system OK Relay on the Rack Interface I/O Module to a Not OK state.

Configuration Fault

This indicates if the 16-Channel Relay Module configuration is invalid. Bypass

This indicates if some condition has caused the system to bypass any channel in the 16-Channel Relay Module. Any of the following conditions can cause the system to bypass the Relay Module:

• A channel has never been configured • The Relay Module is in configuration mode • A Fatal error was found during self-test • Rack Alarm Inhibit has occurred

• A channel has an invalid configuration • Any active channel is bypassed

Alarm 1 Active

This indicates that one or more channels of the 16-Channel Relay Module is in alarm.

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Table 2-1: Location of Module Statuses

Statuses Comm. Gateway Module Rack Configuration Software Operator Display Software 3500/94 VGA Display Module OK X X X

Module Configuration Fault X Module Bypass X

Module Alert/Alarm 1 Active X X X

2.2.2 Channel Status

OK

This indicates that the associated channel of the 16-Channel Relay Module has detected no fault. If the Channel OK status goes not OK, then the module will drive the system OK Relay on the Rack Interface I/O Module to a Not OK state.

Bypass

This indicates if some condition has caused the system to bypass the

associated 16-Channel Relay Module channel. Any of the following conditions can cause the system to bypass the channel:

• The channel has never been configured • The Relay Module is in configuration mode • A Fatal error was found during self-test • Rack Alarm Inhibit has occurred

• The channel has an invalid configuration

• The channel is bypassed using a software switch

Channel Off

This indicates if the associated 16-Channel Relay Module channel has been turned off (not Active). You may turn off the Relay channels (inactivated) using the Rack Configuration Software.

Alarm 1 Active

This indicates if the associated 16-Channel Relay Module channel is in alarm.

Table 2-2 shows where the you can find the channel statuses.

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Section 2 - General Information Table 2-2: Location of Channel Statuses

Statuses Comm. Gateway Module Rack Configuration Software Operator Display Software 3500/94 VGA Display Channel OK X X X X Channel Bypass X X X X Channel Off X X X

Channel Alert/Alarm 1 Active X X X

2.3 LED Descriptions

The LEDs on the front panel of the 16-Channel Relay Module indicate the

operating status of the module as shown in Figure 2-5. Refer to Section 6.2 for all of the available LED conditions.

1. OK LED: Indicates that the 16-Channel Relay Module and the 16-Channel Relay Output Module are operating correctly.

2. TX/RX LED: Flashes at the rate that messages are received.

3. Channel Alarm LED: Indicates that an alarm condition has occurred with this relay. Figure 2-5: 3500/33 Front Panel LEDs

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Section 3 - Configuration Information

3. Configuration Information

You configure 3500 relay modules through the 3500 Rack Configuration Software, by using the Relay Association screen to enter alarm drive logic for each relay channel and the Software Switches screen to set software switches. This section defines the options on these configuration screens. The Rack Configuration and Utilities Guide (part number 129777-01) shows how to operate those screens.

3.1 Hardware Considerations

The slots in the 3500 rack are numbered from 0 to 15, counting from left to right. The power supplies go into slot 0 and the RIM goes into slot 1. Slots 2 through 15 are called “monitoring positions”. You can install the 3500/33 module into any of the monitoring positions. However, if you will use the 3500/20 Rack Interface Module and Data Manager I/O to interface to DDIX, TDIX or TDXnet, refer to the 3500/20 manual for slot restrictions that this may place on your configuration.

3.2 Entering Alarm Drive Logic

Use the Relay Association screen to define the alarm logic that will determine which alarms will cause the channels in the relay to drive the output.

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3.2.1 Relay Module Configuration Considerations

• Add monitor modules to the rack configuration before configuring the Relay

Module.

• Activate only the Relay Module channels that will be used.

• Note that only monitor modules may be used in the alarm drive logic.

• Plan ahead to determine if you will configure any channels as channel pairs

(DPDT).

• Determine whether your application will need True AND or Normal AND voting

logic.

• Consider using the Copy function if you configure several channels with

similar logic or conditions.

• Note that prior to downloading, the configuration software will determine if

the number of instructions exceeds the limit of your relay module. The software limits the 16-Channel Relay module to 100 logical operations per channel for each of the 16 channels.

• Note that prior to exiting the Relay Association screen, the configuration

software will determine if there are errors in any channel alarm drive logic. The cursor will be placed at the location of the syntax error.

3.2.2 Relay Module Configuration Options

Available Monitors

This field shows the monitors in the rack. Rack Type

This specifies the type of RIM installed in the rack (Standard or TMR). Config ID

This is a unique 6-character identifier that the software enters when downloading a configuration to the 3500 rack.

Relay Slot

This indicates the location in the 3500 rack of the relay module you are configuring.

Active

This check box applies to the selected channel in the Channel Association group. The relay channel drives the output only when this box is enabled (⌧) and the alarm drive logic for the channel is TRUE.

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Section 3 - Configuration Information Latching Relays

When you select this option, the corresponding relay alarm channel will hold the alarm state until it receives a rack reset or the relay is reconfigured. Relay Channel Pair (DPDT)

Selecting this option will group the current channel with its channel pair, thus allowing both channels to have identical configurations and alarm logic. Standard Relay Channel Association

This is a group for you to select the channel, or channel pair, you wish to configure and activate.

Relay NE/NDE Switch Status

This indicates the the relay hardware switch settings on the Relay Output Module. This status is available only after you have uploaded the relay. Available Monitor Channels/Alarms

When you select a monitor, this area shows all the alarms that are available for the relay module.

Alarm Drive Logic

This is the area in which you build the alarm drive logic using the available monitor alarms.

AND Voting Setup

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Normal AND Voting (Default)

With you select this option, if an alarming parameter is Not OK or bypassed (due to either user selection or monitor failure), then the software will remove the parameter from the relay logic. Please note that the software will not remove a “Not-OK” alarming parameter (a parameter intended to alarm on a Not-OK condition) from the alarm logic equation.

True AND Voting

True AND logic causes alarming parameters that are Not OK or bypassed to remain in the relay logic. True AND logic will not drive an alarm if an alarming parameter being ANDed is

• Not OK (parameters are not intended to alarm on a Not-OK

condition), or

• in bypass.

Application Advisory

Take care when selecting the AND voting to be used. You should consider the configuration settings for the channel you

intend to use as an alarm parameter. Not OK Channel Defeat (single channel measurements), Not OK Channel Pair Defeat

(paired channel measurements), Timed OK Channel Defeat and Latching vs. Non-Latching Not OK modes all affect the

circumstances that cause a channel to be "Not OK" or bypassed.

Note in particular that the following channel types have special scenarios that you must consider:

Thrust Position: Monitor reports an Alarm (not a "Not OK" condition) to the relay module for a transducer not OK.

Overspeed, Zero-Speed, Rotor Speed:

These channel types have optional "OK Voltage Checks" that will determine if the monitor will or will not report a Not OK status to the relay module due to a transducer voltage error.

Eccentricity: "Direct Channel Above 600 RPM" affects bypass and Not OK status.

3.3 Software Switches

Software switches for relay modules let you temporarily bypass or inhibit the relay module and channel functions. Set these switches on the Software Switches screen under the Utilities Option on the main screen of the Rack

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Section 3 - Configuration Information Configuration Software. Switch settings take affect only after you press the Set button.

3.3.1 Configuration Mode

This module software switch allows you to configure the 16-Channel Relay Module (see Figure 3-3).

Module Switch Number Switch Name

1 Configuration Mode

Figure 3-3: Module Software Switches Screen

To configure a relay module, enable (⌧) this switch and set the key switch on the front of the RIM to the PROGRAM position. When downloading a configuration from the Rack Configuration Software, this switch will automatically be enabled and disabled by the Rack Configuration Software. If the connection to the rack is lost during the configuration process, use this switch to remove the module from Configuration Mode.

The module switch number is used in the Communication Gateway Module.

3.3.2 Bypass

When enabled (⌧), the channel will be turned off and not allow alarming (see Figure 3-4).

Channel Switch Number Switch Name

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Figure 3-4: Channel Software Switches Screen

The channel switch number is used in the Communication Gateway Module.

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Section 4 - Output Module Description

4. Output Module Description

This section describes the output module that is associated with the 16-Channel Relay Module. This section also describes how to use the connectors on the Relay Output Module and describes where to install each Output module.

4.1 16-Channel Relay Output Module

The 16-Channel Relay Output Module contains 16 sets of relay contacts (1 set for each channel). You can set up the module so that each channel (in groups of 4 channels) is Normally Energized or Normally De-energized. You must install the 16-Channel Relay Output Module behind the 16-Channel Relay Module (in a Rack Mount or a Panel Mount rack) or above the 16-Channel Relay Module (in a

Bulkhead rack). NE NDE RELAY MODE NDE NE 3 4 1 2

1. I/O module (front view) 2. I/O module (left side view)

3. Terminals for connecting to the single-pole, double-throw (SPDT) relays.

4. DIP switches for configuring the relays for Normally Energized (NE) or Normally De-Energized (NDE) operation. The numbers refer to relay channel groups. For example, CH1-4 corresponds to relay channels 1 through 4.

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3500/33 16 Channel Relay Module Operation and Maintenance Manual 1 2 3 1. Screwdriver 2. Module cover 3. DIP Switch

Figure 4-2: Configuring the Normally Energized and Normally De-Energized Relays

CAUTION

The output module can carry high voltages while installed in the rack with power applied to

the rack. High voltages can shock or burn service personnel and damage the output module during the relay configuration process.

Remove power from the rack and remove the output module from rack before attempting to

configure the relays.

NOTE

Relay contacts are marked NC (Normally Closed), NO (Normally Open), and ARM (Armature). NC and NO define the state

of the relay contacts with no power applied to the relay coil (de-energized,

non-alarm state).

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Section 4 - Output Module Description

1

2

3

1. No Power/ No Alarm (shelf state) 2. With Power/ No Alarm

3. With Power/ In Alarm

Figure 4-3: Normally Energized (NE) Relay States

2

3 1

1. No Power/ No Alarm (shelf state) 2. With Power/ No Alarm

3. With Power/ In Alarm

Figure 4-4: Normally De-Energized (NDE) Relay States

4.2 Wiring Euro Style Connectors

To remove a terminal block from its base, loosen the screws attaching the

terminal block to the base, grip the block firmly and pull, as shown in Figure 4-5. Do not pull the block out by its wires because this could loosen or damage the wires or connector.

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Figure 4-5: Removing Terminal Block From a Typical 3500 Output Module

DANGER

High voltage may be present on the relay contacts or relay wiring. High voltage can result in shock, burns, or death. Use

proper isolation techniques and remove all power when working with the relays.

Refer to the 3500 Field Wiring Diagram Package for the recommended wiring. Do not remove more than 6 mm (0.25 in) of insulation from the wires.

Figure 4-6: Connnecting Wire to Relay Terminal Block

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Section 5 - Maintenance

5. Maintenance

You cannot repair the boards and components inside of 3500 modules in the field. 3500 rack maintenance consists of testing module channels to verify that they are operating correctly. You should replace modules that are not operating correctly with a spare.

When performed properly, you may install the main module into or remove the modoule from the rack while power is applied to the rack. You should install or remove the relay output module only after removing the power to the rack. Refer to theRack Installation and Maintenance Manual (part number 129766-01) for the proper procedure.

This section shows how to verify the operation of the 3500/33 16-Channel Relay Module.

5.1 Verifying a 3500 Rack - Relay Module

The 3500 Monitoring System is a high precision instrument that requires no

calibration. You must, however, verify the functions of Relay Module channels at regular intervals. At each maintenance interval, we recommend that you use the procedures in this section to verify the operation of all active channels in the Relay Module.

Section Number

Topic Page

Number

5.1.1 Choosing a Maintenance Interval 21

5.1.2 Required Test Equipment 22

5.1.3 Typical Verification Test Setup 22

5.1.4 Using the Rack Configuration Software 23

5.1.5 Standard Relay Channels 24

5.1.1 Choosing a Maintenance Interval

Use the following approach to choose a maintenance interval:

• Start with an interval of one year and then shorten the interval if either of

the following conditions apply:

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- The 3500 rack is operating in a harsh environment, such as in extreme temperature, high humidity, or in a corrosive atmosphere.

• At each interval, use the results of the previous verifications and ISO

Procedure 10012-1 1992(E) to adjust the interval.

5.1.2 Required Test Equipment

The test equipment you will need to simulate the inputs for the relay channel will depend on the type of monitor providing inputs to the Relay Alarm Drive Logic. You can identify this equipment under “Required Test Equipment” in the

Maintenance section of the specific monitor manual.

5.1.3 Typical Verification test setup

The following figure shows the typical test setup for verifying a Relay Module. The test equipment is used to simulate the transducer signal to selected monitors and the laptop computer is used to observe the output from the rack.

1. 3500 Rack 2. Test Equipment

3. RS-232 communications 4. Laptop Computer

Figure 5-1: Typical Test Setup

You can connect transducers to a 3500 rack in a number of ways. Depending on the wiring option for the I/O module of your monitor, connect the test equipment to the Monitor Module and Relay Module using one of the following methods:

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1. Connect test equipment here. 2. Inputs

3. Monitor I/O Module (Internal Termination)

4. External Termination Block (Euro Style Connectors) 5. External Termination Block (Terminal Strip Connectors)

Figure 5-2: Test Setup Wiring Methods

1. Outputs

Figure 5-3: 16-Channel Relay Output Module

5.1.4 Using the Rack Configuration Software

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parameters in the rack. To perform the test procedures in this section you must be familiar with the following features of the Rack Configuration Software to

• upload and save configuration files • display the Verification screen

TheRack Configuration and Test Utilities Guide (part number 129777-01) explains how to perform these operations.

NOTE

Save the original rack configuration before doing any maintenance or

troubleshooting procedures.

The Verification screen displays relay channel output from a 3500 rack as shown in Figure 5-4. Information such as Alarm Drive Logic, Channel Alarm State and Channel OK State are used to verify relay channels.

Figure 5-4: 3500 Rack Configuration Software Verification Screen

5.1.5 Standard Relay Channels

Verify relay channels by forcing alarms from the monitors that provide inputs for the Relay Alarm Drive Logic. When the logic is true, the Channel Alarm State will change to Alarm on the Verification screen and the alarm relay and front panel LED for that channel will change state. Verify only those channels that are active and configured.

To verify that a 16-Channel Relay channel is working correctly.

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Section 5 - Maintenance 1. Run the Rack Configuration Software on the test computer.

2. ChooseVerification from the Utilities menu. A screen prompting for the slot and channel number of the relay to be tested will appear.

3. Choose the proper Slot number and Channel number and then click on the Verify button. The Verification screen will appear.

4. Verify that the Channel OK State status on the Relay Verification screen readsOK.

5. Use the Relay Verification screen to determine what inputs must be simulated.

6. Simulate the required Alarm Drive Logic inputs to cause the relay to change states.

For example, for a 3500 Rack with the following configuration:

Slot Number Module Type

1 Rack Interface Module

2 3500/42 – 4 Channel Monitor

3 3500/42 – 4 Channel Monitor

4 3500/42 - 4 Channel Monitor

5 3500/33 - 16-Channel Relay

and a relay channel with the following Alarm Drive Logic: ( S02C01A1 * S03C01A1 ) + S04C01A2

send test signals to the monitors in the rack to cause Slot 2 Channel 1 AND Slot 3 Channel 1 to be in Alert OR cause Slot 4 Channel 1 to be in Danger. 7. Verify that the Channel Alarm State status on the Relay Verification screen

changes to Alarm. Verify that the relay contacts change state and the front panel LED illuminates.

8. If the Relay channel does not respond correctly, check the inputs to ensure they meet the Alarm Drive Logic requirements. If the module still does not meet specifications, go to Section 5.1.6 (If a Channel Fails a Verification Test).

9. Select the next channel to be tested by using the Channel drop down list on the Verification screen. Repeat steps 4 through 8 to test the next relay channel.

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5.1.6 If a Channel Fails a Verification Test

When handling or replacing circuit boards always be sure to adequately protect against damage from Electrostatic Discharge (ESD). Always wear a proper wrist strap and work on a grounded, conductive work surface.

1. Use the Rack Configuration Software to save the configuration for the module.

2. Replace the module with a spare. Refer to the installation section in the 3500 Monitoring System Rack Installation and Maintenance Manual (part number 129766-01).

3. Return the faulty module to Bently Nevada LLC for repair.

4. Use the Rack Configuration Software to download the configuration for the spare module.

5. Verify the operation of the spare.

5.2 16-Channel Relay Firmware Upgrade Procedure

Occasionally you may need to upgrade the original firmware that ships with the 3500/33 16-Channel Relay Module. The following instructions describe how to upgrade the existing firmware using the 3500 Configuration software. You must use the 3500 Rack Configuration Software to reconfigure the module after

upgrading its firmware.

Application Advisory

During the following procedure you must not not interrupt power to the rack

or remove the monitor that you are upgrading from the rack. Either of thse

events may cause the monitor to become inoperable.

1. Start the 3500 Configuration software and connect to the rack.

2. Upload and save the current configuration of the monitor, the upgrade process will erase any configuration in the monitor.

3. Under the Utilities menu option select Upgrade Firmware.

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4. Select the module you wish to update and click on the OK button.

5. The software will request you to download the file. Select the file and click on the Open button.

6. The software will now download the file.

7. After the download completes, reload the configuration to the monitor. If the process fails (simultaneous flashing alarm LEDs), depending on the failure mode, the module may revert to its old code. See Section 6.2, “LED Fault Conditions” for an explanation of the failure mode. Under no

circumstances should you remove the module until it the download process finishes.

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6. Troubleshooting

This section describes how to use the module self-test, the LEDs, and System Event List to troubleshoot a problem with the 16-Channel Relay Module or the Output module.

6.1 Self-test

To perform a self-test:

1. Connect a computer running the Rack Configuration Software to the 3500 rack (if needed).

2. SelectUtilities from the main screen of the Rack Configuration Software. 3. SelectSystem Events/Module Self-test from the Utilities menu.

4. Press theModule Self-test button on the System Events screen.

Application Advisory

Machinery protection will be lost while the module performs its self-test.

5. Select the slot that contains the relay module and press the OK button. The relay module will perform a full self-test and the software will display the System Events screen. Note that the list will not contain the results of the self-test.

6. Wait 30 seconds for the module to run a full self-test.

7. Press theLatest Events button. The software will update the System Events screen to include results of the self-test.

8. Verify if the relay module passed self-test. If the module failed the self test, refer to Section 6.3.

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Section 6 - Troubleshooting

6.2 LED Fault Conditions

The following table shows how to use the LEDs to diagnose and correct problems with the 16-Channel Relay Module.

Table 6-1: OK and TX/RX LED Fault Condition Diagnostics

OK LED TX/RX Condition Solution

1 Hz 1 Hz Relay Module is not configured. Reconfigure the Relay Module.

5 Hz _applicableNot

Relay Module or the Relay Output Module has detected an internal fault and are not OK.

Check the System Event List.

ON Flashing Relay Module and the Relay Output_{Module are operating correctly.} No action is required.

OFF Not

applicable

Relay Module is not operating

correctly. Replace the Relay Module.

Not applicable

Not flashing

Relay Module is not

communicating correctly or the Relay Module is not associated with any monitors in the rack that are communicating.

Check the System Event List or configure the alarm logic of at least one active relay channel.

Table 6-2: Alarm LED Fault Condition Diagnostics

Alarm LED Condition Solution

ON Channel is in Alarm. No action is required.

OFF Channel is not in Alarm. No action is required.

All LEDs Flashing (5 flashes in 3 seconds)

Failed firmware download due

to a recoverable error. Re-attempt firmware download.

All LEDs Flashing at (5 flashes in 5 seconds)

Failed firmware download due to a non-recoverable error.

Replace the relay module with a spare. Return the relay module to a Bently Nevada service center for repair.

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6.3 System Event List Messages

This section describes the System Event List Messages that are entered by the 16-Channel Relay Module. Table 6-3 is an example of a System Event List Message.

Table 6-3: Example of a System Event List Message Sequence Number Event Information Event Number Class Event Date

(DDMMYY) Event Time

Event

Specific Slot 0000000123 EEPROM Memory

Failure 13 1 02/01/90 12:24:31:99 5 Sequence Number: This is the number of the event in the System Event List (for

example 123).

Event Information: This provides the name of the event (for example EEPROM Memory Failure).

Event Number: This identifies the specific event that occurred.

Class: This indicates the severity of the event. The following classes are available:

Table 6-4: System Event List Classes

Class Value Classification

0 Severe/fatal event

1 Potential problem event

2 Typical logged event

3 Reserved

Event Date: This specifies the date that the event occurred. Event Time: This specifies the time that the event occurred.

Event Specific: Provides additional information for the events that use this field.

Slot: This identifies the module with which the event is

associated. If the module is a half-height module in the upper slot or a full-height module, this field will be 0 to 15. If the module is a half-height module in the lower slot then this field will be 0L to 15L. For example, this field would identify a half-height module in the lower position of slot 5 as 5L.

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Section 6 - Troubleshooting The 16-Channel Relay module may place following System Event List Messages, which are listed in numerical order. Events marked with a star (*)will not drive relays on the 16-Channel Relay Output Module. If you are unable to solve any problems contact your nearest Bently Nevada LLC office.

Flash Memory Failure Event Number: 11

Event Classification: Potential Problem

Action: Replace the Relay Module as soon as possible. * Internal Network Failure

Event Number: 30

Event Classification: Severe/Fatal Event

Action: Replace the Relay Module immediately. Resync Internal Network

Event Number: 31

Action: Replace the Relay Module immediately. Device Not Communicating

Event Number: 32

Action: Determine whether one of the following components is faulty:

• the Relay Module • the rack backplane

Device Is Communicating Event Number: 33

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Fail Relay Coil Sense

Event Number: 55

Action: Verify that the Relay Output Module is installed. If installed, determine whether one of the following components is faulty:

• the Relay Module

• the Relay Output Module

Pass Relay Coil Sense Event Number: 56

I/O Module Mismatch Event Number: 62

I/O Module Compatible Event Number: 63

Fail I/O Jumper Check (Fail read I/O module ID)

Event Number: 64

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Section 6 - Troubleshooting Event Classification: Potential Problem

Pass I/O Jumper Check (Pass read I/O module ID)

Event Number: 65

Fail Main Board +5V-A (Fail Main Board +5V - upper Power Supply) Event Number: 100

Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, Determine whether one of the following components is faulty:

• the Power Supply installed in the upper slot

Pass Main Board +5V-A (Pass Main Board +5V - upper Power Supply) Event Number: 101

Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise, determine whether one of the following components is faulty:

Fail Main Board +5V-B (Fail Main Board +5V - lower Power Supply) Event Number: 102

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Event Classification: Potential Problem

• the Power Supply installed in the lower slot

Pass Main Board +5V-B (Pass Main Board +5V - lower Power Supply) Event Number: 103

* Fail Main Board +5V-AB (Fail Main Board +5V - upper and lower Power Supplies)

Event Number: 104

Event Classification: Severe / Fatal Event

• the Power Supply installed in the lower slot • the Power Supply installed in the upper slot

Pass Main Board +5V-AB (Pass Man Board +5V - upper and lower Power Supplies)

Event Number: 105

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Section 6 - Troubleshooting

* Fail Main Board +3.3V (Fail Main Board +3.3V Supply) Event Number: 162

Pass Main Board +3.3V (Pass Man Board +3.3V Supply)

Event Number: 163

Device Configured Event Number: 300

Event Classification: Typical logged event Action: No action required.

* Configuration Failure Event Number: 301

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Action: Replace the Relay Module immediately.

Configuration Failure Event Number: 301

Action: Download a new configuration to the Relay Module. If the problem still exists, replace the Relay Module as soon as possible.

* Module Entered Cfig Mode Event Number: 305

Event Classification: Typical logged event Action: No action required.

Software Switches Reset Event Number: 305

Action: Download the software switches to the Relay Module. If the software switches are not correct. replace the Relay Module as soon as possible.

Fail I/O Board +5V-AB (Fail OUTPUT Board +14V Supply)

Event Number: 390

• the Relay OUTPUT Module • the Relay Module

Pass I/O Board +5V-AB (Pass OUTPUT Board +14V Supply)

Event Number: 391

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Section 6 - Troubleshooting Action: Verify that noise from the power source is not causing the problem.

If the problem is not caused by noise, determine whether one of the following components is faulty:

• the Relay Output Module • the Relay Module

Fail I/O Board +14V-AB (Fail OUTPUT Board +14V Supply) Event Number: 396

Pass I/O Board +14V-AB (Pass OUTPUT Board +14V Supply)

Event Number: 397

Fail I/O Module DIP Sw (Fail Output Module DIP switch) Event Number: 398

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3500/33 16 Channel Relay Module Operation and Maintenance Manual Event Classification: Potential Problem

Action: Verify that the Relay Output Module is installed. If the Relay Output Module is installed, replace the Relay Output Module as soon as possible.

I/O Module Detect Fault (Pass Output Module DIP switch – there was a detected fault that is no longer present)

Event Number: 399

Action: Verify that the Relay Output Module is installed. If the Relay Output Module is installed, replace the Relay Output Module as soon as possible.

Pass Module Self-test Event Number: 410

Event Classification: Typical Logged Event Action: No action required.

Enabled Ch Bypass (Enabled Channel Bypass) Event Number: 416

Event Classification: Typical logged event Event Specific: Ch x

Action: No action required.

Disabled Ch Bypass (Disabled Channel Bypass) Event Number: 417

Event Classification: Typical logged event Event Specific: Ch x

Action: No action required.

Invalid Alm Drive Logic (Invalid Alarm Drive Logic) Event Number: 451

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Section 6 - Troubleshooting Action: Download a new configuration to the Relay Module. If the problem

still exists, replace the Relay Module as soon as possible. Fail Slot Id Test

Event Number: 461

Action: Verify that the Relay Module is fully inserted in the rack. If the Relay Module is installed correctly, determine whether one of the

following components is faulty:

Pass Slot Id Test

Event Number: 462

Action: Verify that the Relay Module is fully inserted in the rack. If the Relay Module is installed correctly, determine whether one of the

following components is faulty:

Fail I/O Board +15V-A (Fail Output Board +15V - upper Power Supply) Event Number: 554

Pass I/O Board +15V-A (Pass Output Board +15V - upper Power Supply) Event Number: 555

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Fail I/O Board +15V-B (Fail Output Board +15V - lower Power Supply) Event Number: 556

Pass I/O Board +15V-B (Pass OUTPUT Board +15V - lower Power Supply) Event Number: 557

Fail I/O Board +15V-AB (Fail OUTPUT Board +15V - upper and lower Power Supplies)

Event Number: 558

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Section 6 - Troubleshooting Action: Verify that noise from the power source is not causing the problem.

If the problem is not caused by noise, determine whether one of the following components is faulty:

Pass I/O Board +15V-AB (Pass Output Board +15V - upper and lower Power Supplies)

Event Number: 559

Action: Verify that noise from the power source is not causing the problem. If the problem is not caused by noise determine whether one of the following components is faulty:

6.4 Alarm Event List Messages

The 16-Channel Relay Module may place the following messages in the Alarm Event List.

Table 6-5: Alarm Event List Messages and Their Causes

Alarm Event List Message When the message will occur

Entered Not OK Module went Not OK

Left Not OK Module returned to the OK state

Relay Activated Condition for driving the relay channel met

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7. Ordering Information

This section contains the ordering information for the 3500/33 16-Channel Relay Module.

7.1 16-Channel Relay Module

Part number 3500/33- AXX - BXX A:Output Module

0 1 16-Channel Relay Output Module B: Agency Approval Option

0 0 None

0 1 CSA-NRTL/C

7.2 Spares

149968

16-Channel Relay Control Module 149992-01

16-Channel Relay Output Module 00580453

Connector Header, 16-position 162291-01

3500/33 Relay Module Manual 04425545

Grounding Wrist Strap (single use only)

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Section 8 - Specifications

8. Specifications

This section contains the specifications for the 3500/33 16-Channel Relay Module.

8.1 Relays

Type

Single-pole, double-throw (SPDT) relays Environmental sealing Epoxy-sealed Arc suppressors 250 Vrms, installed as standard. Contact Ratings (resistive load)

Max switched power

DC: 160 W AC: 1500 VA Min switched current 100 mA @ 12 Vdc Max switched current 6 A Max switched voltage DC: 300 Vdc AC: 400 Vac Contact Life 100,000 @ 5 A, 24 Vdc or 250 Vac

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Operation

Groups of four channels are switch selectable for Normally De-energized or Normally Energized.

8.2 Environmental Limits

Temperature -30 ºC to 65 ºC (-22 ºF to 150 ºF) operating -40 ºC to 85 ºC (-40 ºC to 185 ºC) storage Humidity 95% non-condensing

8.3 Mechanical

Impact 10 g’s for 11 ms Shipping

Per mil Std 81D – Category G Equipment Vibration Sinusoidal, 3 g at 5 to 100 Hz

8.4 Electromagnetic Compatibility

EN50081-2 Radiated Emissions EN 55011, Class A Conducted Emissions EN 55011, Class A 44

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Section 8 - Specifications EN50082-2 Electrostatic Discharge EN 61000-4-2, Criteria B Radiated Susceptibility ENV 50140, Criteria A Conducted Susceptibility ENV 50141, Criteria A Electrical Fast Transient EN 61000-4-4, Criteria B Surge Capability EN 61000-4-5, Criteria B Magnetic Field EN 61000-4-8, Criteria A Power Supply Dip

EN 61000-4-11, Criteria B Radio Telephone

ENV 50204, Criteria B Low Voltage Directives

Safety

Requirements

EN61010-01

8.5 Approvals

CSA-NRTL/C

2291B1 3500 33 16

Operation and Maintenance Manual

Operation and Maintenance Manual

3500/33 16-Channel Relay Module

3500/33 16-Channel Relay Module

Copyright 2002. Bently Nevada LLC.

Copyright 2002. Bently Nevada LLC.

All rights reserved.

All rights reserved.

Contact Information

Contact Information

Copyright 2002. Bently Nevada LLC.

Copyright 2002. Bently Nevada LLC.

All rights reserved.

All rights reserved.

Contact Information

Contact Information

Additional Information

Additional Information

Notice:

Notice:

3500 Monitoring System Rack Installation and Maintenance Manual

3500 Monitoring System Rack Installation and Maintenance Manual (Part

(Part

Number 129766-01)

Number 129766-01)

3500 Monitoring System Rack Configuration and Utilities

3500 Monitoring System Rack Configuration and Utilities Guide (Part

Guide (Part

Number 129777-01)

Number 129777-01)

3500 Monitoring System Computer Hardware and Software Manual

3500 Monitoring System Computer Hardware and Software Manual (Part

(Part

Number 128158-01)

Number 128158-01)

3500 Field Wiring Diagram Package (Part Number 130432-01)

3500 Field Wiring Diagram Package (Part Number 130432-01)

Contents

Contents

1.

1.

Receiving

Receiving and

and Handling

Handling Instructions

Instructions ...

...

...

... 1

1

2.

2.

General

General Information

Information ...

...

...

...

... 3

3

3.

3.

Configuration

Configuration Information

Information ...

...

...

... 11

11

4.

4.

Output Module

Output Module Description

Description...

...

...

... 17

17

5.