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User Manual Spotlight Compressor Monitoring System:
A3910 Spotlight Controller A3920 Spotlight PUC Module
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Legal Notices Copyright ©2018 Windrock Incorporated. All rights reserved.
No part of this manual may be reproduced or transmitted in any form or by any mean without the
written permission from Windrock Incorporated.
Software and Firmware License Notice
Your license agreement with Windrock Incorporated authorizes the number of copies which can
be made and the computer systems on which they may be used. Any unauthorized duplication or
use of Windrock software or firmware in whole or in part, in print, or in any other storage and
retrieval system, is forbidden.
Disclaimer
The manual is provided for informational purposes. Windrock Incorporated makes no warranty
of any kind with regard to this material, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose. Windrock Incorporated shall not be liable
for errors, omissions, or inconsistencies which may be contained herein or for incidental or
consequential damages in connection with the furnishing, performance, or use of this material.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Windrock Incorporated. Any software described in this document is
furnished under a license agreement or nondisclosure agreement. The software may be used or
copied only in accordance with the terms of the agreement.
Important Safety Notices
When used in accordance with the instructions in this manual and the associated control
drawings, Windrock Spotlight is approved for use in Class 1 Division 2 and unclassified areas.
Failure to follow this manual may result in an explosion hazard when used in hazardous
locations or improper operation.
The examples and diagrams in this manual are included for illustrative purposes. Because of the
many variables and requirements associated with any particular installation, Windrock Inc.
cannot assume responsibility or liability for actual use based upon examples and diagrams.
For any questions, problems, or service for any Windrock products, including Windrock
Spotlight, visit the Windrock web site at www.windrock.com. Inquiries may also be directed to
[email protected] or 1-865-330-1114.
Windrock, Inc
1832 Midpark Drive, Suite 102
Knoxville, TN 37921
www.windrock.com
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Table of Contents 1 A3910 Spotlight Controller 5
1.1 Connections 5
1.2 Operation 6
2 A3920 Spotlight Peripheral Universal Connection (PUC) Module 6
2.1 Features 6
2.2 Connections 7
2.3 Internal Accelerometer 7
2.4 Activity Icons 7
2.5 Operation 7
3 Included Accessories 8
3.1 General 8
3.2 A6088N Compressor DC Pressure Sensors 8
3.3 A3012 Magnetic Pickup Sensor 9
3.4 Controller WiFi Antennas 10
3.5 02113000 Spotlight Trunk Cable 10
3.6 A3932 Spotlight Magnetic Pickup Cable 10
3.7 Hose Clamp Kits and Neoprene Rubber Strips 10
4 Optional Accessories 10
4.1 General 10
4.2 A6400 Portable Analyzer 11
4.3 A6420 Shaft Encoder 11
4.4 A3934 Spotlight Shaft Encoder Cable 11
4.5 A6410 Strobe (Timing) Light 11
4.6 02113010 Spotlight Mag Pickup (MPU) Extension Cable 11
4.7 02201070 Magnet 11
4.8 021103040 Y-Adapter Connector 11
5 System Installation 11
5.1 General 11
5.2 Hazardous Locations 12
5.3 Installation Overview 13
5.4 Magnetic Pickup Mounting 16
5.5 Controller Mounting 16
5.6 Power Requirements 17
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5.7 PUC Mounting 17
5.8 Gateway Mounting 18
5.9 Shaft Encoder 19
5.10 Environment 19
6 Maintenance and Cleaning 19
7 Specifications 20
8 Appendix. 21
8.1 Entity Parameters 22
8.2 CD-A3910-01 Controller Specification 23
8.3 CD-A3920-01 PUC Module Specification 24
8.4 Controller Mounting Options 25
8.5 PUC Module Mounting Options 26
CAUTION: THIS PRODUCT CONTAINS NEODYMIUM MAGNETS. Neodymium magnets are much more powerful than other kinds of magnets. They can affect pacemakers, ICDs, and other implanted medical devices. They can damage magnetic media such as floppy disks, magnetic I.D. cards, credit cards, cassette tapes, video tapes, or other devices. Avoid placing magnets near electronic appliances. Strong magnetic fields can influence compasses, such as used in air transport, smartphone, and GPS devices.
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1 A3910 Spotlight Controller
THE A3910 IS FOR USE WITHIN A WINDROCK SPOTLIGHT SYSTEM ONLY.
LE A3910 DOIT ÊTRE UTILISÉ DANS UN SYSTÈME WINDROCK SPOTLIGHT UNIQUEMENT.
THE A3910 CONTAINS NO USER SERVICEABLE COMPONENTS. ANY ATTEMPT TO MODIFY THIS DEVICE, USE FOR OTHER THAN ITS INTENDED PURPOSE, OR SUBSTITUTION OF COMPONENTS MAY DAMAGE THIS DEVICE LEADING TO UNRELIABLE OPERATION AND DECREASED PROTECTION FOR THE DEVICE BEING MONITORED.
LE A3910 NE CONTIENT AUCUNS RÉPARABLE. TOUTE TENTATIVE DE MODIFIER CE DISPOSITIF, UTILISER D'AUTRE QUE SA DESTINATION, OU LA SUBSTITUTION DE COMPOSANTS PEUT ENDOMMAGER CET APPAREIL MENANT À UNE OPÉRATION PEU FIABLE ET A DIMINUÉ LA PROTECTION DU DISPOSITIF SURVEILLÉ.
1.1 Connections
Connections marked with in this manual or on the product are incendive and possible explosion hazards when installed in a hazardous environment. Other connections are non-incendive when installed in accordance with this manual, the associated control drawings in the appendix, the National Electrical Code and/or Canadian Electrical Code, and the authority having jurisdiction. Consult the control drawing for proper and safe connection to field devices.
PWR - Power is applied via the integral power cable. NOTE: EQUIPMENT SHALL BE POWERED BY AN APPROVED SELV LPS POWER SOURCE. Power connection and mounting requirements are both detailed in Section 5, System Installation.
PUC 1, PUC 2, PUC 3, PUC 4 – Non-incendive 8-pin output to PUC Modules. Four connectors are provided on the Controller unit, one for each PUC Module. PUCs are connected using Windrock cable part number 02113000. Connection to any other equipment or using any other cables other than those specified by Windrock may compromise system integrity.
TDC Input – Non-incendive 3-pin input for TDC. In order for the Windrock Spotlight system to operate properly, an accurate TDC signal is required. Use ONLY magnetic pickup sensors with entity parameters as described in Section 8, Entity Parameters. The magnetic pickup generates a signal as it crosses an artifact (pin or hole) in a spinning steel disk such as the flywheel. Use cable part number A3932-CBL-0-5 and connect from TDC Input of this Controller to the magnetic pickup.
Multiple Controller Note: The Spotlight system is capable of monitoring more than four cylinders per compressor. Use Y-Adapter part number 02113040 to connect Mag Pickup Cable A3932-CBL-0-5 to separate controllers using MPU Extension cable part number 02113010 (sold separately).
For further information regarding magnetic pickup sensors, see Section 3.3, Magnetic Pickup Sensor.
TDC Output – Non-incendive buffered outputs for TDC. This 3-pin connector outputs a voltage representative of the TDC Input signal. This output allows the signal to be used in conjunction with a Windrock A6400 Portable Analyzer:
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – AVANT DE DECONNECTOR L’EQUIPMENT, COUPER LE COURENT OU S’ASSURER QUE L’EMPLACEMENT EST DESIGNE NON DANGEREUX.
WARNING: EXPLOSION HAZARD. Input voltage must not exceed Vmax of any associated device connected to sensor inputs on A3920.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – TENSION D'ENTRÉE NE DOIT PAS DÉPASSER VMAX DE N'IMPORTE QUEL DISPOSITIF ASSOCIÉ AUX ENTRÉES CAPTEUR A3920.
Figure 1-1. A3910 Controller
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Portable Analyzer Measurements. Connecting TDC Output to a Windrock 6420 Shaft Encoder enables convenientmonitoring using a Windrock 6400 Portable Analyzer (A6420 Shaft Encoder and A6400 Portable Analyzer soldseparately). Use cable part number A3934-CBL-0-3 (sold separately) and connect from TDC output to the TDCconnection on a Shaft Encoder.
CAUTION: BUFFERED OUTPUTS HAVE A COMMON GROUND WITH THE REST OF THE WINDROCK SPOTLIGHT SYSTEM. USE OF A PORTABLE MONITOR SUCH AS WINDROCK’S 6420 IS RECOMMENDED. CONNECTING THE BUFFERED OUTPUT GROUND TO EQUIPMENT AT A DIFFERENT POTENTIAL WILL RESULT IN IMPROPER OPERATION.
ADVERTISSEMENT –SORTIES DE TAMPONNÉ ONT UN TERRAIN D'ENTENTE AVEC LE RESTE DU SYSTÈME WINDROCK SPOTLIGHT. UTILISATION D'UN MONITEUR PORTABLE COMME DE WINDROCK 6420 EST RECOMMANDÉ. BRANCHER LA SORTIE TAMPONNÉE AU SOL À L'ÉQUIPEMENT À UN POTENTIEL DIFFÉRENT SE TRADUIRA PAR UN FONCTIONNEMENT INCORRECT.
WiFi - The Windrock Spotlight Controller has two RP-SMA connectors located on the top of the unit for connection to WiFi antennas. The standard Spotlight Controller includes two WiFi antennas.
1.2 Operation
The A3910 does not have a local display. Under normal operation, no configuration is needed. Any necessary configuration can be accomplished via a web interface on the A3930 Gateway.
For installation sequence, refer to Section 5, System Installation.
WARNING: If A3910 is not operating properly, then unit must be returned to Windrock for repair service. Contact your sales representative or Windrock directly.
AVERTISSEMENT : Si A3910 ne fonctionne pas correctement, puis doit être renvoyé à Windrock des réparations. Contactez votre représentant commercial ou Windrock directement.
2 A3920 Spotlight Peripheral Universal Connection (PUC) Module
2.1 Features
Multiple mounting options (magnetic, bolt-down, or epoxy)
Two integral pressure sensor cables
One integral RTD temperature sensor
One internal accelerometer
Figure 1-2 Controller Connections - Top
Figure 2-1, A3920 PUC Module
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Activity icons for each sensor type
2.2 Connections
Note: All connections to the Spotlight PUC Modules are non-incendive.
Controller connection – Non-incendive 8-pin input from Controller. Connects to Windrock 8-pin cable part number 02113000. Connection to any other equipment or using any other cables other than those specified by Windrock may compromise system integrity.
Sensor Connections (x2) – Two integral cables are used to connect to a single cylinder’s pressure sensors. One cable connects to the Head End pressure sensor, while the other connects to the Crank End pressure sensor. The end of each cable has a label that indicates which sensor end to which it must connect. Connect to sensors as described in Section 3, Included Accessories.
For further information, see Section 8, Specifications.
2.3 Internal Accelerometer
Each PUC Module contains an industrial accelerometer that employs a shear sensing geometry with a ceramic sensing element. This ceramic sensing element provides excellent resolution and durability in noisy environments, and is designed to supply low-frequency and high-frequency measurements. Shear sensing geometry is preferred because of the inherent insensitivity to adverse environmental influences, such as case or base strain and thermal transients.
Dynamic expectations are application-specific and refer to the frequency range of measurement and the anticipated amplitudes of vibration. After careful review of the machinery to be monitored, minimum and maximum measurement frequency range may be established. The minimum measurement frequency is normally related to any sub-harmonics of running speed or any lower frequencies where vibration data is to be collected. The maximum measurement frequency of interest is determined by the maximum number of harmonics of an event like running speed, bearing frequencies, or gear mesh impacting. This measurement frequency range should be well within the specified frequency range of the sensor.
Amplitude range refers to the anticipated levels of vibration to be measured. These values are related to the alarm levels set for the machine. By carefully evaluating the idiosyncrasies of the machinery, the predictive maintenance engineer can estimate the minimum expected vibration levels and ensure that the electrical noise floor of the accelerometer is less than those levels.
2.4 Activity Icons
Each PUC Module has a number of activity icons located on the top of the unit. Figure 2-3 illustrates the symbols and their activity meaning.
Crank-End Pressure
Temperature Head-End Pressure
Vibration
2.5 Operation
Under normal and proper operation, the PUC Module is used by the Controller to gather sensor readings. Periodically, the activity icons will light as the controller unit is collecting and recording data.
It is not necessary to interact with the A3920 locally as its operation can be observed within the Windrock Enterprise software.
PUCs contain several local status indicators for sensors and power. During the periodic controller polling, sensor indicators light up to indicate activity. Refer to Table 2-4 for specific pattern identification.
Figure 2-3, PUC Module Status Indicators
TO
CONTROLLER
Figure 2-2, A3920 Controller Connection
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PUC ACTIVITY PATTERN MEANING
Slow clockwise rotation of LEDs on all PUCs sampling in progress
Brief clockwise rotation on all PUCs, then nothing for 10 seconds at a time
no error, just delay between samples
Ping pong between outer LEDs on PUC 1 NO TDC SIGNAL. (Note: this display will persist until the next polling interval even after TDC is restored. Polling interval is initially set to 5 minutes; it can be changed remotely once the system is brought up.)
Ping pong between inner LEDs on PUC 1: not (yet) connected to WiFi
Table 2-4, Controller Status Indication Patterns
For installation sequence, refer to Section 5, System Installation.
WARNING: If A3920 is not operating properly, then unit must be returned to Windrock for repair service. Contact your sales representative or Windrock directly.
AVERTISSEMENT : Si A3920 ne fonctionne pas correctement, puis doit être renvoyé à Windrock des réparations. Contactez votre représentant commercial ou Windrock directement.
3 Included Accessories
3.1 General
Spotlight systems have ONLY been approved for use using the accessories listed in Section 3 and Section 4.
NOTE: THE SAFETY OF ANY SYSTEM INCORPORATING THE EQUIPMENT IS THE RESPONSIBILITY OF THE INSTALLER OF THE SYSTEM.
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.
3.2 A6088N Compressor DC Pressure Sensors Pressure sensors have been included with your system. These sensors meet parameters listed in Section 8, Specifications.
Further information regarding pressure sensors:
A transducer is a device which provides a usable output in response to a specified physical condition.
In the case of a pressure transducer, the usable output is an electric signal and the specified physical condition is an application of pressure. Pressure transducers are able to convert applied pressure to an electric signal through various technologies. The technology used in the A6088N series of pressure transducers is inorganically bonded strain gauge.
The Model A6088N pressure transmitter is a complete pressure measurement device for use in online reciprocating compressor monitoring systems. These transmitters are ideally designed to be incorporated in head-end and crank-end indicator ports. Using these specifically designed transmitters, the Spotlight system is capable of producing online PT/PV pressure traces.
PRINCIPLE OF OPERATION
The A6088N pressure sensor provides a standard two-wire current loop output and has been designed for harsh environments.
…CONTINUED ON NEXT PAGE…
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For installation sequence, refer to Section 5, System Installation.
3.3 A3012 Magnetic Pickup Sensor
The system is designed to accept inputs from magnetic pickup Windrock series A3012. Magnetic pickups are sold separately.
Further information regarding magnetic pickup sensors:
At the heart of a VRS/Magnetic pickup is a permanent target that creates a magnetic field. An output is generated by changing the strength of this field, which is caused by the approach and passing of a ferrous metal target near the sensing area. The target is typically either a magnet, a hole in a ferrous metal disk, or a protrusion such as a bolt. The amplitude and waveform of the sensor output is affected by the speed of the sensed device and the shape of the target.
Proper TDC detection is the most important factor when measuring the performance of reciprocating machines, so a reliable TDC signal is essential. The sensor must be rigidly held within close proximity from the target. The mount must not move as the machine vibrates, and should not be located where routine maintenance is likely to move it. The target does not have to be located at TDC, as a fixed offset may be applied in software. It is essential that only one target be “seen” per revolution of the machine.
The output signal should have a magnitude of approximately 2V peak-to-peak. In order to achieve this output, Windrock recommends epoxying a small 1/4” target diameter magnet into the target area. It may be necessary to move the sensor closer or farther from the target. Slow speed machines need closer and larger targets than high speed machines.
With an A6400 Portable Analyzer and A6420 Shaft Encoder, you can verify the offset of the target from TDC and enter this into the geometry setup in the Windrock MD software. TDC should be marked on the flywheel sufficient for the timing light to illuminate when the machine is running. TDC offset may be advanced or retarded in software to correct any discrepancies.
COMPATIBLE MAG PICKUPS
Windrock Part Num. OEM OEM p/n Thread Thread Length Notes
A3012-10-00 Dynalco M231 5/8-18 UNF-2A 4” Intrinsically safe; CSA Approved
A3012-00-00 Honeywell A3042A 5/8-20 UNF-2A 1.4” Intrinsically safe
NOT SOLD BY WRI Honeywell 3090A35 5/8-20 UNF-2A 4.8” Intrinsically safe
…CONTINUED FROM PREVIOUS PAGE…
MACHINE CONNECTION
Cylinders must be drilled and tapped into the clearance volume (for compressors, both the head end and crank end) where the piston will not cover the opening.
The sensor requires five (5) inches minimum clearance in line with the end of the valve so as to leave enough room to install and remove.
Keep the connection as short as possible. Avoid using elbows if at all possible. Elbows may obstruct the pressure flow into the sensor.
Indicator ports allow pressure measurement inside the cylinder and are required on any compressor cylinder requiring pressure measurements.
Install a full-opening valve with a ½" NPT connector for the sensor. A straight-through port of 1/8" diameter or larger is acceptable in a valve. Restricted port valves such as needle valves are not desirable for compressor analysis as they dampen higher frequencies.
We recommend a Whitey Valve with PEEK material or Kiene valve for easy shutoff and removal of the sensor for calibration and replacement.
Table 3-1, Spotlight Mag Pickup Compatibility List
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Incorrect connector pin polarity will cause installation problems, however polarity can be changed in the setup. Refer to Table 3-1, Spotlight Mag Pickup Compatibility List for Spotlight-tested compatible mag pickups. For installation sequence, refer to Section 5, System Installation.
3.4 Controller WiFi Antennas
The Controller uses two WiFi antennas as shown in Figure 3-2. Antennas are installed after the unit is mounted. Refer to Section 5, System Installation.
3.5 02113000 Spotlight Trunk Cable
The Controller connects to each PUC Module using the Spotlight Trunk Cable. This circular 8 position cable has male and female ends. This allows for connecting multiple cables together if a longer length of cable is required for installation. Contact your Windrock representative to purchase additional cables. Spotlight Trunk Cable part number is 02113000.
3.6 A3932 Spotlight Magnetic Pickup Cable
The Spotlight Magnetic Pickup Cable connects on one end to the magnetic pickup. On the opposite end, the 3 position connector can either connect directly to the TDC IN of the Controller, or to a Spotlight MPU Extension Cable (Section 4.6). Spotlight Magnetic Pickup Cable part number is part number is A3932-CBL-0-5.
3.7 Hose Clamp Kits and Neoprene Rubber Strips
Each standard Spotlight System comes with hose clamp kits and neoprene rubber strips. These are used to mount the PUC Module integral temperature sensor on the compressor intake pipe. Refer to Section 5, System Installation for further details.
4 Optional Accessories
4.1 General
Spotlight systems have ONLY been approved for use using the accessories listed in Section 3 and Section 4.
Items listed in Section 4 are not standard and therefore must be purchased separately. If interested, contact Windrock Sales for a quote.
NOTE: THE SAFETY OF ANY SYSTEM INCORPORATING THE EQUIPMENT IS THE RESPONSIBILITY OF THE INSTALLER OF THE SYSTEM.
EXTERNAL WIFI The A3910 controller is designed to permit use of an external WiFi antenna, connected to the controller ANT2 jack, if needed to improve connectivity with the A3930 gateway. Such an antenna must be designed for use with 2.4 GHz frequency (compatible with IEEE 802.11 b/g standards); the cable must terminate in an RP-SMA connector to mate with the ANT2 jack. In the United States, if a directional WiFi antenna with gain higher than 6 dBi is used with the controller, FCC regulations require that the transmit power of the controller be reduced by 1 dB for every 3 db that the directional gain of the antenna exceeds 6 dBi. This rule applies only if the equipment is used for fixed, point-to-point operation; greater power reduction may be required when directional WiFi antennas are used in other circumstances. The operator of the equipment, or if the equipment is professionally installed, the installer, is responsible for ensuring that this power reduction is implemented and that the system is used exclusively for fixed, point-to-point operations. (Reference: Title 47, Code of Federal Regulations, part 15.247.) In general, it is the responsibility of the installer and operator, respectively, to ensure that legal requirements for installation and operation are followed. Contact Windrock for information on how to reduce controller transmitter power.
Figure 3-2, Controller with WiFi Antennas
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IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.
4.2 A6400 Portable Analyzer
Windrock’s A6400 Portable Analyzer is used to collect sensor point data for diagnostic analysis and performance measurements. Using a Portable Analyzer in combination with a Spotlight system expands the potential analysis of the machine for preventative maintenance.
4.3 A6420 Shaft Encoder
Windrock’s A6420 Shaft Encoder is used to provide the TDC phasing signal to A6400 Portable Analyzer. The Encoder generates a pulse per revolution (PPR) signal for tracking crankshaft motion. Spotlight Controllers connect to the A6420 Shaft Encoder to allow the A6400 Portable Analyzer to reference machine TDC.
For connection details, refer to Section 5, Shaft Encoder.
4.4 A3934 Spotlight Shaft Encoder Cable
The Spotlight Shaft Encoder cable is used in conjunction with the A6420 Shaft Encoder. The Windrock part number for this cable is A3934-CBL-0-3.
For connection details, refer to Section 5, Shaft Encoder.
4.5 A6410 Strobe (Timing) Light
Windrock’s A6410 Strobe (Timing) Light is used to correct for phase angle from TDC measurements.
For connection details, refer to Section 5, Shaft Encoder.
4.6 02113010 Spotlight Mag Pickup (MPU) Extension Cable
The Spotlight MPU Extension Cable is a 3 position cable with male and female ends. The cable part number is 02113010 and is used in two possible ways:
1) Controller expansion: The MPU Extension Cable connects from the Y-Adapter to the TDC IN of the Controller.See Section 5, Installation Overview for details. In addition, multiple MPU Extension Cables can be connected together to accommodate larger cable runs.
2) Magnetic Pickup Cable expansion: The MPU Extension Cable extends the reach of the A3932 MPU Cable to the Spotlight Controller.
4.7 02201070 Magnet
A small diameter magnet, part number 02201070, can be used as a target for the Magnetic Pickup Sensor as described in previous Section 3.3 as well as Section 5, System Installation.
4.8 021103040 Y-Adapter Connector
The Y-Adapter Connector is used to split the MPU signal between two (or more) Controllers. The connector part number is 02113040.
5 System Installation
5.1 General
NOTE: THE SAFETY OF ANY SYSTEM INCORPORATING THE EQUIPMENT IS THE RESPONSIBILITY OF THE ASSEMBLER OF THE SYSTEM.
IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.
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NOTICE – Review this section of the manual prior to installation. For questions regarding installation, contact your Windrock salesperson or Windrock Customer Support.
ADVERTISSEMENT – Cette section du manuel est uniquement à des fins de référence. Contacter votre vendeur Windrock ou Windrock service clientèle pour toute question concernant l'installation.
5.2 Hazardous Locations
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS 1, DIVISION 2, GROUPS A-D OR NON-HAZARDOUS LOCATIONS ONLY.
SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS 1, DIVISION 2
ALL WIRING MUST BE IN ACCORDANCE WITH APPROPRIATE SECTIONS OF THE NATIONAL ELECTRICAL CODE AND/OR IN ACCORDANCE WITH THE CANADIAN ELECTRICAL CODE AND IN ACCORDANCE WITH THE AUTHORITY HAVING JURISDICTION.
Unless otherwise marked on the equipment, modules have a temperature code of T4A when operating in a -20°C to +50°C (Controller) or -20°C to +80°C (PUC) ambient temperature.
Refer to the Section 8 for control drawings and entity parameters.
WARNING – EXPLOSION HAZARD – DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – AVANT DE DECONNECTOR L’EQUIPMENT, COUPER LE COURENT OU S’ASSURER QUE L’EMPLACEMENT EST DESIGNE NON DANGEREUX.
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5.3 Installation Overview
Figure 5-1, 4 Cylinder Connection Diagram
Figure 5-2, Multiple Controller Connection Diagram
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Order of installation:
1) Ensure compressor is both de-energized and locked out/tagged outper facility’s standard procedures. Adhere to all safety proceduresrequired by the facility and acquire all necessary work permits.
2) Choose Gateway mounting location. For details, See Section 5.8.
Important: Gateway location is central to all Controllers in vicinity.
3) Drill holes at Gateway mounting location. If using aluminummounting bars AND wall thickness is larger than 0.125”, customermust supply four 1/4”-20 screws longer than supplied in the Windrock kit (1/4”-20 x 1”).
4) Assemble Gateway. Install router on DIN rail and mount feet on bottom of enclosure. For details, see Section 5.8.
5) Mount A3930 Gateway unit. If using the aluminum mounting bars,attach using 1/4”-20 screws, lock washers, and nuts provided with the system. If using the plastic mounting feet, provide #10 screws (supplied by customer).
6) Customer must provide supply voltage at desired mounting location.For details, see Section 5.6. Ensure power is de-energized.
7) Install disconnecting device, clearly marked (supplied by customer).
8) Attach WiFi antenna to Gateway. Orientdirection of antenna according to Figure 5-3,
NOTE: Hold the antenna steady inposition shown while screw-mountingthe connection. Improper techniquecan damage the antenna.
9) Attach both Cellular LTE antennas to DIV and ANT label on router. Orient direction of antennas according to Figure
5-3. NOTE: Hold the antenna steady in position shown while screw-mounting the connection. Impropertechnique can damage the antennas.
10) Connect internal power cable to router PWR.
11) Connect Ethernet cable to router LAN.
12) Connect 24Vdc integral power cable todisconnecting device.
a. White conductor is positive.
b. Black conductor is ground return.
13) Energize A3930 Gateway unit. If necessary, see A3930 Manual for further details.
14) Install pressure sensors into either ½” NPT port or Whitworth port. Dual port Kiene valves orright angle adapters sold separately.
15) Mount and gap magnetic pickup sensor. Fordetails, see Section 5.4.
16) Choose A3910 Controller mounting location. For details, see Section 5.5.
a. Location is within unobstructed line-of-sight of Gateway, ideally less than 50 feet.
Letter Part Router Connection
A WiFi Antenna WiFi
B Cellular LTE Antenna DIV
C Cellular LTE Antenna ANT
D Internal Power Cable PWR
E External Cellular LTE Antenna Connection (Not Typically Used) DIV
F External WiFi Antenna Connection (Not Typically Used) WiFi
G External Ethernet Connection (Not Typically Used) LAN
H External Cellular LTE Antenna (Not Typically Used) ANT
I External Power Cable -
Figure 5-3, Gateway Connections
Figure 5-4, Gateway status page
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b. Location is within 16ft (5m) of the magnetic pickup sensor, taking intoaccount cable routing. Attach cable to sensor and route to proposed Controller mounting location. If longer length is needed, use a MPUExtension Cable (sold separate).
c. Location is within 32ft (10m) of the furthest compressor crosshead,taking into account cable routing.
17) Drill holes at Controller mounting location. This can be a control cabinet (de-energize as necessary), or a mounting plate (supplied by customer). If wall thickness is larger than 0.125”, customer must supply four 1/4”-20 screws longer than supplied in the Windrock kit (1/4”-20 x 1”).
18) Customer must supply a source of SELV LPS 24VDC Power at desiredcontroller mounting location. For details, see Section 5.6. Ensure power is de-energized.
19) Install disconnecting device, clearly marked (supplied by customer).
20) Attach WiFi antennas to Controller.
21) Mount A3910 Controller unit using 1/4”-20 screws, lock washers, and nuts.
22) Connect integral power cable to +24Vdc disconnecting device.
a. White conductor is +24Vdc.
b. Black conductor is ground return.
23) Connect Spotlight Trunk Cables to each Controller PUC connection (fourtotal).
24) Place the first PUC Module on compressor Cylinder # 1.
25) Connect the PUC1 Trunk Cable to this module.
26) If necessary, refer to separate Kiene valve installation procedure document.
27) Install both Pressure Sensors on Cylinder.
28) Connect Head End pressure sensor cable on PUC Module to Head EndPressure Sensor.
29) Connect Crank End pressure sensor cable on PUC Module to Crank EndPressure Sensor.
30) Place the RTD sensor from PUC Module on the neck of the intake pipe. CoverRTD sensor with included pad and tighten using hose clamp (clamp and pad included with system).
31) Mount the second PUC Module on compressor Cylinder # 2.
32) Repeat steps 24) through 29) using the PUC2 Trunk Cable.
33) Mount the third PUC Module on compressor Cylinder # 3.
34) Repeat steps 24) through 29) using the PUC3 Trunk Cable.
35) Mount the fourth PUC Module on compressor Cylinder # 4.
36) Repeat steps 24) through 29) using the PUC4 Trunk Cable.
37) The hardware for the Controller and PUC Module units are now connected.
Gateway Status Page Each row in the bottom of Figure 5-4, Gateway status page, reports the status of Controllers that the Gateway has seen. Stale updates (>10 minutes old) are in gray. Recent reports are shown in green. Your first indication that the new controller is working will be to see a new ID appear here in green. The status page does not currently refresh itself, you have to reload it.
The controllers emit several of these reports at 5 second intervals when they boot, and afterward at 5 minute intervals. The firmware in the controller currently at the site doesn’t wait until the wifi link is up before emitting those status messages, with the result that it will take at least 5 minutes using that firmware before the gateway status page will show that controller’s report.
The ID column is the Controller serial number.
The TDC column indicates whether the controller is seeing a usable TDC signal. The indications on the PUC 1 LEDs will likely appear before the indication on the status page.
The Update Date/Time is in GMT based on the gateway’s clock. Compare it to the GMT time at the top of the status page to see how old the last update is.
Gateway Dump Page
The Gateway Dump Page, shown in Figure 5-5 displays a list of timestamps that reflects all of the data files collected during the past 24 hours. Click on the bottom one (scroll down if necessary) to see the latest data. The format of the file is YYYY-MM-DDTHH:MM:SSZ xxxxxxxxx where xxxxxxxxx is the controller serial number.
Once you click on a link, the data collected will be displayed and plotted. Note that y axes of the graphs aren’t scaled to the data range – they all show the raw 16-bit range from 0 to 65535. If you want to see scaled values, you can click on a link at the top of the page.
Figure 5-6 shows a screenshot of a single data dump:
Show Scaled Plots shows the plots windowed so that the vertical excursion is full scale.
JSON File dumps the raw JSON file (which a browser can usually parse and display) and also allows a JSON file to be downloaded by the client machine.
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38) For a single Controller installation, directly connect the magnetic pickup sensor cable to Controller TDC IN connection.
39) To verify Controller operation, you can connect your phone or laptop tothe gateway’s WiFi using
a. SSID: WindrockIIoT (two capital I’s)
b. Password: (unique to each Gateway)*
*Contact Windrock customer support for WiFi Password.
40) Verify Controller and Gateway connectivity using the Gateway Status Page (see sidebar on previous page)
a. http://192.168.3.1:8888/status
41) Verify valid Sensor activity on the Gateway Dump Page (see sidebar on previous page)
a. http://192.168.3.1:8888/status/dump
42) Once configured, it is not necessary to interact with the A3930 locally as its status and operation can be observed within the Cloud and accessed from WindrockEnterprise and downloaded to Windrock MD.
5.4 Magnetic Pickup Mounting
When using the magnetic pickup for TDC (top dead center) triggering in reciprocating machine analysis, it is extremely important that the pickup triggers data acquisition exactly at TDC. Errors of only 2 degrees can produce measurement errors of up to 5% in horsepower and throughput calculations. For the magnetic pickup to operate properly with Spotlight systems, several issues must be addressed.
PICKUP DISTANCE FROM TARGET
Often, the magnetic pickup is placed too close to the target. When this happens, the pickup can trigger data acquisition on scratches, nicks, or magnetic deformities in the flywheel or shaft. Usually, a gap of about 1/8 inch is sufficient.
TARGET TYPE
Some sort of target must be placed on the flywheel or shaft to trigger the magnetic pickup. The target must be of a ferrous material. To ensure a proper signal, a small magnet has been provided with this system. This will produce the largest magnetic interference of any other scratch, hole, or deformity in the flywheel or shaft. Place a drop of adhesive on the magnet and position the magnet center at TDC of the machine.
Installers must fabricate a mounting bracket for the magnetic pickup sensor. Make a clearance hole using a 37/64” drill bit. Use a tee-handle 5/8”-18 UNF tap coated with cutting fluid to cut threads into the hole.
Thread the magnetic pickup into the bracket with a 1/8” gap between the pickup and the magnet on the flywheel or shaft.
For very high speed machines, adhesive might not be sufficient to hold the magnet onto the flywheel. In such cases, the recommended target is a pin.
5.5 Controller Mounting
Care must be taken when choosing the location for the Spotlight Controller. At least four main considerations must be taken into account:
Figure 5-6, Gateway dump page (2 of 2)
Figure 5-5, Gateway dump page (1 of 2)
5 OR MORE CYLINDER INSTALLATION Multiple Controllers can be connected to the same Compressor by using Y-Adapter Connector as shown in Figure 5-2. Connect the Y-Adapter to MPU Cable and split the signal to separate Controllers using two MPU Extension Cables. Repeat steps 14) to 35) for additional Controller.
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a. Location is within unobstructed line-of-sight of Gateway, ideally less than 50 feet.
b. Location is within 16ft (5m) of the magnetic pickup sensor, taking into account cable routing.
c. Location is within 32ft (10m) of the furthest compressor crosshead, taking into account cable routing.
d. Do not position the Controller so that it is difficult to operate the disconnecting device.
The Spotlight Controller is intended to be mounted on the exterior of any sheet metal enclosure or flat wall surface. The mounting hole pattern is shown in Section 8. Standard systems includes four sets of 1/4”-20 X 1” screws, flat washers, split lock washers, and hex nuts. Depending on site conditions, longer screws may be needed to complete installation. Mount Controllers as high as practical, and within line-of-sight of the A3930 Gateway. Mounting Controllers on the side of a compressor control cabinet could be a convenient location. The omnidirectional WiFi Antennas work best in a vertical arrangement. Ensure that all cables exiting the bottom of the Controller have sufficient slack and are within reach of their intended device. Bottom cables include the four Spotlight Trunk Cables, one Spotlight Magnetic Pickup Cable, and integral power cable.
5.6 Power Requirements
Windrock Spotlight is designed to be powered from an approved SELV LPS 24VDC power source. Locations that do not have 24VDC available will require the addition of 24Vdc power supplies rated for the installed location. The amount of power required is detailed in Section 7, Specifications.
All A39xx modules will operate properly with a supplied voltage of 20Vdc to 30Vdc. However, this input voltage is applied to sensors, so it must be chosen to not exceed the Vmax of any attached sensor. For example, if an attached 4-20mA sensor has a Vmax of 24V, then then maximum supplied voltage to the Windrock Spotlight is 24V. All Windrock sensors have a Vmax of at least 24V, so 24Vdc +0%/-5% is the recommended safe supply voltage.
PERMANENTLY CONNECTED EQUIPMENT must have a circuit breaker or switch included in the installation. It must be suitably located and easily reached. It must be marked as the disconnecting device for the equipment. It must be rated for the environment, the voltage, and the amount of power required by the entire system. Access to disconnect devices must not be obstructed.
Both A3910 Controller and A3930 Gateway are supplied with integral 30’ long 22AWG power cables. It is recommended for the installer to terminate 24Vdc into an approved junction box near equipment installation location. Conductors must be of sufficient size to carry the amount of current required for the entire system.
5.7 PUC Mounting
PUC Modules are intended to mount to the compressor crosshead. Each PUC contains an internal accelerometer for assessing the health of the crosshead. There are two methods for mounting PUCs:
WARNING – EXPLOSION HAZARD. DO NOT SUPPLY WINDROCK SPOTLIGHT WITH A VOLTAGE HIGHER THAN VMAX OF ATTACHED SENSORS. IF NON-INCENDIVE ENTITY PARAMETERS AS LISTED IN THE A39XX CONTROL DRAWINGS AND THE ATTACHED DEVICES ARE NOT FOLLOWED, THEN CONNECTIONS MUST BE CONSIDERED INCENDIVE.
ADVERTISSEMENT – RIAQUE D’EXPLOSION – N'ALIMENTEZ PAS WINDROCK SPOTLIGHT AVEC UNE TENSION SUPÉRIEURE À VMAX DE CAPTEURS CI-JOINT. SI NON-INCENDIAIRE ENTITÉ PARAMÈTRES AS FIGURANT DANS LES DESSINS DE CONTRÔLE A39XX, ET LES PÉRIPHÉRIQUES CONNECTÉS NE SONT PAS RESPECTÉES, ALORS DES CONNEXIONS DOIVENT ÊTRE CONSIDÉRÉES INCENDIAIRE.
WARNING – SUPPLYING WINDROCK SPOTLIGHT WITH LESS THAN 20VDC MAY RESULT IN IMPAIRED OPERATION.
ADVERTISSEMENT – FOURNITURE WINDROCK SPOTLIGHT AVEC MOINS DE 20 VDC PEUT PROVOQUER UN FONCTIONNEMENT AVEC FACULTÉS AFFAIBLIES.
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1) Magnet Mounting: Each PUC Module comes with neodymium magnets pre-installed. While magnets are the easiestand quickest way to install the PUCs, care must be taken in regards to maximum operating temperature at the mounting location. For extended periods over 175°F, the magnetic strength of the neodymium magnets will begin todegrade. If the crosshead temperature exceeds this value, choose one of the remaining two mounting methods.
Prepare a clean smooth, flat mounting surface, ideally using a spot face tool. A minimum surface finish of 63 Fin (0,00016 mm) generally works best. After cleaning the surface and checking for burrs, wipe on a light film of silicone grease, machine oil, or similar-type coupling fluid.
Mount the magnet/PUC assembly to the prepared test surface by gently "rocking" or "sliding" it into place.
Note: Magnetically mounting accelerometers carelessly has the potential to generate very high (and very damaging) acceleration (g) levels. To prevent damage, install the assembly gently. If unsure, please contact the Windrock Support for assistance.
2) Bolt-Down Mounting: Carefully remove the neodymium magnets from the PUC Module. . Clean the surface of the crosshead as well as the bottomsurface of the module. Mark the two screw locations on the crosshead using the slotted bracket on the PUC Module as a template. Spot face the surface and drill a ½” blind hole into the crosshead using a 13/64” (#7) drill bit. Use atee-handle ¼”-20 tap coated with cutting fluid to cut threads into the hole.Fasten each end of the module using the included ¼”-20 x 1” screw and lockwasher provided.
Refer to Section 8 for PUC Module mounting drawings.
5.8 Gateway Mounting
Care must be taken when choosing the location for the Spotlight Gateway. A few considerations must be taken into account:
a. Location is within unobstructed line-of-sight of Controllers, ideally less than 50feet from the furthest Controller.
b. Do not position the Gateway so that it is difficult to operate the disconnecting device.
c. Mount the Gateway such that the router indicators are easily visible through the windowed enclosure.
The Spotlight Gateway is intended to be mounted on the exterior of any sheet metal enclosure or flat wall surface.
Prior to mounting, some assembly is required. To prevent damage during shipment, the router is packaged separately within the Gateway enclosure. Mount the router onto the DIN rail and reconnect internal power cable and ethernet cable as shown in Figure 5-3.
The Gateway can be structurally mounted in two different ways. The first way (Option # 1, Figure 5-7) uses two slotted aluminum mounting bars that accept 10-32 screws. Windrock recommends using this mounting method. Attach the mounting bars to the enclosure using the flathead screws included with the plastic mounting feet (Option # 2, Figure 5-9).
Once done, the enclosure should be mounted using the fastener stack shown in Figure 5-8. These fasteners are included with a standard system:
CAUTION: THIS PRODUCT CONTAINS NEODYMIUM MAGNETS. Neodymium magnets are much more powerful than other kinds of magnets. They can affect pacemakers, ICDs, and other implanted medical devices. They can damage magnetic media such as floppy disks, magnetic I.D. cards, credit cards, cassette tapes, video tapes, or other devices. Avoid placing magnets near electronic appliances. Strong magnetic fields can influence compasses, such as used in air transport, smartphone, and GPS devices.
Figure 5-7, Gateway Option #1 Mounting
Figure 5-8, Option # 1 Controller Mounting DimensionsMounting Fasteners
Figure 5-9, Gateway Option #2 Mounting
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Item 1, Four (4) 1/4”-20 X 1” screws
Item 2, Eight (8) flat washers
Item 3, Four (4) split lock washers
Item 4, Four (4) hex nuts.
Depending on site conditions, longer screws may be needed to complete installation. Mount the Gateway such that the router indicators are easily visible through the windowed enclosure.
Gateway Mounting Option #2 can also be used to secure the Gateway Enclosure. The OEM polycarbonate enclosure includes a plastic mounting foot kit. If this option is better suited for the installation, install each of the four feet to the enclosure using the included flat head screws. #10 screws (not included) must then be used to fasten the enclosure to a structure.
Mounting hole dimensions are shown in Figure 5-7 and Figure 5-9 as well as in Section 8.
5.9 Shaft Encoder
The A6420 Shaft Encoder is used to provide TDC phasing for the A6400 Portable Analyzer. Connect the A3932 cable between TDC OUT on the Controller and TDC on the Shaft Encoder. Power the Shaft Encoder on and choose the MAG PICKUP input. Enable the RF icon on the Shaft Encoder screen to communicate with the Portable Analyzer.
The A6410 Timing light is used with the Analyzer to determine TDC phase angle. Once machine TDC is connected to the Analyzer, activate and point the Timing light at the TDC mark on the flywheel. Adjust the Timing light forward or backwards as necessary. Make note and record the degrees offset indicated on the Analyzer.
5.10 Environment
This equipment has been rated for outdoor use for use in weather with an ambient temperature range from -20°C to +50°C for the Controller and from -20°C to +80°C for the PUC Module. Enclosures exposed to sunlight may also be heated above the rated temperature. Supplemental cooling may be required in these environments.
6 Maintenance and Cleaning
The Windrock Spotlight contains no user serviceable parts and requires no routine maintenance. Repair and support are provided by Windrock Inc. only.
Firmware and software updates are available periodically. Both the Gateway and Controller automatically installs updates as needed.
The use of cleaning chemicals is not recommended. Dust and dirt may be removed with a soft cloth.
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7 Specifications
Mechanical
Enclosure Dimensions
A3910-00-00 6.75" x 4.4" x 4.3"
A3920-00-00 5.23” x 5.23” x 1.54”
Weight A3910-00-00 4lb
A3920-00-00 2lb
Mounting
A3910-00-00 Wall Mount, for dimensions see Section 8
A3920-00-00 Compressor Crosshead, for dimensions see
Section 8
Environmental
Temperature Range A3910-00-00 Operating: -20°C to +50°C
A3920-00-00
(PUC Module)
(Suction Temperature RTD)
Operating: -20°C to +80°C
Operating: -20°C to +200°C
Ingress Protection
Rating
A3910-00-00 IP55
A3920-00-00 IP65
Electrical
Input Voltage
A3910-00-00
Nonhazardous locations
20VDC - 30VDC using approved
SELV LPS power source
Class I, Div 2 locations
24VDC (+0%, -5%) using approved
SELV LPS power source
A3920-00-00 Nonhazardous & Class I, Div 2 locations
24VDC @ 1W max
5VDC @ 0.25W mx
Input Power A3910-00-00 13W max
Accelerometer A3920-00-00 100mV/g with 50g max
Industry Certifications & Approvals
Hazardous Area ISA-12.12.01/CSA 213, Class I, Division 2
Emmissions/ Immunity FCC Part 15, Subpart B; ICES-003
Safety UL 61010-1; CAN/CSA C22.2 No. 61010-1-12
Certifying Body SGS Q-Mark Certification
8 Appendix.
8.1 Entity Parameters
8.2 CD-A3910-01 Controller Specification
8.3 CD-A3920-01 PUC Module Specification
8.4 Controller Mounting Options
8.5 PUC Module Mounting Options
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Entity ParametersModel Prefix
Ref Designator*
Connection Pin # VOC ISC CA LA VMAX IMAX CI LI
A3910
J1, J2, J3, J4
PUC1,
PUC2, PUC3, PUC4
Pin 1 24V 100mA 0.46µF 5mH - - - -
Pin 2, Pin 3, Pin 4, Pin 5 24V 3.5mA 0.46µF 100mH 24V 25mA 20pF 0mH
Pin 6, Pin 7 - - - - - - - -
Pin 8 5V 20mA 1000µF 100mH - - - -
J5 TDC IN
Pin 1 2.5V 250µA 5µF 100mH - - - -
Pin 3 - - - - - - - -
Pin 4 2.5V 25mA 5µF 100mH - - - -
J6 TDC OUT Pin 1, Pin 4 9V 16mA 5µF 100mH - - - -
Pin 3 - - - - - - - -
J1, J2, J3, J4 J5 J6
A3920
J11 CONTROLLER
Pin 1 - - - - 24V 100mA 810pF 0µF
Pin 2, Pin 3,Pin 4 24V 30mA 0.4µF 50mH - - - -
Pin 5 - - - - 28V 20mA XXpF XXµF Pin 6, Pin 7 - - - - - - - - Pin 8 - - - - 6V 20mA 1000pF 0mF
J12, J13 HEAD END PRESSURE, CRANK END PRESSURE
Pin A 24V 100mA 0.43µF 5.3mH - - - - Pin B, C, E, F - - - - - - - -
Pin D - - - - 24V 30mA 6.5nF 22µH
J11
J12, J13
Definition of Parameters
VMAX Maximum voltage that may safely be applied to the intrinsically safe apparatus.
IMAX Maximum current that may safely be applied to the intrinsically safe apparatus.
CI / LI Internal unprotected capacitance/inductance of the intrinsically safe apparatus.
VOC Maximum open-circuit voltage that can appear across the intrinsically safe connections of the associated apparatus under fault conditions.
ISC Maximum short-circuit current that can be drawn from the intrinsically safe connections of the associated apparatus under fault conditions.
CA / LA Maximum capacitance/inductance that can safely be connected to the associated apparatus. When the electrical parameters of the wire are unknown, ANSI/ISA RP12.6 states the following default values may be used: Capacitance 60.0 pF/ft (196.9 pF/m) Inductance .20 μH/ft (.66 μH/m)
*Reference designators are assigned as shown on control drawing CD-A3910-01 and CD-A3920-01
Revision History
1.0 5.8.18 Release
2.0 5.16.18 Added external WiFi note
