Machine Monitoring Systems

DOPS
Digital Overspeed – Protection System
● Microcontroler based
measuring system
● Up to 6 limit values per
channel, different operating
modes depending on
installed back plane
● Two current outputs per
channel with zoom function
and dual current function,
one of them galvanically
isolated
● Mutual comparison of pulses
and output signals between
all channels
● Redundant power supply
● Self-test functions for
electronic circuits and
transducers
● Simplified fault detection by
display messages in plaintext
● Galvanical isolation of binary
input and output signals
● Wiring by means of
preformed cables and
converters in the control
cubicle
● RS 232 interface for
parameter setting
● RS 485 interface for data
exchange with the epro MMS
6850 analysis and diagnosis
system
● Hot swap of boards during
operation

Short description:
The speed measurement and With a suitable sensor arrangement The system includes an extended
protection system DOPS serves at the trigger wheel of the machine fault detection function. The three
measurement of and protection it is possible to detect the direction speed sensors are continuously
against inadmissible overspeeds at of rotation. checked on operating within the
any kind of rotating machinery. The integrated peak value memory permitted limits. Moreover, the
With the consistent three channel permits reading out the maximum channels mutually check and
construction, starting with the signal speed value that has occurred supervise the output signals of each
detection via signal processing up before the machine was switched other. If the internal fault detection
to the evaluation of the measured off. This function provides important circuit detects an error, this will be
speed, the system offers the maxi- information for evaluating the indicated via the output contacts
mum safety for the machines to be mechanical machine load caused and shown on the display as
monitored. by the overspeed. plaintext.
Safety relevant limits (e.g. over- Alarm outputs and error messages By using preformed connection
speed limit values), are combi ned in are output via potential-free opto- cables and screw terminals, the
a 2 out of 3 logic and operate in the coupler outputs. Beside this, the system may be integrated
closed circuit mode. Thus it can be alarm outputs, combined in a 2 out economically in a 19“ cabinet.
ensured that beside operational of 3 logic, as well as message line
safety, the protection function on a and channel clear line of the
high level standard is met as well. channel supervision, are output via
potential-free relay contacts.
 Machine Monitoring Systems

Technical data:
Signal inputs: Max. speed: Reset Latch:
Differential input, nonreactive, 65.535 rpm (limited to max. To reset the latch function of
open-circuit and short-circuit 18 teeth at the trigger wheel function and alarm outputs
proof by the max. input frequency Test input:
Input voltage range: of 20 kHz) For testing the monitoring
0...27,3 V DC Max. number of teeth at the functions with an internally
Limit range: trigger wheel generated test value
0...30 V 255 (max. 4700 rpm) Binary outputs:
Input resistance: Current outputs of Altogether six function outputs
> 100 kOhm characteristical values: with separate function or limit
Sensor signal outputs: Calculation of characteristical setting. The functions of the
SMB front sockets, buffered, values and evaluation binary outputs as well as the
open-circuit and short-circuit depend on the functions switching characteristics are
proof, non-reactive defined during the defined during configuration.
Signal output: configuration Limit setting:
0...4,1 V; output = 0.15 x Current output 1: by parameter setting, depend-
sensor signal 0/4...20 mA galvanically ing on the assigned function.
Accuracy: isolated Visualization of the condition:
±1% of f.s.d Accuracy: With a red LED for each of the
Frequency range: ±0.1% of f.s.d. /16 bits function-/ alarm outputs.
0...16 kHz (-3dB) ±20% Current output 2: Limit data for binary outputs:
Permissible load: 0/4...20 mA galvanically not Output 1 -3
> 1 MOhm isolated, with feed back of the C - E open:
Internal resistance: output signal for comparison max. UCE 48 V
10 kOhm of analog results C - E conducting:
Dynamic outputs: Accuracy: max. ICE 50 mA
TTL – output: ±0.1% of f.s.d. /16 bits Output 4 –6
The prepared input pulses Speed zoom: C - E open:
are output as TTL – pulses. One speed zoom per current max. UCE 48 V
TTL – Pulse: output, accuracy 0,1% of C - E conducting:
open circuit and short-circuit f.s.d. /16 bit max. ICE 100 mA
proof, nonreactive Channel supervision and Communication interface
Nominal range: visualization: RS 232:
0...5 V SS Each channel does not only Front socket to connect a
Frequency range: check the signal of the accom- laptop for configuration and
0Hz...20 kHz panying speed sensor con- visualization
Permissible load: tinuously, but also compares RS 485:
> 1 MOhm pulses and current outputs of Bus interface for communi-
Internal resistance: the other two channels with cation with the epro MMS
5,1 kOhm those of the own channel. 6850 analysis and Diagnosis
Pulse outputs: Thus a maximum in safety can system via the MMS 6831
The prepared input pulses be ensured. Faults are indicated interface card.
are output via potential-free with two green LEDs at the Power supply:
opto couplers monitor front. Signalling of the Two redundant inputs,
Max. voltage: channel supervision is carried decoupled via diodes, for
+24 V at UC, +48 V at the out via opto-decoupled collector nominal +24 V with common
collector /emitter lines. ground
Max. current, C-E conducting: Status = fault: Permissible voltage range:
100 mA Umax. = 48 V DC 18...31,2 V DC according to
Signal conditioning for Status = o.k.: IEC 654-2 class DC 4
characteristical values: Imax. = 100 mA Sensor supply:
Binary inputs: Decoupled and galvanically
Before processing, the input
The binary inputs of the isolated to the system vol-
signals are standardized by the
module are galvanically tages and to the supply vol-
processor. The characteristical
isolated, but however, have a tage. Open circuit and short-
value is proportional to the
common GND. circuit proof.
speed, i.e. to the input pulse
Signal level:
frequency divided by the
Low: 0...+3 V
number of teeth of the trigger
High: +13...+48 V
wheel.
External blocking:
Max. measuring range:
To disable the function-/ alarm
limited by the max. signal
outputs, e.g. for service and
frequency of 20 kHz at the
maintenance works etc.
input
 Machine Monitoring Systems

Technical data:
Supply voltage: Temperature for storage and Width:
26.75 V dc transport with display 14 TE
Residual ripple: -30...+85°C (approx. 71 mm)
< 20 mVpp (at nominal current Rel. humidity 5...95% non- without display 6 TE
20 mA) condensing (approx. 30 mm)
Max. current: Protection class: Connector:
35 mA IP 00, open construction DIN 41 612, type F 48 M
Environmental conditions: according to DIN 40050 Dimension of the total system:
Application class: EMC DOPS
KTF according to DIN 40 040 according to EN 50 081-1 / 42 TE (approx. 213 mm)
Reference temperature: EN 50 082-2 fulfilled DOPS AS
+25°C Mechanical design of the 42 TE (approx. 213 mm)
Nominal operating range: printed circuit board:
0...+65°C Euro-format (100 x160 mm)
according to DIN 41 494
Measuring modes:
The speed measurements are Since at this measuring mode The measuring time for this
based on time measurements bet- the result directly depends on mode depends on the actual
ween pulses generated by the the precision of the trigger speed, e.g. 20 ms at 3000 rpm.
trigger wheel. There are two differ- wheel, it is essential to use The higher the speed of the
ent measuring modes: precisely manufactured trigger machine, the shorter the
wheels to get exact measuring measuring time.
1. n Measurements per results. This measuring mode is
revolution particularly suitable to measure
With this measuring mode the 2. One measurement per the speed very exactly since
incoming pulses from the pulse revolution mechanical influences caused
wheel are measured within a The time for one revolution of by differences between the
variable time window of 5...10 the machine shaft is measured teeth of the pulse wheel are
ms and the speed calculated and from the result of this eliminated over a complete
from the result of these meas- measurement the speed value shaft revolution.
urements. Thus the measuring is calculated.
time with this mode is between
5...10 ms.
Programmable measuring parameters:
- Measuring range - Test value 2 - Stand still detection
- Speed zoom - Hysteresis - Gap limit
- Gear transmission ratio - Channel identification by - Trigger levels
- Analog difference means of KKS numbers or - Channel clear limits
- Number of trigger wheel teeth freely selectable designations - Preferred direction of rotation
- Warning and alarm limits - Current outputs - Measuring mode
- Principle of action - Current calibration - Peak value latch
- Alarm functions - Current suppression - Pulse comparison
- Test value 1 - Current smoothing
- Duty cycle

Different system configurations:

DOPS DOPS AS DOPS TS
Replacement of Turloop speed
- 3 x MMS 6350/D (incl. firmware - 3 x MMS 6350 (incl. firmware measurement system in the Turloop
application no. 0) application no. 2) frame
- 1 x MMS 6351/00 - 1 x MMS 6351/10 - 3 x MMS 6350 (incl. firmware
- 1 x MMS 6352 - 1 x MMS 6352 application no. 1)
- 6 x MMS 6361 - 6 x MMS 6361 - 3 x MMS 6353/TS
- 6 x MMS 6360 - 6 x MMS 6360 - 1 x MMS 6950 W
- 1 MMS 6950 W - 1 MMS 6950 W
alternatively alternatively With this replacement version
- 3 x MMS 6350 (incl. firmware - 3 x MMS 6350/D (incl. firmware not all functions of DOPS or
application no. 0) application no. 2) DOPS AS are at disposal. How-
ever, all functions and specifi-
cations of the Turloop system are
fulfilled.
 channel A channel B channel C

MMS 6350 MMS 6350 MMS 6350

module 01 module 02 module 03

Fig. 1
RS RS I pulse probe supply RS RS I pulse probe supply RS RS I pulse probe supply
232 485 control detection channel clear control 232 485 control detection channel clear control 232 485 control detection channel clear control
signal conditioning signal conditioning signal conditioning
characteristic calcul. characteristic calcul. characteristic calcul.
RPM RPM RPM
zoom zoom zoom

error RPM channel error RPM channel error RPM channel

control zoom A control zoom B control zoom C

data
data
data

limit detection limit detection limit detection

MUX MUX MUX

1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
TTL TTL TTL

Imp TTL A

Imp. A
Imp TTL C

Imp TTL B
Imp. C

Imp. B
Iout C2

RS 485 Bus
Iout A2
Iout B2

Iout A1
Iout B1
Iout C1

CFA

A3
B3
CFC
C3

CFB

A2
B2
C2

A1
B1
C1

+24 V

A1.1 B1.2 CFA1 CFB2 A2.1 B2.2 CFA3 A3.1 B3.2

backplane
MMS 6351/00

B1.1 C1.2 CFB1 CFC2 B2.1 C2.2 CFB3 B3.1 C3.2

C1.1 A1.2 CFC1 CFA2 C2.1 A2.2 CFC3 C3.1 A3.2

K2 K3 K2 K5 K3
Principle circuit diagram of DOPS with back plane MMS 6351/00

A1, B1, C1 CFA, CFB, CFC A2, B2, C2 CFA, CFB, CFC A3, B3, C3

A4
A5
A6
B4
B5
B6
C4
C5
C6

2 of 3 2 of 3 2 of 3 message line 2 of 3

19" Rack MMS 6352

Machine Monitoring Systems
 Machine Monitoring Systems

Principle circuit diagram DOPS AS with back plane MMS 6351/10:

Backplane
MMS 6351/10

48 V/DC
Imax 8A
n>110% trip C

K3
Imp. TTL C 10 kOhm

TTL
channel clear C Imax 25 mA short-circuit proof
channel clear control

characteristic calcul.
signal conditioning
data
probe supply
channel C

channel
data communication C 768 Ohm

MUX
C

6
n>110% trip C Imax 25 mA short-circuit proof

5
limit detection
n>90% C Imax 25 mA short-circuit proof

4
n<300 RPM C Imax 25 mA short-circuit proof
zoom
RPM

3
n<4 RPM C Imax 25 mA short-circuit proof
detection
pulse
MMS 6350
module 03

2
stand still (0 RPM) C Imax 25 mA short-circuit proof
1
control

Imp. C Umax 24 V/DC Imax 25 mA short-circuit proof

I

Iout C2 0/4...20 mA
zoom
RPM
485
RS

Iout C1 0/4...20 mA

48 V/DC
control

Imax 8A
error
232
RS

n>110% trip B

K2

48 V/DC
Imax 8A
n>90 RPM in 2 of 3

K5
Imp. TTL B
TTL

10 kOhm
channel clear control

characteristic calcul.
signal conditioning

data
channel clear B Imax 25 mA short-circuit proof
probe supply
channel B

channel

data communication B 768 Ohm

MUX
B

n>110% trip B Imax 25 mA short-circuit proof

19" Rack MMS 6352

5
limit detection

n>90% B Imax 25 mA short-circuit proof

4

n<300 RPM B Imax 25 mA short-circuit proof

zoom
RPM

n<4 RPM B Imax 25 mA short-circuit proof

detection
pulse
MMS 6350
module 02

stand still (0 RPM) B Imax 25 mA short-circuit proof

1
control

Imp. B Umax 24 V/DC Imax 25 mA short-circuit proof

I

Iout B2 0/4...20 mA
zoom
RPM
485
RS

Iout B1 0/4...20 mA
control

48 V/DC
Imax 8A
error
232
RS

n>110% trip A
K1

48 V/DC
Imax 8A

n<4 RPM in 2 of 3
K4

Imp. TTL A
TTL

10 kOhm
channel clear control

characteristic calcul.
signal conditioning

data
channel clear A Imax 25 mA short-circuit proof
probe supply
channel A

channel

data communication A 768 Ohm

MUX
A

n>110% trip A Imax 25 mA short-circuit proof

5
limit detection

n>90% A Imax 25 mA short-circuit proof

4

n<300 RPM A Imax 25 mA short-circuit proof

zoom
RPM

n<4 RPM A Imax 25 mA short-circuit proof

detection
pulse
MMS 6350
module 01

stand still (0 RPM) A Imax 25 mA short-circuit proof

1
control

Imp. A Umax 24 V/DC Imax 25 mA short-circuit proof

I

Iout A2 0/4...20 mA
zoom
RPM
485
RS

Iout A1 0/4...20 mA
control

+24 V
error
232
RS

RS 485 Bus
Fig. 2
 Machine Monitoring Systems

Limit value-/ function supervision

The MMS 6350 module provides Description of the function outputs: Dual current Out 2
> LIMIT
altogether 6 so-called function out- if current output 2 is operated as
puts. These function outputs may Speed limit, the output switches dual current output, the function
be used as alarm outputs as well as at exceeding the limit value. The output indicates the switching
for indication of individual meas- output will be reset to its initial over from the lower to the upper
uring states. Moreover, the sixth state after the measuring value current range.
function output offers the possibilityhas fallen below the limit value Pulse comparison
to provide a digital signal for an minus hysteresis value. in case of differences between
< LIMIT
external digital speed indicator or to the pulse outputs, this will be
output speed pulses. Speed limit, the output switches indicated via this function
The following functions can be at falling below the limit value. output.
assigned to function outputs 1 to 5: The output will be reset to its Ext. Display
Aus initial state after the measuring (Only function output 6)
- > Limit value has exceeded the limit If this function has been chosen,
- < Limit value plus hysteresis value. an external display to indicate
- > LIMIT + Latch > LIMIT + Latch the speed value may be
- < LIMIT + Latch same as > LIMIT but with connected to this output
latching function Pulse output
- Standstill
< LIMIT + Latch (Only function output 6)
- Direction of rotation same as < LIMIT but with If this function has been
- Dual current Out 1 latching function activated, digital pulses can be
- Dual current Out 2 Standstill transmitted to an external
- Pulse comparison standstill of the machine is system. The pulses of the
indicated via the function output trigger wheel are prepared,
Beside this, function output 6 in- Direction of rotation buffered and transmitted via this
cludes the following functions: the function output shows the output. Each pulse at the signal
- Ext. display machine's direction of rotation input effects the output of one
- Pulse output Dual current Out 1 pulse at this output.
if current output 1 is operated as
dual current output, the function When using the DOPS AS
output indicates the switching system with the MMS 6351/10
over from the lower to the upper backplane, the 768 ohm resis-
current range. tors must be bridged by using
solder jumpers (see fig. 2).

Dual current function:

On activating this function, a selec - Fig.Iout
3 shows an example for a dual
table range, e.g. 0...300 rpm (see current output 0...300...3000 rpm to
fig. 3) is output as current range 20current output 0...20 mA.
amA
0/4...20 mA. For the use of this function, the
When exceeding the limit of 300 galvanically isolated current output
rpm, the module switches over and has to be used.
will then output the complete
measuring range as current range
0/4...20 mA.
The switching between the two 2
current ranges is indicated via the mA
n
relevant function output. 300 3000
Fig. 3

Speed zoom function:

By means of this function, a certain For the use of this function, the
speed range to be defined with start galvanically isolated current output
and end speed can be spread to the has preferably to be used. When
current output range 0/4...20 mA. using the other current output, no
analog comparison of the channels
will be performed below the start
value of the zoom range.
 Machine Monitoring Systems

Module/transducer supervision:
The internal module supervision - System watch – dog Reasons for module disturbances
comprises the following functions: can be read out in detail via the
- Transducer signal within a During the change from the error to communication interface or, at
predefined good range the ok-state and after power-on of modules with a display, directly on
- Wiring between sensor and the module, all functions of the the display. This permits the
module (interruption, short- module are blocked for a delay time technicians to locate the reason for
circuit of sensor supply) of 5s. the fault immediately.
- System supply voltage within Indication of a fault runs, depending
predefined limits on the chosen back plane, via own
- Measuring values within opto coupler outputs or, however,
measuring range via the trip limit. See also principle
diagrams fig. 1 and fig. 2.

Operating elements at the module front:

One nonreactive sensor signal 6 yellow LEDs: adjacent channels fails, this
output via SMB socket: One LED for each of the will be indicated via this LED.
Range: 0...4,1 V function- limit values
Load resistance: ≥1 MOhm 1 Mini DIN diode socket:
Internal resistance: 10 kOhm 2 green LEDs RS232 interface for connection
LED 1 of a computer for configuration
One nonreactive pulse output via Channel supervision for the and data interchange with the
SMB socket: channel assigned to this card module.
Range: 0...5 V LEDs 2,3
Load resistance: ≥1 MOhm Indication of the state of the Handle:
Internal resistance: 5,1 kOhm two adjacent system To pull out and insert the
channels. If one of the module and for labelling
purposes.

Power supply:
Redundant supply input via two Supply voltage: Power consumption:
supply inputs, decoupled via 18....24....31.2 V DC according max. 20 W (max. 840 mA at
diodes. At least one supply input is to IEC 654-2, class DC4 24 V)
required for the supply of the
module. Other supply voltages can be
realized with additional system
power supplies.

Environmental conditions:
Protection class: Permissible relative humidity: Permissible shock:
module: IP 00 according to DIN 5....95%, non condensing according to IEC 68-2, part 29
40050 peak value of acceleration:
2
Front plate:: IP21 according to Permissible vibration: 98 m/s
DIN 40050 according to IEC 68-2, part 6 nominal shock duration:
Climate conditions: Vibration amplitude: 16 ms
according to DIN 40040, class 0.15 mm in range 10...55 Hz
KTF EMC resistance:
operating temperature range: Vibration acceleration: according to EN50081-1 /
2
0....+65°C 16.6 m/s in range 55...150Hz EN50082-2
Temperature range for storage
and transport:
-30....+85°C

Requirements on configuration PC:

Configuration of modules is made Processor: Capacity of fixed disk:
via the RS 232 interface on the 486 DX, 33 MHz min. 5 MB
module front or via the RS 485 bus Interfaces: Required working memory:
by means of a computer (laptop) one free RS 232 interface (COM min. 620 KB
with the following minimum 1 or COM 2) with FIFO type Operating system:
®
specifications: 156550 UART WIN 95/98 or NT 4.0
 Machine Monitoring Systems

Backplane MMS 6351/00:

MMS 6361

Terminal
block:

Trigger wheel and mounting angle of sensors:

The more precise the trigger wheel
has been fabricated, the more exact
the speed measurement can be
performed. PR 6423/..
A tooth depth of 1 mm has proved
to be advantageous when using the
PR 6423/.. sensor with a measuring
range of ± 1 mm. With this tooth
depth a continuous distance super-
vision of the sensor is possible.
The mounting angles of the sensors
should be chosen in such way, that
one tooth in each case is placed
directly below a sensor, at the
second sensor the tooth is just
leaving the sensor range and at the PR 6423/..
third sensor the tooth is just moving
into the sensor range.
These settings are important for a
correct detection of the signal
pulses and the direction of rotation.

As example for this see fig. 4 on the

right side.

Printed in Germany. Due to continuous research and product development,

PR 6423/..

Fig. 4

Order numbers:
the specification are subject to change without notice.

MMS 6350 Speed measurement card ............................................................................... 9100 – 00039

MMS 6350/D Speed measurement card with digital indicator ............................................... 9100 – 00040
MMS 6351/00 Backplane DOPS.................. ..............…………………………………………… 9100 – 00047
MMS 6351/10 Backplane AS..................................……………………………………………… 9100 – 00049
MMS 6352 19“ Mounting rack.......................................................................................... 9100 – 00053
MMS 6353/TS Adapter card replacement AEG Turloop (MMG 1222)..................................... 9120 – 00001
MMS 6360 Connection cable 25-pole SUB D..................................................................... 9510 – 00006
6010 – 00031 01/03 Reh

MMS 6361 Adapter 25 pole SUB D on screw terminals .................................................... 9100 – 00052
MMS 6950 W Configuration software ..................................................................................... 9510 – 00005

© epro GmbH
Jöbkesweg 3 D-48599 Gronau Weitere Informationen:
Tel. +49 (0) 2562/709-245 Internet: www.epro.de
Fax +49 (0) 2562/709-255 E-Mail: [email protected]