Installation and Operation Manual

Bently Nevada* Asset Condition Monitoring

3500 Monitoring System

Part Number 163860-01
Rev. D (09/15)
3500 Monitoring System

©2002 - 2015 Bently Nevada, Inc.

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

* Denotes a trademark of Bently Nevada, Inc., a wholly owned subsidiary of General Electric
Company.

The following are trademarks of the legal entities cited:

Modbus is a registered trademark of Schneider Electric USA, Inc.

Printed in USA. Uncontrolled when transmitted electronically.

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

1631 Bently Parkway South

Mailing Address Minden, Nevada USA  89423

USA
1.775.782.3611
Telephone
1.800.227.5514
Fax 1.775.215.2873
Internet www.GEmeasurement.com

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Additional Information
NOTE
This manual does not contain all the information required to operate and maintain the product. Refer to the
following manuals for other required information.

3500 Monitoring System Installation and Maintenance Manual (part number 129766-01)

3500 Monitoring System Rack Configuration and Utilities Guide (part number 129777-01)

3500 Field Wiring Diagram Package (part number 130432-01)

3500/40M Monitor Manual (part number 143488-01)

3500/42M Monitor Manual (part number143489-01)

3500/40M Proximitor Monitor Data Sheet (part number 141535-01)

3500/42M Proximitor Monitor Data Sheet (part number 143694-01)

Product Disposal Statement

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

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Contents
1. Receiving and Handling Instructions 1
2. Installing a New System 2
2.1 Receiving, inspecting, and handling 2
2.2 Installing the rack 2
2.3 Connecting Power 14
2.4 Connecting devices to the Rack Interface Module 17
2.5 Connecting the field wiring to the I/O modules 18
3. Operating the System 20
3.1 Verifying Configuration 20
3.2 Operating Switches 21
3.3 System Contacts 21
3.4 Reading the LEDs 22
3.5 Collecting Data from Output Terminals 26
4. Common Maintenance Procedures 28
4.1 Changing configuration 28
4.2 Module Configuration Retention and Storage 28
4.3 Replacing Modules 30
4.4 Verifying channels 34

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1. Receiving and Handling Instructions

Visually inspect the module for obvious shipping damage. If you detect shipping damage, file a
claim with the carrier and submit a copy to Bently Nevada, Inc.

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.

l Do not discharge static electricity onto the circuit board.

l Avoid tools or procedures that would subject the circuit board to static damage. Some
possible causes include ungrounded soldering irons, non-conductive plastics, and similar
materials.

l Use a suitable grounding strap before handling or performing maintenance on a printed

circuit board.

l Transport and store circuit boards in electrically conductive bags or foil.

l Use extra caution during dry weather. Relative humidity less than 30% tends to multiply the
accumulation of static charges on any surface.

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2. Installing a New System

This section shows how to install a 3500 Monitoring System rack that is fully assembled and that
has a complete configuration downloaded. If your rack is not fully assembled, contact your local
representative.

The section is divided into the following parts:

l Receiving, inspecting, and handling

l Installing the rack
l Connecting power
l Connecting devices to the Rack Interface Module
l Connecting field wiring to the I/O modules

Note that in order to connect field wiring to the I/O modules, you will need additional information
provided in the 3500 Field Wiring Diagram Package, part number 130432-01.

2.1 Receiving, inspecting, and handling

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, Inc.

Verify that your rack is fully assembled. A fully assembled rack has modules or covers labeled
“Future Expansion” in all slots on the front of the rack and has I/O modules or connector covers
on all slots on the back of the rack. If your rack is not fully assembled, contact your local
representative.

Customers and third parties that are in control of product at the end of its life or at the end of its
use are solely responsible for proper disposal of product. No person, firm, corporation,
association or agency that is in control of product shall dispose of it in a manner that is in
violation of United States state laws, United States federal laws, or any applicable international
law. Bently Nevada, Inc., is not responsible for disposal of product at the end of its life or at the
end of its use.

2.2 Installing the rack

The 3500 rack has three mounting configurations as shown in the following table. To mount your
rack, refer to the appropriate instructions.

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Table 2-1: 3500 Rack Mounting Configurations
Configuration
Panel Bulkhead Rack mount
type

Illustration

See "Installing a panel mount See "Installing a Bulkhead See "Installing a rack-mount
Refer to
rack" on page 3 mount rack" on page 8 rack" on page 10

Installing a panel mount rack

A Panel Mount rack allows you to install a 3500 rack behind a panel through a sheet metal cutout
and clamp into place. The following figures show the dimensions of a panel mount for a full sized
rack and for a mini rack.

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Panel mount cutout dimensions

1. 265.94 mm (10.470 inches)

2. 482.60 mm (19.000 inches).
3. 441.96 mm (17.400 inches).
4. 246.38 mm (9.700 inches).
5. 349.25 mm (13.750 inches), 422.91 mm (16.650 inches) if used with internal barriers

Figure 2 - 1: Dimensions of a Panel Mount 3500 Full-Size Rack

Caution
Do not use clamps as handles while carrying or installing the rack. The clamps may fall off resulting in injury to
personnel and damage to the rack.

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1. 452.1 ± 1.5 mm (17.80 ± 0.06 inches).

2. 3.2 mm (0.125 inches) radius, maximum.
3. 251.5 ± 1.5 mm (9.90 ± 0.60 inches).

Figure 2 - 2: Cutout for a Panel Mount 3500 Full-Size Rack

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1. 265.94 mm (10.470 inches).

2. 304.80 mm (12.000 inches).
3. 264.16 mm (10.400 inches).
4. 246.38 mm (9.700 inches).
5. 349.25 mm (13.750 inches), 422.91 mm (16.650 inches) if used with internal barriers

Figure 2 - 3: Dimensions of a Panel Mount 3500 Mini-Rack

Caution
Do not use clamps as handles while carrying or installing the rack. The clamps may fall off resulting in injury to
personnel and damage to the rack.

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1. 274.3 ± 1.5 mm (10.80 ± 0.06 inches).

2. 3.2 mm (0.125 inches) radius, maximum.
3. 251.5 ±1.5 mm (9.90 ± 0.60 inches).

Figure 2 - 4: Panel cutout for the panel mount of 3500 Mini-Rack

To install a panel mount rack

1. Cut panel cutout to the required dimensions.
2. If installed, remove the panel mount clamps from the rack. Slide rack through panel cutout.

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3. Assemble the clamp.

(1) Rear of Rack.

(2) Clamp.

4. Align the rack in the cutout.

5. Tighten the clamping screws.

Installing a Bulkhead mount rack

A 3500 Bulkhead rack is attached to a wall and lets you change the field wiring from the front of
the rack.

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Dimensions of a bulkhead mount rack

1. 482.60 mm (19.000 in)

2. 459.59 mm (18.094 in)
3. 133.35 mm (5.250 in)
4. 190.50 mm (7.500 in)
5. 133.35 mm (5.250 in)
6. 532.64 mm (20.970 in)
7. 266.70 mm (10.500 in)

Figure 2 - 5: Dimensions of a Bulkhead Mount 3500 rack

To install a bulkhead mount 3500 rack

Install the 3500 rack using No. 10 flat washers (8 places) and 10-32 screws (8 places) in the
locations shown in the diagram below.

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Installing a rack-mount rack

A Rack Mounted 3500 system is installed into a standard 19-inch EIA cabinet. The following
figures show the dimensions for a full-sized rack-mount rack and for a mini rack.

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Dimensions of a full-sized rack-mount rack

1. 265.94 mm (10.470 inches).

2. 190.50 mm (7.500 inches).
3. 457.40 mm (18.008 inches).
4. 482.60 mm (19.000 inches).
5. 441.96 mm (17.400 inches).
6. 246.38 mm (9.700 inches).
7. 349.25 mm (13.750 inches), 422.91 mm (16.650 inches) if used with internal
barriers

Figure 2 - 6: Dimensions of a Rack Mount 3500 Full-Size Rack

To install a rack mount 3500 full-size rack

Install the 3500 rack using No. 10 flat washers (4 places) and 10-32 screws (4 places) at the
locations shown by the arrows in the diagram below.

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Dimensions of a rack mount 3500 mini rack
The Mini-Rack Mounted 3500 system is installed into a standard 19-inch EIA cabinet by using the
mini-rack Adapter Panel.

1. 265.94 mm (10.470 inches).

2. 190.50 mm (7.500 inches).
3. 279.60 mm (11.008 inches).
4. 304.80 mm (12.000 inches).
5. 264.16 mm (10.400 inches).
6. 246.38 mm (9.700 inches).
7. 349.25 mm (13.750 inches), 422.91 mm (16.650 inches) if used with internal
barriers

Figure 2 - 7: Dimensions of a Rack Mount 3500 Mini-Rack

To install a rack mount 3500 Mini-rack

Install the Mini-rack adapter panel into the EIA rack using No. 10 flat washers (4 places) and 10-32
screws (4 places). Next, install the 3500 Mini-rack onto the adapter panel using No. 10 flat washers
(4 places) and 10-32 screws (4 places).

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1. 3500 Mini-rack
2. Adapter Panel
3. Standard 19-inch EIA rack

Figure 2 - 8: Rack mount 3500 Mini-rack

2.3 Connecting Power

Connect power wires to the Power Supply I/O module. This module is located behind the power
supply module on rack and panel mount racks and above the power supply module on bulkhead
mount racks. If your rack has two power supplies, the upper supply is the primary supply and the
lower one is the backup.

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To connect power to your 3500 rack:
1. Identify the type of I/O module by using the following table.

Table 2-2: Power Supply I/O Modules

Module Type Low Voltage AC High Voltage AC High Voltage DC Low Voltage DC

85 to 125 Vac 175 to 250 Vac

88 to 140 Vdc 20 to 30 Vdc
Power Requirement 4.5 A 2.3 A
2.5 A 10 A
47 to 63 Hz 47 to 63 Hz

I/O Module

2. Verify that the power source matches the values listed under “Power requirements” in the
table above
3. Install a power switch or circuit breaker close to the rack and mark the switch or breaker as
the disconnect device for the rack.

WARNING
HAZARDOUS VOLTAGE
RISK OF ELECTRIC SHOCK OR BURN.
Multiple power sources may be present.

Power supply and relay contacts can contain hazardous voltages.

User proper isolation techniques and remove all power prior to servicing.

4. Open the hinged protector that covers the power terminals.

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1. Hinged terminal protector

5. Connect the power cable as shown in the following figure and table:

(1) Power cable. Select a wire gage and type that meets the local code requirements
and meets the power requirements as listed in Table 2-1: Power Supply I/O Modules,
using Table 2 2: Power wire legend to identify the wires.

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(2) Chassis ground. To minimize ground loop noise, a single point earth ground (GRD)
to the system common connection is recommended. When two supplies are used in
the same system, both connections are considered a single point.

(3) Lug Connector. A #6 stud size Spade Lug Connector with an insulated ferrule must
be used when wiring the Power Input Module. Ensure that the ferrule completely
covers any exposed wire.

Figure 2 - 9: Hinged protector over power terminals

Table 2-3: Power wire legend

6. Close the hinged terminal protector. The terminal protector must remain in place to guard
against inadvertent contact.

2.4 Connecting devices to the Rack Interface Module

OK Relay System Contacts

The OK Relay is normally energized and is used to indicate System contacts let you use external contacts to
whether the 3500 Monitoring System is OK. control the operation of the rack.

OK Relay contact rating: 5 A @ 24 Vdc or 5 A @ 120 Vac Wiring recommendations: 18 AWG to 22 AWG
50/60 Hz or 3 A @ 220 Vac 50/60 Hz resistive maximum. stranded 2-wire shielded with insulating sheath.

Note
Shields are spliced into a single wire then grounded at the stud marked “SHIELD”. Shields should be insulated.

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Table 2-4: System contacts

Label Name Description

Temporarily increases the alarm (Alert and Danger) setpoint values by a specific multiple
Trip (usually two or three). This function is normally applied by manual (operator) action during
TM
multiply startup to allow a machine to pass through high vibration speed ranges without monitor alarm
indications.

Rack
Used to prevent an alarm from being declared on any monitor or relay in the 3500 rack. This is
INHB alarm
typically used when performing maintenance functions.
inhibit

Used to signal when the modules in the 3500 rack are to be reset. This contact has the same
RST Reset
function as the Rack Reset switch on the front panel of the Rack Interface Module.

2.5 Connecting the field wiring to the I/O modules

Connect transducer field wiring to a 3500 rack by either internal or external termination. The type
of termination is determined by the type of I/O modules that are installed on the rack.

Internal termination External termination

Connect transducer wires Simplify wiring at the rear of the rack by using cables to connect external
directly to the I/O modules termination I/O modules to external termination blocks.

(1) To Transducers. (1) To Transducers.

(2) Internal Termination I/O (2) External Termination Blocks.

Modules. (3) External Termination I/O Modules.

Refer to the 3500 Field Wiring Diagram Package, part number 130143-01, for information about
how to connect transducer field wiring to the I/O modules in your rack.

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3. Operating the System

This section shows how to use the various indicators and connections of a 3500 rack to control
operation and collect data.

The section is divided into the following parts:

• Verifying configuration

• Operating switches

• Reading LEDs

• Collecting data from output terminals

3.1 Verifying Configuration

A 3500 rack can contain a variety of modules that can be set up to operate different ways. The
process of setting system, module, and channel options so that all the modules in the 3500 rack
work together is called configuration.

After power is applied to the rack, the configuration LED (CONFIG OK) indicates that the rack
contains a complete and correct configuration.

If the configuration LED is not ON, contact your local representative.

Figure 3 - 1: Config OK LED

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3.2 Operating Switches
Hardware switches let you control the operation of the rack as follows:

Reset switch
Clears latched alarms and resets Timed OK Channel Defeat indications. If the Configuration LED is
blinking at 5 Hz, it will be stopped. This switch performs the same function as the Rack Reset
contact on the Rack Interface I/O Module.

Key Switch
Prevents unauthorized changes to the configuration settings. When the switch is in the RUN
position, the 3500 rack cannot be configured. When the switch is in the PROGRAM position, the
3500 rack can be configured and the rack continues to operate normally. By removing the key,
you can lock the Rack Interface Module in the RUN or PROGRAM position.

Figure 3 - 2: Operating Switches

3.3 System Contacts

System contacts provide additional control by connecting external contacts to the rack.

Trip multiply ( TM )
Temporarily increases the alarm (Alert and Danger) setpoint values by a specific multiple (usually
two or three). This function is normally applied by manual (operator) action during startup to

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allow a machine to pass through high vibration speed ranges without monitor alarm indications.

Rack alarm inhibit ( INHB )

prevents an alarm from being declared on any monitor or relay in the 3500 rack. This is typically
used when performing maintenance functions.

Reset ( RST )
Same function as pressing in the RESET switch on the front of the rack.

Figure 3 - 3: System Contacts

3.4 Reading the LEDs

The LEDs on the front panel of 3500 modules indicate the operating status of the module.

Figure 3 - 4: LEDs

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3500 LED Descriptions
LED Detailed description
3500 Module Description
label see page…

3500/15 Power SUPPLY all of the output voltages from the supply are within
below
Supply OK specification.

See "OK and TX/RX

OK The module and I/O module are operating correctly.
LEDs" on page 24

Flashes at the rate that messages are sent from the See "OK and TX/RX
Most 3500 modules TX/RX
module. LEDs" on page 24

Some of the monitor functions are temporarily See "Bypass LED" on

BYPASS
suppressed. page 25

See "TM LED" on

TM Indicates whether the rack is in Trip Multiply mode.
page 24
3500/20 RIM Module
CONFIG See "Config OK LED"
The configuration of the rack is correct.
OK on page 24

CHn An alarm condition has occurred with this relay. See "Relay Alarm
3500/32 and 34 Relay
ALARM (Where “n” is the channel number 1 through 4.) LED" on page 25

TEST
3500/53 Overspeed The module is in test mode See "Test mode" on
MODE
Protection system page 26
ALARMS

Power Supply OK LED

Supply OK Condition Solution

On All of the output voltages from the supply are within specification No action required

Off An output voltage from the supply is not within specification Refer to the following procedures

1. If the Power Supply OK LED is off, check the following items:

2. Verify that the correct voltage is connected to the Power Input Module.
3. Verify that the installed Power Input Module matches the installed Power Supply. For
example, an AC Power Input Module with the AC version of the Power Supply.
4. Check to see if the fuse on the Power Input Module has blown. If the fuse is blown, replace it.
A blown fuse may be due to:

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l Severe overvoltage on the Power Input Module.
l A fault within the 3500 Power Supply.

OK and TX/RX LEDs

OK TX/RX Condition Solution

Module is not configured or is in Reconfigure the module (see 3500 Rack Configuration
1 Hz 1 Hz
configuration mode Guide, part number 129777-01)

Module has detected an internal

5 Hz XX Check the System Event List
fault and is not OK

ON Flashing Module is operating correctly No action required

Not
XX Module is not operating correctly Check the System Event list
flashing

XX = behavior of the LED is not related to the condition

Event lists
Contain records of things that happen to the rack. The system maintains two event lists -- the
Alarm Event list and the System Event list. To view these lists, refer to the 3500 Monitoring System
Configuration Guide, part number 129777-01.

TM LED
Trip multiply temporarily increases the alarm (Alert and Danger) setpoint values by a specific
multiple (usually two or three). This function is normally applied by manual (operator) action
during startup to allow a machine to pass through high vibration speed ranges without monitor
alarm indications.

TM LED Condition Solution

ON Rack is in Trip Multiply No action required

OFF Rack is not in Trip Multiply No action required

Config OK LED
Configuration is the process of setting system, module, and channel options so that all the
modules in a 3500 rack work together.

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CONFIG
Condition Solution
OK

Configuration information for every module in the rack is

ON No action required
valid.

Check the System Event List. Press the

5 Hz One of the selected security options has not been met
Rack Reset Switch to clear.

One or more of the following

configuration problems exist:

l a module in the rack is not

At least one module in the rack has a configuration fault A configured
OFF l the configuration in the RIM does
non-configured active Power Supply is present in the rack
not match the physical
configuration of the rack
l a configuration security option
condition is not met

Bypass LED
Bypass is an operating condition of a 3500 monitoring module where functions of all 4 channels
in the monitor are suppressed. When the channels in a bypassed 3500 monitor go in alarm, the
alarm events are posted to the Alarm Event List but any relays that use the alarms from the
monitor in the relay alarm logic will not be activated.

BYPASS Condition Solution

OFF Alarm Enabled No action required

ON Some or all alarming in the module disabled No action required

Relay Alarm LED

Relay alarm is the alarm status of a 3500 relay channel. A relay channel is in alarm if the alarm
logic as defined in the configuration for the relay channel is true. Use the 3500 Configuration
program to view the alarm logic for relay channels.

TM LED Condition Solution

ON Relay channel is in alarm No action required

OFF Relay channel is not in alarm No action required

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Overspeed Detection System
Test mode
The 3500 Overspeed Detection Module has an on board frequency generator that can generate
a test signal for testing the overspeed detection function of the monitor. When the test function is
enabled in the configuration software (option box is checked), you can invoke the function by
closing a contact on the Overspeed Detection I/O module or via a software switch. When the test
is invoked, the test frequency sweeps through a start RPM and an end RPM. (The start and end
RPM are set in the configuration for the module.) When the test input speed exceeds the over
Alert/ /Alarm 1 and Overspeed (Danger) setpoints, the associated alarms will be driven.

TEST MODE Condition Solution

ON The overspeed module is in test mode. No action required

OFF The overspeed module is not in test mode. No action required

Alarm LED
The 3500 Overspeed Detection System (ODS) consists of mulitiple ODS modules that operate as a
group. The alarms generated from this group are the result of a voting process that is set up in
configuration. The alarm LEDs on the modules in overspeed detection systems indicate the result
of this voting. Use the 3500 Configuration program to determine how this voting has been
configured for the modules in the ODS.

ALARM Condition Solution

OFF Relay is not in alarm No action required

ON Relay is in alarm No action required

3.5 Collecting Data from Output Terminals

Buffered Transducer Outputs provide the unfiltered output from the channels in the modules. All
outputs are short circuit protected.

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Figure 3 - 5: Buffered Outputs

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4. Common Maintenance Procedures

Once a 3500 Monitoring System is operating, it continuously measures and monitors a variety of
supervisory parameters. The boards and components inside of 3500 modules cannot be repaired
in the field and require no calibration. This section provides information for common tasks
required under normal operating conditions. For procedures that require more detailed
information, refer to the manuals listed in 3500 Field Wiring Diagram Package (130432-01)

This section includes the following topics:

l Changing configuration
l Replacing modules
l Verifying channels

4.1 Changing configuration

The process of setting system, module, and channel options so that all the modules in the 3500
rack work together is called configuration. These settings are established and adjusted by using
the 3500 Rack Configuration program.

Configuration settings are usually protected by security settings. The security setting for a typical
3500 Monitoring System that is operating normally is “Change Setpoints in Program Mode”. This
section shows how to adjust setpoints. To change other configuration settings, refer to the 3500
Monitoring System Rack Configuration and Utilities Guide, part number 129777-01.

4.2 Module Configuration Retention and Storage

Bently Nevada 3500 Monitoring Systems and components are built un-configured at the factory.
When a configuration is successfully downloaded to a module, the module will store that
configuration in non-volatile memory until the module is reconfigured. If a configured module is
removed or replaced in a rack following the original configuration being successfully completed,
it will maintain the configuration that was provided. This may cause conflicts if the module is
placed in a slot with a different I/O module or inputs that do not match the configuration.

It is recommended to store the current rack configuration file for a particular rack onto a PC and
then reconfigure the rack upon making any changes. The OK LED on the device will not go solid
green if the configuration for that device is not valid.

To adjust alarm setpoints

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1. Place the rack in program mode by using the key switch on the Rack Interface Module.
2. In the 3500 Rack Configuration program, click Setpoints .

3. Click on the monitor module to be adjusted.

The Configuration Setpoint dialog for that monitor module appears.

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4. Select the monitor channel to be adjusted in the Monitor Channel list box.
5. For all measurement parameters except phase, adjust the setpoint level by dragging the
bar in the bar graph or by entering a value in the text box above or below the parameter.

Note that setpoints can be adjusted only for those parameters that are enabled and that
some parameters have both upper and lower setpoint values. Parameters are enabled or
disabled by using the Channel Option screen. Refer to the 3500 Monitoring System Rack
Configuration and Utilities Guide for more information.

6. For phase setpoints, enter the values for the beginning and ending setpoint in the text
boxes below the phase diagrams.
7. Apply the adjusted setpoints to the rack by clicking OK and then download the revised
configuration to the rack.

4.3 Replacing Modules

The boards and components inside of 3500 modules cannot be repaired in the field and require
no calibration. For 3500 modules that are not operating properly, use the information in this
section to replace the module with a spare and then contact your local representative for
information about returning the faulty module for failure analysis.

Replacing a Main Module

1. Save the configuration of the module to be replaced.

3500 modules must have valid configuration settings in order to operate properly.
Replacement modules are not configured. By saving the configuration, you can download
the original configuration settings to the replacement module. The 3500 Monitoring System
Configuration and Utilities Guide, part number 129777-01, shows how to save configuration
files.

2. Remove the module to be replaced.

3. Insert the new module
4. Download the configuration to the new module. The 3500 Monitoring System Configuration
and Utilities Guide, part number 129777-01, shows how to download configuration files.
5. Verify operation.

l Check that the LEDs for the replaced module are indicating correct operation.

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l The values of the measurement parameters of a channel are verified by using the
Verification utility in the 3500 Rack Configuration program and the verification procedure in
the reference manual for that module.

Replacing an I/O Module

This procedure applies only to the I/O module of a monitor or the PIM of a power supply that is to
be replaced. Prior to removing any module, refer to the applicable reference manual to see how
rack behavior may be affected and for any special handling requirements required for personal
safety.

1. If necessary, upload and save the configuration of the module to be replaced.

3500 modules must have valid configuration settings in order to operate properly.
Replacement modules are not configured. By saving the configuration, you can download
the original configuration settings to the replacement module.

The 3500 Monitoring System Configuration and Utilities Guide, part number 129777-01,
shows how to save configuration files.

2. Remove the main module from the rack.

3. Remove the field wiring from the I/O module.

If the wires connected to the I/O module are not labeled, label the wires before you remove
them.

4. Remove the old I/O module from the rack.

5. Install the new I/O module into the rack.
6. Connect the field wiring to the new I/O module.
7. Install the main module into the rack.
8. Download the configuration to the new module.

The 3500 Monitoring System Configuration and Utilities Guide, part number 129777-01, shows
how to download configuration files.

9. Verify operation.

l Check that the LEDs for the replaced module are indicating correct operation (see Reading
the LEDs in section 2.4.1).

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l The values of the measurement parameters of a channel are verified by using the
Verification utility in the 3500 Rack Configuration program and the verification procedure in
the reference manual for that module.

Removing and inserting a main module

When performed properly, modules may be removed from or installed into the rack while power is
applied to the rack.

To remove the old full-height module

This procedure shows how to remove any full-height 3500 module. Refer to the reference manual
for the module for details and safety considerations.

1. Loosen the screws to the main module so that they are free of the rack chassis, but still
attached to the main module.
2. Use the ejectors to pry the main module loose from the backplane connectors.

3. Once freed from the backplane, the main module can be removed completely from the rack

To install a spare full-height module

1. Ensure that the ejectors are in their normal position, flush with the front of the module.

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2. Slide the main module into place, ensuring that they are properly in the guides provided on
the floor and roof of the rack chassis.
3. Tighten the screws securely.

Application Advisory: It is important to tightly secure the thumb screws to ensure each module
is Chassis grounded. Loose thumb screws may allow noise to show on the channel readings.

To Add or Remove a Half-Height Card Guide

Figure 4 - 1: Installing the Card Guide

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Figure 4 - 2: Removing the Card Guide

4.4 Verifying channels

The boards and components inside of 3500 modules cannot be repaired in the field. Maintaining
a 3500 rack consists of testing module channels to verify that they are operating correctly.
Modules that are not operating correctly should be replaced with a spare. When performed
properly, modules may be removed from or installed into the rack while power is applied to the
rack.

The 3500 Monitoring System is a high precision instrument that requires no calibration. The
functions of the 3500 modules, however, must be verified at regular intervals. All modules in the
3500 Monitoring System should be verified at these maintenance intervals. The procedures in the
Maintenance and Troubleshooting sections of the module reference manuals describe the
verification and troubleshooting process. (Refer to the reference manuals listed in 3500 Field
Wiring Diagram Package (130432-01)

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