Bently Nevada 3500/42M Module Validation Procedure
Part No.: 176449-02 | Firmware: v4.10+ | Compliance: API 670 5th Ed.
Pre-Test Requirements
-
Safety Preparation
- Verify chassis ground resistance ≤ 2 Ω (ANSI/IEEE C62.41)
- Disconnect field wiring at TB3/TB4 terminals
- Use ESD wrist strap (1 MΩ series resistance)
-
Test Equipment
- Calibrated DC source (Fluke 724/ProcessLINK compatible)
- Precision shunt resistor: 250 Ω ±0.1% (for current loop simulation)
- DIN rail power supply: 18-30V DC (ripple < 100mVpp)
Module Power-Up Verification
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1. Apply 24V DC to PWR+/PWR- terminals (TB1)
2. Confirm indicators:
• PWR LED: Solid green
• FAIL LED: Off
• CHK CONFIG LED: Amber (should extinguish after 45s)
3. Measure backplane voltage:
• TP1-GND = -17.5V DC ±0.25V
• TP2-GND = -24V DC ±0.5V
Channel Functional Testing
Step 1: Proximitor Simulation
| Channel | Test Point | Simulated Input | Expected Reading | Tolerance |
|---|---|---|---|---|
| Ch A | J1-1 to J1-2 | -18V DC | 3500 SW: -17.8V | ±0.15V |
| Ch B | J2-1 to J2-2 | -22V DC | 3500 SW: -21.7V | ±0.15V |
Step 2: Current Loop Verification
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1. Connect 250Ω shunt between Ch A OUT+ and OUT-
2. Apply -20V DC to Ch A IN+
3. Measure voltage across shunt:
• Normal operation: 1.00V DC = 4mA
• Alarm condition: 5.00V DC = 20mA (simulate gap voltage < -2V)
Diagnostic Fault Injection
Controlled Failure Modes:
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[Test 1: Power Supply Fault]
- Reduce input voltage to 16.5V DC → FAIL LED flashes (1 Hz)
[Test 2: Sensor Open Circuit]
– Disconnect Ch B input →
• CHK CONFIG LED solid amber
• 3500 SW displays “SENSOR OPEN”
[Test 3: Over-temperature]
– Apply 150% load for 15min →
• Module auto-derates at 85°C
• Analog output clamped at 21.5mA
Post-Test Actions
-
Performance Validation
- Dynamic response test: 0.5-12 kHz sine sweep (settling time < 3ms)
- Crosstalk rejection: ≤ -80 dB @ 10 kHz (per API 670 Sect. 4.9.3)
-
Configuration Restore
iniCopy Code[3500 Rack Config]
Module_Type = 42M
Firmware_Ver = 4.10
Cal_Date = YYYY-MM-DD
Damping_Filter = ON ; 2-pole Bessel
Critical Warnings
TEST PROHIBITIONS
- Never exceed -30V DC input (irreversible Zener diode damage)
- Do not hot-swap modules without rack isolator (PN 3500/15-01-01-00)
- Avoid grounding OUT- terminals (causes current loop offset)
SAFETY INTERLOCKS
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REQUIRED: Install transient suppressor (P/N 146449-01) when:
• Cable runs > 15m
• Location NEC Class I Div 23500/42 176449-02+128229-01 Bently Nevada PDF
3500-42 176449-02 128229-01 Bently Nevada
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