Description
1. Product Overview
Part Number: 3500/65, Order No. 172103-01
Manufacturer: Bently Nevada. It is a standard single-slot functional module for the 3500 rotating machinery protection and condition monitoring system. 172103-01 is the fixed factory part number and hardware revision. It supports TMR triple modular redundant architecture and serves as the standard critical spare part for temperature monitoring of bearings, stators and oil circuits in steam turbines, gas turbines and large compressors.
Compatible Rack: Standard 19-inch 3500 series system rack, seamlessly networked with power supply modules, frame interface modules, relay output cards and communication boards. Channel type, measuring range, alarm threshold and filter parameters are configured via 3500 Rack Configuration Software. Monitoring data is uploaded to System 1 asset management platform, plant-wide DCS and SCADA systems, meeting SIL2~SIL3 safety protection requirements for units.
Product Definition: High-density 16-channel integrated temperature acquisition monitor card. A single module supports mixed input of isolated tip Thermocouple (TC) and 3-wire / 4-wire Platinum RTD signals. It performs hardware conditioning, AD conversion and numerical calculation for multi-channel temperature signals, and outputs two-stage Alert pre-alarm and Danger trip interlock commands. Each channel supports independent configurable bypass, with standard recorder analog transmission output. It is specially applied to multi-point temperature collection, over-limit alarm and protection trip logic for unit bearing metal temperature, motor winding, lubricating oil and exhaust cavities.
2. Six Core Hardware Functional Units
2.1 16-Channel Isolated Signal Conditioning & Acquisition Unit
16 fully electrically isolated input loops are integrated, with input impedance＞1MΩ per channel. Each channel can be individually configured for E/J/K/T thermocouple, 3-wire or 4-wire 100Ω RTD. Channels are mutually isolated without crosstalk. On-board surge clamping, EMI filtering and differential amplification circuits suppress interference from long transmission cables, eliminating temperature reading drift and false alarms caused by stray noise. The module is powered from the backplane without external power supply for sensors.
2.2 Programmable Threshold & Filter Calculation Unit
Upper/lower pre-alarm and trip temperature setpoints are defined per channel via configuration software, with configurable alarm delay to suppress false tripping from transient interference. Built-in digital filtering with adjustable averaging duration distinguishes slow temperature rise and impulse noise. The module automatically identifies sensor open circuit, short circuit and over-range faults with locked fault location, differentiating sensor failure from actual equipment overtemperature faults.
2.3 Front Panel Indication & Bypass Management Unit
Three front-panel LED indicators: OK steady on for normal self-test and backplane power; TX/RX flashing for backplane bus data communication; Bypass lit when the module is bypassed with all alarm and protection logic locked temporarily. Two bypass modes (single-channel / whole module) are available for maintenance without disabling the entire module or other measuring points.
2.4 Analog Transmission Output Unit
Any channel temperature reading can be configured into standard 4~20mA analog output, compatible with PLC AI cards, paperless recorders and central control acquisition loops. The output range automatically matches the configured measuring span for on-screen display and process closed-loop control linkage.
2.5 Backplane Bus & Redundancy Voting Unit
Rear gold-finger edge connector interfaces with the 3500 parallel backplane bus to upload temperature values, fault codes, alarm events and self-test status. It supports simplex, dual redundant and TMR triple redundant deployment. In TMR mode, three identical modules execute data voting to minimize maloperation and protection refusal risks from single-point faults, complying with redundancy design specifications for critical large units.
2.6 Industrial Reinforced Conformal Coating Unit
The multi-layer gold-plated FR-4 PCB is fully coated with conformal coating against moisture, salt fog and corrosion. Fanless passive heat dissipation relies on rack airflow. It withstands high temperature inside sealed cabinets, long-term low-frequency vibration from unit base and humid coastal environment. No adjustable potentiometers or consumable fuses are equipped for 24/7 unattended maintenance-free operation.
3. Technical Specifications
3.1 Basic Hardware & Channel Parameters
| Item | Specification |
|---|---|
| Model | 3500/65 Order No.172103-01 16-Channel Temperature Monitor Module |
| Rack Slot | 1 standard full-height slot of 3500 rack |
| Input Channels | 16 independent isolated temperature inputs, mixed TC/RTD configurable |
| Supported Sensors | E/J/K/T Thermocouple; 100Ω 3-wire & 4-wire Platinum RTD |
| Per Channel Input Impedance | ＞1MΩ |
| Typical Power Consumption | 3W |
| Net Weight | Approx. 0.45kg |
| Dimension | 241.3mm × 24.4mm × 99.1mm |
| Origin | Original USA Manufacture |
3.2 Electrical & Communication Parameters
- Power Supply: Powered centrally from 3500 rack power module via backplane, no external power required
- Alarm Logic: Independent Alert pre-alarm & Danger trip threshold per channel, software adjustable delay
- Analog Output: Configurable 4~20mA transmission output for third-party system data acquisition
- Backplane Bus: Native 3500 parallel backplane bus, Modbus RTU supported for upper system data transmission
- Redundancy Rule: TMR triple redundancy requires three adjacent slots with identical modules for voting
3.3 Environmental & Safety Compliance
- Operating Temperature: -40℃ ~ +85℃
- Storage & Transport Temperature: -40℃ ~ +125℃
- Humidity: 5%~95%RH non-condensing, no corrosive gas or salt fog deposition
- Ingress Rating: IP20, for indoor cabinet installation only
4. Product Advantages
- High integration density: 16 measuring points per single slot greatly reduces rack slot occupation, cabinet wiring and spare part inventory management workload compared with 1/4-channel temperature cards.
- Multi-sensor compatibility: No hardware modification needed to mix TC and RTD inputs; channel type can be switched via software configuration for on-site renovation without hardware replacement.
- Fine-grained maintenance bypass: Single-channel bypass isolates only the faulty sensor loop while other channels remain under protection, eliminating unit load reduction or shutdown for single-point maintenance.
- Comprehensive self-diagnosis: Precisely identifies open/short circuit, over-range and communication faults with pop-up alarm hints on upper HMI to shorten troubleshooting time.
- Native 3500 ecosystem compatibility: Configuration files can be backed up and imported. Drop-in replacement of identical part number units is recognized automatically without reconfiguration.
- High-reliability redundant architecture: TMR voting eliminates single-point fault risks of false trip or protection failure, fully meeting strict safety interlock standards for power, nuclear and chemical critical units.
5. Application Scenarios
1. Combined-Cycle Gas & Steam Turbine Power Plants
Continuous monitoring of thrust/journal bearing temperature, generator stator winding and cooling medium temperature. Overtemperature triggers unit turbine trip, serving as standard monitoring hardware for GE & Siemens gas turbine 3500 control systems.
2. Petrochemical Large Process Compressor Units
Monitoring of bearing, seal gas and cylinder temperature for cracking gas and recycle gas compressors to predict shaft wear and seal leakage, interlocking anti-surge and unit shutdown protection to ensure continuous chemical production safety.
3. Large & Medium Hydropower Generator Excitation & Governor Systems
Temperature collection of turbine bearing, generator stator and cooling medium adapted to humid hydropower plant environment, coordinating with governor and excitation systems for stable grid-connected operation.
4. Metallurgy Blast Furnace Fans & Large Pump Station Centrifugal Fans
Online temperature early warning of main fan bearing and motor winding to prevent severe equipment damage such as shaft seizure.
5. Legacy 3500 System Expansion & Fault Replacement
Direct in-situ upgrade or replacement for aging temperature modules with damaged channels or insufficient measuring points; existing configuration parameters are imported for reuse with minimal system modification.
