The Emerson A6500-TP Temperature Process Card is a core functional component of the Emerson AMS 6500 ATG Machinery Protection System, specially designed for the accurate monitoring of temperature and process signals of critical rotating equipment, featuring multi-channel measurement, flexible signal adaptation and high security. Adopting a 3U-sized, 1-slot plug-in design, this card cuts the cabinet space requirement by half compared with the traditional 4-channel, 6U-sized cards, and supports hot-swappable operation, which greatly improves the convenience of system maintenance and space utilization efficiency.
Its core functions cover temperature measurement (thermocouple, RTD), standard process signal acquisition (voltage, current), digital signal interaction and alarm output. All measured data is transmitted to the A6500-CC Communication Card via the internal RS 485 bus, converted into the Modbus RTU/TCP/IP protocol and then connected to the upper computer or analysis system. It also enables PC-side configuration and data visualization through the USB interface. In addition, it supports 4 channels of 0/4-20 mA analog output, and the output end is designed with electrical isolation between common grounding and system power supply, ensuring the stability and security of signal transmission.
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Core Functions and Signal Configuration
The A6500-TP card enables multi-scenario signal monitoring through a 4-channel basic configuration + expandable functions, with the specific functions and signal adaptation rules as follows:
1. Temperature Measurement Function
RTD (Resistance Temperature Detector) Measurement: Supports four types including Pt100 (α=0.00385), Ni100 (α=0.00618), Ni120 (α=0.00672) and Cu10 (α=0.00427), compatible with 2-wire, 3-wire and 4-wire technologies (2-wire is not supported for Cu10). It features a measurement accuracy of ±1K, an excitation current of 500μA, a maximum allowable resistance of single conductor < 120Ω (including the impedance of safety barriers in explosion-proof applications), and a temperature drift of ±1K within the operating temperature range of -20°C to +70°C.
Thermocouple Measurement: Supports five types including E, J, K, T and N, with a measurement accuracy of ±1K and optional internal or external Cold Junction Compensation (CJC) — external compensation is implemented via RTD sensor input, and the card itself is not equipped with a built-in CJC temperature sensor, requiring one channel to be occupied for CJC signal acquisition. The total capacitance of the sensor cable must be < 10μF, with a temperature drift of ±1K within the operating temperature range of -20°C to +70°C.
Channel Expansion Feature: In thermocouple mode, the number of temperature sensor channels can be expanded to 8, meeting the demand for centralized monitoring of multiple measuring points. All channels share the CJC configuration, simplifying the system commissioning process.
2. Process Signal Measurement Function
It covers two types of standard industrial signals (voltage and current), and is suitable for the indirect monitoring of parameters such as pressure, flow and liquid level in process industries:
- Voltage Signal Input: Range of 0-10V, accuracy of ±1% of full scale, input impedance > 100kΩ, and temperature drift of ±0.5% of full scale within the operating temperature range of -20°C to +70°C.
- Current Signal Input: Range of 0/4-20mA, accuracy of ±1% of full scale, input impedance < 200Ω, and temperature drift of ±0.5% of full scale within the operating temperature range of -20°C to +70°C.
3. Digital Signal and Alarm Output Function
- Digital Input: 2 digital signal acquisition channels, supporting the input of equipment status feedback and external trigger signals, with short-circuit protection to ensure the safety of signal input.
- Digital Output: 6 dedicated digital output channels for alarm signal output. The association between channels and measuring channels is freely configurable, allowing users to customize alarm logic according to equipment fault levels (e.g., early warning, emergency shutdown) for rapid response to abnormal working conditions.
Hardware Performance and Environmental Adaptability
1. Core Hardware Parameters
Measurement Accuracy Assurance: Equipped with a 24-bit ADC (Analog-to-Digital Converter) to ensure high-resolution acquisition of all input signals, providing a hardware foundation for the accurate monitoring of temperature and process parameters. The 4 input channels adopt a galvanic isolation design compliant with IEC 60204-1/IEC 61131-2 standards, avoiding inter-channel signal interference and improving measurement stability.
Self-Testing and Protection: Built-in hardware self-test function that real-time monitors hardware status, power input, hardware temperature, and the connection status of sensors and cables. Alarms are triggered rapidly upon detection of abnormalities (e.g., sensor disconnection, power fluctuation), reducing the risk of equipment failure.
Power Supply and Power Consumption: With a maximum power consumption of only 5W, it has a minimal impact on the total system energy consumption. The card must be installed in the A6500-SR system rack, with unified power supply and signal connection provided by the rack to ensure power supply stability.
2. Environmental Adaptability
Designed for complex industrial environments, the card delivers excellent performance in terms of temperature and humidity resistance, vibration resistance and anti-interference, with the specific parameters as follows:Operating temperature: -20°C to 70°C (forced cooling); -20°C to 55°C (non-forced cooling)Storage temperature: -40°C to 85°C (-40°F to 185°F)Relative humidity: 5%-95% (non-condensing)Protection rating (conformal coating): IP20 (compliant with IEC 60529)Vibration resistance: Compliant with IEC 60068-2-6: 0.15mm amplitude in 10-55Hz frequency band, 20m/s² acceleration in 55-150Hz frequency bandShock resistance: 150m/s² acceleration, 4000 shocks per axisElectromagnetic interference (EMR) resistance: Compliant with EN50081-1/EN50082-2 standardsContaminant resistance rating: Compliant with ISA-S71.04-1985 Grade G3 air contaminant standardsMaterial standard: HumiSeal 1B31 EPA coating, compliant with IPC-CC-830B and IPC-A 610 standards
In addition, the physical dimensions of the card follow the PCB/EURO card format of DIN 41494 standard, with a size of 100×160mm (3.937×6.300 inches) and a weight of approximately 200g (excluding packaging). It is compatible with 3RU/6HP rack slots, featuring high installation compatibility.
System Integration and Application Scenarios
1. System Integration Features
Communication Protocol Support: Multi-protocol conversion is realized via the A6500-CC Communication Card, which supports Modbus RTU (for serial communication) and Modbus TCP/IP (for Ethernet communication), enabling seamless connection to plant DCS (Distributed Control System), PLC (Programmable Logic Controller), historical databases or analysis systems. It also supports the OPC UA protocol to meet the data interaction requirements of modern Industrial Internet of Things (IIoT).
Configuration and Visualization: Connect a PC/laptop via the USB interface on the front panel of the rack to complete card parameter configuration (e.g., channel signal type, alarm threshold) and measurement result visualization. When paired with Emerson Machine Studio software, rapid configuration can be achieved through an intuitive graphical interface, which supports automated documentation functions such as system configuration reporting and change management, reducing operation and maintenance costs.
Software Compatibility: It is compatible with AMS Machinery Manager Version 5.7 and above. Combined with the software’s functions such as vibration analysis and early bearing fault detection (PeakVue Technology), it can upgrade from data monitoring to fault prediction. It also supports the AMS ATG View mobile application, allowing users to access equipment monitoring data anytime and anywhere and improving the flexibility of operation and maintenance.
2. Typical Application Scenarios
As a core component of the AMS 6500 ATG Machinery Protection System, the A6500-TP card is mainly used for health monitoring of critical rotating equipment, with typical application scenarios including:
- Energy Industry: Steam turbines and gas turbines in thermal/nuclear power plants, and water turbines in hydropower plants – monitoring key parameters such as bearing temperature and winding temperature to prevent equipment damage caused by overheating.
- Oil, Gas and Chemical Industry: Gas transmission pipeline compressors, refinery catalytic compressors and offshore platform compressors – monitoring parameters such as temperature and pressure (indirectly monitored via process signals), and adapting to the requirements of explosion-proof environments.
- General Industry: Boiler feed water pumps, blowers, superchargers, turbine exhausters and other equipment – realizing fault early warning through multi-channel monitoring and reducing unplanned downtime.
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