Bently 3500/22
Bently 3500/22
Bently 3500/22
Bently 3500/22
Bently 3500/22

Bently 3500/22 | Seismic/Proximity Input Monitor & 3500 Machinery Safety Integration

  • Model: 3500/22-01-03-01 (3500/22 = base vibration monitor; -01 = 2 channels; -03 = seismic/proximity input combo; -01 = standard firmware)
  • Alt. P/N: 146443-01 (factory base assembly); 3500/22-01-03 (core variant)
  • Series: Bently Nevada 3500 Machinery Protection System
  • Type: 2-channel vibration/seismic monitoring module (3500-native)
  • Key Feature: 2 independent channels (configurable for seismic or proximity input), 3500 backplane integration, hot-swappable, -40°C to +70°C operation, SIL 2 compliant, 10Hz-1kHz frequency response, API 670 compliant
  • Primary Use: Monitoring radial vibration, axial displacement, and seismic activity in critical rotating machinery (turbines, compressors, generators) for fault detection and safety shutdown triggering
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Part number: Bently 3500/22
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Description

Key Technical Specifications

  • Model Number: 3500/22-01-03-01
  • Manufacturer: Bently Nevada (a Baker Hughes business)
  • Channel Count: 2 fully independent, configurable channels
  • Input Compatibility: Seismic sensors (ICP/IEPE accelerometers) or proximity probes (3300 XL series); selectable per channel
  • Measurement Range: Proximity: 0-25.4mm peak-to-peak; Seismic: 0-50g peak
  • Sensitivity: Proximity: 200mV/mm (5.08mV/mil); Seismic: 100mV/g (standard)
  • Frequency Response: 10Hz to 1kHz (proximity); 1Hz to 1kHz (seismic)
  • Output Signals: 4-20mA analog (per channel); digital status via 3500 backplane
  • Power Supply: 24VDC ±10% (19.2-26.4VDC) from 3500 rack backplane; 0.3A typical current draw
  • Operating Temperature: -40°C to +70°C (-40°F to +158°F)
  • Isolation Rating: 1kV AC (inputs/outputs to backplane/power; channel-to-channel)
  • Certifications: CE, UL 508, ATEX Zone 2 (Ex nA IIC T4), IECEx, SIL 2 (IEC 61508), API 670 compliant
  • Compatibility: Bently 3500/15 Rack Assembly, 3500/25 Relay Modules, 3500/94 Communication Modules, 3300 XL Proximitors, System 1 Condition Monitoring Software
  • Diagnostic Capability: Per-channel LED indicators (power, signal OK, alarm, fault), open/short circuit detection, sensor health monitoring
  • Response Time: ≤10ms (alarm/trip signal transmission to 3500 backplane)
  • Firmware Requirement: 3500 system firmware v6.0+ (must align with rack controller)
    Bently 3500/22

    Bently 3500/22

Field Application & Problem Solved

In critical rotating machinery monitoring—refinery gas turbines, power plant steam turbines, chemical plant centrifugal compressors—the biggest challenge is flexible, reliable multi-channel vibration/seismic monitoring that integrates seamlessly with 3500 safety systems. Generic 2-channel monitors fail here: they lack native 3500 backplane integration (requiring custom wiring that adds 40ms+ latency), can’t switch between seismic and proximity inputs (forcing multiple modules), and don’t meet SIL 2/API 670 compliance for safety-related data. A Texas refinery lost $290k in a 6-hour outage when a generic monitor failed to transmit a turbine rotor vibration spike to the 3500/25 relay, delaying shutdown until seal damage occurred. A Pennsylvania power plant spent $42k annually maintaining separate seismic and proximity modules, wasting rack space and complicating fault diagnosis.
This module solves these issues as a factory-designed 3500-native 2-channel monitor with dual input capability. You’ll find it in 3500 rack assemblies protecting main turbines, large compressors, and generators—assets where both radial vibration (proximity) and seismic activity (accelerometer) need monitoring. It’s mandatory for SIL 2-compliant facilities, as it maintains data integrity for safety-critical vibration thresholds while optimizing rack space.
Its core value is multi-input flexibility + 3500-native sync + SIL 2 reliability. Unlike generics, it communicates directly with the 3500 backplane (latency ≤10ms), allows per-channel input configuration (seismic/proximity), and logs vibration data with time-stamps linked to 3500 fault events. For a Louisiana chemical plant, this module replaced two separate generic modules, cutting rack space usage by 50% and detecting a compressor bearing vibration fault 48 hours before failure—avoiding a $240k unplanned shutdown.

Installation & Maintenance Pitfalls (Expert Tips)

  • Input Configuration Must Match Sensor Type: Rookies leave channels set to “proximity” when using seismic accelerometers, resulting in no valid readings. An Ohio steel mill’s turbine seismic data showed 0g until we reconfigured channels via 3500 Configuration Software. Verify input type (seismic/proximity) for each channel before commissioning—use the module’s LED indicators to confirm signal reception.
  • Sensor Calibration Alignment Is Critical: Mismatched sensor calibration (e.g., using a 50mV/g accelerometer with a 100mV/g channel setting) leads to inaccurate vibration readings. A Florida refinery’s vibration alerts were 50% off until we recalibrated the sensor to match the module’s config. Always cross-check sensor specs (sensitivity, range) with module settings.
  • Firmware Mismatch Breaks Backplane Communication: Outdated module firmware (pre-v7.0) causes “module not recognized” faults with 3500 racks running v8.0+. A Michigan paper mill’s technicians wasted 7 hours troubleshooting until we updated the module via the rack’s USB port. Use Bently’s firmware compatibility tool to avoid mismatches—they corrupt data transmission to 3500/25 relays.
  • Grounding: Single-Point at Rack Ground Bar: Improper grounding (e.g., grounding sensors to machinery instead of the 3500 rack) introduces 60Hz noise. A North Carolina refinery’s vibration data had persistent hum until we reconnected sensor shields to the 3500 rack’s ground bar. Use 14 AWG stranded copper wire for ground connections—keep runs under 1m.
  • Ignore Diagnostic LEDs at Your Peril: Rookies blame sensors for “no signal” faults while the module’s “fault” LED is lit. A Texas chemical plant’s tech spent 3 hours testing sensors until we pointed out the red LED—traced to a loose backplane connection. Learn the LED codes: green = power/OK, flashing amber = data transmission, red = fault (input/backplane).
    Bently 3500/22

    Bently 3500/22

Technical Deep Dive & Overview

The Bently 3500/22-01-03-01 is a 2-channel vibration/seismic monitoring module engineered to be the frontline of 3500 Machinery Protection System data acquisition. At its core, a dedicated 32-bit microprocessor processes signals from either seismic accelerometers or proximity probes: for proximity inputs, it converts impedance changes (from shaft vibration) into linear voltage signals; for seismic inputs, it conditions and amplifies millivolt-level signals from accelerometers. This processed data is then transmitted to the 3500 backplane for relay to 3500/25 safety relays (for shutdowns) and external DCS/condition monitoring systems (for trending).
Unlike generic monitoring modules, its 3500-native integration eliminates compatibility issues and reduces latency to ≤10ms—critical for safety-critical vibration thresholds. The hot-swappable design allows module replacement without powering down the 3500 rack, maintaining 24/7 protection for critical assets. The 1kV AC isolation between channels and backplane blocks EMI from VFDs, motor cables, and industrial equipment, ensuring signal integrity in noisy environments.
What sets it apart is its fault-tolerant, flexible design. SIL 2 compliance is achieved through redundant internal signal processing and cyclic redundancy checks (CRC) on all data transfers. The per-channel input configuration (seismic/proximity) eliminates the need for multiple modules, optimizing rack space. For maintenance and reliability teams, this module isn’t just a data collector—it’s a critical link in predictive maintenance: it detects early signs of fault (e.g., bearing wear, rotor unbalance, resonance) and ensures fast, reliable transmission of safety-critical data to the 3500 system. Its seamless 3500 integration, multi-input flexibility, and rugged design make it the gold standard for 2-channel vibration/seismic monitoring in harsh industrial settings.

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