BENTLY 3500/42M 176449-02

Description

Detailed parameter table

BENTLY 3500/42M 176449-02

Product introduction

The BENTLY NEVADA 3500/42M 176449-02 is a high-performance advanced multi-channel transducer signal conditioner module, engineered to serve as a centralized processing hub for diverse industrial sensors in complex machinery monitoring systems. Building on the capabilities of the 3500/40M series, this module integrates seamlessly with signal conditioning amplifiers like the 135799-01, eddy current sensors such as the 87199-01, and thermocouples, providing comprehensive signal processing for critical machinery parameters.

Designed for large-scale industrial applications, the 3500/42M 176449-02 features 16 input and 16 output channels, making it ideal for monitoring multiple points across complex machinery such as turbines, compressors, and large rotating equipment. It excels at processing conditioned signals from the 135799-01 amplifier, which enhances the weak outputs of 87199-01 eddy current sensors, ensuring accurate measurement of shaft vibration, position, and speed. Additionally, its direct support for 7 thermocouple types eliminates the need for external transmitters, simplifying system architecture.

By converting raw sensor signals into standardized 4-20mA outputs, the module enables seamless integration with downstream 3500 series components like the 3500/60 163179-01 relay module and 3500/50 133388-02 display module, as well as external systems such as DCS and SCADA. Its Ethernet port facilitates remote configuration and data streaming, enhancing flexibility in large installations. The 3500/42M 176449-02 acts as a critical intermediary, ensuring that high-quality sensor data is available for real-time monitoring, alarm management, and in-depth analysis via 170180-01-00 software.

Core advantages and technical highlights

Expanded channel capacity: With 16 input and 16 output channels, the 3500/42M 176449-02 can handle multiple sensor types across large machinery or entire process lines. This capacity allows it to process signals from numerous 87199-01 sensors (via 135799-01 amplifiers) and thermocouples simultaneously, reducing the need for multiple modules and simplifying system integration.

Superior signal processing: Equipped with 24-bit ADC resolution and a wide filtering range (0.01Hz to 20kHz), the module delivers exceptional measurement accuracy and noise reduction. This high resolution ensures that subtle signal variations from 87199-01 sensors—amplified by the 135799-01—are preserved, enabling early detection of machinery issues such as bearing wear or rotor imbalance. The configurable filters allow optimization for specific sensor types and operating conditions.

Direct thermocouple support: Unlike basic modules, the 3500/42M 176449-02 natively supports 7 thermocouple types (J, K, T, E, R, S, B), eliminating the need for external transmitters. This integration reduces signal loss and potential points of failure, while the module’s cold junction compensation ensures accurate temperature measurement even in varying ambient conditions.

Enhanced connectivity and remote access: The integrated Ethernet port enables remote configuration via 170180-01-00 software, eliminating the need for on-site access during setup or adjustments. It supports real-time data streaming to cloud platforms or SCADA systems, enhancing visibility in distributed facilities. The RS-485 port allows daisy-chain communication with other modules, simplifying wiring in large installations.

Advanced isolation: With 5kVrms channel-to-channel and channel-to-backplane isolation, the module provides superior protection against ground loops, voltage transients, and electrical interference—critical in high-voltage industrial environments. This isolation ensures measurement integrity when processing signals from 135799-01 amplifiers and thermocouples, even in noisy environments like power plants and steel mills.

BENTLY 3500/42M 176449-02

Typical application scenarios

In a combined-cycle power plant, the 3500/42M 176449-02 monitors multiple parameters of gas and steam turbines. It processes signals from 8 87199-01 eddy current sensors (via 135799-01 amplifiers) measuring shaft vibration and position, and 8 K-type thermocouples monitoring exhaust gas temperatures. The module conditions these signals, filters out noise from the plant’s electrical systems, and converts them to 4-20mA outputs. These outputs are sent to the 3500/60 163179-01 relay module, which triggers cooling adjustments or shutdowns if thresholds are exceeded, and to the 170180-01-00 software for trend analysis. The Ethernet port streams data to a central monitoring system, providing plant-wide visibility of turbine health.

Within a steel mill’s hot rolling line, the module processes signals from 87199-01 sensors (via 135799-01 amplifiers) monitoring roll vibration and R-type thermocouples measuring roll temperature. Its high isolation (5kVrms) protects against electrical noise from nearby motors, ensuring accurate measurements. The module’s 16 channels allow monitoring of multiple rolls, with conditioned signals displayed on the 3500/50 133388-02 module for operator visibility. If roll temperature or vibration exceeds safe limits, the 3500/60 163179-01 activates relays to adjust furnace heat or stop the line, preventing equipment damage. Remote engineers use the Ethernet port to adjust filtering settings via 170180-01-00 software, optimizing signal quality without interrupting production.

In a chemical processing plant, the 3500/42M 176449-02 integrates with hazardous area sensors (via intrinsic safety barriers) to monitor reactor parameters: 87199-01 sensors (via 135799-01) for agitator shaft vibration, S-type thermocouples for reactor temperature, and 4-20mA pressure transducers. It conditions these signals and sends them to both the 3500/50 133388-02 display and 3500/60 163179-01 relay module. If temperature or pressure spikes, the relay module triggers emergency vents, while the Ethernet port alerts the plant’s DCS via the 3500/93 gateway. This multi-layered approach ensures rapid response to critical conditions, enhancing plant safety.

Relationship with 135799-01 and other modules

The 3500/42M 176449-02 serves as a high-performance processing hub that complements the 135799-01 amplifier and integrates with other 3500 series components:

With 135799-01: The 3500/42M 176449-02 is optimized to receive and process the amplified ±5V output of the 135799-01 signal conditioner, which enhances the weak signals from 87199-01 eddy current sensors. This partnership ensures that subtle vibration and position details are preserved through the signal chain, from sensor to analysis software. The module’s high-resolution ADC and configurable filters further refine these signals, ensuring accurate measurement and reliable alarm triggering.

With 87199-01: While the 87199-01 sensor’s raw output is first conditioned by the 135799-01, the 3500/42M 176449-02 provides additional processing to convert these signals into standardized outputs. It preserves the sensor’s frequency response up to 20kHz, ensuring that high-frequency components critical for fault detection are accurately captured and transmitted to downstream systems.

With 170180-01-00: The software configures the 3500/42M 176449-02’s parameters, including input types, filtering, and scaling for both 135799-01-processed signals and thermocouples. It retrieves high-resolution data from the module, enabling real-time monitoring, trend analysis, and spectral analysis of vibration signals. Engineers use the software to correlate data from multiple channels, identifying interrelated issues across complex machinery.

With 3500/60 163179-01: The relay module receives conditioned signals from the 3500/42M 176449-02, including those derived from 135799-01 and 87199-01. When parameters exceed thresholds, the module sends signals to the 3500/60 163179-01 to activate alarms or shutdowns, ensuring rapid response to critical conditions. The 3500/42M 176449-02’s accurate processing reduces false alarms, improving system reliability.

Related model recommendations

3500/42M 176449-03: A variant with 32 channels and redundant Ethernet ports, suitable for large-scale industrial facilities.

135799-01: Signal conditioning amplifier that enhances 87199-01 sensor signals for processing by the 3500/42M 176449-02.

87199-01: Eddy current proximity sensor whose signals, after conditioning by 135799-01, are processed by the module.

170180-01-00: Software for configuring the 3500/42M 176449-02 and analyzing data from connected sensors.

3500/60 163179-01: Relay module that acts on conditioned signals from the 3500/42M 176449-02.

3500/50 133388-02: Display module that visualizes data processed by the 3500/42M 176449-02.

3500/05: Rack interface module that aggregates data from the 3500/42M 176449-02 and distributes it to the system.

Installation, calibration and maintenance instructions

Installation preparation: Install the 3500/42M 176449-02 in a 3500 series rack, occupying 2 consecutive slots. Power off the rack and use an anti-static wrist strap during installation. Ensure the module is positioned to facilitate wiring from multiple sensors, including 135799-01 amplifiers connected to 87199-01 sensors and thermocouples. Required tools include a torque wrench (0.5-0.7Nm), wire strippers, and terminal block screwdrivers.

Wiring and connection: Connect 135799-01 amplifiers (with attached 87199-01 sensors) to the module’s input channels using shielded twisted-pair cable (e.g., 149992-01), ensuring proper grounding to avoid ground loops. Connect thermocouples directly to designated input channels using thermocouple-grade wire. Wire output channels to downstream devices such as the 3500/60 163179-01 relay module or DCS inputs. Connect the Ethernet port to the plant network for remote access. Label all connections clearly.

Calibration: Use 170180-01-00 software to calibrate the 3500/42M 176449-02. For channels connected to 135799-01 amplifiers, set input type to “eddy current (amplified)” and configure scaling based on the 87199-01’s measurement range. For thermocouple channels, select the appropriate thermocouple type and perform cold junction compensation calibration using a reference thermometer. Use a signal generator to apply known inputs and verify linearity across the full range. System-level calibration should include the 135799-01 in the signal path to ensure overall accuracy.

Maintenance suggestions: Perform monthly visual inspections to check for loose connections, corrosion on terminal blocks, or damage to wiring. Clean terminals with a dry cloth and tighten connections as needed. Quarterly, verify the module’s filtering and signal conditioning by comparing outputs to a reference signal generator. Re-calibrate annually using 170180-01-00 software to account for drift, especially for thermocouple channels. Test Ethernet connectivity and update firmware as needed to ensure compatibility with the latest software versions. If channel isolation or signal accuracy degrades, contact technical support for repair or replacement.

Service and guarantee commitment

The 3500/42M 176449-02 comes with a 15-month warranty covering manufacturing defects, including signal processing errors, channel isolation failures, or communication issues. During this period, we provide free repair or replacement of faulty units and 24/7 technical support for integration with the 135799-01 amplifier, 87199-01 sensor, and other 3500 series modules.

Optional extended warranties (up to 5 years) include priority technical assistance, annual calibration checks, and on-site support for system integration. Backed by BENTLY NEVADA’s expertise in advanced signal conditioning and machinery protection, the 3500/42M 176449-02 is guaranteed to deliver reliable performance, ensuring that sensor data—including critical measurements from 135799-01-conditioned signals—is accurately processed and integrated into your monitoring system.