CSI 4500 Machinery HealthTM Monitor

Product Data Sheet 

0-4500-091306 

September 2006 

Machinery Health TM Management 

CSI 4500 Machinery Health TM Monitor 

n Automated, continuous, 

predictive machinery health 

monitoring of your plant’s 

most critical rotating 

machines 

n Real-time machinery health 

feedback integrates to 

process control so you can 

run your process with confidence 

n Field-based intelligence 

and event-based adaptive 

monitoring transforms 

vibration monitoring into 

predictive machinery health 

alerts 

n PeakVue ® provides 

unique bearing fault detection 

capabilities to maintenance 

personnel 

n Transient analysis for 

turbines empowers 

decisions through the 

live turbine dashboard like 

nothing on the market 

Delivers real-time machinery health information so you can 

run your process with confidence. 

Five percent of the machines 

in every plant have the ability to 

bring production to a halt. These 

critical machines require special 

attention by both maintenance and 

operations–and almost always 

have shutdown protection in place 

to prevent catastrophic failure. 

But is that really enough to ensure 

production schedules will be met? 

Is the plant really protected? 

Today more facilities are upgrading 

their protection systems with 

prediction capabilities. With 

prediction, the machine can be 

allowed to continue performing 

within acceptable parameters 

and repaired at the time most 

economically convenient to the 

plant. Adding prediction is the 

difference between just saving 

the machine itself and saving 

the production schedule. Prediction 

is protection for your bottom line. 

The CSI 4500 Machinery Health 

Monitor provides machinery 

prediction that complements 

an existing protection system 

providing real-time feedback to 

both maintenance and operations. 

As part of Emerson’s PlantWeb ® 

digital plant architecture, the CSI 

4500 delivers real-time machinery 

health information when and where 

it is needed. Integration with the 

plant’s process automation system 

and AMS Suite: Machinery Health 

Manager software empowers 

decision-making and reduces 

www.assetweb.com



machinery health faults. When 

both prediction and protection are 

required, Emerson delivers with 

a complete asset management 

strategy for your most critical 

rotating machines. 

PlantWeb Alerts give clear, powerful indications of developing problems to an 

operator at a DeltaV station. 

Real-time Machinery Health 

Feedback to Process 

Automation 

Machinery health information 

is nothing new–maintenance 

personnel have long benefited 

from the predictive capabilities 

of vibration analysis and other 

integrated technologies. But 

without vibration monitoring 

feedback to process automation, 

operators don’t know the effects 

their actions have on the health 

of rotating machines. In fact, 

40% of machine faults are the 

result of process variations. 

The CSI 4500 and the AMS 

Machinery Manager send real-time 

overall vibration levels to operators. 

If process adjustments are 

made, operators see the live 

impact on machinery health. With 

vibration data integrated with 

process automation, informed 

real-time decisions are possible. 

For example, if a mill operator 

adjusts a stretch roll on the paper 

machine and cocks the roll, vibration 

increases immediately. 

Feedback to the operator is provided 

and further adjustments 

head-off premature failure of the 

roll. 

The CSI 4500 provides machinery prediction that complements an 

existing protection system. 

Page 2


PlantWeb Alerts provide 

actionable information. 

There are certain process variations 

that impact rotating machines in 

negative ways. For instance, low 

tank or head levels may increasevibration 

on a pump or hydro 

turbine. Faulty valves, incorrect 

process running conditions, 

upstream loads or downstream 

backups may also impact 

machinery health. 

Process event monitoring with 

adaptive automated vibration 

analysis will send PlantWeb Alerts, 

containing information about the 

fault, to operators at Emerson’s 

DeltaV digital automation system. 

As an example, when a tank level 

sensor indicates the level has 

exceeded a designated low set 

point, the CSI 4500 detects and 

automatically adapts its monitoring 

strategy to begin “watching” for a 

cavitation parameter to exceed a 

defined fault level. A PlantWeb 

Alert labeled cavitation is then 

delivered to the operator at the 

DeltaV station. The operator can 

take action such as adjusting the 

level of an upstream tank to 

decrease vibration and increase 

efficiency on a pump, adjusting 

tank levels 

to stop cavitations, or increasing 

speed of a machine to eliminate 

a resonance condition. 

Machinery Health feedback integrates to process automation systems, 

such as Emerson’s Ovation ® and DeltaV digital automation systems. 

Page 3



Calendar rolls, winders, nip rolls, vacuum rolls, and changing machine speeds 

require event-based adaptive monitoring. 

Information for fast, 

accurate decision-making. 

As plant personnel go about their 

daily activities, the CSI 4500’s 

built in, exception-based processor 

collects and distributes information 

to the right system or user 

only when machinery health 

changes. The CSI 4500 continuously 

monitors the health of your 

machine, but sends alerts or new 

trend data to Emerson’s DeltaV or 

Ovation automation system on an 

exception basis when health 

changes. In addition, the CSI 

4500 and the AMS Machinery 

Manager with the GT2 processor 

option can deliver transient analysis 

and live views specifically 

designed for large 

and critical turbo machinery. 

AMS Machinery Manager also 

integrates with AMS Suite: 

Asset Portal where machine 

health is combined with other 

asset condition and performance 

information for a plant-wide view. 

Event-based monitoring 

links vibration information 

to process states. 

A machine that is in its normal 

operating mode, or production 

state, is far from operating in a 

steady state" condition. With other 

monitoring systems, an increasing 

load means increasing vibration 

levels and false alarms. This can 

necessitate setting vibration 

alarms extremely high to account 

for all process scenarios or events. 

Much like a process automation 

system, the CSI 4500's built-in 

Production State processor more 

accurately monitors process events 

such as speed inputs, changing 

load, temperature, tank level or 

relay closures. The CSI 4500 

Machinery Health Monitor processes 

events, adapts its monitoring, 

and produces a real alarm when 

machine health changes versus a 

false alarm when the load changes. 

Alarms are much tighter and false 

alarms are decreased. This adaptive 

strategy is not limited to adjusting 

alert levels; analysis types and 

the frequency of analysis can automatically 

be adapted as well. 

Page 4


Through AMS Suite: Machinery Health Manager, the PeakVue technology allows 

clear spikes to poke through the noise floor providing early fault 

detection of a Yankee dryer gearbox. 

Predictive Machinery Health 

Monitoring for 

Early Warning and Planning 

for the Maintenance 

Department 

Exception-based reporting 

drives you to the problem and 

reduces troubleshooting time 

Exception-based reporting allows 

the CSI 4500 to keep a close 

watch on the assets, but only 

alert your maintenance staff 

when the machine health 

changes. Exception-based 

reporting produces specific alerts 

and decreases the amount of data 

required for review when it is time 

to troubleshoot the alert. With 

the CSI 4500, troubleshooting 

time can be reduced 90% 

through powerful analysis tools 

such as transient analysis for 

turbines, PeakVue bearing health 

technology, and customizable 

reporting capabilities. 

PeakVue technology is 

best-available bearing and 

gearbox anomaly detector 

PeakVue technology provides 

early, accurate and trendable roller 

bearing and gearbox anomaly 

detection unmatched by all other 

bearing health tools on the market. 

PeakVue’s patented method of 

processing preserves the peak 

amplitude of the stress wave 

emitted from a bearing or gear 

defect. Preserving this peak 

amplitude allows trendable 

bearing health diagnostics. 

Other bearing tools on the market 

use demodulation techniques, 

which subtract carrier frequencies 

and use low pass filters. These 

processes have adverse effects on 

the original peaks that PeakVue 

maintains. If the carrier frequency 

during demodulation is amplitude 

modulated, then the amplitude of 

the resultant bearing energy is 

changing and will be less than the 

original bearing energy collected. 

Furthermore, the amplitude of 

the bearing energy after the low 

pass filter has been applied, 

will increase as the frequency 

of the defect increases. 

Page 5



CSI 4500T Turbine Monitor 

n Live Turbine Dashboard 

n 60 hour Data Recorder 

n Turbine Replay 

n 3D Turbine Graphical 

Representation 

To illustrate the results from 

Emerson’s Machinery Health 

technologies working together 

to provide turbine protection, 

here is a short scenario. 

The AMS Machinery Manager shows live cascade and orbit 

plots for visual comparison provided from the GT2 Processor. 

scenario 

AMS Machinery Manager allows users to select 

live plots for all bearings simultaneously. 

When the Turbine Trips 

You are comfortably home for 

the evening when the phone rings 

and you learn the turbine just 

tripped. The decision to restart the 

equipment is yours. Although you 

feel the pressure, you are confident 

because you have two powerful 

tools to rely on–all the necessary 

data was captured to 

assess the event and a live turbine 

dashboard will provide assurance 

during start-up.Information 

before, during and after the turbine 

trip is waiting for you. As you 

drive to the site, you review the 

facts: 

1. You have the proper setup to 

capture the right data surrounding 

the event. With virtually no setup, 

you can be assured the right data 

and the anomalous event will 

be captured. 

Data extraction session for post processing events or 

baseline comparisons.


In this scenario, the CSI 4500 

along with the AMS Machinery 

Manager allowed the user to 

easily see the information to make 

a confident decision. Emerson’s 

predictive technologies, such as 

the AMS Suite of applications 

and the CSI 4500 along with 

complementary PlantWeb 

Services, allow you to maximize 

availability and performance of 

key production assets to ensure 

operational excellence. 

2. Real-time continuous data 

recording ensures events will not 

be missed. With the CSI 4500, 

a 60 hour running history is 

recorded all of the time. The 

CSI 4500’s continuous data 

recorder will record and buffer from 

60 hours to over one week, 

depending on the number of sensor 

inputs. Auto archiving of data 

is also included so that small, one 

hour, snapshots can be permanently 

and automatically saved to 

a network server. 

3. The live turbine dashboard will 

enable real-time decisions during 

start up. 

When you arrive on site, they have 

already found a plugged oil line to 

the bearing. Now the question is 

“how much damage was done, 

and can we restart?” 

Multi-channel, continuous data 

recording saves you from ever 

missing an event and ensures the 

right information is available to dig 

deeper into the problem. You look 

at the quick views and then extract 

the region of interest for more 

details, which quickly drives you 

to your decision. 

You review the data, compare with 

baseline, and confirm the vibration 

is isolated to one bearing. The 

shaft centerline plots tell you the 

bearing clearance was not exceeded. 

After fixing the oil flow issue, 

you advise restarting the turbine 

as you watch the live turbine dashboard. 

The live turbine dashboard provides 

real-time decision-making 

during start-up. 

The live turbine dashboard, available 

with the CSI 4500 transient 

system,provides live plots that 

were not possible before the GT2 

processor. Live real-time plots 

such as overall levels, orbits, shaft 

centerline, Bode/ Nyquist, cascade, 

waveform and spectrum, on all 

bearings, allow a turbine specialist 

to make real-time decisions. 

Simple Windows displays make 

manipulating screens and plots 

easy. Dual monitor mode helps 

you organize your views 

so you are staged for the startup. 

You can overlay baseline plots 

(from portable or online systems) 

on known good start-up plots 

to view the differences. 

With the transient live turbine 

dashboard, you can make realtime 

decisions with operators and 

production staff to bring the 

turbine up for critical production 

needs or to shut down again 

to save the asset. 

Page 7



Chassis Options 

CSI 4500M Monitor 

The CSI 4500M Monitor is the 

most common model for applications 

in power, refining, oil & gas, 

petrochemical, chemical, pulp and 

paper, and offshore industries. 

The CSI 4500M Monitor (with up 

to 32 sensor input channels, 16 

tachometer input channels and up 

to16 relays) offers the best choice 

in flexibility and cost per channel. 

The CSI 4500M Monitor includes 

the Trip Advisory Monitor for tier 2 

critical machines, The Production 

State Monitor for continually 

changing machine operating 

states, and is upgradeable to the 

CSI 4500T Monitor, which 

includes transient analysis for turbines. 

CSI 4500M Monitor with G2 Processor. 

For more information visit 

http://www.mhm.assetweb.com/technology/online.html 

CSI 4500MS Monitor 

The CSI 4500MS ("S" denoting 

small rack size) Monitor has the 

same functionality as the CSI 

4500M Monitor, but with a smaller 

rack footprint of 12 sensor inputs, 

2 tachometer inputs, and 2 relays. 

The CSI 4500MS Monitor is the 

best choice for remote machines 

or for machine centric monitoring 

applications. The CSI 4500MS 

Monitor is perfect for OEM applications, 

or when a machine needs 

dedicated monitoring and requires 

fewer sensor inputs.The CSI 

4500MS is not upgradable to the 

transient option. 

CSI 4500MS Monitor for small channel-count applications. 

Page 8


CSI 4500Q Monitor 

The CSI 4500Q Monitor 

is a Factory Mutual, 

Class I Div II, Groups C and D rated 

monitor for applications in power, 

refining, oil & gas, petrochemical, 

chemical, and offshore industries. 

The CSI 4500Q Monitor (with 32 

sensor input channels, 16 tachometer 

input channels and 16 relays) 

includes the same functionality as 

the CSI 4500M -- the Trip Advisory 

Monitor for balance of plant critical 

machines, the Production State 

Monitor for continually changing 

machine operating states, but is not 

upgradeable to the CSI 4500T 

Monitor. The CSI 4500Q Monitor's 

only power supply option is the 

24VDC source. 

CSI 4500 Machinery Health Monitor 

Enclosure Specifications 

PN A4500Mx, Where x = 1, 2, 3, 4, 5, 6, 7, 8 

PN A4500Q 

PN A4500Tx, Where x = 3, 4, 7, 8 

PN A4500MS 

Overall System Characteristics 

Enclosure Dimensions 

Environmental for CSI 4500M, 

CSI 4500MS, CSI 4500Q 

Environmental for CSI 4500T 

Ratings 

22.25" width x 26.00" height x 11.56" depth 

180 o opening required for enclosure door 

0 to 110°F (-17 to 43°C); 0 to 120°F (-17 to 

48°C) w/ fan tray accessory (PN B4500FT) 

0 to 95% R.H. noncondensing 

0 to 86°F or 0 to 30°C with Fan tray (fan tray 

required) CSI 4500T is best suited for 

computer room, control room environment 

CE EN50081-2 Emissions 

CE EN50082-2 Immunity 

Ordering Information 

x = 1, 16 sensor input, 0 tachometer, 0 relays 








Page 9



CSI 4500M Machinery Health Monitor 


Input Power 

120 – 240 VAC 50/60 Hz 

System Power Dissipation 

Optional Accessory Output Power 

CSI 4500 Chassis Dimensions 

Chassis Card Slots 

< 25 watts for 32 signals, 16 tachometers, 

16 relays 

< 55 watts with optional fan tray and aux 

power fully loaded 

< 80 watts with optional transient processor 

-24 vdc @ 0.6A for displacement probes 

13.975" width x 12.2" height x 8" depth 

Total 6 slots: 2 slots for sensor cards, 

1 slot for tachometer card, 

1 slot for relay card, 

1 slot for Machinery Health processor card, 

1 slot for power supply card 

For Latest Server Requirements click here. 

Options 

PeakVue ® Bearing and Gearbox 

Fault Detection Technology 

Fan Tray 

PN A474504 

PN B4500FT 

19” Rack Mount Option D25051 (Qty 2 per rack) 

Page 10


CSI 4500M Machinery Health Monitor Processor Card 

Specifications PN B4532MB 

G2 General 

Memory Capacity 3 

2 Mb SDRAM, 8 Mb Flash 

Network Communications 10/100 BaseT Ethernet NIC 

HUB 

May be used for daisy chain 

type network architecture 

Local Communications HUB for laptop or local display, and serial port 

Local Display 

Includes overall vibration readout and internal 

chassis temperature 

Onboard Test Generator All sensor channels, tachometer channels, 

AC, DC amplitude and phase 

CSI 4500 Rack Health Relay One relay will change states based loss of 

power or rack reboot 

G2 Trip Advisory Monitor 

Sensor Channel Scan: 16 ch rms per 500 msec 

Overall Vibration Scan Peak to Peak with Transient Option 

DC Scan Rate 

Simultaneously scanned with overall vibration scan 

(includes DC Gap, temperature, and 

accelerometer bias) 

Overall Level and DC Accuracy 100 dB, all ranges 

Spectral Resolution 

100 to 6400 lines 

Analysis Bandwidth Fmax 10 Hz to 40 kHz, discrete steps 

Spectral Scan Rate 

1 second per two channels, 400 lines, 

400 Hz, 1 avg. (depends on analysis configuration) 

Amplitude Accuracy 



CSI 4500M Machinery Health Monitor Sensor Input Card 

Specifications PN B4532MX 

B4532MX Specifications 

Sensor Input Types 

Dynamic displacement probe, accelerometer, 

velocity probe, AC input custom definable 

(Flux, dynamic pressure sensor, dynamic basis 

weight input, etc.), DC input custom definable 

(temperature or other process input), 4-20 mA 

signal. The CSI 4500T has true 

peak to peak input. 

Number of Sensor Inputs 

Analysis Bandwidth 

AC Coupling Corner Frequency 

AC Channel Accuracy 

Analog Integration 

Analog Integrator Accuracy 

16 inputs per card, 2 cards per rack, multiple 

racks linked by Ethernet 

DC to 40 kHz and DC to 2Khz with Transient 

Option 


CSI 4500M Machinery Health Monitor Power Supply Card 

Specifications PN A4532AC 

B4532AC Specifications 

Input Power 

120 – 240 VAC 50/60 Hz 

System Power Dissipation 

< 25 watts for 32 signals, 16 tachometers, 

16 relays 

< 55 watts with optional fan tray and aux 

power fully loaded 

< 80 watts with optional transient processor 

Optional Accessory Output Power -24 vdc @ 0.6 A for displacement probes 

Supplies Power to the Rack 

Supplies Power to 

Auxiliary Equipment 

5 vdc, 12 vdc, 24 vdc, 3.3 vdc, -12 vdc 

+24 vdc, 0.3 A output for optional fan tray 

±24 vdc, 0.6 A auxiliary output for displacement 

transducers or other 

CSI 4500M Machinery Health Monitor Fan Tray 

Specifications PN B4500FT 

B4500FT Specifications 

The fan tray is intended to be used where ambient air temperature around the 

stainless steel enclosure of the CSI 4500 rack is between 110°F and 120°F. 

When ordered with a new CSI 4500 Monitor, the fan tray will be delivered 

installed 

Power to the fan tray is provided by a fan tray power auxiliary output from 

the front panel of the Power Supply card of the CSI 4500 Monitor. 

NOTE: In conditions above 120°F ambient, active cooling or conditioned 

plant air should be installed. 

NOTE: Fan tray required with the CSI 4500T. The CSI 4500T is the CSI 

4500M with the transient option. The CSI 4500T should be installed in a control 

room / computer room environment not to exceed 86F or 30C 

Page 13



CSI 4500M Machinery Health Monitor Tachometer Card 

Specifications PN B4532TA 

B4532TA Specifications 

Number of Tachometer Channels 

16 inputs per rack, 1 card per rack, 

multiple racks linked by Ethernet 

Tachometer Frequency Inputs 

0.1 Hz to 2 kHz (6 RPM to 120,000 RPM) 

Tachometer Frequency Accuracy 0.1% 

Tachometer Resolution 

Tachometer Types 

0.002 Hz @ 60 Hz (0.1RPM) 

Eddy current displacement probe, 

TTL, passive magnetic 

Tachometer Input and trigger pulse range ±0.5 v to ±24 v, 

±25 v CM 

Pulse Characteristics 

Modes 

Input Impedance 

1 pulse per revolution, 500 µS/min. pulse width, 

tach divider on card 

Volt compare, automatic adaptive, divide by N 

1 MΩ (differential) 

CSI 4500M Machinery Health Monitor Relay Card 

Specifications PN B4532IO-x (x = 1, 2, 3, 4 or 5) 

B4532IO Specifications 

Number of Channels 

16 input or output relay channels, 1 card per 

rack, multiple racks linked together by Ethernet 

Relay Types 

Auto Resetting 

Response Time 

System Interface 

Interrupt Output 


Each channel socketed for a standard 

Opto22 style digital plug in module. 

These 4 KV optically isolated modules are 

available in AC/DC inputs or outputs from 

4 V to 280 V or dry contact outputs. 

Voting configurable for thrust or radial 

0 to 10s programmable time delay for 2 sensor 

voting logic 

50 µsec to 50 msec depending on module 

Software polled or interrupt driven 

Interrupt on pattern match or change 

x = 1, [4] inputs IDC5B & [12] outputs ODC5 

(standard) 



x = 4, [16] inputs IDC5B 

x = 5, [16] outputs ODC5 

Page 14


CSI 4500MS Machinery Health Monitor Enclosure 

Specifications PN A4500MS 


Enclosure Dimensions 

11" width x 16.00" height x 11.56" depth 

180° opening required for enclosure door 

Environmental 0 to 100°F (-17 to 50°C); 0 to 120°F 

(-17 to 60°C) w/ fan tray accessory 

(PN B4500FT) 

0 - 95% R.H. noncondensing 

Ratings 

Options 

PeakVue ® Bearing and Gearbox 

Fault Detection Technology 

Mounting Kit for 4500MS 

Without Enclosure 

CE EN50081-2 Emissions 

CE EN50082-2 Immunity 

PN A474514 

PN A4500SK 

Page 15




CSI 4500MS Machinery Health Monitor Sensor Card 

Specifications PN B4532MM-X 

B4532MX Specifications 

Number of Sensor Channels 12 sensor inputs, specifications same as 

B4532MX 

Number of Tachometer Channels 2 tachometer inputs, specifications same as 

B4532TA 

Number of Relay Channels 2 relay channels, specifications same as 

B4532IO 

Number of Cards Per Rack 1 sensor/tachometer/relay card, 

1 processor card, 1 power supply card, 

multiple racks can be linked by Ethernet 


Relay Options B4532MM-x, where x = 2, 3, 4 

x = 2, [2] inputs IDC5B 

x = 3, [2] outputs ODC5 


CSI 4500T Machinery Health Monitor Transient Specifications 

PN B4532DB 

B4532DB Specifications (includes all B4532MB Specifications) 

Number of Channels 

Up to 32 channels 

Memory Capacity 

64 Mb SDRAM, 8 Mb Flash 

AC Channel Accuracy 

80 dB 

Number of Tach Channels 4 fixed channels from the B4532TA tachometer 

card. Requires at least 1 of 4 

Data Recorder 

60+ hours 

Communication 

10 \100base-T Ethernet HUB and NIC 

100 BaseT recommended for Transient 

CSI 4500 Rack Health Relay Relay will change states based on loss 

of power or rack reboot 

For more information visit http://www.mhm.assetweb.com/technology/online.html 

Emerson Process Management 

Asset Optimization Division 

835 Innovation Drive 

Knoxville, Tennessee 37932 

T (865) 675-2400 

F (865) 218-1401 

©2006, Emerson Process Management. 

The contents of this publication are presented for informational purposes only, and while every effort has 

been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express 

or implied, regarding the products or services described herein or their use or applicability. 

All sales are governed by our terms and conditions, which are available on request. We reserve the 

right to modify or improve the designs or specifications of our products at any time without notice. 

Emerson Process Management, PlantWeb, AMS, DeltaV, Ovation, PeakVue, CSI and Machinery Health are 

marks of one of the Emerson Process management family of companies. The Emerson logo is a trademark 

and service mark of Emerson Electric Co. All other marks are the property of their respective owners. 

Online Machinery Health 

Management powers PlantWeb 

through condition monitoring of 

mechanical equipment to improve 

availability and performance. 

www.assetweb.com

CSI 4500 Machinery HealthTM Monitor

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