Bently Nevada 3500 Series: Modules, Applications and Selection Guide
Where to Start With the Bently Nevada 3500
If you look after turbines, compressors, hydro units or other critical rotating machines, the Bently Nevada 3500 Series is likely to come up sooner or later. It is a rack-based machinery protection system built around a simple idea: you choose the modules that match the machine you are protecting.
That flexibility is also what makes buying a 3500 system confusing. There are monitors for vibration, position, speed, temperature, process variables and reciprocating compressors, plus relay, data and display modules, and each one has its own inputs and channel count.
What is the 3500 Series?
The Bently Nevada 3500 is a modular system. Instead of a single fixed monitor, you build a rack from individual modules: monitors that measure the machine, relay modules that decide when to alarm, and a data interface that connects the rack to software.
Every module is configured through the 3500 Rack Configuration Software, where you choose what each channel measures, set alarm limits and program relay logic. Because of that, the same rack design can protect a steam turbine, a hydro unit or a reciprocating compressor.
How a 3500 rack fits together
A 3500 rack has a few positions worth knowing. The power supplies sit at one end, and the 3500/22M Transient Data Interface installs next to them. Relay modules such as the 3500/32M and 3500/33 go in slots to the right of that interface, and the monitor modules take the remaining slots.
The data interface continuously collects steady-state and transient data and sends it over Ethernet to software such as System 1. It does this without affecting the rack’s critical monitoring path.
The four module groups
Two practical details are worth planning early. The 3500/60 and 3500/61 are functionally identical, except that the 61 adds a recorder output for each channel, so choose the 61 if you need to feed a recorder or control system. If you want TMR, the temperature monitors are installed adjacent to each other in groups of three.
Vibration, position, speed
The 40M, 42M, 45, 46M, 50M and 25 measure shaft vibration, thrust position, expansion, speed and phase.
Temperature and process
The 60, 61, 65 and 62 monitor RTD, thermocouple and 4-20 mA signals, and the 64M measures dynamic pressure.
Reciprocating compressor
The 70M, 72M and 77M cover crankcase and crosshead vibration, rod position and cylinder pressure.
Alarms, data and display
The 32M and 33 relays, the 22M data interface for System 1 and the 94M touch-screen display.
How the modules work together
A 3500 rack is easiest to understand as a signal chain. Transducers feed the monitor modules, the monitors compare each measurement with alarm setpoints, and the relay modules act on those alarms. The data interface then passes everything on to your software.
Start with the reference signals. The 3500/25 Enhanced Keyphasor Module turns a once-per-turn shaft mark into a digital Keyphasor signal. The 3500/50M uses the same kind of probe or magnetic pickup to report speed, acceleration and direction. A 3500 system accepts up to four Keyphasor signals, or eight in a paired configuration.
Next come the measurement monitors. On a turbine, that usually means the 3500/40M or 3500/42M for vibration, plus the 3500/45 for thrust and expansion. Hydro units use the 3500/46M, which accepts air gap sensors as well as proximity probes and seismic transducers. Reciprocating compressors use the 3500/70M, 3500/72M and 3500/77M. Temperature and process signals go through the 3500/60, 3500/61, 3500/65 or 3500/62, and dynamic pressure goes through the 3500/64M.
Two practical details are worth planning early. The 3500/60 and 3500/61 are functionally identical, except that the 61 adds a recorder output for each channel, so choose the 61 if you need to feed a recorder or control system. If you want TMR, the temperature monitors are installed adjacent to each other in groups of three.
Finally, the alarm and data layer. The 3500/32M and 3500/33 act on Alert, Danger and Not-OK signals from any monitor channel, using AND/OR voting. The 3500/22M sends data to System 1, and the 3500/94M gives operators a local touch-screen up to 6.1 m (20 ft) from the rack. The table below summarises the main monitor modules.
Module comparison
| Module | Channels | Best for |
|---|---|---|
| 3500/40M | 4 | Proximity inputs: radial vibration, thrust position, expansion |
| 3500/42M | 4 | Proximity and seismic inputs |
| 3500/45 | 4 | Axial position, expansion, valve position |
| 3500/50M | 2 | Shaft speed, acceleration, direction |
| 3500/60 | 6 | RTD and thermocouple temperature |
| 3500/62 | 6 | 4–20 mA and voltage process signals |
| 3500/65 | 16 | RTD and thermocouple, mixed inputs |
| 3500/70M | 4 | Compressor crankcase and crosshead vibration |
| 3500/72M | 4 | Compressor rod position and rod drop |
| 3500/77M | 4 | Compressor cylinder pressure |
Choosing between similar modules
3500/40M or 3500/42M?
Both have four channels. Choose the 42M if you also need seismic inputs, or acceleration, velocity or shaft absolute measurements.
3500/60, 61, 65 or 62?
The 60 and 61 are identical six-channel RTD and thermocouple monitors, except the 61 adds a recorder output per channel.
3500/32M or 3500/33?
Both support programmable voting logic. The 32M has four relays and the 33 has sixteen.
How alarms, redundancy and hazardous-area options work
Each monitor channel compares its measurement with user-programmable alarm setpoints. Relay modules can then act on Alert, Danger, Not-OK or PPL signals from any monitor channel. With AND/OR voting you can require more than one channel to agree before a relay trips, which helps avoid shutting a machine down because of a single faulty signal. Agree the voting logic with your operations and protection teams before commissioning.
For reliability, the 3500/60 and 3500/61 temperature monitors can operate in TMR setups to protect against single-point failures. The 3500/62 process variable monitor offers standard, isolated and intrinsically safe I/O options, including internal barriers that supply safe power to 4-20 mA transmitters in hazardous areas.
If your machine is in a classified area, always confirm the correct I/O option and certification against the datasheet and your site’s safety requirements before ordering.
Did you know?
- The 3500/22M collects data without affecting the rack’s critical monitoring path.
- A 3500 system accepts up to four Keyphasor signals, or eight in a paired configuration, using two-channel 3500/25 modules.
- The 3500/94M can show up to nine custom screens.
Which modules for which machine?
Steam or gas turbine
3500/40M or 42M, 45, 50M, 25, 32M and 22M
Hydro unit
3500/46M, 45, 50M, 25, 60 or 65, 32M and 22M
Reciprocating compressor
3500/70M, 72M and 77M
Temperature and process
3500/60, 61, 65 or 62
Five steps to choose your modules
1. List the measurements
Vibration, thrust position, speed, temperature, pressure or rod position.
2. Count the channels
Most monitors have four channels, tachometer and Keyphasor modules have two, and temperature modules have six or sixteen.
3. Check your transducers
Proximity, seismic, LVDT, RTD, thermocouple or 4–20 mA inputs each need a matching module.
4. Plan the alarms
Choose 32M or 33 relays and decide your voting logic.
5. Add data and display
The 3500/22M feeds System 1, while the 3500/94M provides operators with a local screen.
Buying 3500 modules in the UK and Ireland
Qinstrument is based in Dublin, Ireland, and supplies Bently Nevada products to customers across the UK and EU. Whether your plant is in England, Scotland, Wales, Northern Ireland or the Republic of Ireland, you can send us your part numbers or machine details and we will confirm availability and quote.
Shipments between Great Britain, Northern Ireland and the EU can involve customs paperwork, VAT and duties. We offer delivery to the UK and EU with duties and taxes included, so there are no extra taxes or duties to deal with on delivery. Please confirm the terms on your quote.
For equipment going into hazardous areas, check the datasheet and your site’s compliance requirements, including any markings needed in your region, before you order. If you are not sure, send us the part number and we can help you check.
Need a Bently Nevada 3500 quote in the UK or Ireland?
Send us the module numbers or your machine details and we will confirm and quote. We deliver across the UK and EU with duties and taxes included.
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