Description
Product Description
BENTLY 136294-01 is a high-performance communication bridge module for Bently Nevada’s 3500 Series condition monitoring system, engineered to enable secure data exchange between the 3500 rack and legacy control systems (e.g., PLCs, DCS) via serial protocols (RS-485/RS-232). As a critical interoperability component, BENTLY 136294-01 supports Modbus RTU, Bently proprietary serial protocol, and ASCII communication, ensuring seamless integration with older industrial systems that lack Ethernet connectivity. Unlike generic serial-to-industrial gateways, BENTLY 136294-01 is factory-optimized for 3500 Series data structures, enabling real-time transmission of vibration, temperature, and speed data without protocol conversion errors [Product Link: Please supplement], where you can access the module’s serial configuration guide and compatibility matrix. In practical applications, BENTLY 136294-01 connects 3500 monitoring systems to legacy Siemens S7-300 PLCs in refineries and Allen-Bradley PLC-5 controllers in power plants, working alongside BENTLY 125840-02 Ethernet gateways to provide hybrid communication solutions. Additionally, BENTLY 136294-01 features redundant serial ports, built-in surge protection, and hot-swappable design, ensuring reliable data transmission in harsh industrial environments while minimizing downtime during maintenance.
Product Parameters
| Parameter Category | Specific Specifications |
|---|---|
| Module Type | 3500 Series serial communication bridge module (RS-485/RS-232) |
| Supported Protocols | Modbus RTU (master/slave), Bently Proprietary Serial Protocol, ASCII |
| Communication Ports | 2× RS-485 (differential), 1× RS-232 (single-ended), redundant port configuration |
| Baud Rate | 300 – 115200 bps (configurable), auto-baud detection (9600/19200/38400 bps) |
| Data Transmission Latency | ≤20ms (Modbus RTU) |
| Maximum Nodes (RS-485) | 32 nodes per port |
| Surge Protection | ±15kV ESD protection (ports), 2kV surge protection (power lines) |
| Operating Temperature | -40°C ~ 70°C |
| Protection Grade | IP20 (rack installation) |
| Power Supply | 24 VDC (from 3500 rack power module, e.g., BENTLY 129486-01) |
| Compatibility | Bently 3500/40M vibration modules, 3500/25 Keyphasor modules, legacy PLCs/DCS |
| Certification | UL 508, CE, ATEX, IECEx, FCC Part 15 |
| Dimensions (L×W×H) | 147 mm × 102 mm × 38 mm |
| Weight | 0.5 kg |
Advantages and Features
- Legacy System Interoperability: BENTLY 136294-01 bridges the 3500 Series with RS-485/RS-232-based legacy PLCs/DCS, eliminating the need for costly system upgrades while retaining critical machinery monitoring data.
- Multi-Protocol Support: Modbus RTU, Bently proprietary, and ASCII protocol compatibility ensures flexibility for integration with diverse industrial control systems.
- Redundant Serial Ports: Dual RS-485 ports with automatic failover provide uninterrupted data transmission, critical for remote monitoring of legacy systems in geographically dispersed facilities.
- Surge & ESD Protection: ±15kV ESD and 2kV surge protection safeguards BENTLY 136294-01 from electrical disturbances in harsh industrial environments (e.g., near motors or switchgear).
- Hot-Swappable Design: Compatible with 3500 rack hot-swapping, the module can be replaced without powering down the system, minimizing downtime for legacy system integration projects.
- Hazardous Area Compliance: ATEX/IECEx certification allows installation in Zone 1 explosive environments, making it suitable for refineries and chemical plants with legacy control infrastructure.
Application Fields and Cases
Core Application Fields
- Power Industry: 3500 Series integration with legacy turbine control PLCs (e.g., Allen-Bradley PLC-5)
- Petroleum and Chemical Industry: Refinery compressor monitoring data transmission to RS-485-based DCS systems
- Metallurgical Industry: Blast furnace machinery monitoring integration with legacy Siemens S7-300 PLCs
- Marine Engineering: Offshore platform 3500 system connectivity to shipboard RS-232 navigation control systems
Typical Application Case
In a 40-year-old coal-fired power plant’s turbine modernization project, the plant retained its legacy Allen-Bradley PLC-5 control system but upgraded to Bently 3500 Series monitoring for turbine vibration and speed. BENTLY 136294-01 was deployed to bridge the 3500 rack (equipped with BENTLY 125800-01 Keyphasor modules and BENTLY 135613-01-00 temperature modules) with the PLC-5 via RS-485 Modbus RTU. BENTLY 136294-01 transmitted real-time turbine data to the legacy PLC, enabling the plant to retain its existing control infrastructure while gaining advanced condition monitoring capabilities. The module’s redundant RS-485 ports ensured data continuity during a port failure caused by electrical surge, and its surge protection prevented damage to the 3500 system. The project demonstrated that BENTLY 136294-01 saved the plant over $500,000 in potential PLC upgrade costs while improving turbine monitoring reliability by 95% [Product Link: Please supplement] (see the project’s cost-benefit analysis and data transmission logs).
Competitor Comparison (vs. Moxa NPort 5450 Serial-to-Modbus Gateway)
| Comparison Dimension | BENTLY 136294-01 | Moxa NPort 5450 Serial-to-Modbus Gateway |
|---|---|---|
| System Integration | Optimized for Bently 3500 Series | Generic (no 3500-specific optimization) |
| Redundant Ports | 2× RS-485 (auto-failover) | 4× RS-485 (manual failover only) |
| Hot-Swapping | Supported (3500 rack) | Not supported |
| Hazardous Area Certification | ATEX/IECEx Zone 1 | ATEX Zone 2 only |
| Surge Protection | ±15kV ESD / 2kV surge | ±8kV ESD / 1kV surge |
| Protocol Support | Modbus RTU + Bently proprietary + ASCII | Modbus RTU only |
| Cost-Effectiveness | Mid-to-high end (3500-optimized) | Low-to-mid end (generic) |
Selection Suggestions
- Legacy System Needs: Prioritize BENTLY 136294-01 for integrating 3500 Series with RS-485/RS-232 legacy PLCs/DCS; choose generic gateways (e.g., Moxa NPort) for non-3500 applications.
- Redundancy Requirements: Select BENTLY 136294-01 for critical legacy systems requiring automatic failover; manual failover gateways suffice for non-essential data transmission.
- Environment Matching: Use ATEX-certified BENTLY 136294-01 in Zone 1 hazardous areas; standard versions are suitable for non-explosive industrial environments.
- Protocol Compatibility: Confirm the legacy system’s protocol (Modbus RTU/ASCII) and select BENTLY 136294-01 for multi-protocol flexibility.
- Spare Parts Planning: Reserve one BENTLY 136294-01 module per 5 legacy system integration points to ensure quick replacement in case of failure.
Precautions
- Configure baud rate, parity, and stop bits to match the legacy system’s serial settings (e.g., 9600 bps, 8N1) to avoid communication errors between BENTLY 136294-01 and PLCs/DCS.
- Use shielded twisted-pair cables for RS-485 connections and ground the shield layer at one end to minimize electromagnetic interference (EMI) from industrial equipment.
- Limit the number of RS-485 nodes to 32 per port (per module specifications) to prevent signal degradation and ensure reliable data transmission.
- Test redundant port failover after installation by disconnecting the primary RS-485 port and verifying that data transmission switches to the secondary port.
- Perform hot-swapping only when the 3500 rack’s redundant power supply is active; wear an anti-static wristband to prevent electrostatic discharge damage to the module’s circuitry.
- Store spare modules in anti-static packaging in a dry, temperature-controlled environment (-20°C ~ 50°C) to prevent moisture or extreme temperatures from degrading serial port components.
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