Product Specification Document: Bently Nevada PWB78434-01

1. Product Overview

2. Basic Product Information

Manufacturer and Model Identity

• Manufacturer: Bently Nevada (Baker Hughes)

• Model Number: PWB78434-01 (Alternative Part Numbers: 78434-01, NP0968-2)

• Product Type: 110 VAC Input Relay Circuit Board (Assembled PWB)

• System Compatibility: 3500 Series Rack System; 3500/22M TDI Module; 3500/32M Relay Output Module; System 1 Software

• Country of Origin: United States

Electrical Characteristics

• Input Voltage: 110 VAC nominal (range: 85–132 VAC, 50/60 Hz)

• Relay Contact Rating: 250 VAC / 1 A resistive load; maximum switching capacity 500 W at 240 VAC

• Input Current: Up to 10 A (surge); continuous 5 A

• Isolation: 250 VAC input-to-output and channel-to-backplane isolation

• Relay Type: Electromechanical, single-pole double-throw (SPDT)

• Contact Life: 100,000 mechanical operations (rated load)

• Power Consumption: ≤5.0 W (24 VDC from 3500 rack backplane)

Physical and Mechanical

• Enclosure: Rugged metal chassis, EMI-shielded, conformal-coated PCB for harsh environments

• Dimensions: 241.3 mm × 24.4 mm × 241.8 mm (9.50 in × 0.96 in × 9.52 in)

• Net Weight: ~0.75 kg (1.65 lb)

• Rack Slot: Full-height, single-slot; installs in any 3500 monitor slot

• Front Panel Indicators: Power LED, input status LED, relay actuation LED, fault LED

• Enclosure Rating: IP20 (indoor use; finger-contact protected)

• Terminations: Rear-panel screw terminals for 110 VAC input and relay output wiring

Environmental Limits

• Operating Temperature: −20°C to +85°C (−4°F to +185°F)

• Storage Temperature: −40°C to +100°C (−40°F to +212°F)

• Relative Humidity: 5%–95% RH (non-condensing)

• Vibration Resistance: 10 g (5 Hz–1 kHz); 20 g shock (11 ms half-sine)

• EMI Immunity: Meets IEC 61000-6-2; CE marked for industrial noise immunity

Compliance and Certification

• Standards: API 670 (4th edition), ISO 10816, IEC 61000-6-2, IEC 61000-6-4

• Certifications: cULus, CE, FCC; SIL 2 capable

• Quality: ISO 9001 manufacturing; 100% factory tested, calibrated, and burn-in tested

• Lifecycle Status: Active production; fully supported for new installations and retrofits

3. Function and Product Positioning

Core Functions

• 110 VAC Input Monitoring: Detects and conditions 110 VAC external signals (e.g., remote alarms, ESD triggers, system status) for integration into the 3500 system.

• Isolated Relay Switching: Provides SPDT dry-contact outputs to drive external loads (alarm beacons, solenoid valves, PLC inputs) with 250 VAC / 1 A rating.

• Signal Isolation: Ensures electrical isolation between high-voltage AC inputs and the 3500 low-voltage DC backplane, protecting system components from damage.

• Fault Diagnostics: Detects input overvoltage, undervoltage, relay coil failure, and wiring faults; reports status to the 3500 system via front-panel LEDs and backplane communication.

• Hot-Swappable Operation: Supports replacement without rack shutdown, minimizing maintenance downtime for critical systems.

Operational Features

• Conformal-Coated PCB: Protects against moisture, dust, and chemical contaminants in harsh industrial environments.

• Software-Configurable Logic: Relay actuation (latching/non-latching, normally open/normally closed) programmed via 3500 Rack Configuration Software.

• LED Status Indication: Clear visual feedback for power, input presence, relay state, and fault conditions on the front panel.

• Robust Terminal Design: Rear screw terminals accommodate 12–22 AWG wiring for secure field connections.

Product Positioning

• API 670-compliant integration of 110 VAC external control signals into turbine, compressor, and generator protection systems.

• Driving external alarm and ESD interlock devices requiring dry-contact relay outputs.

• Retrofit projects replacing legacy 3300 series relay boards in existing monitoring systems.

• SIL 2 applications requiring reliable isolation and switching of high-voltage AC signals.

4. Core Performance Parameters

Input Performance

• Nominal Input Voltage: 110 VAC (50/60 Hz)

• Input Voltage Range: 85–132 VAC (operational)

• Input Impedance: 10 kΩ nominal

• Response Time: ≤100 ms (input detection to relay actuation)

Relay Performance

• Contact Configuration: SPDT (common, normally open, normally closed)

• Rated Load: 250 VAC / 1 A (resistive)

• Maximum Switching Power: 500 W (240 VAC)

• Mechanical Life: 100,000 operations (full load)

• Electrical Life: 50,000 operations (rated load)

Communication and Integration

• Backplane Communication: 3500 high-speed proprietary bus (to TDI module)

• Data Outputs: Input status, relay state, fault codes (to System 1 software)

• System Compatibility: 3500/22M TDI (required for configuration/data logging); 3500/32M relay coordination

Reliability

• MTBF: >180,000 hours (25°C, full load)

• Warranty: 1 year (standard); extended warranties available

• Maintenance: No scheduled maintenance; periodic contact resistance verification recommended every 2–3 years

5. General Matching Accessories

Installation and Mounting

• 3500 rack mounting hardware (standard with rack)

• Shielded 12–22 AWG wiring (for 110 VAC input/relay output)

• EMI-shielded cable glands (rear panel wiring entry)

• Front panel key lock (security for configuration access)

System Compatibility

• 3500/22M TDI Module (required for configuration and data transfer)

• 3500/15 Power Supply Module (rack 24 VDC power)

• 3500/32M Relay Output Module (external alarm/ESD coordination)

• System 1 Machinery Management Software (v4.0+) (trending and diagnostics)

Maintenance and Spares

• Conformal coating touch-up kit (PCB protection)

• Replacement relay contacts and coils (field repair)

• Firmware update kit (via TDI module)

• Factory calibration and test report (included with new units)

Documentation

• PWB78434-01 Datasheet and Installation Manual

• 3500 Series Relay Interface Application Note

• API 670 Compliance Guide for Auxiliary I/O Modules

• 3500 Rack System Planning Guide

6. Applicable Equipment and Industry Fields

Primary Applications

• Power Generation: Steam/gas turbines, generators, and critical compressors in thermal, combined-cycle, and nuclear plants (integrating 110 VAC ESD and remote alarm signals).

• Oil and Gas: Centrifugal compressors, turboexpanders, and large pumps in refineries, LNG facilities, and offshore platforms (driving alarm beacons and solenoid interlocks).

• Petrochemical: Process compressors, reactors, and high-speed rotating equipment (isolating high-voltage AC signals from low-voltage monitoring systems).

Secondary Applications

• Heavy Industry: Steel mill rolling mills, industrial fans, and blowers (remote status signaling and interlock control).

• Marine: Ship propulsion turbines and generators (110 VAC shipboard system integration).

• Utilities: Water treatment large pumps and blowers (alarm annunciation and ESD triggering).

Compatibility Notes

• 110 VAC Only: Designed for 110 VAC nominal inputs; not compatible with 220 VAC without external step-down transformers.

• Requires TDI Module: Full configuration and fault logging require a 3500/22M TDI module in the same rack.

• Dry-Contact Outputs: Relay outputs are passive dry contacts; external power required for load operation.

• Hot-Swap Limitation: While hot-swappable, reconfiguration via System 1 is recommended after replacement。