Is the 3500 mechanical monitoring system “obsolete”? Our answer is this: while we recommend that all new installations commissioned after 2020 utilize the Orbit 60—an integrated machine condition monitoring and protection system—whenever possible due to its enhanced capabilities and superior value, the 3500 product line remains fully supported, despite having been on the market for 24 years. Why? The reason is simple: the 3500 remains a practical, reliable mechanical protection system that enjoys widespread global recognition. To date, over 80,000 3500 systems have been deployed worldwide, with approximately 5,000 new installations added annually. We remain steadfast in our commitment to supporting our customers rather than forcing product obsolescence.
The Bently Nevada 3500 system encapsulates over 60 years of Bently Nevada’s expertise and best practices in the fields of mechanical protection and condition monitoring, integrating them into a highly flexible and scalable rack-based platform. Refined through more than two decades of continuous product research, development, and improvement, the system is meticulously engineered to focus on the reliable protection of critical machinery. Furthermore, it supports the use of Bently Nevada’s System 1†—advanced software for mechanical protection and diagnostics capable of performing detailed and precise machinery analysis, which is essential for effective condition-based maintenance programs.
Both our customers and Bently Nevada agree that existing 3500 systems remain fit for purpose; unless there is a specific need (or desire) to leverage the advanced features of our newer monitoring systems—such as the Orbit 60—there is no compelling reason to immediately upgrade these installed systems.
The following is a brief comparative overview of some of the key enhancements in the Orbit 60, designed to help you make the best decision for your application and organization.
3500 vs. Orbit 60: Comparative Overview
Model 3500 products are manufactured, tested, and assembled in Minden, Nevada—a testament to the consistent high quality and reliability of Bently Nevada products. Electronic manufacturing capabilities in Minden include a recent investment of over $10 million dedicated to PCBA prototyping, as well as three brand-new, advanced PCBA production lines equipped with the latest inspection, tracking, and testing capabilities.
Bently Nevada is committed to supporting its global installed base of 3,500 systems. In 2016 and 2017, the company invested millions of dollars to comprehensively upgrade all electronic components, circuit boards, and layouts for its 3500 PCBA modules to ensure compliance with RoHS standards. The green circuit boards have now been replaced by blue ones, establishing a lead-free product line. Improvements in circuit board design—coupled with investments in a brand-new manufacturing infrastructure—have enabled nearly 100% automation in component placement, 3D X-ray inspection, and laser profile analysis of solder joints. Concurrently, the company continues to refine its testing processes to ensure the highest product quality.
Furthermore, Bently Nevada has taken proactive measures to address component and tooling obsolescence; the company has executed lifecycle management contracts with suppliers for critical components and has completed the documentation and library development for its firmware. Currently, the 3500 Rack Configuration Software is being updated to fully leverage the latest software technologies.