U
PID A/D
RAM F
GLOBAL SUPPLIERS OF TURBINE
ID
AND COMPRESSOR CONTROL SYSTEMS
IM300/H
Series 3 Plus Hardware Referencemanual
Series 3 Plus Hardware Reference
Publication IM300/H (6.2.4) April 2010
Documentation Feedback Form 4725 121st Street Des Moines, Iowa 50323, U.S.A. Phone: (515) 270-0857 Fax: (515) 270-1331 Web: www.cccglobal.com
© 1987-2001, Compressor Controls Corporation. All rights reserved. This manual is for the use of Compressor Controls Corporation and is not to be reproduced without written permission. Air Miser, Guardian, Recycle Trip, Reliant, Safety On, SureLink, TTC, Total Train Control, TrainTools, TrainView, TrainWare, Vanguard, Vantage, WOIS, and the TTC and impeller logos are registered trademarks; and COMMAND, TrainPanel, and the Series 3++ and Series 5 logos are trademarks of Compressor Controls Corporation. Other company and product names used in this manual are trademarks or registered trademarks of their respective holders. The control methods and products discussed in this manual may be covered by one or more of the following patents, which have been granted to Compressor Controls Corporation by the United States Patent and Trademark Office: 4,949,276 5,622,042 5,879,133 6,116,258 6,494,672
5,347,467 5,699,267 5,908,462 6,217,288 6,503,048
5,508,943 5,743,715 5,951,240 6,317,655
5,609,465 5,752,378 5,967,742 6,332,336
Many of these methods have also been patented in other countries, and additional patent applications are pending. The purpose of this manual is only to describe the configuration and use of the described products. It is not sufficiently detailed to enable outside parties to duplicate or simulate their operation. The completeness and accuracy of this document is not guaranteed, and nothing herein should be construed as a warranty or guarantee, expressed or implied, regarding the use or applicability of the described products. CCC reserves the right to alter the designs or specifications of its products at any time and without notice.
Series 3 Plus Hardware Reference
3
Document Scope This manual provides the information you will need to physically install and maintain Series 3 Plus Controllers: Chapter 1
describes the controller and its major components, and discusses basic maintenance strategies and spare parts stocking.
Chapter 2
tells how to mount, replace, disassemble, reassemble, and convert controllers, and discusses general troubleshooting.
Chapter 3
describes the parameter memory and tells how to view or alter parameter values or run tests from the engineering panel.
Chapter 4
provides installation and troubleshooting instructions for the serial communication circuits.
Chapter 5
provides installation and troubleshooting instructions for the discrete input and output circuits.
Chapter 6
provides installation, calibration, and troubleshooting instructions for the Analog PCB’s analog input and output circuits.
Chapter 7
describes and tells how to install, calibrate, and troubleshoot the high-current output and speed and position inputs.
Chapter 8
describes the fault indicators and redundant controller set up.
Appendix A
describes each configuration or tuning parameter discussed in the body of this manual.
Appendix B
describes the controller test procedures that can be executed from the Engineering Panel of a Series 3 Plus Controller.
Additional information can be found in the following supporting documents, which are included at the back of this manual:
April 2010
DS300/P
lists the replaceable components of the Series 3 Plus Controller.
DS300/H
specifies the physical and electrical characteristics of Series 3 Plus Compressor Controllers.
DS307/H
specifies the physical and electrical characteristics of Series 3 Plus Turbine Controllers.
DS300/T
specifies the physical and electrical characteristics of Series 3 Plus Compressor Controller Field Termination Assemblies.
DS307/T
specifies the physical and electrical characteristics of Series 3 Plus Turbine Controller Field Termination Assemblies.
DS300/R
describes the Series 3 Plus Redundant Control Selector.
IM300/H (6.2.4)
4
Contents
Document Conventions The document title appears in the header of each odd-numbered page, while the chapter or appendix title appears in the header of even-numbered pages. Odd-page footers list the document number and revision level [IM300/H (6.2.4)], while even-page footers provide the publication date (April 2010). Acronyms are defined in the sections of this manual that discuss the corresponding subjects, by placing them in parentheses following the spelled-out terms they represent. As an example, a three-letter acronym (TLA) is a way to represent a three-word subject by combining and capitalizing the initial letters of those three words. Most are also listed under Symbols and Acronyms on page 10. Cross-references to other documents specify a section and chapter, while cross-references between chapters of this document specify a page number. References that do not specify a location are internal to the chapter in which they appear. In computerized versions of this manual, all such references are hot-linked to their target locations and appear in green. Entries in the tables of contents, illustration and table lists, and index are also hot-linked but are not green. Attention may be drawn to information of special importance by using this text styling or one of the following structures:
Note:
Notes contain important information that needs to be emphasized.
Caution:
Cautions contain instructions that, if not followed, could lead to irreversible damage to equipment or loss of data.
Warning!
Warnings contain instructions that, if not followed, could lead to personal injury. The appearance of this electrical hazard warning symbol on CCC equipment or the word Warning appearing in this manual indicates dangerously-high voltages are present inside its enclosure. To reduce the risk of fire or electrical shock, do not open the enclosure or attempt to access areas where you are not instructed to do so. Refer all servicing to qualified service personnel. The appearance of this user caution symbol on CCC equipment or the word Caution appearing in this manual indicates damage to the equipment or injury to the operator could occur if operational procedures are not followed. To reduce such risks, follow all procedures or steps as instructed.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
5
Table of Contents Document Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Symbols and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CPU PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-Current Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineering Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 2
Installation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
April 2010
Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Power Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing and Adjusting Internal Components . . . . . . . . . . . . . . . . . Model Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 13 14 14 16 17 17 17 18 19 19 19 19 20 20 20 21 22 23 26 27 28 28 29 30 31 33 33 34 35 35 36 37 38
IM300/H (6.2.4)
6
Contents General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Blank Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Visible Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Power Supply Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Chapter 3
Chapter 4
April 2010
Configuration and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Alternate Parameter Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Parameter Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Configuration Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Data Groups and Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Key Sequence Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Viewing and Changing Parameter Values . . . . . . . . . . . . . . . . . . . .46 Key Sequence Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Enabling Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 List Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Numeric Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Parameter Memory Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Bad CRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Com# POF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 CS= XXXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Error! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 No Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Isolated Port Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Configuring Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 RS-232 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Modbus TCP Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Serial Port Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Termination Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Serial Port Activity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Serial Communication Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Chapter 5
Chapter 6
Chapter 7
April 2010
7
Discrete Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Output Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factory Testing Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic I/O Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Controllers with FIOM . . . . . . . . . . . . . . . . . . . . . . . . 24 Vdc Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extended I/O Turbine Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . 24 Vdc Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . Discrete Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
67 69 69 70 71 71 71 71 72 72 72 72 73 73 73
Analog PCB I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Early-Model Analog PCB Replacement . . . . . . . . . . . . . . . . . . . Compression-Terminal Back Connections . . . . . . . . . . . . . . . . . Field Input-Output Module Connections . . . . . . . . . . . . . . . . . . . Field Input Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . Analog Output Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
75 76 77 78 79 80 81 82 83 83 85 85 86 87 87 88
Extended I/O Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-Current Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inductive Load Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Output Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daughter Board Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miscellaneous Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-Current Output Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Input Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89 89 90 90 91 92 92 92 93 93 93 94 94
IM300/H (6.2.4)
8
Contents Position Input Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Output Circuit Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Loopback Circuit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 High-Current Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . .101 Speed Input Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Position Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Chapter 8
Fault Detection and Redundancy . . . . . . . . . . . . . . . . . . . . . . .103 Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Power Supply Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Redundant Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Switching Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Tracking Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Serial Port Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Redundant Control Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 RCS Power Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Appendix A
Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Appendix B
Controller Test Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Glossary/Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
List of Figures Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 Figure 1-11 Figure 1-12 Figure 1-13 Figure 1-14
Series 3 Plus Controllers share a common hardware platform . . . . . .13 Major components of Series 3 Plus Controller . . . . . . . . . . . . . . . . . .15 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Performance and Speed Controller Front Panels . . . . . . . . . . . . . . . .21 The Engineering Panel mounts behind the Front Panel . . . . . . . . . . .22 Basic compressor and turbine controller backs. . . . . . . . . . . . . . . . . .23 CPC backs for extended I/O controllers . . . . . . . . . . . . . . . . . . . . . . .24 Field Input Module (FIM) for turbine controllers. . . . . . . . . . . . . . . . . .25 Field Output Module (FOM) for turbine controllers . . . . . . . . . . . . . . .25 Field Input Output Module (FIOM) for compressor controllers . . . . . .25 AC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Using a PC to Configure Series 3 Plus Controllers . . . . . . . . . . . . . . .30
Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5
Mounting a Series 3 Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . .31 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Power Cable connector configurations . . . . . . . . . . . . . . . . . . . . . . . .33 Panel-mounted controller with extender board installed . . . . . . . . . . .37 Voltage test points on Analog PCB . . . . . . . . . . . . . . . . . . . . . . . . . . .40
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
9
Figure 3-1 Figure 3-2
Alternate parameter set memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Series 3 Plus Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6
Serial port terminals on standard Back Panels . . . . . . . . . . . . . . . . . FTA Serial port features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring diagrams for Ports 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting to an RS-422/485 host port. . . . . . . . . . . . . . . . . . . . . . . Connecting to an RS-232 host port . . . . . . . . . . . . . . . . . . . . . . . . . . Terminating resistor DIP switch on the CPU PCB . . . . . . . . . . . . . . .
59 60 61 62 63 64
Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5
Discrete I/O terminals on basic controller back panels . . . . . . . . . . . Discrete I/O features of Field Termination Assemblies . . . . . . . . . . . CPU PCB Discrete output jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . Basic compressor controller discrete input wiring . . . . . . . . . . . . . . . Basic compressor controller discrete output wiring . . . . . . . . . . . . . .
67 68 69 70 70
Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7
Analog I/O features of Field Termination Assemblies . . . . . . . . . . . . Analog I/O terminals on basic controller back panels . . . . . . . . . . . . Early Analog PCB Assembly input configuration resistors. . . . . . . . . Analog I/O connections for basic compressor controller . . . . . . . . . . Analog output jumpers on inside of Back Panel. . . . . . . . . . . . . . . . . Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration connections for basic compressor controllers . . . . . . . . .
75 76 77 78 81 83 84
Figure 7-1 Figure 7-2 Figure 7-3 Figure 7-4 Figure 7-5 Figure 7-6
Operation of bipolar output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back panel speed input and high-current output terminals . . . . . . . . Field Termination Assembly extended I/O terminals . . . . . . . . . . . . . Jumper locations on the Auxiliary PCB . . . . . . . . . . . . . . . . . . . . . . . Daughter card configuration jumper. . . . . . . . . . . . . . . . . . . . . . . . . . High-current output functional diagram . . . . . . . . . . . . . . . . . . . . . . .
89 91 92 93 93 95
Figure 8-1 Figure 8-2 Figure 8-3 Figure 8-4 Figure 8-5
Fault and Tracking LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . Series 3 Plus dual-redundant fault tolerance . . . . . . . . . . . . . . . . . . Typical redundant switching relay circuit . . . . . . . . . . . . . . . . . . . . . Switched I/O signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Redundant Control Selector connections . . . . . . . . . . . . . .
103 105 106 107 108
List of Tables Table 2-1
Power supply voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 3-1
Data groups and pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 7-1 Table 7-2
Expected output readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Expected output readings for commonly used actuators . . . . . . . . . . 96
April 2010
IM300/H (6.2.4)
10
Contents
Symbols and Acronyms Ω
ohm (electrical resistance measurement)
%
percent (parts or divisions per hundred)
# AC AD1 to AD8
Alternating Current Analog-to-Digital variables
ADC
Analog-to-Digital Converter
ALT
ALTernate readout
AUX
AUXiliary readout
BCC
Basic (I/O) Compressor Controller
BTC
Basic (I/O) Turbine Controller
C# CCC CH1 to CH8 COND
Capacitor (for example, C9) Compressor Controls Corporation analog input CHannels signal CONDitioning
CPC
Circular Plastic Connector
CPU
Central Processing Unit
CRC
Cyclic Redundancy Checksum
CR1 to CR5 DC DCS D1 to D7 DEV DI01 to DI16 DIP DO1 to DO9
Control Relays (discrete outputs) Direct Current Distributed Control System compressor controller Discrete Input DEViation readout turbine controller Discrete Input Dual Inline Package Discrete Outputs (control relays)
ECC
Extended (I/O) Compressor Controller
ETC
Extended (I/O) Turbine Controller
EPROM EEPROM F# FIM FIOM April 2010
generic symbol for any number or numeric key
Erasable Programmable Read-Only Memory Electrically-Erasable Programmable Read-Only Memory Fuse (for example, F1) Field Input Module Field Input/Output Module IM300/H (6.2.4)
Series 3 Plus Hardware Reference FOM FREQ1 to FREQ6 FTA GRD H HDIC Hz I1 to I3
Frequency input (speed measurement) Field Termination Assembly electrical ground terminal electrical hot terminal High-Density Interconnect Cable Hertz (frequency in cycles per second) analog current-loop output Current-to-Hydraulic signal converter
I/O
Input and Output (circuits or signals)
IP
Internet Protocol
I/P
Current-to-Pneumatic signal converter
J# JB# k or kkW LED LVDT
Intended Valve Position Jumper (for example, J3) Jumper Block (for example, JB10) kilo (symbol or prefix for one thousand) kilo-Watt Light Emitting Diode Linear Variable Differential Transformer (position input)
m or m-
milli (symbol or prefix for one-thousandth)
M or M-
mega (prefix for one million)
mA MPU N NEMA NO/NC OUT OUT1 to OUT3 PC PCB PI
April 2010
Field Output Module
I/H
IVP
11
milli-Ampere Magnetic PickUp electrical neutral terminal National Equipment Manufacturer’s Association Normally-Open or Normally-Closed OUTput display analog OUTputs (IBM-PC compatible) Personal Computer Printed Circuit Board Proportional-Integral control
PID
Proportional-Integral-Derivative control
PIO
Programmable Input/Output computer chip IM300/H (6.2.4)
12
Contents PLC PV
Process Variable readout
R#
Resistor (for example, R33)
RAM
Random Access Memory
RCS
Redundant Control Selector
RMA
Returned Material Authorization
RTU
Remote Terminal Unit
RVDT RX S SCADA SP SPEC SV1 to SV8 TB
Rotary Variable Differential Transformer (position input) serial port reception channel (for example, RX3) Solenoid Supervisory Control And Data Acquisition Set Point readout SPECial response Signal Variables Terminal Block
TCP
Transmission Control Protocol
TTC
Total Train Control®
TX V
serial port transmission channel (for example, TX3) Voltage
Vac
alternating-current Voltage
Vdc
direct-current Voltage
V1 to V2
analog Voltage output
W Xmtr
April 2010
Programmable Logic Controller
Watt (electrical power measurement) transmitter
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Chapter 1 IM300/H
13
Description
Series 3 Plus Hardware Referencemanual
This chapter describes the controller and its major components, and discusses basic maintenance strategies and spare parts stocking.
Compressor Performance and Antisurge Controllers SP
AUX
Steam Turbine Speed and Extraction Controllers
OUT
Series 3 Plus Controller AUTO MAN
∆ ∇
Dual-Loop and Air Miser Controllers
Gas Turbine Fuel and Nozzle Controllers COMP CONTROLS CORPORATION
Figure 1-1
Components and Configu ations
April 2010
Series 3 Plus Controllers share a common hardware platform All Series 3 Plus Controllers use a common hardware platform consisting of the following major components: • The CPU PCB Assembly provides the controller’s primary computational, serial communication, and discrete I/O capabilities. • The Analog PCB Assembly provides most (if not all) of the controller’s analog input and output circuits. • The Auxiliary PCB Assembly provides the added I/O and computational capabilities needed for turbine control applications. • The Front Panel Assembly provides the controller’s operator display and input functions. • The Engineering Panel Assembly provides the controller’s configuration and tuning functions. • The Power Supply Assembly converts the input power to the voltages required by the controller’s internal circuitry. • The Back Panel Assemblies and optional Field Termination Assemblies (FTAs) provide wiring terminals for the controller’s input and output circuits. IM300/H (6.2.4)
14
Chapter 1: Description
Mounting Configu ation
With the exception of the externally-mounted FTAs, all of the controller’s components are usually housed in an extruded aluminum case for mounting in a control panel cutout (see Figure 1-2). This is referred to as the panel-mounted configuration. In this configuration, the Back Panel (which will cause few maintenance or repair problems) can usually be treated as part of the case. The remaining components can be replaced from the front of the case without removing it from the panel. Alternately, the components of one or more controllers can be housed in a NEMA rated enclosure. This is referred to as the enclosure-mounted configuration, an option most frequently used in Air Miser applications. Most enclosure-mounted controllers use FTAs. In this configuration, the Front and Engineering Panels are mounted in the door of the enclosure and connect to the CPU PCB via a ribbon cable. The CPU and Analog PCBs, Power Supply, and Back Panel Assemblies are mounted as one unit within the enclosure, along with any FTAs, to which they connect using High-Density Interconnect Cables (HDICs).
Component Configu ation
Series 3 Plus Controllers can be divided into four basic component configurations, depending on whether or not they are equipped with an Auxiliary PCB Assembly and whether or not the Back Panel features compression terminals or circular plastic connectors (CPCs). Compressor control applications rarely require the Auxiliary PCB, while turbine applications usually do. Thus, component combinations that do not include it are referred to as compressor controller configurations and those that do are referred to as turbine controller configurations. However, Antisurge and Performance Controllers can use a turbine controller configuration when the application requires Auxiliary PCB features. Similarly, a compressor controller configuration can be used for Extraction Controller applications that do not require features provided by the Auxiliary PCB Assembly. Because the I/O capabilities of turbine controller FTAs exceed those of the compression-terminal Back Panel for the same controllers, controllers that include CPC-style Back Panels are referred to as extended I/O configurations and those with compression terminal backs are referred to as basic I/O configurations. However, both the basic and extended I/O compressor controller configuration offer an essentially identical combination of inputs and outputs.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference Front Panel Assembly
Case
Engineering Panel Assembly Analog PCB Assembly CPU PCB Assembly
Mounting Slide
15
Slide Adjuster
Rear Panel Assembly Power Supply Assembly Auxiliary PCB Assembly
Auxiliary PCB Daughter Card
Figure 1-2
Major components of Series 3 Plus Controller In summary, the four basic component configurations can be referred to as: • The Basic Compressor Controller (BCC), which has neither an Auxiliary PCB nor a CPC-style Back Panel Assembly. • The Extended Compressor Controller (ECC), which has a CPC Back Panel Assembly but no Auxiliary PCB. • The Basic Turbine Controller (BTC), which has an Auxiliary PCB but not a CPC-style Back Panel Assembly. • The Extended Turbine Controller (ETC), which has both a CPC Back Panel and an Auxiliary PCB Assembly. Each component configuration can use either an AC or DC power supply (which require different Back Panels) and can be provided in either the panel- or enclosure-mounted configuration.
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IM300/H (6.2.4)
16
Chapter 1: Description
RAM
EEPROM
EEPROM
Analog Board Connectors
I/O Chip
DO2 Jumper Discrete Output Relays
NO/NC Jumpers CPU
I/O Chip Power Supply Connector
Speaker Termination Resistor DIP Switch Auxiliary Board Connector Engineering Panel Connector
Figure 1-3
CPU PCB Assembly
Factory-Test Jumpers Back Panel Connector
CPU PCB Assembly The CPU PCB provides the controller’s central processor, memory, serial communication, and discrete I/O capabilities. The major components of this assembly (see Figure 1-3) are: • a Zilog Z80 CPU chip (central processing unit); • a RAM chip (random access memory) in which the results of internal calculations are stored (that is, the working memory); • two EEPROM chips (electrically-erasable programmable readonly memories) that store the control program and parameters; • two I/O chips that provide four serial ports, eight discrete inputs, and communication between the main CPU and the microprocessors on the Engineering Panel and optional Auxiliary PCB; • a super-capacitor that powers the RAM during power outages, thus preserving the working memory; • eight electro-mechanical relays (discrete outputs), with jumpers that set their normally-open / normally-closed configurations; • isolating power supplies for the serial ports; • terminating resistors for the serial communication networks, and a set of DIP switches for including them in those circuits; and • a speaker for audible feedback. Storing configuration parameters in EEPROMs protects them from being lost or corrupted during power failures (see page 41), while still allowing them to be easily changed from either the Engineering Panel keyboard or via serial communication from a computer workstation running controller support software. Similarly, storing the control program in the EEPROMs means it can also be updated from a computer running our Download software.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
17
In panel-mount controllers, the CPU PCB slides into grooves in the case. For enclosure-mount applications, it is mounted on the back of the enclosure. Either way, the Analog PCB, Auxiliary PCB (when present), and Power Supply are bolted to the CPU PCB and communicate with it via connectors mounted between them. The CPU PCB communicates with the Back Panel via a 120-pin connector along its trailing edge, and with the Engineering Panel via a 20-pin connector along its leading edge. In enclosure-mounted controllers, the CPU PCB and Engineering Panel Assemblies are connected by a ribbon cable. Serial Ports
The CPU board’s two I/O chips provide four serial ports (Ports 1 to 4) that are compatible with the EIA RS-485 standard. Ports 1 and 2 are used for communications with other Series 3 Plus Controllers, while Ports 3 and 4 are used for communication with host computers or control systems using the Modbus protocol. Port 5 is not used.
Discrete Inputs
The CPU board’s I/O chips provide eight discrete inputs that are referred to as D- or DI-1 through 8: • Compressor controllers have terminals for and thus support only seven of these inputs. • Turbine controllers support all eight. Consult the configuration manual for each specific controller to determine the functions of these inputs.
Discrete Outputs
The CPU board provides eight electro-mechanical relays that can be used to control external alarms or as inputs to other control or monitoring systems. These are referred to as DO- or CR-1 to 8: • All compressor controllers have terminals for and thus support only the first five of these relays. • Basic turbine controllers support seven relays, while extended I/O turbine controllers support all eight. All turbine controllers also support the Auxiliary PCB’s fault relay (DO/CR9). The function of each relay can be independently selected by setting its Relay Assigned Function [MODE:D RA #] parameter. Consult the configuration manual for your controller to determine what control relay functions it provides. CR1 is of particular interest, because it is normally energized and thus fails off. This provides an automatic indication of hardware failure or power loss. In models equipped with Revision B or later CPU PCBs, CR2 can also be configured as a fault relay.
Note: April 2010
Some compressor controller CPU PCBs have only five relays, which are generally too few to support turbine control applications. IM300/H (6.2.4)
18
Chapter 1: Description
EPROM RAM CPU I/O Chip
Speaker
Figure 1-4
Auxiliary PCB Assembly
Daughter Board
Analog Board Connection
Auxiliary PCB Assembly The Auxiliary PCB provides the additional computational and I/O capacity needed for speed control and valve positioning. All turbine controllers except the Extraction Controller require this board. It can also be installed in Compressor Controllers that require its valve positioning loop, speed inputs, or high-current output circuit. The major components of this assembly (see Figure 1-4) are: • the Motorola 68332 central processing unit (CPU); • two random access memory (RAM) chips, in which the results of internal calculations are stored (the board’s working memory); • the EPROM chip (erasable programmable read-only memory) that stores the control program for this board; • a super-capacitor that powers the RAM when the controller is unplugged and during power outages; • an analog output that can provide a bipolar current-modulated signal of up to 200 mA, and the jumpers to configure it; • a programmable input/output (PIO) chip that provides eight additional discrete inputs; • one electro-mechanical relay (discrete output) and a jumper to configure it as normally open or closed, used for fault detection on the Auxiliary PCB; and • a daughter board that provides the speed and position inputs. The only currently-available Daughter Board provides: • three frequency inputs for use as rotational speed inputs; • one LVDT and one 4 to 20 mA position inputs; and • a demodulation circuit for the frequency feedback signal of a Rosemont 3311 pneumatic transducer.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
19
The Auxiliary PCB Assembly is mounted to and above the Analog PCB Assembly, which it completely covers (see Figure 1-2).
Note: Frequency Inputs
Early models of the Auxiliary PCB that do not include the daughter card provide two LVDT inputs but support only three MPUs. The Daughter Board provides three inputs for reading the rotational speed signals from a steam or gas turbine’s magnetic pickups: • Basic turbine controllers have back-panel terminals for only three of these inputs (FREQ 1 to 3). • Extended I/O controllers have FOM terminals for all three inputs (MPUs 1 through 3).
High-Current Output
The Auxiliary board includes an analog output circuit that can provide virtually any current-modulated signal (up to 200 mA) that might be required for control valve positioning. Thus, this circuit is usually called the High-Current Output. Its wiring terminals are located on the basic turbine controller back panel (OUT 1) or Field Output Module (Current Output 1). This output can be jumper-configured for a maximum current of 20, 60, or 200 mA. The control program can then be configured to map its output signal to any portion of the selected current range.
Position Inputs
The only currently-available Daughter Board provides one LVDT (Linear Variable Differential Transformer) and one 4 to 20 mA analog input for measuring the position of control valves or inlet guide vanes. These are supported only by extended I/O turbine controllers. Terminals for these inputs (Position In 1 and the Auxiliary Input) are located on the Field Input Module (FIM). The Daughter Board also includes circuitry to decode a frequency signal that has been modulated onto the High-Current Output. For example, it could recover the pressure feedback signal of a Rosemont 3311 pneumatic transducer. This feature is available in both the basic and extended I/O configurations.
Discrete Inputs and Outputs
The Auxiliary PCB provides eight discrete inputs (in addition to the eight provided by the CPU PCB): • Basic turbine controller configurations support only one of these inputs (D9). • Extended I/O configurations support all eight (DI-9 through -16). As described in the individual controller manuals, each input can be configured to trigger specific responses when the input is active. The Auxiliary PCB also has a single discrete output (DO/CR9) that signals Auxiliary board faults in the same way that DO/CR1 indicates a CPU board failure or power loss.
April 2010
IM300/H (6.2.4)
20
Chapter 1: Description Calibration Potentiometers
Configuration Jumpers
Figure 1-5
Analog PCB Assembly
Analog PCB Assembly
The Analog PCB Assembly (see Figure 1-5) provides eight analog inputs and two analog outputs. It is mounted on and toward the front of the CPU PCB (see Figure 1-2).
Analog Inputs
The Analog board’s inputs are referred to as either Analog Inputs 1 to 8 or CH1 through CH8: • Basic turbine controller configurations support only four of these inputs (CH1 to 4). • All other controller configurations support all eight analog inputs. All eight of these circuits must be configured as either current or voltage inputs by placing all of the board’s configuration jumpers in either the C (20 mA) or V (5 Vdc) positions.
Note: Analog Outputs
Early models of the Analog PCB were factory configured for all 5 Vdc or all 20 mA inputs and did not include configuration jumpers. For compressor controllers, the Analog PCB outputs are called OUT1 and OUT2. They are factory-set as either 20 mA or 5 Vdc circuits by setting a jumper on the inside of the Back Panel Assembly. When set up for current-loop modulation, they are sometimes called I-1 and I-2. When set up for voltage-modulation, they are also referred to as V-1 and V-2. For turbine controllers, these outputs are referred to as OUT2 and OUT3 (OUT 1 is the High-Current Output provided by the Auxiliary PCB). The compression terminal back panel has a jumper (similar to that of the basic compressor controller) that configures them as either current (I2 and I3) or voltage (V2 and V3) outputs. In contrast, the FOM provides terminals for both the current- and voltage-modulated forms of these outputs. However, only one form of each output can be used at any given time.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
90.0
PV
3620
90.0 50.4 SP
AUX
2122 Performance Controller
Auto Manual Remote
AUTO MAN
∆
Local
LOCAL
Tracking
∇
TranFail Fallback ComErr
SP
OUT
Speed/Remote AUX Auto Manual Remote
Speed Controller AUTO MAN
∆
Local
REMOTE Limit
RPM
3620 50.1
OUT
KW=
21
OPERATING MODE
∇
Limit
RESET
ComErr
ENTER
SET POINT MODE
MENU
SCROLL
Stop Idle Run ShutDn
DISPLAY LOOP2
DISPLAY LOOP3
Tracking
MENU Fault
COMPRESSOR CONTROLS CORPORATION
Figure 1-6
Front Panel Assembly
SCROLL
Alarm Cascade Fault
COMPRESSOR CONTROLS CORPORATION
Performance and Speed Controller Front Panels The Front Panel Assembly provides the primary operator interface for the Series 3 Plus Controller. It is attached to the Engineering Panel by a swing-out hinge and communicates with it via an eight conductor ribbon cable. Regardless of which model you purchase, the general features of this panel are always the same. As shown in Figure 1-6, each has: • two five-digit numeric readouts that usually display the controlled variable and its set point, • a three-digit numeric readout that displays the value of the controller’s output signal (in percent) • a twelve-character alphanumeric readout for displaying process or controller variables, • fourteen LEDs for indicating status conditions, and • eight control keys. Each model does have a unique overlay that identifies the type of controller you have, the function of each control key, and the meaning of each status LED that it utilizes. The configuration manuals (IM3##) provide detailed information about each controller’s frontpanel and operator interface.
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IM300/H (6.2.4)
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Chapter 1: Description
Figure 1-7
Engineering Panel Assembly
The Engineering Panel mounts behind the Front Panel The chief feature of the Engineering Panel is the Engineering Keyboard (see Figure 3-2), which can be used to enter and change the configuration and tuning parameters that adapt each controller to its specific application. In Series 3 Plus Controllers, the Engineering Panel is equipped with an embedded microprocessor that controls both the Engineering Keyboard and the Front Panel. Off-loading these functions from the main CPU allows the controller to run more demanding control algorithms while still providing a responsive user interface. The Engineering Panel is mounted on the front of the controller, immediately behind the Front Panel (see Figure 1-7). It is accessed by loosening the screw at the bottom of the Front Panel, pulling its left side forward about an inch, and then swinging the entire assembly forward and to the left.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Compressor
Turbine CH 1 –
CH 2
CH 3
CH 1 + –
CH 2 + –
CH 3 + –
CH 4 + –
OUT 1 +
OUT 2 +
CH 5 + –
CH 6 + –
CH 7 + –
CH 8 + –
CR1 1 2
CR2 1 2
OUT 3 +
CR1 1 2
CR2 1 2
CR3 1 2
CR4 1 2
CR5 1 2
DISCRETE IN D1 D2 D D3 D4 D5
CR6 1 2
CR7 1 2
CR9 1 2
PORT 1 TX/RX 1 + –
PORT 2 TX2 RX2 + – 2 + –
PORT 3 TX3 RX3 3 + – + –
TX5 + –
PORT 5
NOT USED
RX5 + –
23
24VDC DISCRETE + – D6 D7
PORT 4 TX4 RX4 4 + – + –
96-264 VAC 21-32 VDC
+
+
–
PORT 1 1 TX/RX – +
+
CH 4
+
–
CR3 1 2
FREQ2 + –
OUT 1
+
CR4 1 2
OUT 2 +
CR5 1 2
DISCRETE IN D1 D2 D D3 D4 D5
PORT 2 TX2 RX2 + – 2 + –
PORT 3 TX3 RX3 3 + – + –
FREQ1 + –
–
24VDC DISCRETE +
–
D6 D7
DISCRETE PORT 4 D8 D9 TX4 RX4 4 + – + –
96-264 VAC 21-32 VDC
FREQ3 + –
Port 5 - Not Used MADE IN USA
Figure 1-8
Back Panel Assemblies
N GRD H 35 W max
N GRD H 35 W max
MADE IN USA
Basic compressor and turbine controller backs All I/O wiring and the input power cable connect to the controller’s Back Panel Assembly. Each controller is equipped with one of four basic versions of this panel: • • • •
the basic compressor controller Back Panel, the extended I/O compressor controller Back Panel, the basic turbine controller Back Panel, or the extended I/O turbine controller Back Panel.
Each of these assemblies is available for either AC or DC power supply configurations and either panel or enclosure mounting. The I/O terminals for the basic controller configurations are mounted directly on the Back Panel (see Figure 1-8). In order to facilitate replacement of these controllers, two-piece terminals are used. After permanently attaching each wire to the removable half of its connector, you can unplug each group of wires by detaching that half of the connector from the controller. The two extended I/O versions of the Back Panel are designed to be used with separately-mounted Field Termination Assemblies (FTAs), to which they are connected using High-Density Interconnect Cables (HDICs) with circular plastic connectors (CPCs). April 2010
IM300/H (6.2.4)
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Chapter 1: Description
Compressor
Turbine
MADE IN USA
MADE IN USA
1
4
1
4
INPUTS/ OUTPUTS (J1) 60
63
INPUTS (J1) 60
63
1
4
OUTPUTS (J2) 60
21-32 VDC
N
G
H
96-264 VAC
35 W max
Figure 1-9
63
21-32 VDC
N
G
H
96-264 VAC
35 W max
CPC backs for extended I/O controllers Extended I/O compressor controllers use a Back Panel with one CPC connector, while the Back Panel for extended I/O turbine controllers have two (see Figure 1-9). For panel-mounted controllers, the Back Panel Assembly is bolted to the back of the case. In enclosure-mounted applications, the Back Panel is mounted on the back of the enclosure using angle brackets. In either case, the optional FTAs snap onto standard instrument mounting rails. Extended I/O Controllers can be purchased without FTAs. We then supply pigtail I/O cables with CPC connectors on the controller ends only. The Series 3 Plus Compressor Controllers Field Termination Assembly data sheet [DS300/T] and Series 3 Plus Turbine Controllers Hardware Specifications [DS307/H] list the I/O signals assigned to the color coded wires on the unterminated ends.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference Discrete Input Fuses and 24 Vdc Fuses Config. Blocks and Config. Block
Terminals for Discrete Inputs
CPC Connector for Controller Data Cable
Terminal Block for Valve Position Inputs
Figure 1-10
Analog Input Fuses and Config. Blocks
Terminals for Frequency Inputs
Terminal Blocks for Analog Inputs
Field Input Module (FIM) for turbine controllers
CPC Connector for Controller Data Cable
Terminal Blocks for Serial Ports 1 to 4 (Port 5 is not used)
Figure 1-11 Ribbon Cable Connectors for Serial Port Bus
25
Discrete Output Fuses and Config. Blocks
Terminal Block for Analog Outputs Terminal Block for 24 Vdc
Terminal Blocks for Discrete & Misc. Outputs
Field Output Module (FOM) for turbine controllers DB-9 Connectors for Modbus Ports
HDIC Connector
Analog Input Cfg. Blocks
Discrete Output Cfg. Blocks
24 VDC Cfg. Block Serial Port Cfg. Blocks
Terminal Block for Serial Ports 1 to 4 (P5 is not used) Terminal Block for 24 VDC and Instrument Ground
Figure 1-12 April 2010
DISCONTINUED
Fuses for 24 VDC Power Circuits Terminal Blocks for Analog I/O Circuits
Fuses for Analog Inputs Discrete I/O Fuses
Terminal Block for Discrete Outputs Terminal Block for Discrete Inputs
Field Input Output Module (FIOM) for compressor controllers IM300/H (6.2.4)
26
Chapter 1: Description
Field Termination Assemblies
Because there is simply too little room on the Back Panel to provide terminals for all of their CPU, Analog, and Auxiliary PCB I/O circuits, extended I/O turbine controllers are provided with remotely-mounted Field Termination Assemblies (FTAs): • The Field Input Module (or FIM, see Figure 1-10) has terminals for all input signals. • The Field Output Module (or FOM, see Figure 1-11) handles all output and serial communication connections. The Series 3 Plus Turbine Controllers Field Termination Assembly data sheet [DS307/T] lists the specifications for these FTAs. In addition to supporting additional I/O circuits, the use of FTAs can reduce panel design and wiring costs. They also include fusing and dropping resistor options that would otherwise be quite difficult to install. Other FTA design features facilitate connecting the controller’s I/O signals to a DCS or other supervisory control system, and simplify wiring of the serial communication networks used to coordinate the actions of multiple controller systems.
Note:
The Field Input/Output Module (FIOM), shown in Figure 1-12 and specifed in Series 3 Plus Turbine Controllers Field Termination Assembly data sheet [DS307/T] is a discontinued part and is no longer available. Because the FTAs have no active components, they should never fail or need replacement. In the remote event one does, the terminal blocks can be disconnected and reinstalled on a replacement FTA without disturbing the field wiring.
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5 Vdc Potentiometer (R33)
Fuse
Figure 1-13
Power Supply Assembly
AC Power Supply Assembly All Series 3 Plus Controllers are equipped with either an AC or a DC power supply that automatically adapts to a wide range of input voltages (Figure 1-13 illustrates the AC Power Supply): • the AC power supply accepts any voltage from 96 to 264 Vac, 50 to 60 Hz, while • the DC power supply accepts any voltage from 21 to 32 Vdc. The Back Panel of each controller is clearly labeled to indicate which power supply it is equipped with. Either provides regulated +5, +15, –15, and +24 Vdc output voltages, and either galvanically isolates the controller’s internal circuitry from the power source. The ground conductor of the power cable should be connected to a suitable earth ground. This grounds the case (for electrical safety), provides the reference potential for internal power supply voltages and analog outputs, and serves as a sink for any high-frequency components of the analog input signals. The 24 Vdc output, which is connected to the 24 VDC terminals on the Back Panel or FTA, can be used to power your field transmitters. This transmitter power output is isolated so that a faulty transmitter will not affect the controller’s internal voltages. The Power Supply Assembly is mounted on and toward the rear of the CPU PCB Assembly (see Figure 1-2), to which it connects via an 18-pin connector with 15 individual conductors.
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Chapter 1: Description
Maintenance Strategies
The simplest approach to maintaining Series 3 Plus Controllers is to replace suspect units with identical spares. The faulty unit can be sent to Compressor Controls Corporation for diagnosis and repair. Because Back Panel problems are extremely rare, you can usually employ the considerably easier remedy of replacing only those components that can be removed from the front of the controller. It is often possible to determine which component is malfunctioning (for example, the Analog PCB Assembly), in which case you can replace just that component and return it for repair or replacement (we advise against attempting board-level repairs). Due to the almost complete interchangeability of parts across the entire Series 3 Plus line, this approach can significantly reduce your required spare parts inventory. Most models of the Series 3 Plus Controller can be converted into any other by changing the Front Panel and loading the appropriate control program. You might also have to add or remove the Auxiliary PCB Assembly, and make sure the CPU PCB has enough control relays (turbine controllers generally require eight, while some compressor controllers have only five). If the controllers are equipped with different Back Panels, you might also have to change the Rear Panel Assembly or reuse the Case and Rear Panel from the controller you are replacing.
Spare Parts
If your chosen maintenance strategy is to replace malfunctioning units, one identical Series 3 Plus Controller should be stocked for every five in use. If the cost or consequences of downtime are unusually severe, a higher ratio of spares might be in order. On the other hand, if you choose to do board-level troubleshooting and replacement, you should stock spare assemblies at the same one-to-five level. One or more complete, spare controllers should also be stocked for use while troubleshooting suspect units.
Warning!
To prevent damage from static-electric discharges, all spare circuit boards should be stored and transported in static-resistant pouches. The Series 3 Plus Controller Spare Parts List [DS300/P] lists the major assemblies used in Series 3 Plus Controllers. Your spare parts inventory should be based on the total number of installed controllers using each assembly. To avoid complicating maintenance and spare parts procedures, we will normally try to configure all of your controllers to use identical Analog and Auxiliary PCBs. However, if this is impossible or you install controllers on different turbomachinery trains at different
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times, you may have multiple versions of these assemblies. Appropriate care must then be taken when ordering and replacing them.
Note: Return Procedure
If you have both compressor and turbine controllers, all of your CPU PCBs should have eight discrete output relays. If you have any with only five, contact CCC for information on replacing them. To return a controller or assembly for repair, call CCC at 515-2700857 and ask to talk to the Return Goods Coordinator. You will be asked to identify your controller model (for example, a Series 3 Plus Performance Controller), provide its serial number, and describe the problem you are experiencing. He or she will then schedule your repair and assign a Return Material Authorization (RMA) number. Package the items carefully (if needed, the Return Goods Coordinator will send you appropriate packing materials) and ship them prepaid and insured to: Compressor Controls Corporation ATTN: Service Department 4725 121st Street Des Moines, IA 50323 U.S.A. The RMA number should be clearly displayed on all shipping cartons and noted in all correspondence. Your equipment will usually be repaired and shipped back within five days of their arrival at the factory.
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Chapter 1: Description
DEV ALT AUX
Figure 1-14
Support Software
DEV
OUT
Antisurge Controller AUTO MAN
∆
RESET SAFETY ON
∇
ALT AUX
OUT
Antisurge Controller AUTO MAN
∆
RESET SAFETY ON
∇
PV SP
OUT
AUX Performance Controller AUTO MAN
∆
RESET SAFETY ON
∇
DISPLAYDISPLAY SURGE LIMIT COUNT
DISPLAYDISPLAY SURGE LIMIT COUNT
DISPLAYDISPLAY SURGE LIMIT COUNT
MENU SCROLL
MENU SCROLL
MENU SCROLL
Using a PC to Configure Series 3 Plus Controllers Since the Series 3 Plus Controllers were first brought to market, CCC has offered different software packages for monitoring and maintaining them using IBM-PC compatible computers. Each included utility programs that can can read, edit, and replace a Series 3 Plus Controller’s configuration parameter set and update its control program via one of its Modbus RTU serial ports (see Ports 3 and 4 on page 63): • The Toolbox Software package was a set of Series 3 Plus support programs for the MS-DOS operating system, including: • a Configurator program that could read, modify, store, compare, and write configuration parameter sets, and • a Download program that could replace the control program (application software) of a Series 3 Plus Controller. • The Workstation Operator Interface Software (WOIS) was a group of Series 4 and 3 Plus software packages developed for 16-bit Windows 95/98/ME operating systems. The WOIS Series 3 Plus Configurator utility could read and replace controller parameter sets and update their control programs. • The current TrainTools Software Packages are collections of programs developed for the 32-bit Windows 2000 and XP Professional operating systems. In particular, the Platform Engineering Utilities package includes the WOIS Series 3 Plus Configurator program, which can reprogram and reconfigure controllers via the TrainTools Series 3 OPC Server program. Instructions for doing so can be found in the Series 3 Engineering Utilities user manual [UM5513].
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Chapter 2 IM300/H
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Installation and Maintenance
Series 3 Plus Hardware Referencemanual
This chapter tells how to mount, replace, disassemble, reassemble, and convert controllers, and discusses general troubleshooting.
Mounting Slide
Slide Clamp
Pressure Screw
1 2
Figure 2-1
Controller Mounting
Note:
3
Mounting a Series 3 Plus Controller Refer to the Series 3 Plus Compressor Controllers Hardware Specifications [DS300/H] or Series 3 Plus Turbine Controllers Hardware Specifications [DS307/H] for panel cutout dimensions and Figure 2-1 for an illustration of the slide clamps (these are located on the top and bottom of the controller case). If your controller has Field Termination Assemblies (FTAs), refer to the Series 3 Plus Compressor Controllers Field Termination Assembly [DS300/T] or Series 3 Plus Turbine Controllers Field Termination Assembly [DS307/T] data sheet for information on mounting rails and data cables. Panel cutouts must have specified dimensions after painting. Use the following procedure to mount your controller in a properly sized cutout: Step 1: Loosen the slide clamp pressure screws, then remove the clamps from the case.
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Chapter 2: Installation and Maintenance Step 2: Remove the slides from the case by sliding them to the back. Step 3: Slide the controller case back into the panel cutout until the flanges contact the panel. Step 4: Reinstall the slides and slide clamps from behind the panel. Step 5: Tighten the pressure screws until the slides are tight against the panel. Step 6: If using locally-mounted FTAs (in the same cabinet as the controller), snap them onto mounting rails, connect them to the controller with high-density interconnect cables (HDIC), and ground both of each HDIC’s shield pigtails. If using remotely-mounted FTAs, only the controller ends of the HDICs should be grounded (grounding both ends can create an electric shock hazard if the ground potentials differ). In order to safely comply with CE electromagnetic requirements, connect both ends of each HDIC to equal-potential grounds.
Caution:
Grounding both ends of a long HDIC can create a hazardous ground loop.
Warning!
When mounting a Turbine Controller, make sure you connect the FOM to the Back Panel “Outputs” socket and the FIM to the “Inputs” socket. Step 7: Connect your field wiring to the appropriate terminal blocks on the Back Panel or FTAs. Step 8: Configure and connect the power cable to the controller and an appropriate power supply (observe the caution on page 33). Step 9: Use the Program Version [MODE TEST 2] and Program Checksum [MODE TEST 8] tests to determine the software revision and CRC, then record them on a configuration form. Step 10: If the controller was not preconfigured, enter appropriate values for all configuration and tuning parameters, as described in the controller’s instruction manual. Be sure to keep a record of these values and the resulting parameter checksum. If your controller was preconfigured, verify that the Parameter Checksum [MODE LOCK 4] matches that recorded on the supplied configuration form. If not, identify and correct any changed parameters.
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M630
Figure 2-2
Power Cable
Power Cable As shown in Figure 2-2, each pair of panel-mounted controllers is currently supplied with a 14-foot (4.3 meter) power cable, both ends of which are fitted with connectors that plug into the Back Panel power receptacle. This cable can be cut at any point to provide maximum flexibility in choosing the length of the two resulting cables. The configuration of the power cable connectors depends on which power supply (AC or DC) is installed, as shown in Figure 2-3.
Caution:
Because the power cable connector is not designed to assure the ground conductor is the first connection made and the last broken, there is a risk of electric shock while connecting or disconnecting the cable to the controller. AC Cable Cable
Controller
DC Cable – (Black) Ground (White)
Line (Black)
+ (Red)
Ground (Green)
Cable
Neutral (White)
Figure 2-3
Input Power Filter
Controller
Power Cable connector configurations Series 3 Plus Controllers meet CE-specified electromagnetic compatibility requirements only if each controller is equipped with a dedicated input power filter that is an exact electrical equivalent of the Corcom model 3VB3 filter. If the controller is mounted in an enclosure or cabinet, this filter must be installed within the same enclosure. Otherwise, it must be installed within twelve inches (30 cm) of the controller.
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Chapter 2: Installation and Maintenance
Controller Replacement
April 2010
Use the following procedure to replace a malfunctioning controller: Step 1: Obtain a spare unit from your company stores. If needed, convert it to the correct model by replacing the Front Panel. When converting between compressor and turbine controllers, you might also have to change the Back Panel and install or remove the Auxiliary PCB. Chapter 1 describes the potential hardware differences between controller models. Step 2: Transfer control of your process to an alternate device. Step 3: Unplug the power cable from the Back Panel of the malfunctioning controller. For FTA-equipped controllers, also disconnect the data cable(s). For those without FTAs, unplug the Back Panel terminal strips (rather than disconnecting the individual wires from the terminal blocks). Step 4: Loosen and remove the slide clamps from the case, remove the slides and pull the controller forward from the panel cutout. Step 5: Verify that all of the replacement unit’s internal switches and jumpers are set the same as in the controller being replaced. Step 6: Temporarily connect a spare power cable to the Back Panel of the replacement controller. Step 7: Connect a PC running one of our Series 3 Plus Controller support software packages (see Support Software on page 30) to a controller Modbus port (see Ports 3 and 4 on page 63). Step 8: Power up the new controller, computer, and converter, and configure them to communicate with each other. Step 9: Use the Program Version [MODE TEST 2] test to verify that the replacement contains the desired control program. If not, load that software using the Download or Configurator utility. Step 10: If the replacement was not preconfigured, use the Configurator program to load the correct parameter set. If the replacement has been preconfigured, use the Parameter Checksum [MODE LOCK 4] test to verify that its parameter settings match those of the original. If not, use the Configurator utility to determine which parameters differ and correct them. Step 11: Use the Engineering Panel MODE COMM 0 key sequence to set the replacement’s Controller and Computer ID Numbers to match those of the original controller. Step 12: Disconnect the temporary power cable and install the replacement controller into your panel by following steps 1 to 5 of the previously described Controller Mounting instructions. Step 13: Reconnect the FTA data cable(s) or Back-Panel terminal strips and power cable.
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Internal Component Access
35
With the exception of the Back Panel, any internal component of a panel-mounted controller can be removed from the front of the panel. The components of an enclosure-mounted unit are readily accessible by opening the enclosure door.
Caution:
Disconnect the power cable before disassembling the controller or disconnecting any internal component. Failure to do so is dangerous and can severely damage the controller.
Warning!
Never disassemble a Series 3 Plus Controller or handle any of its circuit boards without taking steps to prevent static discharge. Spare parts must be stored in static-protective bags. Failure to follow these precautions can result in severe damage to the controller’s internal components.
Disassembly
Use the following procedure to disassemble a panel-mounted Series 3 Plus Controller (if installed, it is not necessary to remove the controller from the panel): Step 1: Transfer control of your process to an alternate device. Step 2: Disconnect the power cable from the rear of the controller. Step 3: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left. Step 4: To separate the Front and Engineering Panels (optional unless replacing only one of these components), unplug the cable connecting them, then squeeze the top and bottom of the wire hinge until you can pull it away from the Engineering Panel. Step 5: Remove the Engineering Panel Assembly (and Front Panel, if still attached) from the case by removing the four galvanized screws at its corners and pulling the entire assembly forward to disengage it from the CPU PCB. Step 6: Remove the CPU PCB, Analog PCB, Power Supply, and Auxiliary PCB (if present) as a unit by pulling them forward and out of the case. Considerable force may be required to disengage the CPU PCB from the connector on the Back Panel. Step 7: To separate the Auxiliary PCB (if present), remove the four machine screws that attach it to the standoffs on the Analog PCB, then disengage the pins on its rear side from their connector on the CPU PCB. Step 8: To separate the Analog PCB, remove the four screws or standoffs that attach it to the standoffs on the CPU PCB, then disengage the connector joining those circuits boards. Step 9: To separate the Power Supply, disengage the connector near its trailing edge and remove the four machine screws that attach it to the standoffs on the CPU PCB.
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Chapter 2: Installation and Maintenance
Reassembly
To reassemble the controller, you basically reverse the disassembly procedure: Step 1: Align the Power Supply’s mounting holes with the corresponding standoffs on the CPU PCB, reinstall the four machine screws that attach it to those standoffs, and re-engage the power supply connector to the pins protruding from the top side of its trailing edge. Step 2: Align the pins on the Analog PCB’s rear side with the connectors on the CPU PCB, then reinstall the machine screws or standoffs that attach it to the standoffs on the CPU board. Step 3: If the controller includes an Auxiliary PCB, align the pins on its rear side with the corresponding connectors on the CPU PCB, then reinstall the four machine screws that attach it to the standoffs on the Analog board. Step 4: Slide the CPU PCB, Analog PCB, Power Supply, and Auxiliary PCB (if so equipped) into the case as a unit. The CPU PCB fits into the left-most set of grooves in the top and bottom of the case. Press fairly hard until you feel the CPU PCB “pop” back into the connector on the front of the Back Panel. Step 5: Align the tabs on the sides of the Engineering Panel’s mounting brackets with the grooves in the sides of the case, then slide it back until the front of those brackets is flush with the front of the mounting flange. Secure this assembly by reinstalling the four screws at its corners. Step 6: Install the Engineering Keyboard (if necessary) by aligning its mounting holes with the standoffs on the circuit board behind it (this should align the eight pins protruding from its lower rear side with the connector on the circuit board). Then reinstall the four black screws that hold this assembly together. Step 7: To reinstall the Front Panel (if necessary), insert either end of the wire hinge into its hole in the Engineering Panel’s mounting bracket, then squeeze the top and bottom of the hinge together until you can insert the other tang into its hole. Then plug the ribbon cable from the Engineering Panel into the connector on the back of the Front Panel. Step 8: Swing the Front Panel back and to the right until it contacts the front of the case. Pull its left edge forward about an inch, until you can engage the tab on its right rear side into the slot in the right side of the case. Push the left side back until the panel is parallel to the front of the case, then secure it by tightening the retaining screw at the bottom of the panel. Step 9: Reconnect the power cable to the controller.
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Figure 2-4
Testing and Adjusting Internal Components
Caution:
37
Panel-mounted controller with extender board installed Because the internal components of a panel-mounted controller can be accessed only by disassembling it, you can test or calibrate such controllers only by using a test bench or Extender Board. Care should be taken to minimize the unavoidable risk of electric shock while testing a powered controller. A test bench can be constructed from a spare Back Panel, which the CPU PCB, Analog PCB, and Power Supply Assemblies can be plugged into as a unit. Ideally, it should also include Engineering and Front Panel Assemblies and a ribbon cable (like that used in enclosure-mounted units) for connecting them to the CPU boards you will be testing. This approach provides full access to both the Analog PCB and the Power Supply Assemblies.
Warning!
Your test bench and work area must be fully protected against the possibility of static discharge. Failure to provide adequate grounding for both your equipment and personnel can result in severe damage to the controller’s internal components. In contrast, using the Series 3 Plus Extender Board provides access only to the Analog PCB, but does allow you to work on the controller in place. Use the following procedure to install one of these boards: Step 1: Transfer control of your process to an alternate device. Step 2: Disconnect the power cable from the rear of the controller. Step 3: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left. Step 4: Remove the Engineering Panel Assembly (and attached Front Panel) by removing the four screws at its corners and pulling the assembly forward to disengage it from the CPU PCB. Step 5: Remove the CPU PCB, Analog PCB, Power Supply, and Auxiliary PCB (if present) as a unit by pulling them forward and out of the case. Considerable force may be required to disengage the CPU PCB from the connector on the Back Panel.
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Chapter 2: Installation and Maintenance Step 6: Slide the Extender Board into the left-most set of grooves in the top and bottom of the case (you can determine the proper orientation by comparison with the CPU PCB). Press fairly hard until you feel the CPU PCB “pop” back into its Back-Panel connector. Step 7: Reinstall the CPU PCB, Analog PCB, and Power Supply into the case as a unit, (the CPU PCB fits into the left-most grooves in the top and bottom of the case). Press hard enough to seat the CPU PCB into its connector on the front of the Extender Board. Step 8: If desired, reinstall the Engineering Panel (and connected Front Panel) by plugging it into the front of the CPU PCB. Step 9: Reconnect the power cable to the Back Panel of the controller. When you are through testing or calibrating the unit, the Extender Board can be removed by simply reversing these steps.
Model Conversion
Although any model Series 3 Plus Controller can be converted into any other, it is easiest to interconvert those with the same Component Configuration (see page 14) so you only need to replace the Front Panel and load the desired software and parameters: Step 1: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left. Step 2: Unplug the cable connecting the Front and Engineering Panels. Step 3: Squeeze the top and bottom of the wire hinge together until you can pull it away from the Engineering Panel. Step 4: Reverse steps 1 to 3 to install the new panel. New software can then be installed using the Download module of our optional Toolbox support software. If you have that program, its Configurator module is the best tool for loading the new parameters. To convert a controller into a model having a different component configuration, you might also have to add or remove the Auxiliary PCB Assembly and make sure the CPU PCB has enough control relays (turbine controllers generally require eight, while some compressor controllers have only five). If the controllers have different Back Panels, you might also have to change it or reuse the Case and Rear Panel from the controller you are replacing.
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General Troubleshooting
39
This section contains information you will need to troubleshoot general problems with the controller. Because it is not practical to fully discuss control system troubleshooting in this manual, we are including only basic information that should be helpful to a reasonably experienced troubleshooter. Detailed troubleshooting information concerning each type of input or output is included in the appropriate chapter. For example, Chapter 4 includes information on troubleshooting serial communication. In addition, each controller provides several diagnostic tests that can be performed from the Engineering Keyboard. A general discussion of them can be found in Chapter 3, while Appendix B describes them in detail. If a controller malfunction is suspected, transfer control of your process to a backup device. Then try to determine whether the problem is in this controller, another controller with which it communicates, or elsewhere in your control system (for example, a failed transmitter). If the problem is in a controller, verify that it is not due to incorrect engineering parameters. If you have an up-to-date configuration worksheet, the Parameter Checksum [MODE LOCK 4] procedure provides a quick check for changed parameters. Additional information or assistance can be obtained by contacting the Technical Service Department at Compressor Controls.
Caution:
Always transfer your process to a backup control device before powering down or trouble-shooting a Series 3 Plus Controller. In most cases, the process signals should also be disconnected while testing the controller.
Blank Front Panel
If a controller is inadequately protected (see Surge Suppression on page 61 and Output Isolation on page 84), excessive Port 3, Port 4, or analog output voltages can cause the Front Panel to light its Fault LED and blank all other LEDs and readouts. Normal functioning can then be restored by temporarily unplugging the controller.
Visible Damage
With the controller disconnected from its power supply, examine the Front and Back Panels and all interior components for physical damage, signs of overheated components, broken wires, and such. If obvious physical damage is detected, try to identify and correct any external causes before replacing the damaged assemblies — otherwise you risk damaging the replacement parts as well.
Controller Faults
Every Series 3 Plus Controller has a front-panel Fault LED and one or more fault relays that indicate various internal failures (see Fault Indicators on page 105).
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Chapter 2: Installation and Maintenance
C16 (24 Vdc)
C9 (5 Vdc)
Figure 2-5
Power Supply Voltages
C7 (–15 Vdc)
C5 (+15 Vdc)
Voltage test points on Analog PCB The voltages produced by the power supply must be within the ranges shown in Table 2-1. All voltages should be measured across the indicated capacitors on the Analog PCB Assembly (see Figure 2-5). This means panelmounted controllers must be tested using either a test stand or an Extender Board. If any voltage is outside its indicated range, measure the voltage of the input power. Other possible causes include a faulty power supply or malfunctioning internal components. Overloading by field transmitters or transducers can reduce the transmitter power supply voltage but will not affect the internal voltages.
Caution:
While testing the controller’s internal voltages, care should be taken to minimize the unavoidable risk of electric shock. If all the output voltages measure at or near zero and there is power at the input voltage terminals, the fuse on either the Power Supply (see Figure 1-13) or the CPU PCB (see Figure 1-3) may be blown. The 5 Vdc signal can be adjusted by setting potentiometer R33 (see Figure 1-13). Replace the power supply if any other voltage is outside its indicated range for reasons other than improper loading.
Table 2-1
Power supply voltages. Power Supply Output +5 Vdc4.75 to 5.25 Vdc –15 Vdc–14.4 to –15.6 Vdc +15 Vdc14.4 to 15.6 Vdc +24 Vdc19.0 to 34.5 Vdc 1
April 2010
Transmitter Power Supply 24 Vdc +22.8 to 25.2 Vdc
Input Power Source AC:96 to 264 Vac DC:21 to 32 Vdc
Make all electrical measurements with a 20 kW/V or higher impedance multimeter of 0.1% or better accuracy. IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Chapter 3 IM300/H
41
Configu ation and Testing
Series 3 Plus Hardware Referencemanual
Each Series 3 Plus Controller is adapted to its specific application by setting the configuration and tuning parameters that govern its operation. These can be viewed or changed from the Engineering Panel or from a computer running our Series 3 Plus Configurator utility (see Support Software on page 30). Each controller model also offers several diagnostic tests that can be run from the Engineering Panel. This chapter describes the parameter memory and tells how to view or alter parameter values or run tests from the engineering panel. Detailed test procedure descriptions can be found in Appendix B. Stored In RAM
Stored in EEPROM Store 3 Store 2 Store 1
Download
Present Set
Keyboard
Figure 3-1
Parameter Memory
automatic
Long-Term Alternate Set Set 1
Alternate Set 2
Alternate Set 3
Recall 1 Recall 2 Recall 3
Alternate parameter set memory All Series 3 Plus Controllers store two copies of their configuration parameters. The long-term set is stored in an Electrically Erasable Programmable Read Only Memory (EEPROM) that “remembers” them even if the controller is powered down for years. The present set is stored in a Random Access Memory (RAM) that would “forget” them if the controller was powered down long enough (about a week) to discharge the supercapacitor that powers the RAM under such circumstances. The controller usually keeps both parameter sets identical by continuously comparing the values in the present set to their long-term counterparts, and correcting any that differ. Any changes, however entered, are made to both sets.
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Chapter 3: Configuration and Testing
Alternate Parameter Sets
Most Series 3 Plus Controllers allow you to define three Alternate Parameter Sets, which are also stored in the EEPROM. Special Parameter Memory Procedures (see page 56) are provided for defining these parameter sets, determining which one (if any) is in use, and switching to a different one. Some controllers also allow you to select an Alternate Parameter Set by clearing or asserting a discrete input.
Parameter Checksum
Each parameter set has an associated cyclic redundancy checksum (CRC) that is calculated by applying a standard algebraic function to all of its parameter values. Changing any parameter will produce a new checksum. You can tell if two parameter sets are identical by comparing their checksums. Both the Engineering Panel and our controller support programs provide easy ways to determine these checksums.
Note: Configu ation Forms
Parameter checksums are displayed as hexadecimal numbers (for example, F10C), in which each digit can have any one of sixteen values. Those greater than nine are represented by the letters A (10) through F (15). Two forms are available for planning and recording the configuration of each controller. Configuration Worksheets (FM3##/C) group the parameters by Data Groups and Pages, while the Configuration Planners (FM3##/L) list them according to the associated feature. Whenever you permanently change any parameters, you should record the new values and the resulting parameter checksum on one of these worksheets. Determining whether or not the controller’s configuration has been changed then becomes a simple matter of comparing the current checksum to that on the worksheet.
Data Groups and Pages
Each controller’s parameters are divided into data groups and pages to facilitate their entry from the Engineering Panel (see page 43). As shown in Table 3-1, each data group has an associated key and key color, and each group/page combination has a unique abbreviation (the last character of which indicates the data page). For example, the abbreviation for PID parameters on the device page is PID:D. Throughout the Series 3 Plus documentation set, the key sequence used to view or enter a parameter or execute a test begins with the abbreviation for its data group and page (for example, Transmitter Status Test [MODE:D ANIN –]). Procedures that are not assigned to a specific data page indicate only the data group key (for example, Reset Controller [MODE COMM]).
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Series 3 Plus Hardware Reference Table 3-1
Data groups and pages Data Group Key
Color
Data Pages
Abbreviation
Blue
Antisurge Cascade Device Extraction Gas Turbine Performance Speed
PID:A PID:C PID:D PID:E PID:G PID:P PID:S
Red
Antisurge Cascade Device Extraction Gas Turbine Performance Speed
MODE:A MODE:C MODE:D MODE:E MODE:G MODE:P MODE:S
CONDitioning
Green
Antisurge Cascade Device Extraction Gas Turbine Performance Speed
COND:A COND:C COND:D COND:E COND:G COND:P COND:S
SPECial RESPonse
Yellow
Antisurge Gas Turbine Speed
SPEC:A SPEC:G SPEC:S
PID
MODE
Engineering Panel
43
The Engineering Panel not only allows you to display or change parameter values but also provides the only method of executing the process and controller test procedures described in Appendix B. It consists of three main sections: • an eight-character alphanumeric readout across the top, • four data group keys across the bottom, • and sixteen data keys in the middle. The controller beeps and displays a confirming message as each key is pressed. If you do not complete a key sequence, the controller will beep and clear this display after 45 seconds of keyboard inactivity. Certain Diagnostic Messages (see page 57) may also be displayed by this panel’s readout. To expose this panel, loosen the screw at the bottom of the Front Panel and swing the bezel out and to the left. This allows simultaneous access to both the operator and configuration interfaces.
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Chapter 3: Configuration and Testing
ENGINEERING PANEL
∞∞∞∞∞∞∞∞ PB – fA Q G HIGH fC M
Figure 3-2
Key Descriptions
Kr 1 fB CONST r
fD β
4
Td 2 SS GAIN
Tf 3 MOR BIAS
K 5 REV ALARM
b 6 LOCK DISPLAY
TL LOW fE IN
RT 7 MVAR LVL
SO 8 TEST OUT
C 9 RA SP
CLEAR
d • AN IN f (X)
A 0 COMM X
ENTER
PID
SPEC RESP
MODE
COND
Series 3 Plus Engineering Panel The data group keys are used only to initiate a new key sequence, at which point one of them is pressed one or more times to select the desired data page and group. Pressing a data group key at any other point in a sequence causes an error that aborts the procedure. The two gray data keys are used primarily to end key sequences: • Pressing CLEAR either aborts a sequence without entering any changes or, when entering a numeric value, clears the digits you have entered so you can start over. • Pressing ENTER at the end of a parameter entry sequence records the new value. Although pressing it at any other point usually causes an error, some multi-parameter sequences allow you to press ENTER to display the value of the second parameter without first defining a new value for the first. The other fourteen multi-colored data keys are divided into four sections. One is gray, each of the others is the same color as a data group key. The function of each such key depends on when it is pressed in a key sequence. If pressed immediately after a data group key, it has the value labeled in the matching-colored area. Otherwise, it enters the value shown in the gray area.
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For example, consider the key in the upper right hand corner: • Pressing the blue PID key defines this as the Tf key:
PID:
PID Tf
Tf
• Pressing the red MODE key defines it as the MOR key:
MODE:
MODE
MOR
MOR
• Pressing the green COND key defines it as the BIAS key:
COND:
COND
BIAS
BIAS
• If pressed at any other point in a sequence, it is the three key:
COND:
COND
OUT
OUT 3
Key Sequence Illustrations
OT3
Although a confirming message is displayed as each key is pressed, key sequence illustrations (such as those shown in Appendix B) usually show only the most important of these messages (to save space). For clarity’s sake, they also show only the effective value of the data keys at each point in the sequence. Thus, the initial steps of a sequence that might require you to press the data group key more than once (for example, the Transmitter Status Test [MODE:D ANIN –]) would be shown as: repeat
MODE
AN IN
April 2010
until you see –
MODE:
D
AN1 GOOD
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Chapter 3: Configuration and Testing In contrast, the initial steps of a sequence that is not assigned to a specific page (for example, the Signal Values Test [MODE TEST 4]) would be shown as: MODE
Viewing and Changing Parameter Values
TEST
4
Inputs
The parameter listings in the appendix of each instruction manual include each parameter’s Engineering Panel key sequence and confirming display. Pressing the indicated keys will elicit the listed display, which consists of a prompt followed by the current value: • Enabling Parameters can have the value Off and one or more others such as On, High, Low, or single digits. These ranges are indicated as “OFF/ON”, “OFF/HIGH/LOW”, or “Off/#”. • List Parameters have a limited number of possible values that are generically indicated as “Value” or “Valu”. • Numeric Parameters can have any value within the listed range, the precision of which is indicated by the number of “#” symbols used to represent its digits. The position of the decimal point, if any, is fixed. The space before a negative value is replaced by a “–”. A hexadecimal ten leading digit shows as “A” (A0.0 is 100.0). For parameter arrays, the prompt also includes a digit corresponding to the element index and represented by the character “#”.
Note:
You may examine the value of any configuration parameter while the controller is on line without affecting the controller output or your process, and without entering the configuration password. If you attempt to change a parameter without enabling reconfiguration, the No Store diagnostic message will be displayed and the new value will be discarded. After a parameter’s current value or status has been displayed, you can terminate the procedure and clear the display by pressing the gray CLEAR key. Or, if you have entered the Enable Reconfiguration [MODE LOCK 5 1] procedural key sequence, you can enter a new value. The required procedure depends on the parameter type: • Enabling Parameters are changed by pressing the corresponding key (0 for Off, 1 for On, HIGH, LOW, or a digit) followed by the ENTER key. Until you do press ENTER, you can change your mind and press as many of the allowed value keys as you need. • List Parameters are changed by pressing the decimal key until the desired value is displayed and then pressing ENTER.
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• Numeric Parameters are changed by pressing the indicated number of numeric keys, including any leading or trailing zeroes, then ENTER. Any decimal point is placed automatically. A negative value is defined by pressing the minus (–) key before the first digit. A hexadecimal ten leading digit is defined by pressing the HIGH key (100.0 is entered as HIGH 0 0). If you make a mistake prior to pressing ENTER, you can press CLEAR to start over. For any parameter, pressing ENTER to finalize a value change also clears the confirming display.
Caution: Key Sequence Examples Enabling Parameters
To prevent process upsets, parameters should only be changed with the controller in manual or off-line. The following examples illustrate the procedures for viewing and changing the various types of parameters. When possible, they are device page parameters that are common to most if not all models of the controller. Most Enabling Parameters are assigned to the MODE data groups and simply enable or disable a controller feature. A good example is Modbus Register Scaling, which determines the scaling of Modbus register values transmitted through Port 3 (Off selects the maximum range, On selects a reduced range). The listing for this parameter gives its sequence as MODE:D LOCK 7 and its display as “LOC7 OFF/ON”. Thus, pressing those keys displays the current status of that option as follows: repeat
MODE
until you see 7
LOCK
MODE:
D
LOC7 OFF LOC7 ON
or
You can then press CLEAR to retain that status, enter 0 to disable that feature, or enter 1 to enable it: 0
1
or
LOC7 OFF LOC7 ON
ENTER
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Chapter 3: Configuration and Testing Other Enabling Parameters either disable the associated feature (Off) or select one of two possible modes of operation (High or Low). An example would be the Speed Controller’s Alternate MW Input (Off) disables the redundant MW input, High configures the controller to use the highest of the two inputs, Low selects the lowest). The listing for this parameter gives its sequence as MODE:S SS 3 and its display as “SS3 OFF/HIGH/LOW”. Thus, pressing those keys displays the current status of this option as follows: MODE
repeat
until you see 3
SS
MODE:
S
SS3 HIGH
or
SS3 LOW
or
SS3 OFF
You can then press CLEAR to leave it unchanged, or enter HIGH, LOW, or 0 to select the desired new configuration: HIGH
LOW
or 0
or
SS3 HIGH SS3 LOW SS3 OFF
ENTER
A few Enabling Parameters allow you to select from options that are intuitively numeric by pressing the corresponding decimal key. They usually either disable a feature or select the companion controller or analog input from which a given signal is to be obtained. An example is the Performance Controller’s Mass Flow Input, which selects the input for its mass flow rate calculation (Off disables that calculation, any digit from 1 to 8 configures it to use that analog input).
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The listing for this parameter gives its sequence as MODE:D fD 1 and its display as “fD1 OFF/#”. Thus, pressing those keys displays the current status of this option as follows: repeat
MODE
until you see 1
fD
or
MODE:
D
fD1
OFF
fD1
#
You can then press CLEAR to leave this feature unchanged, enter 0 to disable it, or enter the desired input number: 0
#
or
fD1
OFF
fD1
#
ENTER
where the digit key used to enter the new value is represented as #. Parameters that define decimal point positions for front panel display variables are a variant of this type of parameter. An example is the Measured Variable Decimal parameter arrays, of which each element defines the position of the decimal point in the corresponding measured variable display (Off means no decimal). The listings for these parameters gives their sequence as COND:D DISPLAY 0 # • and their display as “0#. 4321 (selected digit is replaced by •)”. Thus, pressing those keys displays the current decimal position (in this example, it follows the second digit): repeat
COND 0
DISPLAY
until you see #
•
COND:
D
0#. 43.1
where the fourth key you press is the digit corresponding to the analog input, as is the number (#) in the resulting display.
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Chapter 3: Configuration and Testing You can then press CLEAR to leave that variable’s decimal position unchanged, or change it by pressing the numeric key (0 to 4) corresponding to the desired decimal position: 0
0#. 4321
1
0#. 432.
or 2
0#. 43.1
or 3
0#. 4.21
or 4
0#. .321
or
You can continue pressing numeric keys in any order until the desired decimal point position is displayed. Finally, press CLEAR to exit the procedure without changing the parameter, or press ENTER to accept the displayed position: ENTER
List Parameters
Like Enabling Parameters, List Parameters are usually assigned to the MODE data groups and also have a limited number of values. However, few if any of those values intuitively correspond to data keys, so they are selected by repeatedly pressing the decimal (•) key until the desired value is displayed. A universal example is the Port 2 Baud Rate, which defines the data transmission rate for serial Port 2 (2400, 4800, or 9600 bits per second, which appear to be numeric values but are in fact selected from a list). The listing for this parameter gives its sequence as MODE:D COMM 2 and its display as “PT2 Valu”. Thus, pressing those keys displays the current value (2400 baud in this example): repeat
MODE
COMM
April 2010
until you see 2
MODE:
D
PT2 2400
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You can then press CLEAR to leave this baud rate unchanged, or press the decimal key (•) until the desired new rate is displayed and then press ENTER: •
PT2 4800
•
PT2 9600
•
PT2 2400
ENTER
Label parameters are entered as a series of characters that are individually selected from a list. An example are the Measured Variable Label parameters, each of which defines the label shown when the corresponding measured variable is viewed in the Auxiliary Display and can have up to eight characters. The listing for these parameters gives their sequence as COND:D DISPLAY 0 # – and their display as “AAAAAAAA (selected symbol flashes)”. Thus, pressing those keys displays the current value as follows: repeat
COND 0
until you see #
DISPLAY
–
COND:
D
AAAAAAAA
where the fourth key you press is the digit corresponding to the variable’s analog input and the first character (shown here in blue) would be flashing. You can then press CLEAR to leave the entire label unchanged, or change the flashing character by pressing the decimal (•) key to advance it to the next possible symbol or the minus (–) key to back up to the previous possible symbol:
AAAAAAAA •
–
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BAAAAAAA AAAAAAAA
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Chapter 3: Configuration and Testing You can also hold either key down to scroll rapidly through the available symbols. When the desired symbol appears (P in this example), press ENTER to accept it and edit the next: •
PAAAAAAA PAAAAAAA
ENTER
Repeat this procedure to edit each succeeding character. Once you have accepted a character, you cannot return to it without saving the entire label and starting over. Entering the last character accepts the entire label:
Pd (bar) ENTER
Another variant are parameters that have both a sign (+ or –) and a list value. An example is the Relay Assigned Function parameter array, each element of which selects the conditions under which the corresponding discrete output is triggered (if the assigned function is positive, the relay will be energized when the associated condition exists; if the value is negative, the relay will de-energize). The listing for these parameters gives their sequence as MODE:D RA # and their display as “RA#±Valu (press HIGH or LOW to select sign, then press • to select function)”. Thus, pressing those keys displays the current value as follows: repeat
MODE
until you see #
RA
MODE:
D
RA#±AAAA
where the third key you press is the digit corresponding to the discrete output number, as is the digit (RA#) in the resulting display. To change the normally energized/de-energized circuit configuration, press HIGH or LOW: HIGH
LOW
or
April 2010
RA#+AAAA RA#-AAAA
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Pressing the decimal key will advance the display to the next available function (BBBB): •
RA#±BBBB
You can press any of these keys as many times as necessary to display the desired configuration. Pressing ENTER accepts the displayed relay configuration: ENTER
Numeric Parameters
Because Numeric Parameters have virtually continuous ranges, their desired values must be defined by pressing the corresponding digit keys. A good example is the Dual-Loop Controller’sTransmitter Failure Limit, which defines the minimum valid value (00.0 to 99.9 percent) for any offset zero inputs. The listing for this parameter gives its sequence as MODE:D ANIN LOW and its display as “ANL ##.#”. Thus, pressing those keys displays the current value as follows: repeat
MODE
until you see LOW
AN IN
MODE:
D
ANL ##.#
You can then press CLEAR to leave that value unchanged, or enter the desired new value: #
#
#
ANL # . ANL ##. ANL ##.#
ENTER
where each key used to define the new value is represented as # and the decimal point is placed automatically. The precision of such a parameter is indicated by the number of “#” symbols in its listed display. When changing its value, you must press that many digit keys, even if they correspond to leading or trailing zeroes. A hexadecimal ten leading digit is entered by pressing the HIGH key and is displayed as “A” (100.0 is entered as HIGH April 2010
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Chapter 3: Configuration and Testing 0 0 and displays as “A0.0”). A negative value is defined by pressing the minus (–) key before the first digit key. If you make a mistake prior to pressing ENTER, you can press CLEAR to start over.
Note:
Most numeric parameters can range from zero to some power of ten. When the routines for entering them from the keyboard do not permit you to enter a hexadecimal leading ten by pressing HIGH, the parameter listing will show the maximum value as .999, 9.99, or 99.9. However, such parameters can be given a maximum value of one, ten, or one hundred (1.000, 10.00, or 100.0) from a computer workstation and the Engineering Panel will consequently display them as such (.A00, A.00, or A0.0). Characterizing functions are arrays that define the values of one variable that correspond to ten specific values of another: • For some functions, the independent variable (X) values are predefined in even steps from zero to one, ten, or one hundred (for example, 00.0, 11.1, 22.2, ..., 88.8, 100.0). • For others, only the first and last X values are fixed (0 and 1.000, 10.00, or 100.0). The eight intermediate steps (which must have increasing values) are defined by an array entered using a COND X # # key sequence (the first digit is the function number, the second is the element index). In either case, however, the values of the dependent variable (Y) are defined by the corresponding elements of an array entered using a MODE f(X) # # sequence. An example is the Antisurge Controller’s Reported Flow Characterizer, which defines how it calculates the flow rate it reports to its companion controllers from the flow rate used in its own proximityto-surge calculation. The listing for this parameter gives its sequences as COND:A f(X) 2 # and X 2 # and its displays as “X2# #.##” and “Y2# #.##”. Thus, you must define both arrays for this particular characterizer. Press these keys to view point N’s argument (X2,N = #.##): repeat
COND 2
X
until you see #
COND:
A
X2# #.##
where the fourth key you press is the digit corresponding to the characterizer point, as is the first digit (X2#) in the resulting display.
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Press CLEAR to leave it unchanged, or enter the desired new value: #
#
#
X2# #.##
ENTER
where each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically. Press these keys to view point N’s result (Y2,N = #.##): repeat
COND 2
until you see #
f(X)
COND:
A
Y2# #.##
where the fourth key you press is the digit corresponding to the characterizer point, as is the first digit (Y2#) in the resulting display. Press CLEAR to leave it unchanged, or enter the desired new value: #
#
#
Y2# #.##
ENTER
again, each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically.
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Chapter 3: Configuration and Testing
Parameter Memory Procedures
Because the present parameter values stored in the controller’s working memory (RAM) are subject to random (albeit extremely rare) changes, the controller continuously compares them to their long-term counterparts and corrects any errors. Before you can change any parameters from the Engineering Panel, this feature must be disabled by entering the Enable Reconfiguration [MODE LOCK 5 1] key sequence. Otherwise, any attempt to enter a new parameter value will only elicit a No Store message on the panel’s alphanumeric readout. While reconfiguration is enabled, the controller will not automatically correct any errors that might develop in its present parameter set. To restore this protection, you should enter the Disable Reconfiguration [MODE LOCK 5 0] sequence when you finish configuring the controller. If you do not, the controller will automatically disable reconfiguration after 30 minutes of keyboard inactivity. The Parameter Checksum [MODE LOCK 4] procedure displays the checksum values of the controller’s various parameter sets. You can also determine which of these parameter sets (if any) agree with those recorded on your configuration forms by comparing these checksums to those recorded on those worksheets. For controllers with Alternate Parameter Sets (see page 42), the following procedures can be used to define these parameter sets, determine which one (if any) is in use, or switch to a different one: • Each Alternate Set is defined by assigning the desired values to the Present and Long-Term parameters and using the Store Alternate Parameters [MODE LOCK 3 •] procedure to copy them to an Alternate Set. • You can switch to one of the Alternate Sets by using the Recall Alternate Parameters [MODE LOCK 3 • •] procedure to copy it back to the Present and Long-Term Sets. • You can determine which (if any) of the Alternate Sets is in use by using the Parameter Checksum [MODE LOCK 4] procedure to compare their Parameter Checksums with that for the Present and Long-Term Sets. You can also determine which of these parameter sets (if any) agree with those recorded on your configuration forms by comparing these checksums to those recorded on those worksheets.
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Diagnostic Messages Bad CRC
57
The following paragraphs explain the various messages that can appear on the Engineering Panel’s eight-character display. This message indicates the controller has found and corrected a difference between the present and long-term Parameter Memory.
Com# POF
For a description of this message and its explanation, see Serial Communication Errors on page 66.
CS= XXXX
This message indicates the power-up sequence has detected an unreasonable parameter setting and substituted a default value (XXXX is the new checksum). It usually appears only after installing a new EEPROM, downloading updated software, or using Toolbox to change parameter values. If the controller beeps repetitively and flashes this message, the EEPROM is probably damaged.
Error!
This message indicates you have entered an unrecognized key sequence. This is typically caused by: • pressing a parameter (multi-colored) key without first pressing the correct data group (solid-colored) key, • failing to press the data group key enough times to access the correct data page, • pressing the wrong number of data keys, • pressing the decimal key in sequences that automatically place the decimal point, or • entering an out-of-range value for a numeric parameter.
No Store
This message indicates you tried to change a parameter without first entering the Enable Reconfiguration [MODE LOCK 5 1] sequence.
Reset
This message indicates a control program restart, which causes the controller to check its parameters to make sure they are reasonable, reset its serial ports and analog inputs, and begin a new scan cycle. This occurs when the controller is powered up, a fault is detected (see page 105), critical parameters are changed or alternate parameters are recalled, the controller is reconfigured from a workstation, or the Reset Controller [MODE COMM] key sequence is executed. Most controllers always execute a soft reset, which does not change the operating state or analog output. However, the Speed Controller will execute a hard reset (which initiates an emergency shutdown) when it is powered up or detects a fault.
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Serial Ports
Series 3 Plus Hardware Referencemanual
This chapter provides installation and troubleshooting instructions for the serial communication circuits (Ports 1 to 4) provided by the CPU PCB. The Engineering Panel serial port (Port 5) is not used.
PORT 1 TX/RX + –
1
PORT 2 TX2 RX2 + – 2 + –
PORT 3 TX3 RX3 3 + – + –
PORT 4 TX4 RX4 4 + – + –
Port 5 is not used
TB6
Figure 4-1
Installation
Serial port terminals on standard Back Panels Because each serial port supports communication among several devices connected to a single cable, we will refer to the wiring for each as a network. The locations of the field wiring terminals for these networks are shown on Figure 4-1 and Figure 4-2. The Field Input/Output Module (FIOM) provides several convenient serial port wiring features, including DB9 connectors for Ports 3 and 4 and ribbon cable connectors for interconnecting the ports of all the controllers in a control panel.
Note:
This controller configuration option (FIOM) is discontinued and no longer available. Regardless of which controller configuration is used, all four serial ports are galvanically isolated from the instrument ground, each other, and all other I/O circuits.
Isolated Port Grounding
April 2010
It is usually best to interconnect the ground terminals of all isolated serial ports on a given network. In addition, those terminals should be collectively connected to instrument ground through a single small resistor (100 ohms works well), and should not be grounded at any other point (Figure 4-3 on page 61 provides an example).
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Chapter 4: Serial Ports FIOM
Serial Bus In
JB2
JB1
Serial Bus Out
FOM Port 3 DB9
Port 4 DB9
Resistor Switches JB10 JB11 JB12 JB13
Port 1
Port 2
Port 3
DISCONTINUED TB2/Port 2 TB1/Port 1
TB4/Port 4 TB3/Port 3
Figure 4-2
Configu ing Communications
TB5/Port 5 (Not Used)
Port 4
FTA Serial port features In order for two devices to successfully communicate, both must be set up to send and receive information at the same speed and in the same basic format (for example, number of bits per character): • There are no configuration parameters for Port 1. • The Port 2 Baud Rate [MODE:D COMM 2] can be 2400, 4800, or 9600. It is normally set to 9600. If you wish to mix Series 3 and Series 3 Plus Controllers, however, you must set the Port 2 baud rate to the 2400 bps rate used by the older controllers. • The Port 3 Baud Rate [MODE:D COMM 3] can be 4800, 9600, or 19.2k baud, while the Port 3 Parity can be odd, even, or none. The same options are available for the Port 4 Baud Rate and the Port 4 Parity [MODE:D COMM 4]. Both of these ports use one start bit, eight data bits, and one stop bit. • Port 5 is not used. In addition, multidropped ports require a unique identifying number for each controller. The Port 1 protocol uses the Controller ID Number [MODE:D COMM 0], while the Port 2 protocol and Modbus use the Computer ID Number [MODE:D COMM 0 •]. You can also prevent all Modbus access to a Series 3 Plus Controller by enabling its Read and Write Inhibit [MODE:D LOCK 1] parameter, enable write only access by disabling that parameter and enabling Write Inhibit Only [MODE:D LOCK 2], or enable read and write access by disabling both of those parameters.
Note: April 2010
You must enter the Enable Reconfiguration [MODE LOCK 5 1] key sequence before you can change any parameter settings. IM300/H (6.2.4)
Series 3 Plus Hardware Reference
Port 1
Master
Tx/Rx+
Tx/Rx+
Tx/Rx+
Tx/Rx–
Tx/Rx–
Tx/Rx–
Ground
Ground
Ground
Figure 4-3
Surge Suppression
100 Ω
Port 2
61
Slaves
Rx –
Tx +
Tx +
Rx +
Tx –
Tx –
Gnd
Gnd
Gnd
Tx –
Rx +
Rx +
Tx +
Rx –
Rx –
100 Ω
Wiring diagrams for Ports 1 and 2 Serial port voltage spikes can disrupt the normal functionality of the I/O processor. That can disable the discrete inputs, Modbus ports, and communication with the Front Panel, which causes the Fault LED to light and all other front-panel LEDs and readouts to go blank. The potential for such malfunctions can be minimized by installing voltage surge suppressors in all susceptible serial port circuits, and connecting their shield grounds only at the controller end. For more information, refer to technical note on Transient Voltage Protection for Series 3 Plus Controllers [TN23].
Note: Port 1
Port 1 and 2 Ground connections, shown as dotted lines in Figure 4-3, are not required. They are optional. These connections may improve communication quality if the controllers are in different panels, if they are separated by a long distance, or located in a harsh electrical environment. These connections may also be required by other devices, such as fiber optic converters. Serial Port 1 communication is used to coordinate the actions of Series 3 Plus Controllers regulating a single turbomachinery train. In installations where several trains are operated in parallel, there will usually be a separate Port 1 network for each train. Under the Port 1 protocol, each device transmits in turn to all of the others. Thus, these ports are connected in parallel by a single pair of wires (all positive terminals together in one group, and all negative terminals in a second).
Port 2
April 2010
Port 2 is used primarily for load-sharing and performance override control. The protocol it uses designates a single primary controller (the master) that can either broadcast to the other controllers on the network or query a single secondary controller for specific information. The secondary controllers transmit only in response to such queries. Only one secondary controller can transmit at any given time, and then only to the master. IM300/H (6.2.4)
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Chapter 4: Serial Ports Port 2 networks are installed as shown in the right panel of Figure 4-3. The secondary controllers’ receivers are wired in parallel with the master’s transmitter and the secondary controllers’ transmitters are similarly wired in parallel to the master’s receiver.
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Controllers
Host
63
Controllers
Tx/Rx +
Tx +
Tx +
Rx +
Tx +
Tx +
Tx/Rx –
Tx –
Tx –
Rx –
Tx –
Tx –
Ground
Gnd
Gnd
Ground
Gnd
Gnd
Rx +
Rx +
Tx +
Rx +
Rx +
Rx –
Rx –
Tx –
Rx –
Rx –
Figure 4-4
Ports 3 and 4
Connecting to an RS-422/485 host port Serial Port 3 is used to communicate with external computers and supervisory control systems using the Modbus RTU protocol. Port 4 is the same as Port 3, but is intended for communicating with computers running one of our controller monitoring and support software packages (see Support Software on page 30). The Modbus protocol also calls for a single host device. Series 3 Plus Controllers are always slave devices under this protocol. These ports can be directly connected to a host’s RS-422 or RS-485 serial port using either a two-wire or four-wire connection (as shown in Figure 4-4). You should use Belden 8723 twisted-pair cable (or its equivalent), and ground the shield at one end only.
RS-232 Converter
If your host is equipped with serial ports conforming to the more common RS-232C standard, you should connect them to the controllers using an RS-485/232 converter with isolated grounds (for example, the AEG OIC-422). Because Series 3 Plus Controllers do not support any handshaking signals (such as Request-To-Send/Clear-To-Send), it may be necessary to cross-connect those of the host computer. A typical wiring diagram for this application is shown in the left panel of Figure 4-5. In an emergency (say your converter fails and you can not wait for a replacement), you can directly connect a controller’s RS-485 port to a computer’s RS-232 port as shown in the right panel of Figure 4-5. You can not connect very many controllers at a time, and you can not use very long cables, but you can often make it work in a pinch.
Modbus TCP Converter
April 2010
Although Series 3 Plus Controllers do not have ethernet ports, one or more Modbus TCP masters (clients) can be connected to each of their Modbus RTU ports via commercially-available Modbus TCP to RTU converters. This can simplify and reduce the cost of wiring PCs and other master devices to them.
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9 25 pin pin
Host
2 3 4 5 6 7 8 20
TxD RxD RTS CTS DSR GND DCD DTR
3 2 7 8 6 5 1 4
Converter 2 3 4 5 6 7 8 20
Figure 4-5 Serial Port Bus
Controller + – + – G
Rx + Rx – Tx + Tx – Gnd
9 25 pin pin
Host
Controller
2 3 4 5 6 7 8 20
TxD RxD RTS CTS DSR GND DCD DTR
Rx + Rx – Tx + Tx – Gnd
3 2 7 8 6 5 1 4
Connecting to an RS-232 host port The Field Input/Output Module (FIOM) includes ribbon cable connectors for connecting the serial ports of a group of controllers mounted in the same control panel (see Figure 4-2). This serial port bus is cabled by connecting the Bus Output (J5) connector of each controller’s FTA to the Bus Input (J4) connector of the next FTA. If the bus is to include controllers in more than one panel, twisted pair cables should be used to connect the TB1 through TB4 terminal blocks of the last controller in each panel to those of the first controller in the next panel. Each of the four networks on the bus can be divided into segments by removing the corresponding configuration header (JB10 for Port 1, JB11 for Port 2, and so on) from the FIOM for the last controller in each segment. (If the last controller is connected to the next via their terminal blocks, omit that port’s twisted pair connection.) For each Port 2 network segment, one controller must be designated as the master by installing an intact configuration header in the JB2 socket. All others must have a header installed in JB1.
Warning!
Installing headers in both JB1 and JB2 will seriously damage the controller. A Modbus host can be linked into each Port 3 network segment by connecting it to the TB3 terminal block or J2 connector for the first controller in that segment. Similarly, a host can be linked into a Port 4 network segment by connecting it to the first controller’s TB4 terminal block or J3 connector.
Note:
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The serial ports of any two controllers should be interconnected using either the ribbon cable connectors (J4 to J5) or twisted pair terminal blocks (TB1 through TB4) but not both. Do not form loops by connecting the serial ports of the last controller on a network segment to those of the first. IM300/H (6.2.4)
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OPEN
Figure 4-6
Termination Resistors
1
2
3
4
5
6
1
2
3
4
5
6
Terminating resistor DIP switch on the CPU PCB The controller’s RS-485 circuitry supports the parallel connection of up to 30 multiple devices. Such a network can experience reliability problems (caused by reflected signals) if there is not enough resistance in the circuit. Although this is not a concern when connecting our controllers to each other, problems can occur when connecting them to other devices. The receiving circuit of each serial port on the CPU PCB includes a 250 ohm terminating resistor that can be included or removed from the circuit by setting the corresponding DIP switch (see Figure 1-3 for location and Figure 4-6 for detail). Closing a switch connects the resistor to its network, opening it disconnects the resistor. Controllers are shipped with all of these switches open, and we recommend you leave them in that position. If you do experience problems, closing the terminating resistor DIP switch for the first or last receiver on the network (or both) might solve them. Assistance in solving such problems can be obtained by calling CCC. The Field Input/Output Module (FIOM) provides a more convenient set of termination resistors (see Figure 4-2) that should be used for controllers equipped with that FTA. The internal resistors should then be disabled via their CPU board switches.
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Chapter 4: Serial Ports
Troubleshooting
Series 3 Plus Controllers offer several features that can prove useful when trouble-shooting serial communications problems. If you do experience such difficulties, you should verify that no duplicate controller ID numbers have been assigned, that all of them agree with those used in your host program, and that computer communications were not inadvertently inhibited in any controllers. Make sure the baud rate, parity, and number of start, stop, and data bits of the controllers and host agree. If they do and you are experiencing Serial Communication Errors, you may need to enable the Termination Resistors (see page 65) in one or more controllers, most likely the last one in a daisy-chained network. Some hosts, particularly older PLCs, may experience frequent synchronization errors at high baud rates. Thus, communication problems can sometimes be solved by reducing that rate. The Monitor component of our Toolbox Installation and Support Software Package can also be used to test controller/host communication links and the format of the Modbus requests frames you set up within your host program.
Serial Port Activity Test
The Serial Port Activity Test [MODE TEST 3] will elicit a dynamic display that reveals whether the specified serial port is transmitting or receiving data (Port 3 in this example):
PT3 R-T_ The bar after the R will be in the high position if the selected port is currently receiving a transmission, otherwise it will be low. Similarly, the bar after the T will be high only when that port is transmitting. In the above example, Port 3 is receiving but not transmitting.
Serial Communication Errors
Series 3 Plus Controllers indicate the occurrence of serial communication errors by beeping and displaying a message of the following form on the engineering panel:
Com4 POF Where the number in the fourth field identifies the Port on which the error was detected (1 through 4) and the P, O, and F characters appear only if the corresponding type of error occurred: • The P will appear if a parity error was detected. This indicates that the number of set bits (ones) in a received character did not agree with the defined parity for the serial port it arrived on. Continuous parity errors often indicate that you need to change a parity setting in either the transmitting or receiving device. April 2010
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• The O will appear if an overrun error occurred. This means that the controller failed to read an incoming character before the next one arrived. • The F will appear if a framing error was detected. This indicates that the controller was unable to decode an incoming character due to a synchronization error. Continuous framing errors often indicate that the baud rates of the sending and receiving device disagree. The most common cause of frequent or continuous errors is faulty wiring. Other possible causes of serial communication errors include line noise, improper configuration, and power interruptions. However, absence of an error display does not verify normal functioning of the serial communication channels. For example, no errors are displayed if serial communication is not working at all. However, the ComErr LED would reveal such a problem if it prevented the reception of required information. Because the communication protocols employed by the controller reject faulty messages (and usually provide for their re-transmission), isolated errors rarely affect the operation of the controller.
Note:
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If a communication error occurs while you are entering parameter values, the controller will only beep.
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Chapter 5
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Discrete Inputs and Outputs
IM300/H
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This chapter provides installation and troubleshooting instructions for the discrete input and output circuits provided by the CPU and Auxiliary PCB Assemblies. Compressor Controllers
CR1 1 2
CR3 1 2
CR4 1 2
CR5 1 2
Turbine Controllers
CR2 1 2
DISCRETE IN D1 D2 D D3 D4 D5
CR6 1 2
CR1 1 2
CR2 1 2
CR7 1 2
CR9 1 2
CR3 1 2
CR4 1 2
CR5 1 2
DISCRETE IN D1 D2 D D3 D4 D5
DISCRETE
DISCRETE
D6 D7
D6 D7
D8 D9
Figure 5-1
Installation
Discrete I/O terminals on basic controller back panels Each controller includes a CPU PCB that provides up to eight discrete inputs and eight discrete outputs (control relays). If installed, the Auxiliary PCB provides an additional discrete output and up to eight additional discrete inputs: • Compressor controllers can use seven of the CPU’s inputs (D1 through D7) and five of its outputs (CR1 through CR5). • Basic turbine controllers can use all of the CPU’s discrete inputs (D1 to D8) and seven of its outputs (CR1 to CR7). Another input and output (D9 and CR9) are provided by the Auxiliary PCB. • Extended I/O turbine controllers support all of the discrete I/O circuits provided by the CPU (DI1 to DI8 and DO1 to DO8) and Auxiliary PCB (DI9 through DI16 and DO9).
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Chapter 5: Discrete Inputs and Outputs FIM
FOM
Discrete Input Fuses and Configuration Blocks DI1/DI3 DI5/DI7 DI9/DI11 DI13/DI15 DI2/DI4
DI1 to DI6
DI6/DI8
Discrete Output Fuses and Configuration Blocks DO1 DO2 DO4 DO6 DO8 DO3
DI10/DI12 DI14/DI16
DI7 to DI13
DI14 to DI16
DO5
DO7
DO8 and DO9
DO9
DO1 to DO7
FIOM Discrete Output Configuration Blocks CR1 CR2 CR3 CR4 CR5 JB3 JB4 JB5 JB6 JB7
DISCONTINUED
DI1 to DI6
Figure 5-2
Fuses
DI7 and CR1 to CR5
Discrete I/O features of Field Termination Assemblies The location of the Back Panel discrete I/O terminals are shown in Figure 5-1, while the discrete I/O features of the Field Termination Assemblies are shown on Figure 5-2. The discrete outputs are dry contacts (although the controller’s 24 Vdc transmitter power output can be included in their external circuitry) that are galvanically isolated from all other controller circuits. The discrete input circuits are optically isolated from the connected signals. However, depending on the controller hardware configuration, some of these circuits do share a floating common return.
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DO2 Option
NO/NC Operation
JP13
JP5 JP6 JP7 JP8 JP9 JP10 JP11 JP12 NC NC NC NC NC NC NC NC
Fault JP13 Normally De-energized
Figure 5-3
Discrete Output Jumpers
[CR1 (JP5) and CR5 (JP9) are NO, others are NC]
CPU PCB Discrete output jumpers CR1/DO1 and DO9 are normally-energized for use as fault relays, while CR3/DO3 through CR8/DO8 must be energized by the control program. The operation of CR2/DO2 is set by jumper JP13 (see the left panel of Figure 5-3) on the CPU PCB (see Figure 1-3): • If the left and middle pins are connected, CR2 will operate as a normally-energized fault relay that will also be de-energized by the CR1 Relay Assigned Function [MODE:D RA 1]. • If the right and middle pins are connected, it will operate as a normally de-energized relay governed by the CR2 Relay Assigned Function [MODE:D RA 2]. In addition, each discrete output must be configured for normallyopen (NO) or normally-closed (NC) operation by setting its CPU or Auxiliary PCB jumper: • On the CPU PCB, jumper JP5 corresponds to CR1/DO-1, JP6 is for CR2/DO-2, and so on (see the right panel of Figure 5-3). To configure a NC circuit, connect the left and middle pins. To configure a NO circuit, connect the right and middle pins. • On the Auxiliary PCB (see Figure 7-4), jumper JP1 determines whether DO-9 is normally-open or normally-closed. Connect the center and right pins for NO operation, or short the center and left pins for NC operation.
Factory Testing Jumpers
April 2010
Jumpers JP14 and 15, which are located next to the fuse in the lower right corner of the CPU PCB, are temporarily removed during certain factory compliance tests. Because the associated circuits protect the controller from electrical surge damage, these jumpers should never be removed in the field.
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Chapter 5: Discrete Inputs and Outputs Externally Powered DISCRETE IN D1 D2 D D3 D4 D5
Internally Powered DISCRETE IN D1 D2 D D3 D4 D5
30 Vdc (max.)
24VDC DISCRETE
24VDC DISCRETE
+
Figure 5-4
Basic I/O Controllers
+
– D6 D7
– D6 D7
Basic compressor controller discrete input wiring The seven available discrete inputs (D1 through D7) of a basic compressor controller share a common return, symbolized by a small D in a triangle, as do the nine available discrete inputs (D1 through D9) of a basic turbine controller. Figure 5-4 shows how to connect these inputs to external devices. Basic compressor controllers also have five discrete outputs (CR1 through CR5), while a basic turbine controller has eight (CR1 to CR7 and CR9). Each of these relays has two non-directional, drycontact terminals on the Back Panel. Figure 5-5 shows how to connect these control relays to external devices. 28 Vdc, 1/4 A. max.
Load
CR1 1 2
CR3 1 2
Figure 5-5
April 2010
CR4 1 2
CR2 1 2
CR5 1 2
Basic compressor controller discrete output wiring
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Note:
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A Compressor Controller equipped with the Field Input/Output Module (FIOM) provides several discrete input and output configuration options, as shown in the Series 3 Plus Compressor Controllers Field Termination Assembly [DS300/T] data sheet. This controller configuration option (FIOM) is discontinued and no longer available. Each discrete output circuit can be set up to include its own power source or to utilize a common external supply. They can also use onboard fuses or provide their own externally. The discrete inputs can be configured to share the same external source as the outputs, or to use the controller’s 24 Vdc transmitter power output.
24 Vdc Power Circuits
The FIOM has three onboard 24 Vdc power circuits, one each for its analog inputs, discrete inputs, and discrete outputs. The discrete output power circuit can be supplied only by an external source connected to terminals 31 and 32 of TB6. The other two can also be supplied from that source, or from the controller’s transmitter power output (see the Series 3 Plus Compressor Controllers Hardware Specifications [DS300/H] for that circuit’s maximum load). These selections are made by severing jumpers in the JB9 programmable header. All six jumpers are normally left intact, allowing both circuits to draw power from either diode-protected source. To power the discrete inputs from the internal source only, break the 1/12 jumper. To power them from the external source only, break the 4/9 jumper. To power the analog inputs from the internal source only, break the 2/11 jumper. To power them from the external source only, break the 5/8 jumper. If the two power sources are isolated (by breaking either the 6/7 or the 3/10 connection), the analog and discrete inputs must use the same power source.
Discrete Input Circuits
Discrete Output Circuits
Other than selecting the power source, the discrete inputs are not configurable. To complete them, install dry contacts across the corresponding field terminals. Each discrete input is protected by an on-board 50 mA fuse. Each discrete output circuit has a jumper block (JB3 to JB7 in the lower panel of Figure 5-2) that determines whether it includes the FIOM’s on-board power source (from terminals 31 and 32) and fuse. Leaving all of the jumpers intact includes the on-board power and bypasses the on-board fuse. To include the onboard fuse, sever both the 1/8 and 4/5 jumpers. To bypass the onboard power source, cross connect pins 3 and 7 (use header #18-000008-001 if externally-fused and #18-000008-002 if internally-fused).
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Chapter 5: Discrete Inputs and Outputs
Extended I/O Turbine Controllers
As shown in Figure 5-2, an extended I/O turbine controller’s discrete input terminals are on the Field Input Module (FIM), while those for the discrete outputs are on the Field Output Module (FOM). Their configuration is illustrated in the Series 3 Plus Turbine Controllers Field Termination Assembly [DS307/T] data sheet. Each discrete input can be set up to include its own power source or utilize the common onboard supply (which can be either an external source or the controller’s 24 Vdc transmitter power output). Similarly, each discrete output circuit can be configured to include its own power source or utilize a common external supply. They can also use onboard fuses or include their own.
24 Vdc Power Circuit
Note:
The FOM includes an onboard power circuit that can include an external 24 Vdc power source in any of its discrete output circuits. To use this feature, you must connect an appropriate power source to terminals 29 and 30. The controller’s transmitter power output does not have sufficient capacity to drive the discrete output circuits and thus cannot be used for that purpose. In contrast, the FIM can be configured to obtain its 24 Vdc onboard power from either the controller’s transmitter power output or an external source connected to terminals 1 and 2. This choice could be made by selectively installing diodes and jumpers in the 24 Vdc Jumper Block, but it is simpler to install the diodes and jumpers for both sources and remove the fuse for the one you are not using.
Discrete Input Circuits
Each discrete input circuit has a jumper block that configures it to use either the FIM’s onboard 24 Vdc Power Circuit or a separate external source: • To configure one of these circuits to use the onboard 24 Vdc, install jumpers between pins A and D, B and E, and C and F, and install a dry contact across the field terminals. • To configure a discrete input circuit to use a its own power source (external to the FIM), install jumpers between pins A and E and pins B and F.
Discrete Output Circuits
Each discrete output circuit has a jumper block that configures it to use either the FOM’s onboard 24 Vdc Power Circuit or a separate source external to the FOM, and to include its own external fuse or use the one provided on the FOM. You can configure one of these circuits to use the FOM’s onboard 24 Vdc by connecting pin C of its configuration block to pin D, and pin G to H. Alternately, you can bypass the onboard power source by connecting pin C to H. Either way, you can bypass the onboard fuse by installing a jumper between pins A and B.
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This section discusses things you should check when troubleshooting the discrete inputs and outputs of a Series 3 Plus Controller. In general, the inputs are checked by using the Signal Values Test [MODE TEST 4] to verify that they are being properly read. The same procedure will reveal which outputs should be energized. If you know their NO/NC configuration, you can use an ohmmeter to determine if they are.
Discrete Input Troubleshooting
To test the status of the discrete inputs, enter 0 for the MODE TEST 4 channel number. The confirming display will then indicate which inputs are asserted. Although these inputs are rated at 24 Vdc, their trigger level is much lower — they will always be energized above 10 Vdc and de-energized below 2 Vdc. Solid state relays are often used to drive the discrete inputs of CCC controllers. Load specifications of solid state relays must be brought into compliance with the discrete inputs of the CCC controller. Ground-loop problems can also alter the actual voltages applied to these inputs. In addition, most Series 3 Plus Controllers have one or more Input Lockout [MODE LOCK 6] parameters that cause them to ignore some or all of their analog and discrete inputs. This is useful primarily when using a computer simulation to demonstrate or teach the operation of the controller. If your controller is reading its inputs correctly but appears to be unaffected by them, make sure all LOCK 6 parameters are disabled (Off).
Discrete Output Troubleshooting
The controller’s discrete outputs (control relays) can be used to trigger external indicators for various process and controller conditions. Thus, to determine the cause of an alarm, you must know what function has been assigned to its relay. If you are not sure, consult your configuration worksheet or use the Engineering Panel to determine its Relay Assigned Function [MODE:D RA #]. Discrete Output 1 (DO-1/CR1) serves as a Fault Relay — it will always trip when a controller fault is detected or power to the controller is interrupted. For controllers with the Auxiliary PCB, DO-1 signals a main CPU fault and DO-9 indicates an Auxiliary board fault. In some cases, powering the controller down and then restarting it might clear either type of fault. If not, replace the controller immediately. The discrete output relays are located on the CPU PCB Assembly (see Figure 1-3), along with the jumpers that determine whether they are normally open or normally closed (JP5 corresponds to discrete output CR1/DO-1, JP6 is for CR2/DO-2, and so on).
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Chapter 5: Discrete Inputs and Outputs The following procedure can be used to test the operation of these relays: Step 1: Note the position of the NO/NC jumpers. Step 2: For basic I/O controllers, disconnect the field wiring from the CR# terminals by unplugging their terminal blocks from the back panel. For FTA-equipped controllers, it is easiest to connect a spare FOM or FIOM. Alternately, you could disconnect the field wiring from the FTA or temporarily replace the top half of the connectors (which are secured with screws). Step 3: For Compressor Controllers, set MODE:D RA 1 to OFF and RA 2 through 5 to ON (be sure to note their original settings). This should energize all five relays. For Turbine Controllers, set MODE:D RA 1 (and RA 9, if present) to +OFF and all other RA parameters to +ON. Step 4: The resistance measured across each relay’s field terminals should be nearly zero for each normally-open relay and nearly infinite for each normally-closed relay. Step 5: For Compressor Controllers, set MODE:D RA 1 to ON and RA 2 through 5 to OFF. This should de-energize all five relays. For Turbine Controllers, set MODE:D RA 1 (and RA 9, if present) to +ON and all other RA parameters to +OFF. Step 6: The resistance measured across each relay’s field terminals should be nearly zero for each normally-closed relay and nearly infinite for each normally-open relay. Step 7: Restore the original values of any MODE:D RA parameters you changed in step 2 or 4. Step 8: Restore the original field wiring connections. If the resistance measured across a given relay was the same in both step 3 and step 5, that relay is probably not energizing or deenergizing, or else its contacts are not opening or closing properly. In either case, the CPU PCB will need to be replaced. The instruction manual for each controller discusses the available relay assignment codes and the conditions under which they will be triggered.
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Analog PCB I/O
IM300/H
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This chapter provides installation, calibration, and troubleshooting instructions for the Analog PCB’s analog input and output circuits. FOM
FIM Fuses and Jumper Blocks AI-3
AI-5
AI-7
AI-2
AI-4
AI-6
AI-8
Analog Inputs 1, 2, and 3
24 Vdc In
24 Vdc Out
AI-1
Analog Outputs
Analog Inputs 7 and 8
Analog Inputs 4, 5, and 6
FIOM
DISCONTINUED
JB8 RH1 RH2
Analog Analog Inputs Outputs 1 and 2
Analog Inputs 3 to 5
Figure 6-1
Installation
Fuses for Analog Inputs
Analog Inputs 6 to 8
Analog I/O features of Field Termination Assemblies Each Series 3 Plus Controller is equipped with an Analog PCB Assembly that provides eight analog inputs and two analog outputs: • Compressor controllers support all of these circuits as inputs CH1 to CH8 and outputs OUT1 and OUT2. • Turbine controllers support these outputs as OUT2 and OUT3 (OUT1 is the Auxiliary PCB’s High-Current Output, described in Chapter 7). Basic turbine controllers support only four analog inputs (CH1 to CH4). Extended I/O controllers support all eight (CH1 to CH8).
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Chapter 6: Analog PCB I/O Compressor Controllers CH 1 + –
CH 2 + –
CH 3 + –
CH 4 + –
CH 5 + –
CH 6 + –
CH 7 + –
CH 8 + –
OUT 1 +
Turbine Controllers OUT 2 +
+
CH 1 –
CH 2
+
–
CH 3
+
–
CH 4
+
OUT 3
+
24VDC + –
Figure 6-2
OUT 2
+
–
24VDC + –
Analog I/O terminals on basic controller back panels The locations of analog I/O features on various Field Termination Assemblies are shown by Figure 6-1. The locations of the backpanel terminals for these circuits are shown in Figure 6-2.
Analog Input Installation
All eight analog inputs must be set up to accept either current (20 mA) or voltage (5 Vdc) signals by setting jumpers JP1 through JP9 on the Analog PCB (see Figure 1-5 for their locations). Connecting the center pins to the pins labeled C configures these inputs for current signals, while connecting the center pins to the pins labeled V configures them for voltage signals.
Note:
All eight inputs must be configured the same (for either current or voltage signals) by setting all nine jumpers in the same position. FTA-equipped controllers should be configured for all 5 Vdc inputs, which can be adapted to 20 mA transmitters by installing dropping resistors on the FTA. Non-FTA controllers can be given mixed current and voltage inputs by setting all nine jumpers to the V position and installing external dropping resistors across the current inputs. Current-loop inputs should be wired in series with the transmitter and current source. This means that the positive (+) terminal of each load in the circuit should be connected to the negative (–) terminal of the next. However, the polarity convention for the current (power) source requires that its positive terminal be connected to the positive terminal of the first load and its negative terminal must be connected to the negative terminal of the last load.
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Voltage inputs should be wired in parallel with the transmitter. The positive (+) and negative (–) terminals for unused voltage inputs should be jumpered, otherwise the controller might be unable to read its other inputs correctly. A 24 Vdc power output is also provided that can be used to supply transmitters requiring a power source of that type. For basic compressor controllers, this output is available at the Back Panel 24 Vdc terminals and must be wired into each input circuit that uses it. In contrast, the FIM and FIOM have on-board power circuits that can be powered by either the controller’s own 24 Vdc output or an external source. Each input circuit can then be individually configured to include that power source. R14
Figure 6-3 Early-Model Analog PCB Replacement
R18
Early Analog PCB Assembly input configuration resistors Analog PCBs made prior to mid-1993 did not include jumpers JP1 to JP9. When replacing one of these circuit boards, you must match the configuration of its analog inputs, which can be determined by examining resistors R14 through R21 (see Figure 6-3). Resistors R18 through R21 correspond to inputs CH1 to CH4, while R14 through R17 correspond to CH5 to CH8. If the board is set up for all 20 mA inputs, all eight resistors will be rated at 4 W, 100 Ω. For all 5 Vdc inputs, these resistors will be rated at 1/4 W, 360 kΩ. The difference is readily apparent — the resistors on the 20 mA boards are large and black, those on the 5 Vdc boards are small, brown and color-coded. Boards equipped with some 360 kΩ resistors and some precisionwound, 250 Ω resistors are configured for a mixture of 20 mA and 5 Vdc inputs. Such boards are not directly interchangeable with the jumper-equipped versions. Either contact CCC for an exact replacement board, or use a board configured for all 5Vdc inputs and install external dropping resistors across the 20 mA inputs.
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Chapter 6: Analog PCB I/O Current Loops
FT
FY
OUT 1 +
CH 1 + –
CH 8 + –
CompressionTerminal Back Connections
G
Voltage Loops
FY
FT +5
CH 1 + –
OUT 1 +
CH 8 + –
24VDC + –
Figure 6-4
+24
24VDC + –
Analog I/O connections for basic compressor controller On the basic compressor controller back, the analog input terminals are on the top two connectors and are labeled CH1 to CH8. On the basic turbine controller back, the analog input terminals are on the top connector and are labeled CH1 to CH4. Current-loop inputs should be wired as shown for CH1 in the left panel of Figure 6-4. Note that the polarity convention for the power source requires that its positive terminal be connected to the positive terminal of the first load and its negative terminal must be connected to the negative terminal of the last load. Voltage inputs should be wired as shown for CH1 in the right panel of Figure 6-4. Such transmitters rarely require 24 Vdc power, but those that do can be wired as illustrated.
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Note:
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Each FIOM analog input can include either a 20 mA or 5 Vdc transmitter, its own external power source or a common source selected by configuration block JB9, and any other required devices (such as a DCS input), as shown on the Series 3 Plus Compressor Controllers Field Termination Assembly [DS300/T] data sheet. This controller configuration option (FIOM) is discontinued and no longer available. When used with an FIOM, the Analog PCB is internally configured for all 5 Vdc signals. Consequently, voltage transmitters only need to be connected in parallel across the corresponding inputs’ + and – terminals, along with any other needed devices (for example, a DCS). The corresponding connection in header JB8 (for example, JB8-3 for CH3) must also be severed to isolate the circuit from the onboard 24 Vdc. Transmitters requiring 24 Vdc power can draw it from terminals 35 and 36. Any of these inputs can be adapted to a current-loop transmitter by installing a 250 Ω resistor in the corresponding position of configuration block RH1 or RH2 (RH1-1 is for CH1, RH2-1 is for CH5). If the 20 mA transmitter includes its own integral power source (or the current-loop includes its own external power supply), connect the transmitter, power source (if separate), and any other required devices (such as a DCS) in series across the input’s CH+ and CH– terminals. As with voltage inputs, the corresponding JB8 connection should be severed to isolate that circuit from the onboard 24 Vdc. To use the onboard 24 Vdc to power a current-loop input circuit, leave its JB8 connection intact and connect the transmitter across that input’s 24V+ and CH+ terminals. To include a DCS input in such a circuit, sever the JB8 connection and connect the DCS in series across the CH– and 24V– terminals.
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Chapter 6: Analog PCB I/O Field Input Module Connections
Each FIM analog input can include either a 20 mA or 5Vdc transmitter, its own external power source or a common onboard source, and any required external devices (such as a DCS input port), as shown on the Series 3 Plus Turbine Controllers Field Termination Assembly [DS307/T] data sheet. Each input has its own 8-pin (A through H) configuration block and five field wiring terminals (B, C, D, H, and Shield). The B, C, D, and H terminals are directly connected to the corresponding pins of the input’s configuration block. The controller is internally configured to read the voltage drop (0 to 5 Vdc) across terminals C and D. Thus, the simplest application is to connect an externally powered 5 Vdc transmitter in parallel with those two terminals. In the more-likely event that a 4 to 20 mA transmitter is used, you can convert its signal to the required voltage by installing a 250 Ω dropping resistor across pins C and D of the configuration block. If the 20 mA transmitter includes its own integral power source, or the current-loop includes a separate external power supply, the transmitter, power source (if separate), and any other devices should be connected in series across the input’s C and D terminals. To use the onboard 24 Vdc to power a current-loop input circuit, jumper pin A to pin B and pin G to pin F, then connect the transmitter across the B and C terminals. To include a DCS input in such a circuit, jumper pin G to pin H (instead of pin F) and connect the DCS in series across the D and H terminals.
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V2 I2
V2 I2
Figure 6-5
Analog Output Installation
V1 I1
83
Voltage Loops
V2 I2
V1 I1
V2 I2
V1 I1
V1 I1
Analog output jumpers on inside of Back Panel The Analog PCB generates both 4 to 20 mA and 0 to 5 Vdc signals for both of the analog outputs it provides. However, only one of each output’s signals can be connected to a load at any given time. The return terminals for both signals are tied to the instrument ground. For all compressor controllers, permanent jumper settings on the inside of the Back Panel Assembly (see Figure 6-5) determine which of each output’s signals is connected to the Back Panel or FIOM OUT1 and OUT2 terminals. When replacing one of these controllers you must verify that the new unit’s Back Panel has the same output configuration. Changing the Analog PCB does not alter the controller’s output configuration. For extended I/O turbine controllers, both the current and voltage signals are available on the FOM, but only one can be used for each output (OUT2 and OUT3). Basic turbine controllers have jumpers (similar to those on the compressor controller backs) which determine which form of each signal is connected to the Back Panel OUT2 and OUT3 terminals. An Antisurge or Performance Controller can be set up to compare OUT1 to its intended value by looping it back through analog input CH8. Dual-Loop A/P and split-output Performance Controllers can test both outputs by looping OUT1 back to CH7 and OUT2 to CH8. In order to use this feature, the electrical characteristics of the input and output must match. For example, if a single-loop controller is set up to generate a 4 to 20 mA output (OUT1), CH8 can be used for loopback testing only if it is a 4 to 20 mA input. This is a concern only for basic I/O controllers, because the analog inputs of the FIOM can be individually set up for either type of signal. A current-loop output should be connected in series with its control element and any other load, such as a DCS input port. The left
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Chapter 6: Analog PCB I/O panel of Figure 6-4 shows how to connect the 4 to 20 mA outputs of a basic compressor controller using the loopback feature to test OUT1. For a basic turbine controller, which is not equipped with the required CH8 input, the loopback wiring must be omitted. Keep in mind that their polarity convention is the same as that for power sources. Thus, the positive (+) output terminal should be connected to the positive terminal of the first load. If there is more than one load, the negative terminal of the first should be connected to the positive of the second, and so on. The negative terminal of the last load should be connected to the negative (–) output terminal. Voltage outputs should be connected in parallel with the control element and all other loads. That is, the positive (+) output terminal should be connected to the positive terminals of all loads and the negative (–) output terminal should be connected to all of their negative terminals. The right panel of Figure 6-4 shows how to connect the 5 Vdc outputs of a basic compressor controller using the loopback feature to test OUT1. Again, the loopback wiring must be omitted for basic turbine controllers. Output Isolation
Although Series 3 Plus Controllers can withstand occasional analog output voltage transients, excessive or repeated voltage surges in that circuit can disrupt the normal functionality of its I/O processor. That can disable the discrete inputs, Modbus ports, and communication with the Front Panel, which causes the Fault LED to light and all other front-panel LEDs and readouts to go blank. To prevent such problems, we recommend the installation of analog isolators in output circuits that include long cable runs. For more information, please refer to our technical note on Transient Voltage Protection for Series 3 Plus Controllers [TN23].
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R3
R4
R2
Figure 6-6
Calibration
R1
Analog PCB Assembly The analog inputs and outputs of every Series 3 Plus Controller are calibrated prior to shipment and should never need adjustment. However, you should periodically verify their accuracy. Because their calibration pots are normally inaccessible, panelmounted controllers can not be calibrated in place. Thus, you must use an Extender Board or test bench (see Internal Component Access on page 35). In contrast, the calibration pots of an enclosure-mounted controller are easily accessible. Electrical measurements should be made with a 20 KΩ/V or higher impedance multimeter of 0.1% or better accuracy.
Analog Input Calibration
Note:
The analog inputs can only be calibrated as a group — individual miscalibration can only result from variations in their configuration resistors. Thus, you should first check them individually by measuring a signal that is known to be constant. If they all report acceptably equal values for that signal, you should then adjust the calibrating resistors (see Figure 6-6) until those values are accurate. These procedures assume that each input’s Offset Zero Input [MODE:D ANIN #] parameter has been enabled for current inputs and disabled for voltage inputs. If your controller is equipped with 4 to 20 mA inputs only, install jumpers to connect four of them in series with a 12 mAdc current source. Use the Signal Values Test [MODE TEST 4] to verify that the channels agree within ± 0.5%. Repeat this procedure for the other four channels. Any input which reports a value more than ±0.5% different from those reported by the other channels is probably faulty. If the problem persists after completing the calibration procedure, you should replace the Analog PCB Assembly.
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Chapter 6: Analog PCB I/O Current Input to Current Output
Voltage Input to Voltage Output
CH 1 + –
CH 1 + –
CH 2 + –
CH 3 + –
CH 4 + –
mA Figure 6-7
OUT 1 +
OUT 2 +
CH 2 + –
CH 3 + –
CH 4 + –
OUT 1 +
OUT 2 +
Vdc
Calibration connections for basic compressor controllers Basically the same test is used if your controller is equipped with all voltage inputs, except that you must connect the inputs in parallel with an appropriate mid-range voltage signal. If you have mixed current and voltage inputs, test each group separately using the appropriate test for each group. After verifying that all inputs read the same, remove the jumpers and calibrate all eight inputs as a group using the following procedure: Step 1: Connect a current source (such as one of the controller’s own 4 to 20 mA outputs) and an ammeter to any one 4 to 20 mA input (Figure 6-7 shows these connections for a basic Back Panel’s CH1 input); Step 2: Adjust the input signal to 4.8 mA; Step 3: The TEST 4 procedure should report an input value of 05.0 ± 0.1 for that channel; Step 4: If necessary, adjust potentiometer R2 until the desired value is displayed; Step 5: Increase the input signal to 19.2 mA; Step 6: TEST 4 should now report an input of 95.0 ± 0.1; Step 7: If necessary, adjust potentiometer R1 until the desired value is displayed. Step 8: Repeat steps 2 through 7 until the desired values are displayed at both calibration points. If your controller has voltage inputs only, connect a voltmeter as shown in Figure 6-7 and calibrate using equivalent input voltages (for a 5 Vdc input, use 0.25 and 4.75 Volts).
Note: April 2010
Changing the input configuration (current or voltage) should not affect their calibration, but each should be checked in the configuration you plan to use to make sure its individual resistance is correct. IM300/H (6.2.4)
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The first step in the output calibration procedure is to temporarily reset any parameters that would cause the displayed output (OUT) to differ from the actual output, or limit your ability to manually vary the output from 0 to 100 percent. You should verify that the settings of any reverse, output clamp, manual override, limiting variable and start-up parameters will not interfere with the calibration procedure. Be sure to record the original value of any parameters you change, so you can restore them when finished. The following procedures tell how to calibrate the first output (OUT1 for compressor controllers, OUT2 for turbine controllers) by adjusting resistor R4. The same procedures are used for the second output signal (OUT2/OUT3), except that you adjust resistor R3. Only current outputs can be calibrated. If your controller has a voltage output, however, you should still test to see if it is generating the correct voltage.
Current Outputs
Use the following procedure to calibrate a 4 to 20 mA output: Step 1: Connect a DC ammeter in series with the current output terminals on the Back Panel or FTA (Figure 6-7 illustrates the connection for a basic compressor controller). Step 2: If the front-panel Auto indicator is lit, press the AUTO/MAN key to switch the controller to its manual operating mode; Step 3: Use the front-panel Raise (∆) and Lower (∇) keys to set the displayed OUT value to 50.0; Step 4: The ammeter should read 12.0 ± 0.1 mAdc. If not, adjust resistor R4 on the Analog PCB Assembly (see Figure 6-6) until the desired reading is obtained; Step 5: Use the Lower (∇) key to reduce the displayed OUT value to 00.0. The ammeter reading should be 4.0 ± 0.2 mAdc; Step 6: Use the Raise (∆) key to increase the displayed OUT value to 99.9. The ammeter reading should be 20.0 ± 0.2 mAdc. Replace the Analog PCB Assembly if you are unable to obtain the correct readings.
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Chapter 6: Analog PCB I/O Voltage Outputs
Voltage outputs can not be calibrated, but you can use the following procedure to test their output voltages: Step 7: Connect a DC voltmeter in parallel with the voltage output terminals on the Back Panel or FTA (Figure 6-7 illustrates the connection for a Compressor Controller with Standard Back). Step 8: If the front-panel Auto indicator is lit, press the AUTO/MAN key to switch the controller to its manual operating mode; Step 9: Use the front-panel Raise (∆) and Lower (∇) keys to set the displayed OUT value to 50.0; Step 10: If your controller is configured with a 0-to-5 Vdc output, the voltmeter should read 2.5 ± 0.025 Vdc. For a 0-to-10 Vdc output, the reading should be 5.0 ± 0.05 Vdc; Step 11: Use the Lower (∇) key to reduce the displayed OUT value to 00.0. The voltmeter reading should be 0.0 ± 0.01 Vdc for either 0-to-5 or 0-to-10 Vdc outputs; Step 12: Use the Raise (∆) key to increase the displayed OUT value to 99.9. For a 0-to-5 Vdc output, the voltmeter reading should be 5.0 ± 0.05 Vdc. For a 0-to-10 Vdc output, the reading should be 10.0 ± 0.10 Vdc. Replace the Analog PCB Assembly if you are unable to obtain the correct readings.
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Troubleshooting
Warning! Analog Input Troubleshooting
89
Troubleshooting the analog inputs and outputs is basically a question of determining if the problem is in the controller or field wiring. Controller problems are usually fixed by replacing the Analog PCB. Never connect an ammeter in parallel with a current-loop output of an in-service controller. This usually causes the control valve to slam fully open (assuming it fails open). Nor should you connect any device in parallel with a current-loop input. Doing so will trigger a transmitter alarm. The Signal Values Test [MODE TEST 4] can be used to determine if the analog inputs are being read correctly. If none of them are, recalibrating the controller may solve the problem (these inputs cannot be individually calibrated). Keep in mind that values reported by TEST 4 are in percent of span, rather than range. Values less than zero will be reported as 00.0 percent, those equal to or greater than the full-span value will report as A0.0 (which represents 100 percent). The relationship between an actual input signal and its value as reported by TEST 4 is defined by the corresponding Offset Zero Input [MODE:D ANIN #]parameter. If AN IN is On, the TEST 4 value is determined using a 20 percent offset zero (4 mA is reported as 0 by TEST 4). An actual 12 mA input signal will be read as 60.0 percent if AN IN is Off, or as 50.0 percent if AN IN is On. One or more inputs may also read incorrectly if your Analog PCB Assembly is not configured for the specific combination of inputs you are using. Resistors R14 through R21 determine which types of inputs can be connected to CH1 through CH8. The analog input returns are capacitively-isolated from the controller ground to filter out high-frequency signal components. As a result, a ground potential above 10 Vdc (which might be caused by connecting more than one device in series with a single 4 to 20 mA signal) could cause the controller to incorrectly read all of these inputs. To determine if such a condition is affecting any given input, use a high impedance voltmeter (1 MΩ/V minimum) to measure the voltage at both of its Back-Panel or FTA connectors relative to either of the output ground connections (for example, OUT1 ↓). If any of these measurements are greater than 10 Vdc (or less than –10 Vdc), the signal will not be read correctly.
Warning!
Ground loop potentials in excess of 30 Vdc will cause irreparable damage to a Series 3 Plus Controller. In addition, most Series 3 Plus Controllers have one or more Input Lockout [MODE LOCK 6] parameters that cause them to ignore
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Chapter 6: Analog PCB I/O some or all of their analog and discrete inputs. This is useful primarily when using a computer simulation to demonstrate or teach the operation of the controller. If your controller is reading its inputs correctly but seems unaffected by them, make sure all MODE LOCK 6 parameters are disabled (Off).
Analog Output Troubleshooting
The easiest way to trouble-shoot analog outputs is to utilize the output loopback test. The controller will then trigger an external alarm if the output signal varies from its intended value by more than onehalf of a percent. For a current-loop output, this test will reveal problems such as breaks or current leaks in the field wiring. However, it will not reveal problems which would shunt the current around the control element (such as a short across the transducer’s input terminals). For a voltage output, this test can reveal shorts, but will not detect breaks in the field wiring. The calibration procedures discussed in the previous section can also be used to manually test the output signals. If these procedures reveal that the outputs are correctly calibrated, try measuring them with the field wiring connected. If the controller is then unable to maintain its intended output signals, the problem is in the field wiring or valve transducer.
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Extended I/O Circuits
Series 3 Plus Hardware Referencemanual
This chapter describes and tells how to install, calibrate, and troubleshoot the high-current output and speed and position inputs. Unipolar Output 100%
100%
Output to DAC
Output to DAC
0%
0%
Control Signal
On Phase Inverter Off 200 mA Output to Valve –200 mA
Figure 7-1
Description
Bipolar Output
100%
0%
0%
Control Signal
100%
On Phase Inverter Off 200 mA Output to Valve –200 mA
Operation of bipolar output In addition to the discrete inputs and outputs described inChapter 5, the Auxiliary PCB and its daughter board (see Figure 7-4) provide: • a High-Current Analog Output that includes loopback circuitry for measuring its own value and the transducer pressure, • three Speed Inputs for magnetic pickup frequency signals, and • Linear Variable Displacement Transformer (LVDT) and bipolar 20 mA current-loop valve Position Inputs. The speed input circuits are capacitively isolated from the MPUs. The LVDT is powered by this controller, so that circuit is not isolated (because there is no danger of differing ground potentials). Electrical specifications for these circuits can be found on theSeries 3 Plus Turbine Controllers Hardware Specifications [DS307/H].
Note:
April 2010
The Auxiliary PCB can read either the LVDT valve position input or the transducer pressure feedback signal, but not both.
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Chapter 7: Extended I/O Circuits
High-Current Analog Output
For turbine controllers, OUT1 is provided by an Auxiliary PCB circuit that can generate almost any current-loop signal from –200 to +200 mA. Because this greatly exceeds the usual 4 to 20 mA range, this circuit is usually called the high-current output. It includes: • a digital-to-analog converter (DAC) that generates an intermediate 0 to 5 Vdc signal, • circuitry that converts that voltage into a current signal with a jumper-selectable maximum magnitude of 20, 60, or 200 mA, • a phase inverter that can be turned on by the Auxiliary PCB’s CPU when reverse current flow is needed, • an analog-to-digital converter (ADC) that measures the loopback value of this signal, and • circuitry that measures the frequency of any transducer feedback signal modulated onto this output signal. The maximum range of this output signal is set by the Maximum Output Jumpers (see page 95). If necessary, it can be restricted to a portion of that range when setting its calibration gain and bias (see Output Circuit Calibration on page 99). The Auxiliary PCB of a Speed or Fuel Controller can be configured for a bi-directional high-current output (for example, –200 to +200 mA) by enabling its Bipolar Output [COND:D OUT 1 –]. This board’s CPU then calculates the magnitude of its output signal as shown in the top right panel of Figure 7-1, and turns the phase inverter on when a negative current flow is needed. Every controller that supports this output also supports its loopback test, which compares the loopback measurement to the intended output signal. If you enable that test, it must also be scaled and calibrated (see Loopback Circuit Calibration on page 101). In contrast, only the Speed Controller currently supports the transducer feedback test. To use it, the Daughter Board Jumper (see page 95) must configure that board to demodulate the feedback signal instead of reading the LVDT input. You should also remove the Inductive Load Jumper (see page 94).
Position Inputs
This assembly provides two inputs for valve position measurements. LVDT1 is for linear variable differential transformer measurements, while the Auxiliary Input supports bipolar 20 mA position signals. None of the standard control programs supports the Auxiliary input, and only the Speed and Fuel Controllers support LVDT1. To use it, the Daughter Board Jumper (see page 95) must configure it for an LVDT rather than a transducer feedback signal.
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OUT 1 + –
FREQ1 FREQ2 FREQ3 +
–
+
–
+
–
96-264 VAC 21-32 VDC
TB6
MADE IN USA
Figure 7-2
Speed Inputs
N GRD H 35 W max
Back panel speed input and high-current output terminals The speed inputs of a Series 3 Plus Turbine Controller can read the frequency signals from either active or passive magnetic pickups: • If active pickups are used, the controller can read any speed that produces at least a 5 Hz signal. The corresponding minimum speed depends on the number of teeth on the exciter and shaft ratio. For example, a 60-tooth gear mounted on the main shaft would generate a 5 Hertz signal at 5 rpm. • If passive pickups are used, the minimum detectable speed is that at which the voltage of the MPU signal meets the minimum listed on the Series 3 Plus Turbine Controllers Hardware Specifications [DS307/H]. This can be determined from the electrical specifications for your MPUs. In addition to physically connecting them to the MPUs, these inputs must also be enabled and configured to compensate for both the number of teeth on the MPU gear and its shaft ratio. The configuration and tuning parameters for these features are discussed in the Speed and Fuel Controller instruction manuals: • Speed Inputs section in Chapter 4 of IM307 • Speed Inputs section in Chapter 4 of IM311 • Speed Inputs section in Chapter 4 of IM313
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Chapter 7: Extended I/O Circuits FOM
MPU 6– High-Current Output
FIM
MPU 1 to 3
Auxiliary Input MPU 4, 5, 6+
LVDT1
Figure 7-3
Field Termination Assembly extended I/O terminals
Installation
The FIM and FOM provide wiring terminals for all of these circuits, the locations of which are shown in Figure 7-3. In contrast, the Back Panel for Basic Turbine Controllers (see Figure 7-2) provides terminals for the high-current output and three speed inputs (neither the LVDT nor analog position input is supported).
Jumper Settings
When installing a turbine controller or replacing its Auxiliary PCB, you must verify the correct setting of several jumpers on that board (see Figure 7-4).
Inductive Load Jumper
The Auxiliary PCB includes special circuitry to deal with inductive loads on the high-current output. If this output is connected to an electronic I/P transducer (such as the Rosemont 3311), it might be necessary to bypass this circuitry. This circuitry is enabled by installing jumper JP3. For electronic I/P transducers, removing JP3 disables the inductive load circuitry.
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JP6
Figure 7-4 Maximum Output Jumpers
JP3
JP4
95
JP1
Daughter Card JP1
Jumper locations on the Auxiliary PCB The high-current output’s maximum current is set to any of three values by setting jumpers JP4 and JP5: • to select a 200 mA maximum output, short the two top pins of both jumpers (labeled 200 mA), • to select a 60 mA maximum output, short the two center pins of both jumpers (labeled 60 mA), or • to select a 20 mA maximum output, short the two bottom pins of both jumpers (labeled 20 mA). The selected range can then be further restricted by setting the high-current output and loopback calibration parameters.
Figure 7-5 Daughter Board Jumper
JP1
JP1
LVDT1 Excitation
OUT1 Carrier
Daughter card configuration jumper Jumper JP1 (see Figure 7-5) on the Auxiliary PCB daughter board configures it to read one of two frequency signals: • Connecting the center and left-most pins configures it to read the LVDT1 excitation frequency. • Connecting the center and right-most pins configures it to decode a transducer feedback frequency signal modulated onto OUT1.
Miscellaneous Jumpers
Jumper JP1 configures the Auxiliary PCB fault relay (DO9) for normally-closed (NC) or normally-open (NO) operation (see page 71). JP6 enables the termination resistor for the Auxiliary PCB’s unused serial communication port. It does not matter if it is installed or not.
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Chapter 7: Extended I/O Circuits
High-Current Output Installation FY 38 (–)
37 (+)
This current-loop output should be connected in series with its control element and any other load, such as a DCS input port. The loop must not include any other power sources or paths to ground. Keep in mind that this output’s polarity convention is the same as that for power sources. Thus, its positive output terminal (37) should be connected to the positive terminal of the first load. If there is more than one load, the negative terminal of the first should be connected to the positive of the second, and so on. The negative terminal of the last load should be connected to the negative output terminal (38). You must also set this circuit’s Maximum Output Jumpers (see page 95) and set its calibration gain and bias (see Output Circuit Calibration on page 99).
Speed Input Installation
By convention, the black lead of each magnetic pickup (MPU) is connected to the input’s positive terminal and its white lead is connected to the negative terminal. However, the inputs are non-polar and will function correctly even if you do not follow this convention. To prevent ground loops, we recommend connecting the cable’s shield to the shield terminal on the FIM and leaving it ungrounded at the pickup end. The Field Input Module provides individual shield terminals for MPUs 1 through 3. The less-often used MPUs (4 through 6) can use any convenient shield terminals.
Position Input Installation
LVDT leads have five-conductors (plus a shield) — two for the excitation coil, two for the return coil, plus a common. Connect these leads to the FIM’s LVDT 1 terminals, as shown in Figure 7-3 and listed on the Series 3 Plus Turbine Controllers Field Termination Assembly [DS307/T]. If your controller has special software that uses the 20 mA position input, connect it to the FIM’s Auxiliary Input terminals, again as shown in Figure 7-3 and listed on DS307/T. The position input is scaled and calibrated using the Signal Values Test [MODE TEST 4] to read its minimum and maximum values and then setting its range parameters equal to those readings, as discussed in the Speed and Fuel Controller instruction manuals: • Position Input section in Chapter 3 of IM307 • Position Input section in Chapter 3 of IM311 • Position Input section in Chapter 3 of IM313
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Yes
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OutF
Outt Signal Scaling
Loopback Scaling
Out1 Output Circuitry
Outa Loopback Input
I1
I1
To Valve Actuator
Figure 7-6
Output Calibration
High-current output functional diagram As shown in Figure 7-6, the high-current output signal and its loopback measurement are calibrated by setting their scaling gains and biases, which can also restrict this signal to a portion of the range selected by the Maximum Output Jumpers. The Signal Values Test [MODE TEST 4] can be used to view the raw loopback measurement (Outa in the figure, displayed as AD3) and its calibrated value (Outt in the figure, displayed as AD5).
Note:
When checking or changing the calibration of the output or loopback circuits, record any parameter changes you make and restore their original values when you are done. Once you have determined the range of the actuator control signal, you should calculate its ideal, minimum, and maximum acceptable values at 5, 50, and 95 percent of span and record them in a table similar to Table 7-1. The recommended tolerance is ±0.25 percent of the maximum output (for example, ±0.15 mA for a 60 mA output). Table 7-2 gives the recommended ranges for several of the most commonly used actuators.
Warning!
April 2010
Calibrate this circuit only while the turbine is shut down or under some alternate form of control.
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Chapter 7: Extended I/O Circuits Table 7-1
Expected output readings Actuator Range (mA): Measured Current (mA) OUT Display
Ideal
Minimum
Maximum
5.0 % 50.0 % 95.0 %
Table 7-2
Expected output readings for commonly used actuators Measured Current (mA) OUT Display
Ideal
Minimum
Maximum
Actuator Range: 4 to 20 mA 5.0 %
4.80
4.75
4.85
50.0 %
12.00
11.95
12.05
95.0 %
19.2
19.15
19.25
Actuator Range: 20 to 160 mA 5.0 %
27.00
26.60
27.40
50.0 %
90.00
89.60
90.40
95.0 %
153.0
152.6
153.3
Actuator Range: –20 to +20 mA 5.0 %
1.00
0.95
1.05
50.0 %
10.00
9.95
10.05
95.0 %
19.00
18.95
19.05
Actuator Range: –35 to +35 mA 5.0 %
1.00
0.95
1.05
50.0 %
10.00
9.95
10.05
95.0 %
19.00
18.95
19.05
Actuator Range: –60 to +60 mA
April 2010
5.0 %
3.00
2.85
3.15
50.0 %
30.00
29.85
30.15
95.0 %
57.00
56.85
57.15
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Output Circuit Calibration
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The Output Scaling Gain [COND:D GAIN 1] and Output Scaling Bias [COND:D BIAS 1] both calibrate and restrict the range of the high-current output signal. Thus, you should first enter nominal (ideal) values for those parameters based only on the desired range restriction, and then adjust them to precisely calibrate this signal. This circuit is set up to generate a maximum current (Imax ) of 20, 60, or 200 mA by setting the Maximum Output Jumpers. Its range is then matched to that of the actuator by calculating the final output as a percentage of twice that maximum (see Figure 7-6):
I 1 = Ou t 1 ⋅ ( I max ⋅ 2 ) Act ⋅ Gai n 1 Ou t 1 = ------------------------------- + Bias 1 100 where: Act = Bias1 = Gain1 = I1 = Imax = Out1 =
actuator control signal, in percent the Output Scaling Bias the Output Scaling Gain high-current output, in mA maximum high-current output (20, 60, or 200 mA) calculated output signal (decimal)
Because the actuator control signal must be between zero and 100 percent, the actual output can never be less than (Imax · 2 · Bias1), nor more than [Imax · 2 · (Gain1 + Bias1)]. Because I1 can not exceed Imax , the sum of Gain1 and Bias1 should not exceed 0.50. The nominal values of this gain and bias should be calculated as:
I high – I low Gai n 1 = 0.5 ⋅ --------------------------I max
and
I low Bias 1 = 0.5 ⋅ ----------I max
where: Ihigh = 100 percent value of actual high-current output (mA) Ilow = 0 percent value of actual high-current output (mA) For bipolar outputs, Ilow (and thus the nominal bias) must be zero. Negative signals are generated as positive currents which are then reversed by the phase inverter. If Ilow is not zero, there will be a gap around the zero point of the output! To configure a 4 to 20 mA signal, for example, set JP4 and JP5 for a 20 mA maximum signal, so Ihigh = Imax = 20, Ilow = 4, and the nominal Bias1 to 0.1 and the nominal Gain1 to 0.4:
Gai n 1 = 0.5 ⋅ ( 20 – 4 ) ⁄ 20 = 0.4 Bias 1 = 0.5 ⋅ 4 ⁄ 20 = 0.1 April 2010
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Chapter 7: Extended I/O Circuits Use the following procedure to fine-tune the nominal gain and bias or to recalibrate this output signal: Step 1: Disconnect the control element from the OUT1 terminals on the FOM or Back Panel and connect an ammeter in its place. Step 2: Disable the bipolar output, valve positioning loop, and reverse output features (if any of them are initially enabled). Step 3: Manually adjust the controller output to 5, 50, and 95 percent. Compare the resulting ammeter readings to the ranges recorded in your Expected Outputs Table (see Table 7-1). If all of them are acceptable, skip to step 10. Step 4: Manually set the output to 25 percent and record the ammeter reading as OUTlow. Step 5: Manually set the output to 75 percent and record the ammeter reading as OUThi. Step 6: Use the following formula to calculate a new gain value: 0.5 ⋅ Span Gain 1 = Gai n p ⋅ ---------------------------------------- Out hi – Ou t low where Gain1 is the new value, Gainp is the previous value, and Span is the span of the output range (for example, 16 for a 4 to 20 mA output). Set the Output Scaling Gain [COND:D GAIN 1] equal to this new value. Step 7: Set the output to zero (0) percent and adjust the Output Scaling Bias [COND:D BIAS 1] until the meter reading agrees with the desired minimum output signal (generally, add the error divided by twice Imax to the bias). If that signal is zero, make sure it rises with even a slight increase of the intended output. Step 8: Recheck the accuracy of the signal at 5 and 95 percent and repeat steps 4 to 7 until satisfactory results are obtained. Step 9: Manually adjust the output to 50 percent. If the resulting meter reading is not in the acceptable range, the Auxiliary PCB should be replaced. Step 10: Disconnect the ammeter, reconnect the control element, and restore the original values of any parameters you changed.
Note:
April 2010
If this output is set up as a bipolar signal, disable that feature and calibrate the output as a unipolar circuit. Then re-enable the bipolar output and verify that negative signals are generated when the output is below 50 percent. If the controller reverts to automatic operation during this test, it is probably because a limiting control loop or manual override was triggered. Determine which feature is responsible and disable it.
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Loopback Circuit Calibration
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The Loopback Scaling Gain [COND:D GAIN 2] and Loopback Scaling Bias [COND:D BIAS 2] calibrate and adjust that measurement to the actual range of the high-current output signal. As with the output scaling parameters, you should first enter nominal (ideal) values for these parameters based only on the desired range restriction and then adjust them to precisely calibrate this measurement. If valve positioning is supported and enabled, this gain and bias are not used and need not be set. Otherwise, they scale the internal measurement of the actual high-current output for comparison to its intended value (see Figure 7-6):
Ou t t = 100 ⋅ ( Ou t a + Bias 2 ) ⋅ Gai n 2 where: Outa = raw loopback measurement, expressed as a decimal fraction of the maximum high-current output (Imax ) Outt = scaled measurement for loopback test (in percent) Bias2 = the Loopback Scaling Bias Gain2 = the Loopback Scaling Gain The nominal values of this gain and bias can be calculated as: – I low Bias 2 = -----------I max
and
I max Gai n 2 = -------------------------I high – I low
where Ilow and Ihigh define the intended range of the output signal. For example, consider an ideal 4 to 20 mA output:
I low = 4 –4 Bias 2 = ------ = – 0.20 20
I high = I max = 20 20 Gai n 2 = ---------------- = 1.25 20 – 4
If the high-current output is accurately calibrated, you can use the following procedure to fine-tune the nominal loopback scaling or to recalibrate this measurement: Step 1: Make sure the loopback test is enabled and the valve positioning loop and bipolar output are disabled. Step 2: Use the Signal Values Test [MODE TEST 4] to display the scaled loopback signal (AD 5) on the Engineering Panel. Step 3: Observe the AD5 value while you manually vary the displayed output from zero to 100 percent. Although they can differ by up to 5 percent without triggering a loopback failure, they should match as closely as possible. If the calibration is satisfactory, skip to step 11. Step 4: Set the displayed output to 25.0 percent and record the displayed value of AD5 as Inlow . April 2010
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Chapter 7: Extended I/O Circuits Step 5: Set the displayed output to 75.0 percent and record the displayed value of AD5 as Inhigh . Step 6: Press CLEAR to terminate the Signal Values Test. Step 7: Calculate and enter a new Loopback Scaling Gain [COND:D GAIN 2] using the following formula:
Gain 2 = Gai n p ⋅ 50 ⁄ ( In high – In low ) where Gain2 is the new value and Gainp is the previous value. Step 8: Press MODE TEST 4 8 and then the decimal key (several times) to again display AD5 on the Engineering Panel. If necessary, adjust the output so AD5 is not zero. Step 9: Subtract the new value of AD5 from the displayed output and record that error. Step 10: Press CLEAR to again terminate the Signal Values Test. Step 11: Calculate and enter a new Loopback Scaling Bias [COND:D BIAS 2] using the following formula:
error Bias 2 = Bias p + ------------------------------100 ⋅ Gain 2 where Bias2 is the new value and Biasp is the previous value. Step 12: Set the displayed output to 0.00 and redisplay AD5. If it is zero, increase the bias enough to give AD5 a slight positive value (zero or less is always treated as a loopback failure). Step 13: Repeat until satisfactory results are obtained, then restore the original values of any parameters you changed.
Note:
April 2010
It the loopback alarm activates unnecessarily when the output is at its minimum value, make the Bias slightly less negative. If it comes on at maximum output, slightly lower the Gain.
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This section explains the general methods you can use to troubleshoot suspected problems with the Speed or Position inputs. Most Speed and Fuel Controllers have Input Lockout [MODE LOCK 6] parameters that cause them to ignore their speed or position inputs. This is useful primarily when using a computer simulation to demonstrate or teach the operation of the controller. If your controller is reading its inputs correctly but seems unaffected by them, make sure all of its MODE LOCK 6 parameters are disabled (Off).
High-Current Output Troubleshooting
Troubleshooting the high-current output is basically a question of determining if the problem is in the controller or the field wiring. Controller problems are usually rectified by replacing the Auxiliary PCB Assembly.
Warning!
Never connect an ammeter in parallel with the high-current output of an in-service controller. This usually causes the control valve to slam fully closed (assuming it fails closed). The easiest way to troubleshoot the high-current output is to use the output loopback test. The controller will then trigger an alarm if the output signal varies from its intended value by more than five percent. The Output Calibration section of this manual tells how to configure and adjust the loopback measurement, while the manual for each controller that supports this test tells how to enable it: • Output Loopback Test section in Chapter 3 of IM307 • Output Loopback Test section in Chapter 3 of IM308 The loopback test will reveal problems such as breaks or current leakage in the field wiring. However, it will not reveal problems which would shunt the current around the control element (such as a short across the transducer’s input terminals). The calibration procedures discussed in the previous section can also be used to manually test the output signals. If these procedures reveal that the outputs are correctly calibrated, try measuring them with the field wiring connected. If the controller is then unable to maintain its intended output signals, the problem is in the field wiring or valve transducer.
Speed Input Troubleshooting
Magnetic pickups are relatively simple and reliable devices. The most common problems for such inputs are complete loss of signal due to broken leads, misaligned pickups, or excessive temperature. It is important to properly match these pickups to the design of the gear that excites them. Otherwise, high-speed operation may not allow enough time for their signals to decay between the passage of adjacent teeth. Thus, when some sufficiently high rotational speed is
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Chapter 7: Extended I/O Circuits surpassed, the measured speed will suddenly fall to zero! Most versions of the controller would then shut down the turbine. At the other extreme, the voltage of a passive MPU’s signal rises as a function of the rotational speed. The controller cannot read such a signal until some minimum speed is reached. Current versions of the various Turbine Controllers allow you to define this minimum speed, and consider a speed input to have failed if its signal is below that threshold. In addition, controllers that support triple-redundant speed inputs consider an input to have failed if its speed signal deviates from the mean for all three by more than a user-defined percentage. Loss of an MPU input will trigger the Front Panel Alarm LED. You can then use the AUX readout’s Alarm Menu to display the number of the failed pickup. If all of the speed inputs fail, most versions of the controller will shut down the turbine. As an aid to troubleshooting, these controllers provide two ways to display the value of each speed input: • The signal to each input can be displayed (in rpm) via the frontpanel AUXiliary Display’s In/Out Menu. • The Engineering Panel’s Signal Values Test [MODE TEST 4] can be used to view the signal to each input as a percentage of its Maximum Control Speed. Either value will be accurate only if the input has been properly configured. If the inputs appear to be miscalibrated, check the configuration parameters to make sure you have correctly entered the number of teeth on the exciter gear and the speed ratio between the gear and turbine shafts.
Position Input Troubleshooting
As an aid to troubleshooting, the controller offers two ways to view the position input values. When any feature requiring one of these inputs (valve positioning, for example) is enabled, that position signal can be viewed via the AUXiliary Display's In/Out menu (consult the controller’s configuration manual to determine if it applies any scaling to these values). You can also use the Signal Values Test [MODE TEST 4] to view the unscaled values of these inputs on the Engineering Panel.
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Fault Detection and Redundancy
Series 3 Plus Hardware Referencemanual
This chapter describes the fault indicators and redundant controller set up.
AUTO MAN
Compressor Controllers
Turbine Controllers
∆ ∇
Tracking
Tracking
MENU
SCROLL
Fault
COMPRESSOR CONTROLS CORPORATION
Figure 8-1
Fault Indicators
Fault and Tracking LED locations All Series 3 Plus Controllers feature a front-panel Fault LED and at least one normally-energized fault relay (CR1/DO1). In addition, discrete output CR2/DO2 can be set up as a second fault relay and CR9/DO9 serves as an Auxiliary PCB fault indicator. Both the CPU and Auxiliary PCBs include watchdog timers that must be regularly reset by their respective control programs. If either of them does time out, it will de-energize that board’s fault relay and reset its CPU chip, thus causing the control program to restart: • If that restart succeeds, it will reset the time and clear the relay. The Engineering Panel will beep and display “Reset” on the readout (see page 57). • If it fails, the fault relay will remain de-energized, which can indicate either a software error or a hardware problem that prevents the board’s control program from running. If the CPU PCB faults, it will stop communicating with the Front Panel, which will in turn light the front-panel Fault LED and turn the other thirteen off. If the Auxiliary PCB faults, it will stop communicating with the CPU PCB. A Speed or Fuel Controller will then light its
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Chapter 8: Fault Detection and Redundancy Fault LED and initiate an emergency shutdown failure, while an Extraction Controller will merely indicate an “Aux. Board” alarm. The other thirteen LEDs will operate normally. CR1/DO1 can also be given a Relay Assigned Function [MODE:D RA 1], which will not affect the Fault LED but does define the conditions under which the Modbus DO1 discrete bit will be set. You may select any function as long as it is configured to de-energize the relay when it occurs, but the state of this relay should then be interpreted accordingly. If CR2/DO2 is set up as a second CPU fault relay (see Discrete Output Jumpers on page 71), it will de-energize when CR1/DO1 does. Its Relay Assigned Function [MODE:D RA 2] only defines the conditions under which the Modbus DO2 State discrete bit is set. Neither of those Modbus bits, which are strictly software controlled, can indicate a hardware fault. The Auxiliary PC’s fault relay cannot be assigned an additional function and has no Modbus discrete bit. In extreme cases, the controller may go completely dead, in which case all fault relays will obviously de-energize but the Fault LED can not be lit. If power is still being supplied to the controller, check the voltage at the Back Panel or FTA 24 Vdc terminals. If no voltage is present, either the Power Supply or its fuse has probably failed.
Power Supply Failure
A failure of the internal power supply’s 5 Vdc circuit will de-energize all relays and prevent any LEDs from lighting. Failure of the 15 or 24 Vdc circuits will have no direct effect on the fault indicators, but will always cause all analog inputs to read as zero (volts or milliamps). This will generally trigger any relay assigned the Transmitter Failure (Tran) function. Beginning with software revisions 1056-001 and 1156-001, Speed and Extraction Controllers can be configured to indicate a “Power Supply” alarm and trigger any Internal Power Supply and General Failure (PSF and Fail) relays if a designated analog input fails. This will occur whenever the power supply fails (even if the designated input signal does not), because the controller will then be unable to read that input.
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PROCESS Main Controller 00.0
DEV
Analog Inputs
Analog Inputs
4.3 ALT
OUT
Status
RUN
Antisurge Controller
AUX Auto
AUTO
Manual
MAN
RT
RESET SAFETY ON
SO Limit Tracking TranFail Fallback ComErr
Analog Output
REDUNDANT CONTROL SELECTOR
∆ ∇
Back-Up Controller
Selected Output
00.0
4.3
Analog Output
ALT
AUX Auto
Switch to Back-Up
Fault Discrete
DISPLAY LIMIT
MENU
SCROLL
Fault
COMPRESSOR CONTROLS CORPORATION
Antisurge Controller
MAN
∆
RESET SAFETY ON
∇
DISPLAY SURGE COUNT
DISPLAY LIMIT
MENU
SCROLL
AUTO
RT SO Limit Tracking TranFail
DISPLAY SURGE COUNT
OUT
Status TRACK
Manual
MAIN
Fault Discrete
Fallback
BACK-UP
Tracking Discrete
Switch to Main GREEN ACTIVE
DEV
ComErr
Tracking Discrete
RED TRACK
Fault
COMPRESSOR CONTROLS CORPORATION
Port 1 Serial Communications
Figure 8-2
Redundant Controllers
Series 3 Plus dual-redundant fault tolerance Series 3 Plus Controllers can be installed in a dual-redundant, paired configuration. The main controller in each pair will normally regulate your process while its “hot” backup monitors it via serial Port 1 so it can instantly take over if the main controller should fail. Such applications are configured by enabling Redundant Tracking [MODE:D fE 1] in both controllers, giving them the same Controller ID Number [MODE:D COMM 0], and connecting them with a switching device (such as our Redundant Control Selector) that: • clears the Tracking input of the active controller and includes the valve actuator in its output circuit, and • asserts the Tracking input of the redundant controller and excludes the valve actuator from its output circuit. Depending on the application, you may also elect to switch other I/O signals, particularly outputs that affect the behavior of other controllers or devices within your control system. This switch is triggered by one or more of the main controller’s discrete outputs, wired in series with each set up to be de-energized by one of the chosen Switching Conditions. If any such condition is detected, the corresponding relay will de-energize, causing the switch to select the backup controller. Any tracking controller will light its Tracking LED (see Figure 8-1). Most will also provide other indications, such as displaying their operating states as “Tracking” or setting a Tracking discrete output.
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Chapter 8: Fault Detection and Redundancy Main Controller
Backup Controller
CR1 1 2
S
M
R
B
Backup
M
CR1 1 2
Main
SR M
Figure 8-3
Switching Conditions
B
S
R
Typical redundant switching relay circuit Automatic switching is usually triggered by the controller fault relays (CR1 or DO-1, see page 105), which should be set for normallyopen operation. If a fault relay is configured to indicate an additional condition, either that condition or a hardware fault would trigger a switchover. If more than one of the available relay functions should initiate a control transfer, the others should be assigned to normallyclosed relays in series with the fault relay. For turbine controllers, the Auxiliary PCB fault relay (DO-9) should be configured for normally-open operation and wired in series with DO-1, so an automatic switch to the backup controller will occur if either of them de-energizes. Beginning with revision 1056-001 and 1156-001, the Speed and Extraction Controllers offer a General Failure (Fail) relay function specifically intended for redundant switching. It indicates one or more conditions that could stem from internal malfunctions, in which case switching to the backup would allow continued operation.
Switching Logic
Typically, the switching circuitry for redundant Series 3 Plus Controllers provides Main and Backup buttons for manually activating either controller (provided it is healthy) and relay logic that automatically activates the backup controller if it is healthy and its main counterpart is not. Once the backup has been activated, however, control is never automatically returned to the main controller (that must be done by pressing the Main button while that controller is healthy). Figure 8-3 shows a hardwired implementation of this switching logic, with the M and B relays de-energized (both controllers faulted): • If the main controller fails or the Backup button is pressed while the backup controller is healthy, relay S will energize, which in turn energizes and latches switching relay SR. • If the Main button is pressed while the main controller is healthy, relay R will energize, which de-energizes relays S and SR. The normally-open and normally-closed contacts of relay SR are used to open and close the appropriate controller I/O circuits.
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Current-Loop Output and Loopback SR
OUT 1 +
SR
OUT 1 +
+
FY –
SR CH 8 + –
SR
SR CH 8 + –
SR
Tracking Discretes DISCRETE IN D1
D
DISCRETE IN
SR
SR
24VDC – +
Main Controller
Output Connections
D
24VDC – +
1N4004
Figure 8-4
D1
1N4004
Backup Controller
Switched I/O signal connections One function of the redundant switching device is to connect final control elements to the output signals of the active controller. When 4 to 20 mA current loops are employed, that device must also maintain the continuity of the tracking controller’s output circuits. The top panel of Figure 8-4 shows how current-loop outputs from redundant controllers should be connected to their individual loopback inputs (CH8) and a common control element, using normallyopen (NO) and normally-closed (NC) contacts controlled by a single switching relay.
Tracking Input Connections
The other function of the redundant switching device is to energize the tracking input of the tracking controller. For compressor controllers, that is always discrete input D1. For turbine controllers, it must be assigned to an input provided by the CPU PCB (DI-1 through DI8), but never to an Auxiliary PCB input (DI-9 through DI-16). The bottom panel of Figure 8-4 shows how the tracking inputs of redundant compressor controllers should be connected to the 24 volt transmitter power outputs of both through normally-open and normally-closed switching relay contacts.
Serial Port Set Up
April 2010
If Modbus While Tracking [MODE:D LOCK 0] is Off, the main and backup controllers can be given the same Computer ID Number [MODE:D COMM 0 •]. In this case, only the active unit will respond to Modbus data requests and the tracking unit can not be remotely monitored or reconfigured. Redundant controllers with Modbus While Tracking enabled require unique Computer ID Numbers, which allows both to be remotely accessed. IM300/H (6.2.4)
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Chapter 8: Fault Detection and Redundancy Main Controller
RCS Switching Unit
Backup Controller
To Transducer – +
OUT 1 +
CH 8 + –
OUT 1 +
CR1 1 2
CH 8 + –
DISCRETE IN D1
CR1 1 2
DISCRETE IN
D
D1
24VDC – +
D
24VDC –
TB6
TB6
Figure 8-5
Typical Redundant Control Selector connections Both controllers in each redundant pair must be connected to the same inter-controller serial communication networks. The backup controller does not transmit over Port 1, but does track the transmissions of its active counterpart. Similarly, only the active controller responds to Port 2 information requests. Because that port’s address is set by the Computer ID Number, Modbus While Tracking is usually disabled in load-sharing applications so both controllers can have the same Port 2 ID.
Redundant Control Selector
RCS Power Test
Our Redundant Control Selector (RCS) provides sixteen pairs of NO/NC relay contacts, compatible fault relay inputs, onboard and remote manual selection buttons, and the recommended Switching Logic for connecting a redundant pair of Series 3 Controllers.Figure 8-5 shows a typical application of that device, which is described in detail by data sheet DS300/R. The RCS is designed to select one of two redundant 24 Vdc power supplies. Beginning with revision 1056-001 and 1156-001, each Speed or Extraction Controller in a redundant pair can be configured to test and alarm the failure of one of those power supplies. Simply connect any discrete input assigned the -RS24 function in parallel with the RCS power supply. The controller will then energize any +RS24 relays and signal an “RS 24V Fail” alarm if that input is cleared. The failure of either power supply would trigger this alarm in one controller, thus indicating the switch was operating without redundant power. The failure of both would trigger this alarm in both controllers, thus indicating the selector was not operating.
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Appendix A Configu ation Parameters IM300/H
Series 3 Plus Hardware Referencemanual
This appendix describes each configuration or tuning parameter discussed in the body of this manual, including: • its functional name and a description of that function, • the range of values it can be given, • the sequence of keys you must press to view or change it from the Engineering Panel (often used as an alternate name), • its confirming display prompt, • any restrictions on the order in which it must be entered, and • cross-references to the sections of this manual in which the parameter is discussed. Keyboard Entry
As discussed in Chapter 3, pressing the indicated keys will produce the listed confirming display, which consists of a prompt followed by the current value. For array parameters, that prompt will include a “#” representing the digit corresponding to the array element. Values that are selected from a list by pressing the decimal key are shown as “Value” or “Valu”. OFF/ON or OFF/HIGH/LOW choices are shown as such and are selected by pressing the corresponding key (0, 1, HIGH, or LOW). Values that are entered by pressing one or more numeric keys are shown as a series of “#” symbols representing digits, possibly including an automatically-placed decimal point. The space before a negative value is replaced by a “–”. A hexadecimal ten leading digit is entered by pressing HIGH and displays as “A” (100.0 is entered as HIGH 0 0 and displays as A0.0).
COND:A f(X) 2 # and X 2 # Reported Flow Characterizer
COND:D BIAS 1 Output Scaling Bias
Note: April 2010
These parameters characterize an Antisurge Controller’s reported flow measurement in multisection compressor applications. Range: 0.00 to 9.99 percent [X] 0.00 to 9.99 percent [f(X)] Display: X2# #.## [X] Y2# #.## [f(X)] Reference: Numeric Parameters . . . . . . . . . . . . . . . . . . . . 54 For controllers equipped with an Auxiliary PCB, this parameter sets the bias used to scale and calibrate the high-current output signal. Range: .0000 to .9999 Display: B1 .#### Reference: Output Circuit Calibration . . . . . . . . . . . . . . . . 99 COND:D BIAS 1 . . . . . . . . . . . . . . . . . . . . . . 118 BIAS 1 and 2 can only be changed via the Engineering Panel. IM300/H (6.2.4)
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Appendix A: Configuration Parameters
COND:D BIAS 2 Loopback Scaling Bias
For controllers equipped with an Auxiliary PCB, this parameter sets the bias used to scale and calibrate the high-current output’s loopback input signal. Range: –.9999 to .9999 Display: B2 .#### Reference: Loopback Circuit Calibration . . . . . . . . . . . . 101 COND:D BIAS 2 . . . . . . . . . . . . . . . . . . . . . . 118
COND:D DISPLAY 0#– Measured Variable Label
COND:D DISPLAY 0#• Measured Variable Decimal
COND:D GAIN 1 Output Scaling Gain
Note: COND:D GAIN 2 Loopback Scaling Gain
Each of these parameters defines the label shown when the corresponding measured variable is viewed in the Auxiliary Display. Range: any eight symbols from scrolling list Display: AAAAAAAA (selected symbol flashes) Reference: List Parameters . . . . . . . . . . . . . . . . . . . . . . . 51 Each of these parameters defines the position of the decimal point in the corresponding measured variable display. Range:
0 #### (no decimal) 1 ###. (trailing decimal) 2 ##.# 3 #.## 4 .### (leading decimal) Display: 0#. 4321 (selected digit is replaced by •) Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 49 For controllers equipped with an Auxiliary PCB, this parameter sets the gain used to scale and calibrate the high-current output signal. Range: .0000 to .9999 Display: G1 .#### Reference: Output Circuit Calibration . . . . . . . . . . . . . . . . 99 COND:D GAIN 1 . . . . . . . . . . . . . . . . . . . . . 119 GAIN 1 and 2 can only be changed via the Engineering Panel. For controllers equipped with an Auxiliary PCB, this parameter sets the gain used to scale and calibrate the high-current output’s loopback input signal. Range: 00.00 to 99.99 Display: G2 ##.## Reference: Loopback Circuit Calibration . . . . . . . . . . . . 101 COND:D GAIN 2 . . . . . . . . . . . . . . . . . . . . . 119
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For controllers that support valve positioning via the high-current output, this parameter determines whether that output is generated as a unipolar or bipolar electrical signal. Range:
Off unipolar output On bipolar output Display: OT1- OFF/ON Reference: High-Current Analog Output . . . . . . . . . . . . . . 92
MODE:D ANIN LOW Transmitter Failure Limit
MODE:D ANIN # Offset Zero Input
MODE:D ANIN # HIGH Analog Input High Alarm Limit
MODE:D ANIN # LOW Analog Input Low Alarm Limit
April 2010
For a Dual-Loop A/P Controller, this parameter defines the minimum value for any offset-zero input’s analog-to-digital variable, below which that input is considered to have failed. Range: 00.0 to 99.9 percent Display: ANL ##.# Reference: Numeric Parameters . . . . . . . . . . . . . . . . . . . . 53 MODE:D ANIN – . . . . . . . . . . . . . . . . . . . . . . 120 Each of these parameters identifies the zero level of the corresponding analog input signal (relative to its hardware configuration). Range:
Off actual zero (for example, 0 to 5 Vdc) On 20 percent offset zero (e.g., 4 to 20 mA) Display: A# OFF/ON Reference: MODE TEST 4 . . . . . . . . . . . . . . . . . . . . . . . 127 Each of these parameters defines the maximum value for the corresponding analog input’s analog-to-digital variable, above which that input is considered to have failed. Range: 00.0 to 102.4 percent Display: A#H ##.# Reference: MODE:D ANIN – . . . . . . . . . . . . . . . . . . . . . . 120 Each of these parameters defines the minimum value for the corresponding analog input’s analog-to-digital variable, below which that input is considered to have failed. Range: 00.0 to 102.4 percent Display: A#L ##.# Reference: MODE:D ANIN – . . . . . . . . . . . . . . . . . . . . . . 120
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Appendix A: Configuration Parameters
MODE:D COMM 0 Controller ID Number
This parameter identifies the controller in the network connected to its serial Port 1. With the exception of redundant controllers, this ID must be unique within that network. Range: 1 to 8 Display: Ctrl# # Reference: Configuring Communications . . . . . . . . . . . . . 60 Redundant Controllers . . . . . . . . . . . . . . . . . 107 MODE COMM 0 . . . . . . . . . . . . . . . . . . . . . . 121
Note: MODE:D COMM 0 • Computer ID Number
COMM 0 and 0 • can only be changed via the Engineering Panel. This parameter identifies the controller in the networks connected to its serial Ports 2, 3, and 4. With the possible exception of redundant controllers, this ID must be unique within each of those networks. Range: 01 to 64 Display: Comp# ## Reference: Configuring Communications . . . . . . . . . . . . . 60 Serial Port Set Up . . . . . . . . . . . . . . . . . . . . 109 MODE COMM 0 •. . . . . . . . . . . . . . . . . . . . . 121
MODE:D COMM 2 Port 2 Baud Rate
MODE:D COMM 3 Port 3 Baud Rate Port 3 Parity
MODE:D COMM 4 Port 4 Baud Rate Port 4 Parity
April 2010
This parameter defines the data transmission rate for the Port 2 serial communication channel. Range: 2400, 4800, 9600 Display: PT2 Valu (press • to select, then ENTER) Reference: List Parameters . . . . . . . . . . . . . . . . . . . . . . . 50 Configuring Communications . . . . . . . . . . . . . 60 These parameters define the data transmission rate and parity setting for the Port 3 serial communication channel. Range: 4800, 9600, 19k2 (19200) Even, Odd, None Display: PT3 Valu (press • to select, then ENTER) PT3 Valu (press • to select, then ENTER) Reference: Configuring Communications . . . . . . . . . . . . . 60 These parameters define the data transmission rate and parity setting for the Port 4 serial communication channel. Range: 4800, 9600, 19k2 (19200) Even, Odd, None Display: PT4 Valu (press • to select, then ENTER) PT4 Valu (press • to select, then ENTER) Reference: Configuring Communications . . . . . . . . . . . . . 60 IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE:D fD 1 Mass Flow Input
MODE:D fE 1 Redundant Tracking
MODE:D LOCK 0 Modbus While Tracking
115
This parameter selects the analog input for the flow signal (∆Po) used to compute a Performance Controller’s measured total flow. Range:
Off measured total flow not calculated 1 to 8 selects corresponding analog input Display: fD1 OFF/# Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 48 This parameter determines whether the controller will operate in its redundant mode when a Track discrete input is asserted. Range:
Off redundant tracking disabled On redundant tracking enabled Display: fE1 OFF/ON Reference: Redundant Controllers . . . . . . . . . . . . . . . . . 107 If redundant controllers are given the same Computer ID Number [MODE:D COMM 0 •], this parameter must be disabled so that only one of them will respond to Modbus data requests to that address. If they are given different ID numbers, enabling this parameter allows the Modbus host to monitor both controllers. Range:
Off host cannot monitor tracking controller On host can monitor tracking controller Display: LOC0 OFF/ON Reference: Serial Port Set Up . . . . . . . . . . . . . . . . . . . . . 109
MODE:D LOCK 1 Read and Write Inhibit
This parameter and Write Inhibit Only [MODE:D LOCK 2] define the level of access (read/write, read-only, or none) that a host device has to the controller’s Modbus data. Off access defined by Write Inhibit Only On no Modbus access Display: LOC1 OFF/ON Reference: Configuring Communications . . . . . . . . . . . . . 60 Range:
MODE:D LOCK 2 Write Inhibit Only
If Read and Write Inhibit [MODE:D LOCK 1] is disabled, this parameter defines the level of access (read/write or read-only) that a host device has to the controller’s Modbus data. Range:
Off read and write access On read access only Display: LOC2 OFF/ON Reference: Configuring Communications . . . . . . . . . . . . . 60
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Appendix A: Configuration Parameters
MODE:D LOCK 7 Modbus Register Scaling
This parameter determines whether Modbus holding register values transmitted through Port 3 are scaled to their full, maximum range or to a slightly smaller, rounded-off range (minimum to maximum / 1.024), thus providing compatibility with distributed control systems using either scaling convention. Range:
Off the controller uses the maximum range On the controller uses the reduced range Display: LOC7 OFF/ON Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 47
MODE:D LOCK 9 Auxiliary Display Reset
If you use the Front Panel MENU and SCROLL keys to change the variable displayed in the AUX readout, this parameter determines whether it will automatically revert to displaying the controller status: Range:
Off selected display remains until changed On status display restored after one minute Display: LOC9 OFF/ON
MODE:D RA # Relay Assigned Function
Each of these parameters selects the conditions under which the corresponding discrete output is triggered. If the assigned function is positive, the relay will be energized when the associated condition exists. If the value is negative, the relay will de-energize. Range: see “Remote Operator Panel” chapter of each configuration manual Display: RA#±Valu (press HIGH or LOW to select sign, then press • to select function) Reference: List Parameters . . . . . . . . . . . . . . . . . . . . . . . 52 Discrete Output Troubleshooting . . . . . . . . . . 75
MODE:S SS 3 Alternate MW Input
April 2010
This parameter specifies how a Speed Controller’s megawatt droop algorithm selects its analog input (signal variable SV7 or SV8). Range:
Off always select SV7 High select highest of two signals Low select lowest of two signals Display: SS3 OFF/HIGH/LOW Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 48
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
117
Appendix B Controller Test Sequences IM300/H
Series 3 Plus Hardware Referencemanual
This appendix describes the controller test procedures that can be executed from the Engineering Panel of a Series 3 Plus Controller. As described in Chapter 3, each such key sequence begins with a data group key that selects the function of the second key. Unlike the key sequences used to enter configuration parameters, most of these procedural key sequences are not assigned to specific data pages. A data page letter is indicated only when you must press the data group key as many times as needed to display the letter at the end of the first step confirming display. For example, theTransmitter Status Test [MODE:D ANIN –] is assigned to the Device page, as indicated by the MODE:D notation and its “MODE: D” first step confirming display. Pressing the CLEAR key will terminate any of these procedures and clear the display. Otherwise, they time out and automatically clear the display after 45 seconds of keyboard inactivity.
CLEAR 2 CLEAR 3 LED Test
Unless pre-production Front Panel firmware is installed, two key combinations are provided for testing the Front and Engineering Panel alphanumeric readouts and LEDs. To cyclically light individual LEDs and readout positions: hold
CLEAR
2
, then press
All segments for the first symbol in the top Front Panel readout will then light briefly, followed in turn by each subsequent symbol and then those in the second row of readouts. Each LED will then light, from top to bottom, followed by each position in the Engineering Panel and Front Panel AUX readout (which will otherwise display either “LED Test” or “CCC v#.#.#”, where #.#.# is the Front-Panel firmware version). Use the following key combination to simultaneously light all LEDs and readout positions (except AUX, which displays “Check LED’s”): hold
CLEAR
3
, then press
In either case, releasing the CLEAR key will restore normal operation if V1.0.2 or later firmware is installed. If not, the normal displays can be restored by pressing the following key combination: hold
April 2010
CLEAR
1
and press
IM300/H (6.2.4)
118
Appendix B: Controller Test Sequences
COND:D BIAS 1 Output Scaling Bias
For controllers equipped with an Auxiliary PCB, this procedure sets the bias (.0000 to .9999) used to scale and calibrate the high-current output signal. Press these keys to view the current value: repeat
COND
until you see 1
COND:
D
B1 .####
BIAS
Press CLEAR to leave it unchanged, or enter the desired new value: #
#
#
#
B1 .####
ENTER
where each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically.
COND:D BIAS 2 Loopback Scaling Bias
For controllers equipped with an Auxiliary PCB, this procedure sets the bias (–.9999 to .9999) used to scale and calibrate the highcurrent output’s loopback input signal. The key sequence for this procedure is the same as that for the Output Scaling Bias [COND:D BIAS 1] except that the third key you press is 2 and the resulting display is “B2 .####”. To enter a negative value, press the minus (–) key before entering the digits.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
COND:D GAIN 1 Output Scaling Gain
119
For controllers equipped with an Auxiliary PCB, this procedure sets the gain (.0000 to .9999) used to scale and calibrate the highcurrent output signal. Press these keys to view the current value (.####): repeat
COND
until you see 1
COND:
D
G1 .####
GAIN
Press CLEAR to leave it unchanged, or enter the desired new value: #
#
#
#
G1 .####
ENTER
where each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically.
COND:D GAIN 2 Loopback Scaling Gain
For controllers equipped with an Auxiliary PCB, this procedure sets the gain (00.00 to 99.99) used to scale and calibrate the highcurrent output’s loopback input signal. The key sequence for this procedure is the same as that for the Output Scaling Gain [COND:D GAIN 1] except that the third key you press is 2 and the resulting display is “G2 ##.##”.
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IM300/H (6.2.4)
120
Appendix B: Controller Test Sequences
MODE:D ANIN – Transmitter Status Test
This procedure can be used to identify which analog input signal(s) triggered a transmitter alarm. To initiate this test, press the following keys: repeat
MODE
until you see –
AN IN
MODE:
D
AN1 GOOD
or
AN1 HIGH
or
AN1 LOW
The digit in this display is the analog input channel number (AN1). HIGH indicates that signal is above its Analog Input High Alarm Limit, LOW indicates it is below its Analog Input Low Alarm Limit, or GOOD indicates it is between those limits. For a Dual-Loop Controller only, the inputs are checked against a common Transmitter Failure Limit and only test as GOOD or LOW. You can determine the status of each consecutive input signal by pressing the • key: •
AN1 GOOD
or
AN1 HIGH
or
AN1 LOW
This allows you to repetitively cycle through all the inputs. Beginning with software revisions 754-002, 854-002, 954-002, 1056-001, and 1156-001, the status of the displayed input is updated continuously. With previous versions, the conditions of all eight inputs were checked only at the instant that this test was initiated and not updated thereafter.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE COMM Reset Controller
To restart the control program without initializing its operating state and variables (see MODE TEST 6 on page 130), press the following keys: MODE
MODE COMM 0 Controller ID Number
121
COMM
Reset
ENTER
This procedure sets the number (1 to 8) that identifies the controller within its Port 1 serial communication network. With the exception of redundant controllers, this ID must be unique within that network. Press these keys to view the current Controller ID Number: MODE
0
COMM
Ctrl# 1
Press CLEAR to leave it unchanged, or enter the desired ID: #
Ctrl# #
ENTER
where the key used to enter the new value is represented as #.
MODE COMM 0 • Computer ID Number
This procedure sets the number (01 to 64) that identifies the controller within its Port 2, 3, and 4 serial communication networks. With the exception of redundant controllers, this ID must be unique within each of those networks. Press these keys to view the current Computer ID Number: MODE
COMM
0
•
Comp# ##
Press CLEAR to leave it unchanged, or enter the desired ID (you must enter both digits, even if the first is a leading zero): #
#
Comp# ##
ENTER
where the key used to enter the new value is represented as #.
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IM300/H (6.2.4)
122
Appendix B: Controller Test Sequences
MODE COMM – 2 Serial Port 2 Test
To determine if the controller has detected any Port 2 serial communications activity within the past second, press the following keys: MODE
–
COMM
2
or
-2
GOOD
-2
BAD
where the confirming display will be GOOD if a serial transmission has been received during the previous second.
Note: MODE COMM – 3 Serial Port 1 Test
This port is used primarily for performance and extraction load-sharing. Otherwise, Port 2 is usually not even connected to any other controllers and a BAD result for this test is of no consequence. Each controller can be configured to expect Port 1 transmissions from other Series 3 Plus Controllers by enabling any of several features (for example, redundant controller tracking). This procedure reveals whether or not this controller is receiving Port 1 transmissions from the associated controllers. To identify the companion controllers from which Port 1 transmissions are being received, press the following keys: MODE
–
COMM
3
-1
GOOD
-1
BAD
where the digit is a controller ID number. GOOD indicates data is being received from that controller, BAD indicates it is not. Subsequently pressing the decimal key displays the same information for the next possible companion controller. You can cycle through all eight possible ID numbers (including this controller’s own) by pressing that key as many times as you like: •
•
Note:
April 2010
-8
BAD
-1
GOOD
Although transmissions are normally received from all controllers connected to Port 1 (including this one), only those from specified companion controllers are normally of any concern.
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE LOCK 3 • Store Alternate Parameters
123
This procedure (software revisions 752-001, 852-001, 952-001, 1055-002, and 1152-002 and later) copies the controller’s current parameters into any of its three alternate sets. To initiate this procedure, which you can abort at any time by pressing CLEAR, press the following keys: MODE
3
LOCK
•
Store1?
ENTER
This display indicates which alternate set the current parameters will be copied into. To select a different set, press the decimal (•) key: •
Store2?
Pressing ENTER will then copy the current parameters to the indicated alternate set and briefly display that set’s new checksum:
CS= F882
ENTER
MODE LOCK 3 • • Recall Alternate Parameters
This procedure (software revisions 752-001, 852-001, 952-001, 1055-002, and 1152-002 and later) copies any of the three alternate parameter sets into the controller’s current set. To initiate this procedure, which you can abort at any time by pressing CLEAR, press the following keys: MODE
LOCK
3
•
•
ENTER
Recall1?
This display indicates which alternate set will be copied into the working memory. To select a different set, press the decimal (•) key: •
Recall2?
Pressing ENTER will then initiate a recall of the selected alternate parameter set. If it is valid, it is copied into the current set and the controller executes a soft reset. If the selected set is invalid (which probably means it was never defined), “No Match” is displayed to inform you that the recall has been aborted: ENTER
or
April 2010
Reset No Match
IM300/H (6.2.4)
124
Appendix B: Controller Test Sequences
MODE LOCK 4 Parameter Checksum
This procedure displays the checksum values of the controller’s various parameter sets. You can determine which (if any) of the alternate parameter sets is currently in use by comparing the checksum of the Present and Long-Term sets to those for the alternate sets. You can also tell if any of these parameter sets agree with those recorded on a parameter worksheet by comparing these checksums to those recorded on that worksheet. To view the parameter checksums, press the following keys: MODE
LOCK
4
CS= A3C2 P = A76F
or
If the confirming display beings with CS, the present parameter set is the same as that stored in long-term memory. If that display begins with P, the two sets differ and the checksum shown is for the present set. In that case, you can display the long-term parameter checksum by pressing the decimal key: •
L = A3C2
If the two parameter sets are different, you should use the Disable Reconfiguration [MODE LOCK 5 0] procedure to disable reconfiguration. The controller will then correct any errors that occur in the present parameter set. To display the Alternate Parameter Set checksums (revisions 752001, 852-001, 952-001, 1055-002, and 1152-002 and later), continue to press the decimal (•) key: •
•
•
CS1=B94A CS2=632E CS3=44FC
You can cycle through the displays of all four (or five) checksums by continuing to press the decimal (•) key as many times as you want.
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE LOCK 5 1 Enable Reconfiguration
125
To enable alteration of the controller’s configuration and tuning parameters from the Engineering Panel, press the following keys: MODE
LOCK
5
1
LOC5 ON
ENTER
If you make a mistake entering this sequence, the controller will beep and display an Error! message on the confirming display. When you finish reconfiguring your controller, enter the Disable Reconfiguration [MODE LOCK 5 0] sequence to disable further changes (otherwise, reconfiguration will be automatically disabled after thirty minutes of keyboard inactivity):
MODE LOCK 5 0 Disable Reconfiguration
To disable alteration of the controller’s configuration and tuning parameters from the Engineering Panel, press the following keys: MODE
LOCK
5
0
LOC5 OFF
ENTER
If you make a mistake entering this sequence, the controller will beep and display an Error! message on the confirming display.
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IM300/H (6.2.4)
126
Appendix B: Controller Test Sequences
MODE TEST 2 Program Version
This procedure displays the controller’s software version number and the Auxiliary PCB software revision. To determine which revision of the control program is installed in your controller, press the following keys: MODE
2
TEST
1056-001
If the confirming display is blank, production software has not yet been loaded into this controller. For controllers equipped with an Auxiliary PCB, pressing the decimal key (•) will then display its ROM revision: •
SPBD-010
If your controller is not equipped with this assembly, this test displays a series of dashes: •
MODE TEST 3 Serial Port Activity Test
--------
To view a dynamic display of a specified serial port’s communications activity, press the following keys: MODE
3
TEST
#
PT# R-T_
where # is the numeric key corresponding to the port number. The bar after the R will be in the high position if that port is currently receiving a transmission, otherwise it will be low. Similarly, the bar after the T will be high only when that port is transmitting. The port in the above example is receiving but not transmitting. You can then check for communications activity on any other port by pressing the corresponding numeric key (for example, press 4 to view Port 4’s activity): 4
April 2010
PT4 R-T_
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE TEST 4 Signal Values Test
127
This key sequence displays the current values of the analog, frequency, position, and discrete input signals, and the positions of the front-panel control keys. To initiate this test, press the following keys: MODE
TEST
4
Inputs
To display the measured value of any analog input, press the corresponding numeric key. For example, pressing 1 displays the current value of the CH1 input: 1
CH1 45.8
where the number in the display is the corresponding signal variable (values above 99.9 percent display as A0.0). Thus, you can determine if an input is being read accurately by disabling its Offset Zero Input [MODE:D ANIN #] parameter and comparing the resulting TEST 4 value to a volt or ammeter measurement of the corresponding input signal. Alternately, you can display the value of each consecutive analog input by pressing the decimal key (•). To display a turbine controller’s the frequency inputs (MPUs), press the decimal key to scroll past the CH8 input display:
CH8 50.8 •
PU1 00.0
Each input is displayed as a percentage of the defined maximum speed for the corresponding turbine shaft. Because the Extraction Controller does not use these inputs, their values are meaningless.
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IM300/H (6.2.4)
128
Appendix B: Controller Test Sequences To display the Auxiliary PCB’s valve position (see Position Input Installation on page 96) and output loopback signals (see Loopback Circuit Calibration on page 101), scroll past the display for MPU 6:
PU6 00.0 •
•
•
•
•
•
HZ 12345 LV1 35.2 AD3 50.3 AD4 00.0 AD5 01.1 AD6 39.3
These values represent: HZ frequency of the high-current output, which can be controlled by a field element like the Rosemont 3311 pneumatic transducer LV1 unscaled LVDT1 input, displayed as a percentage of its maximum range AD3 raw value of the output loopback signal, in percent of 200 mA. AD4 auxiliary analog input AD5 output loopback value, after applying the Loopback Scaling Bias and Loopback Scaling Gain AD6 meaningless For Auxiliary PCB version 9.0 and later, the analog position input (AD4) is read as a bipolar -20 to 20 mA signal, so that 0 mA is displayed as 50.0 percent. For previous versions, it was read as a 0 to 20 mA signal and 0.0 mA was displayed as 00.0 percent.
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IM300/H (6.2.4)
Series 3 Plus Hardware Reference
129
To determine the status of the discrete inputs, press zero (0). Pressing the decimal key (•) then repeatedly toggles the display between inputs 1 to 8 and 9 to 16: 0
•
•
_2__5___ _A__DE__ _2__5___
Each character will be the input number if that input is asserted or an underscore if it is not. Digits above nine are shown in a modified hexadecimal notation (A=10, B=11, …, G=16). In the above examples, only inputs DI2, 5, 10 (A), 13 (D), and 14 (E) are asserted. To determine which discrete outputs are energized, press nine (9): 9
1__4____
where each character will be either the relay number (if that relay is energized) or an underscore or (if it is not). In the above example, only relays CR1 and CR4 are energized.
Note: 4
8
3
7
2
6
1
5
The status of the Auxiliary PCB Fault relay (DO9) cannot be viewed via this procedure. To determine which front-panel keys are being pressed, press the minus (–) key: –
_2__5___
where each character in the confirming display is an underscore if the corresponding key is not pressed, or the key number if it is. As shown above, only keys 2 (RESET/ENTER) and 5 (SCROLL) are being pressed. This feature is used mostly to determine whether any of these keys are stuck down.
COMPRESSOR
April 2010
IM300/H (6.2.4)
130
Appendix B: Controller Test Sequences
MODE TEST 6 CPU Reset Count
Resetting the main CPU restarts its control program. This occurs when the controller is powered up, a hardware or software fault causes a watchdog time out, critical parameters are changed or alternate parameter sets are recalled, the controller is reconfigured from a workstation, or the Reset Controller [MODE COMM] procedure is executed. This procedure checks the controller’s parameters to make sure they are reasonable, resets its serial ports and analog inputs, and begins a new scan cycle. Most controllers always execute a soft reset, which does not change the operating state or analog output. However, a Speed Controller will execute a hard reset (which trips the turbine) when it powers up or detects a fault. To display the number of times the control program has restarted since this count was last zeroed, press the following keys: MODE
TEST
6
Z80 ####
where #### is the reset count, which can then be reset by pressing the zero key: 0
MODE TEST 7 Front-Panel Reset Count
Z80 0000
To display the number of times the front-panel microprocessor has reset since this count was last zeroed, press the following keys: MODE
TEST
7
Mot ####
where #### is its current value, which can then be reset by pressing the zero key: 0
April 2010
Mot 0000
IM300/H (6.2.4)
Series 3 Plus Hardware Reference
MODE TEST 8 Program Checksum
131
This procedure initiates the calculation and display of a four-digit, hexadecimal (for example, 1AF4) checksum for the controller’s internal binary operating instructions. It is used primarily to verify the successful downloading of a new operating program. To initiate this test, press the following keys: MODE
TEST
8
CRC BusY
This message indicates the controller is calculating the requested checksum. After a brief pause, it will be replaced by:
CRC #### where #### is the checksum for the installed software. Appendix B of each controller instruction manual provides the checksum for the software revision that manual documents.
MODE TEST HIGH Auxiliary PCB Error Count
For Speed and Extraction Controllers (beginning with revisions 1055-004 and 1152-004), this procedure dynamically displays the number of times the Auxiliary PCB has failed to respond to the CPU PCB since this count was last zeroed. To display this count, press the following keys: HIGH
MODE
TEST
332=XXXX
where #### is the communication error count, which can then be reset by pressing the zero key: 0
April 2010
332=0000
IM300/H (6.2.4)
132
Appendix B: Controller Test Sequences
April 2010
IM300/H (6.2.4)
Series 3 Plus Hardware Reference IM300/H
133
Index
Series 3 Plus Hardware Referencemanual
A
Air Miser Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alphanumeric Displays Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Alternate Parameter Set Alternate Parameter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Displaying Checksums . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Parameter Memory Procedures . . . . . . . . . . . . . . . . . . . . . . 56 Storing and Recalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Analog Input Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Transmitter Status Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Analog Output Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Current/Voltage Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Analog PCB Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Early Model Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Auxiliary PCB Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Program Version Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
B
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Back Panel Back Panel Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Basic Compressor Controller Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Basic I/O Configuration Component Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IM300/H (6.2.4)
134
Index Basic Turbine Controller Component Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . 14 Bipolar Output Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
C
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Case Mounting Slides Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CE Certification Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Input Power Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Compressor Controller Configuration Component Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Computer Communications and Control Limiting Modbus Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Computer ID Number Setting Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Configuration Alternate Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Enabling and Disabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Key Sequence Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Key Sequence Illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Parameter Checksums . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Parameter Memory Procedures . . . . . . . . . . . . . . . . . . . . . . 56 Viewing and Changing Parameter Values . . . . . . . . . . . . . . 46 Configuration Parameters Parameter Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Configurator Configuration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Control Keys Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Control Program Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CPU CB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Model Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Program Checksum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Program Version Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Controller ID Number Setting Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Controller Reset IM300/H (6.2.4)
Series 3 Plus Hardware Reference
135
CPU Reset Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 CPU PCB CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CPU Reset Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
April 2010
D
Data Groups Data Groups and Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Data Pages Data Groups and Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Deinstallation Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Disassembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Discrete Input Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Discrete Output Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Download Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Model Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
E
Enclosure Mounted Controller Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engineering Panel Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Engineering Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Engineering Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . 22 Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Testing LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Extended Compressor Controller Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Extended I/O Configuration IM300/H (6.2.4)
136
Index Component Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . Extended Turbine Controller Component Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . Extender Board Analog I/O Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Component Access . . . . . . . . . . . . . . . . . . . . . . . . .
April 2010
14 14 85 35
F
Fault Discrete Output Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Field Input Module Analog I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Auxiliary I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Discrete I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Extended I/O Turbine Controllers . . . . . . . . . . . . . . . . . . . . . 74 Field Input Module Connections . . . . . . . . . . . . . . . . . . . . . . 82 Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . 26 Position Input Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Speed Input Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Field Input/Output Module Analog I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Analog I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Compressor Controllers with FIOM . . . . . . . . . . . . . . . . . . . 73 Discrete I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . 26 Serial Port Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Serial Port Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Field Output Module Analog I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Auxiliary I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Discrete I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Extended I/O Turbine Controllers . . . . . . . . . . . . . . . . . . . . . 74 Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . 26 Serial Port Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Front Panel Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Front-Panel Reset Count . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Testing LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Front Panel Overlay Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
G
Grounding Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 IM300/H (6.2.4)
Series 3 Plus Hardware Reference
137
Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 63
April 2010
H
High-Current Output Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 High-Current Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . 92 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Scaling Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Scaling Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 High-Density Interconnect Cable Back Panel Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 26 Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
I
ID Numbers Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Input Power Filter Input Power Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Installation Controller Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Isolation Analog Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 89 Analog Output Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Discrete I/O Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Serial Port Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
J
Jumper Settings Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 78, 83 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
K
Key Sequence Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Key Sequence Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Key Sequence Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Keyboard Test Configuration and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
M
Maintenance Strategy Maintenance Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Modbus TCP Protocol IM300/H (6.2.4)
138
Index Modbus TCP Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Model Conversion Model Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
April 2010
O
Output Loopback Test Analog Output Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 83 High-Current Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . 92 Loopback Circuit Calibration. . . . . . . . . . . . . . . . . . . . . . . . 101 Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Setting Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Setting Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
P
Panel Mounted Controller Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Parameter Checksum Parameter Checksum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Position Inputs Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Input Signal Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Power Cable Input Power Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Power Supply Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Power Supply Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Program Checksum Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Program Checksum Test . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Program Version Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Program Version Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
R
Reassembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Redundant Controllers Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . 107–110 Selector Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Return Procedure Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
S
Serial Communication Errors IM300/H (6.2.4)
Series 3 Plus Hardware Reference
139
Serial Port 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Serial Port 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Serial Port Activity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Serial Port Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 66 Serial Port Baud Rate and Parity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Slide Clamps Controller Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Spare Parts Stocking Maintenance Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Speed Input Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Speed Input Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Speed Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103 Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Status Indicator Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 LED Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Surge Suppression Modbus Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
T
April 2010
Toolbox Model Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Serial Port Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . 66 Transducer Feedback Test Daughter Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 High-Current Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . 92 Inductive Load Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Transmitter Testing Transmitter Status Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Troubleshooting General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Turbine Controller Configuration Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IM300/H (6.2.4)
140
Index
April 2010
IM300/H (6.2.4)
DS300/P Series 3 Plus Controllers Spare Parts Listdata sheet
U Assembly
Series 3 Plus
Controller Spare Parts List Part Number
Complete Electronics Assembly (note 1): CPU PCB with AC Power Supply and mounted Analog PCB. . . . . . . . . . 15-300000-002 CPU PCB with DC Power Supply and mounted Analog PCB. . . . . . . . . . 15-300010-002 Analog PCB only . . . . . . . . . . . . . . . . . . . . 18-226630-S05 Auxiliary PCB (Speed Board): Assembly with Daughter Card . . . . . . . . 15-300600-C01 Back Panel Assemblies (without terminal blocks): Compressor Controller, AC. . . . . . . . . . . 15-300500-002 Compressor Controller, DC. . . . . . . . . . . 15-300500-D02 Turbine Controller, AC. . . . . . . . . . . . . . . 15-300500-004 Turbine Controller, AC, Plate Mount . . . . 15-300500-005 Turbine Controller, DC . . . . . . . . . . . . . . 15-300510-004 for FIM & FOM, AC . . . . . . . . . . . . . . . . . 15-300500-003 for FIM & FOM, DC. . . . . . . . . . . . . . . . . 15-300510-003 Back Panel Terminal Block Sets Compressor Controller Set . . . . . . . . . . . 15-300510-002 Turbine Controller Set . . . . . . . . . . . . . . . 15-300510-001 Case: Assembly with Slides and Clamps . . . . . 15-300300-001 Mounting Slide . . . . . . . . . . . . . . . . . . . . 50-002422-001 Slide Clamp . . . . . . . . . . . . . . . . . . . . . . 50-002420-001 CPU PCB Assembly with EEPROMs (note 1): without Power Supply . . . . . . . . . . . . . . . 18-211643-001 with AC Power Supply. . . . . . . . . . . . . . . 15-300000-001 with DC Power Supply . . . . . . . . . . . . . . 15-300010-001 EEPROM set (2 chips) . . . . . . . . . . . . . . 40-001190-306
Assembly
Part Number
Field Termination Assemblies, Turbine (w/o term block set): Field Input and Output Modules. . . . . . . .50-203130-148 HDIC (note 2) . . . . . . . . . . . . . . . . . . . . .18-002830-210 Front Panel Assembly (without overlay): with hinge. . . . . . . . . . . . . . . . . . . . . . . . .15-300200-003 hinge only . . . . . . . . . . . . . . . . . . . . . . . .50-002431-001 Front Panel Overlays: Antisurge Controller . . . . . . . . . . . . . . . . .50-001280-001 Performance Controller . . . . . . . . . . . . . .50-001290-001 Dual-Loop A/P Controller. . . . . . . . . . . . .50-001291-001 Speed Controller . . . . . . . . . . . . . . . . . . .50-001270-001 Extraction Controller . . . . . . . . . . . . . . . .50-001271-001 Fuel Controller . . . . . . . . . . . . . . . . . . . . .50-001272-001 Fuses: AC or DC Power Supply (2.5 A. Fast) . . .20-401800-025 CPU PCB (3.0 A. Slow) . . . . . . . . . . . . . .20-401820-030 FTA 50 mA . . . . . . . . . . . . . . . . . . . . . . . .20-401830-500 FTA 100 mA . . . . . . . . . . . . . . . . . . . . . . .20-401830-101 FTA 250 mA . . . . . . . . . . . . . . . . . . . . . . .20-401830-251 FTA 1.0 A . . . . . . . . . . . . . . . . . . . . . . . . .20-401830-102 FTA 5.0 A . . . . . . . . . . . . . . . . . . . . . . . . .20-401830-502 Power Cables (note 3): for AC Power Supply . . . . . . . . . . . . . . . .18-002542-120 for DC Power Supply . . . . . . . . . . . . . . . .18-002542-024 Power Supply Assemblies: 21-to-32 Vdc . . . . . . . . . . . . . . . . . . . . . .50-202401-001 96-to-264 Vac. . . . . . . . . . . . . . . . . . . . . .50-202400-001
Engineering Panel: Assembly with Keypad . . . . . . . . . . . . . . 15-300400-001 Engineering Keypad . . . . . . . . . . . . . . . . 50-002551-001 1. CPUs and EEPROMs are preloaded with test software. Any control application can be downloaded from a PC running the Series 3 Plus Configu ator program. 2. Standard high-density interconnect cable is 10 feet long with two right-angle connectors. Two are required for each turbine controller (one for FIM, one for FOM). Custom lengths will be quoted on request. 3. Standard power cables are 14 feet long with two back-panel connectors, which will yield one long or two short cables. Longer cables will be quoted on request.
DS300/P (6.2.1)
Page 1 of 2
February 2009
Side Views of Series 3 Plus Controller Showing Locations of Major Assemblies
Front Panel Assembly
Case
Mounting Slide
Slide Adjuster
Rear Panel Assembly Power Supply Assembly Auxiliary PCB Assembly
Engineering Panel Assembly Analog PCB Assembly CPU PCB Assembly
Auxiliary PCB Daughter Card
DS300/P (6.2.1)
L Printed in U.S.A.
Page 2
February 2009
COMPRESSOR CONTROLS CORPORATION 4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
DS300/H
Series 3 Plus Compressor Controllers Hardware Specifications
Series 3 Plus Series 3 Plus Compressor Controllers Hardware Specification
Analog Inputs Eight isolated, floating-ground (up to 10 Vdc) inputs. Standard combinations include: • all channels 1-to-5 Vdc (360 kΩ impedance); • all channels 4-to-20 mAdc (100 Ω impedance); Optional Field Termination Assembly uses all 1-to-5 Vdc inputs. Consult the factory for information on optional custom configurations.
Discrete Five single-pole relays, each rated Outputs 1 A at 28 Vdc, jumper-selectable as normally-open or normally-closed. Power Supply Power supply automatically adjusts to a wide range of input voltages: • 21 to 32 Vdc, or • 96 to 264 Vac, 50 to 60 Hz Maximum power consumption is 35 Watts, including transmitter power. Power Cable One 14 ft. (4.3 m) cable per pair of controllers, both ends compatible with selected power supply. AWG 18 (0.8 mm2) conductors.
Analog Outputs One or two analog outputs, each factory-configured for either: • 4-to-20 mAdc, 0 to 750 Ω load impedance, or • 0-to-5 Vdc, 2 kΩ to 200 kΩ load impedance. Controllers may be configured for output reliability tracking. Upper and lower limits can be independently configured at any 0.1 % multiple of full scale.
Transmitter Isolated, regulated, short-circuitPower protected 24 ± 1.2 Vdc, 250 mA maximum; supplies up to 8 external transmitters
Serial Ports Two serial ports for communicating with other CCC devices. Two serial ports with optional support for Modbus communications: • EIA RS-422/485 compatible • asynchronous, bi-directional, fi e line interface: RX+, RX–, TX+, TX–, GND • 4000 ft. (1200 m) maximum cable length • up to 32 transceivers per circuit • 4800, 9600, or 19.2k baud • 8 data bits, 1 start bit, 1 stop bit (odd, even, or no parity) Discrete Inputs Seven inputs with common return, each rated at 30 Vdc (maximum), 2.2 kΩ resistance. Energized state: +10 to +30 Vdc; De-energized state: 0 to +2 Vdc.
April 2010
Field Wiring Removable back-panel compresTerminals sion terminals accept AWG 18 to AWG 14 (0.8 to 2.0 mm2) wire. Optional Field Input/Output Module (see DS300/T) can be mounted up to 100 feet from controller. Power Failure System program and configuration Protection parameters stored in non-volatile EEPROM; process variables stored in RAM with about a five-minute capacitor backup capacity. Scan Time 40 milliseconds. Inputs are sampled every 5 milliseconds. Program Controller software can be updated Updating via serial communications from PC running Download software. Manual Control Output signal(s) and controller set points can be set at any 0.1 % multiple of full scale. Bumpless transfer between automatic and manual operation or between local and remote set point.
Page 1 of 2
Parameter Front panel swings out to provide Setting access to configuration parameter keyboard and 8 character display. Optional Toolbox software allows setup from IBM-compatible PC. DS300/H (6.0.3)
Standard Back Panel
Dimensions Top View
CH 1 + –
CH 2 + –
CH 3 + –
CH 4 + –
OUT 1 +
OUT 2 +
CH 5 + –
CH 6 + –
CH 7 + –
CH 8 + –
CR1 1 2
CR2 1 2
CR3 1 2
CR4 1 2
CR5 1 2
DISCRETE IN D1 D2 D D3 D4 D5
Slide
Pressure Screw Slide Clamp
2.96 75.2
2.68 68.1
19.04 484
1.0 26
Side View PORT 1 TX/RX 1 + –
PORT 2 TX2 RX2 + – 2 + –
PORT 3 TX3 RX3 3 + – + –
TX5 + –
PORT 5
NOT USED
24VDC DISCRETE + – D6 D7
PORT 4 TX4 RX4 4 + – + –
RX5 + –
6.00 153
96-264 VAC 21-32 VDC
TB6
Port 5 - Not Used MADE IN USA
5.50 140
Front Bezel
N GRD H 35 W max
Power Cord
Dimensions given in inches and millimeters
Nameplate 0.42 x 2.56 in. (10.7 x 65 mm) label (Optional) that can accommodate one line of 14-pt type (about 17 characters) or two lines of 10-pt type (about 22 characters each). Ambient Operating Temperature: 32 to 122°F (0 to 50°C). Conditions Storage Temperature: –13 to + 185°F (–25 to +85°C). Relative Humidity: 0 to 95% (if free from condensation).
Mounting Cutout Width: 2.70 in. (68.6 mm) Dimensions Tolerance: +0.02 in. (0.5 mm)/–0.00 Cutout Height: 5.60 in. (142.2 mm) Tolerance: +0.03 in. (0.8 mm)/–0.00 Cabinet Depth: 22 in. (56 cm) from front of panel. Observed MTBF 395000 hours (45.1 years) Electrical Ordinary, non-hazardous areas. Classifications Approved by CE, CSA, and City of L.A.
Weight 7.5 lb (3.4 kg).
April 2010
L Printed in U.S.A.
Page 2 of 2
DS300/H (6.0.3)
COMPRESSOR CONTROLS CORPORATION
4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
DS307/H
Series 3 Plus Turbine Controllers Hardware Specifications
U
Series 3 Plus
Turbine Controllers Hardware Specification
Speed Inputs Standard controller has three frequency inputs for 30-to-16 kHz magnetic pickup signals: • minimum 1.5 V peak-to-peak signal for passive pickups • minimum 8.0 V peak-to-peak signal for active pickups Ratio of pulses per revolution is user-configurable. Position Inputs Standard controller has no valve position inputs, but it can read a frequency signal modulated onto Analog Output 1 (for example, a Rosemont 3311 pneumatic transducer’s pressure feedback signal). Extended I/O controller also has one five-wire Linear Variable Displacement Transformer (LVDT) and one –20 to +20 mA, 250 Ω position input. Discrete Inputs Standard controller has nine discrete inputs (D1 to D9), all of which share a common ground. Extended I/O controller has two groups of eight inputs. DI 1 to 8 have individual grounds. DI 9 to 16 share a common return. All inputs rated at 30 Vdc (max.), 2.2 kΩ resistance. Energized state: +10 to +30 Vdc; De-energized state: 0 to +2 Vdc. User defines function of each input (redundant inputs can be defined for any function).
Analog Inputs Standard controller has four isolated, floating-ground (≤ 10 Vdc) inputs. All four are set up for either 5 Vdc signals (360 kΩ impedance) or 4 to 20 mAdc (100Ω impedance) by setting Analog PCB jumpers. Extended I/O controllers have eight 5 Vdc inputs, any or all of which can be converted for 4-to-20 mA signals by installing 250 Ω dropping resistors on the Field Input Module (see DS307/T). Analog Outputs Output 1: Current-loop driver that can generate any needed signal up to 200 mA. This output may be configured for internal reliability tracking. Outputs 2 and 3: Two analog outputs that are provided as both current-loop and voltage signals (use only one signal per channel): • 4-to-20 mAdc, 0 to 750 Ω load impedance, or • 0-to-5 Vdc, 2 kΩ to 200 kΩ load impedance.
Discrete Standard controller has eight Outputs single-pole relays, each rated 1A at 28 Vdc, jumper-selectable as normally-open or normally-closed. Function of each output is user defined. Extended I/O controllers have nine discrete outputs.
DS307/H (6.0.4)
Page 1 of 4
Serial Ports Two serial ports for communicating with other CCC devices. Two serial ports with optional support for Modbus communications: • EIA RS-422/485 compatible • asynchronous, bi-directional, fi e line interface: RX+, RX–, TX+, TX–, GND • 4000 ft. (1200 m) maximum cable length • up to 32 transceivers per circuit • 4800, 9600, or 19.2k baud • 8 data bits, 1 start bit, 1 stop bit (odd, even, or no parity)
September 2009
Power Supply Power supply automatically adjusts to a wide range of input voltages. Available options are: • 21 to 32 Vdc, or • 96 to 264 Vac, 50 to 60 Hz Maximum power consumption is 35 Watts, including transmitter power. Power Cable AWG 18 (0.8 mm2) conductors. One 14 ft. (4.3 m) cable is supplied per pair of controllers, both ends are plug compatible with specified power supply. Custom cables are available.
Extended I/O Back Panel MADE IN USA
1
4
INPUTS (J1) 60
63
1
OUTPUTS (J2) 63
21-32 VDC
N
G
Field Wiring Standard controller back panel has Terminals removable compression terminals that accept AWG 18 to AWG 14 (0.8 to 2.0 mm2) wire. Extended I/O controllers are usually supplied with two Field Termination Assemblies (see DS307/T) that connect to the controller via HighDensity Interconnect Cables (HDIC) fitted with CPC-23/63 connectors. Standard HDICs are 10 ft. (3 m) long. Custom cables can be made in any length up to 100 ft. (30 m). Extended I/O controllers can be ordered without FTAs. The HDICs are then supplied with CPC plugs on one end and unterminated, color-coded AWG 24 (0.2 mm2) conductors on the other (see page 3 for pinouts). Power Failure System program and configuration Protection parameters stored in non-volatile EEPROM; process variables stored in RAM with about a five-minute capacitor backup capacity. Parameter Front panel swings out to provide Setting access to configuration parameter keyboard and 8 character display. Optional Toolbox software allows setup from IBM-compatible PC.
4
60
Transmitter Isolated, regulated, short-circuitPower Supply protected 24 ± 1.2 Vdc, 250 mA maximum; supplies up to 8 external transmitters
H
96-264 VAC
Program Input signals sampled every 5 Execution milliseconds; output signals Speed updated every 40 milliseconds. Optional valve positioning loop executes once per millisecond. Program Controller software can be updated Updating via serial communications from PC running Download software. Manual Control Output signal(s) and controller set points can be set at any 0.1% multiple of full scale.
35 W max
Page 2 of 4
September 2009
Data Cable Conductor and Pin Assignments The FIM and FOM connect to the Controller Back Panel using High-Density Interconnect Cables (HDICs) with CPC-23/63 connectors. For extended I/O controllers ordered without FTAs, the HDICs are supplied with a CPC plug on one end and unterminated, color-coded AWG 24 (0.2 mm2) conductors on the other. Input Signal
+ Color
+ Pin
– Color
Analog Input 1 Analog Input 2
– Pin
Orange/Brown
58
Brown/Orange
59
Brown/White
41
White/Brown
42
Analog Input 3
Black/Brown
33
Brown/Black
34
Analog Input 4
Blue/Gray
35
Gray/Blue
Analog Input 5
Green/White
49
Analog Input 6
Black/Orange
56
Analog Input 7
Black/Green
51
Analog Input 8
Orange/Green
Output Signal
+ Color
+ Pin
– Color
– Pin
Current Output 1
Blue/Green
Current Output 2
Yellow/Green
19
Green/Blue
18
1
Green/Yellow
2
Current Output 3
Yellow/Orange
3
Orange/Yellow
4
36
Diagnostic Port
Gray/Black
17
Black/Gray
16
White/Green
50
Orange/Black
57
Discrete Output 1
Brown/Red
37
Red/Brown
38
Discrete Output 2
White/Gray
39
Gray/White
40
Green/Black
52
Discrete Output 3
Red/Green
30
Green/Red
31
43
Green/Orange
44
Discrete Output 4
Orange/Violet
28
Violet/Orange
29
Auxiliary Input
Brown/Yellow
32
Violet/Brown
53
Discrete Output 5
Violet/Blue
20
Blue/Violet
21
Discrete Input 1
Yellow/Blue
8
Blue/Yellow
9
Discrete Output 6
Yellow/Gray
12
Gray/Yellow
13
Discrete Input 2
Yellow/Orange
3
Orange/Yellow
4
Discrete Output 7
Blue/White
22
White/Blue
23
Discrete Input 3
Black/Gray
16
Gray/Black
17
Discrete Output 8
Red/Orange
14
Orange/Red
15
Discrete Input 4
Green/Brown
10
Brown/Green
11
Discrete Output 9
Green/Brown
10
Brown/Green
11
Discrete Input 5
Green/Blue
18
Blue/Green
19
Instrument Ground
Yellow/Brown
5
Discrete Input 6
Orange/White
24
White/Orange
25
Instrument Ground
Violet/Brown
53
Discrete Input 7
Yellow/Green
1
Green/Yellow
2
MPU 6
on FIM
Red/Gray
48
Discrete Input 8
Green/Gray
26
Gray/Green
27
Port 1 Tx/Rx
Orange/Green
43
Green/Orange
44
Discrete Input 9
Blue/Red
7
Blue/Violet
21
Port 1 Common
Gray/Blue
36
Discrete Input 10
Red/Blue
6
Blue/Violet
21
Port 2 Rx
Black/Green
51
Green/Black
52
Discrete Input 11
Orange/Red
15
Blue/Violet
21
Port 2 Tx
Green/White
49
White/Green
50
Discrete Input 12
Red/Orange
14
Blue/Violet
21
Port 2 Common
Brown/Orange
59
Discrete Input 13
Gray/Yellow
13
Blue/Violet
21
Port 3 Rx
Gray/Green
27
Green/Gray
26
Discrete Input 14
Yellow/Gray
12
Blue/Violet
21
Port 3 Tx
White/Orange
25
Orange/White
24
Discrete Input 15
White/Blue
23
Blue/Violet
21
Port 3 Common
Blue/Gray
35
Blue/Violet
21
Port 4 Rx
Orange/Gray
62
Gray/Orange
63
Port 4 Tx
Black/Orange
56
Orange/Black
57
Blue/Orange
61
Discrete Input 16
Blue/White
22
Instrument Ground
Yellow/Brown
5
LVDT1 Exc
Gray/White
40
White/Gray
39
Port 4 Common
Orange/Brown
58
LVDT 1 Ret
Red/Brown
38
Brown/Red
37
Port 5 Rx
Orange/Blue
60
MPU 1
Black/Blue
54
Blue/Black
55
Port 5 Tx
Black/Blue
54
MPU 2
Orange/Blue
60
Blue/Orange
61
Spare –
MPU 3
Orange/Gray
62
Gray/Orange
63
Voltage Output 2
Yellow/Blue
MPU 4
Green/Violet
45
Violet/Green
46
Voltage Output 3
48
MPU 5
Gray/Red
47
Red/Gray
MPU 6
Violet/Blue
20
on FOM
24 Vdc Out
Violet/Orange
29
Orange/Violet
Pin 21 (Blue/Violet) is a shared return for Discrete Inputs 9 through 16
DS307/H (6.0.4)
Blue/Black
55
Violet/Brown
53
8
Yellow/Brown
5
Blue/Yellow
9
Yellow/Brown
5
15 Vdc Out
Green/Violet
45
Violet/Green
46
24 Vdc Out
Red/Blue
6
Blue/Red
7
28 Voltage Outputs can be returned on either instrument ground (pin 5 or 53).
Page 3 of 4
Standard Back Panel CH 1 + –
CH 2 + –
CH 3 + –
CH 4 + –
OUT 1 +
OUT 3 +
CR1 1 2
CR2 1 2
CR3 1 2
CR4 1 2
CR6 1 2
CR7 1 2
CR9 1 2
Dimensions Top View
OUT 2 +
Slide
Pressure Screw Slide Clamp
2.96 75.2
CR5 1 2
DISCRETE IN D1 D2 D D3 D4 D5
2.68 68.1
19.04 484
1.0 26
Side View PORT 1 1 TX/RX + –
PORT 2 TX2 RX2 + – 2 + –
PORT 3 TX3 RX3 3 + – + –
FREQ1 + –
FREQ2 + –
24VDC DISCRETE +
–
D6 D7
DISCRETE PORT 4 D8 D9 TX4 RX4 4 + – + –
FREQ3 + –
6.00 153
96-264 VAC 21-32 VDC
TB6 MADE IN USA
5.50 140
Front Bezel
N GRD H 35 W max
Dimensions given in inches and millimeters
Nameplate 0.42 x 2.56 in. (10.7 x 65 mm) label (Optional) that can accommodate one line of 14-pt type (about 17 characters) or two lines of 10-pt type (about 22 characters each). Ambient Operating Temperature: 32 to 122°F (0 to 50°C). Conditions Storage Temperature: –13 to + 185°F (–25 to +85°C). Relative Humidity: 0 to 95% (if free from condensation).
Power Cord
Mounting Cutout Width: 2.70 in. (68.6 mm) Dimensions Tolerance: +0.02 in. (0.5 mm)/–0.00 Cutout Height: 5.60 in. (142.2 mm) Tolerance: +0.03 in. (0.8 mm)/–0.00 Cabinet Depth: 22 in. (56 cm) from front of panel. Observed MTBF 395000 hours (45.1 years) Electrical Ordinary, non-hazardous areas. Classifications Approved by CE, CSA, and City of L.A.
Weight 7.5 lb (3.4 kg).
DS307/H (6.0.4)
L Printed in U.S.A.
Page 4
September 2009
COMPRESSOR CONTROLS CORPORATION 4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
DS300/T
Series 3 Plus Compressor Controllers Field Termination Assemblydata sheet
Series 3 Plus
U
Compressor Controllers Field Termination Assembly
The Field Termination Assembly (FTA) for Series 3 Plus Compressor Controllers is known as the Field Input Output Module (FIOM). It provides terminals for all of their analog, discrete, and serial communication input and output channels.
Mounting Options 3.25" (82 mm)
3.0" (76 mm)
DIN EN 50 035 (TS 32)
DIN EN 50 022 (TS 35)
Note: FIOM is discontinued and no longer available.
Specifications Jumper Blocks Configuration options are selected using programmable header packs that mount in DIP sockets (CCC part #20-000003-0XX, where XX is the number of pins). Fuses Plug-in, 125V microfuses (Littel Fuse PN 273-XXX or equivalent). Recommended amperage clearly labeled next to each socket. Field Terminals Compression terminals accepting AWG 18 (0.8 mm2) to AWG 12 (3.3 mm2) wire. Weight 2.5 lb (1.1 kg).
24 Vdc Power Source The FIOM has three onboard 24 Vdc po wer circuits , one each f or its analog inputs , discrete inputs , and discrete outputs. The discrete output power circuit can be supplied only b y an e xternal source connected to terminals 31 and 32 of TB6. The other two can also be supplied from that source , or from the controller’ s transmitter po wer output (see DS300/H f or that circuit’s maximum load). 24 Vdc
24 Vdc
(to DO circuits) –
+
+
F2
F1
24 Vdc
(to DI circuits)
(to AI circuits)
–
+
12
11
10
9
8
7
1
2
3
4
5
6
F3
31
F4
(external)
DS300/T (6.0.6)
F5
32
24 Vdc
Fuses:
–
F1: 100 mA F2: 5 A F3: 250 mA F4: 100 mA F5: 250 mA F6: 250 mA
J B 9
(from controller)
To power the discrete inputs only from the internal source, break the 1/12 jumper. To power them from the external source only, break the 4/9 jumper. To power the analog inputs only from the internal source, break the 2/11 jumper. To power them from the external source only, break the 5/8 jumper. If the two power sources are isolated (by breaking either the 6/7 or the 3/10 connection), the analog and discrete inputs must use the same power source.
Discrete Input Circuits Other than selecting the po wer source , the discrete input circuits are not configu able. Each is protected by a 50 mA fuse (DI1 to DI7), and the total current f or all seven is limited by fuses F1 and/or F4 (100 mA). To complete one of these circuits , install a dr y contact across the appropriate terminal of TB10 or TB11 (minimum current capacity: 5 mA at 30 Vdc): 50 mA
F6
35
24 Vdc
These selections are made by severing jumpers in the JB9 programmable header. All six connections will normally be left intact, in which case both circuits can draw power from either diode-protected source.
+
24 Vdc (from JB9)
36 –
Dry Contact Discrete Input (in controller)
24 Vdc
(from controller)
Page 1 of 4
April 2010
Discrete Output Circuits Each discrete output circuit has a jumper block (JB3 to JB7) that configures it to use either its wn po wer source or the e xternal source from ter minals 31 and 32; and to use either the onboard 1.0 amp fuse (DO1 to DO5) or provide one of its own. Leaving all of the jumpers intact selects an unfused, internally-powered circuit configuration. To utilize the onboard fuse, sever both the 1/8 and 4/5 jumpers. To utilize an external power source (rather than that from terminals 31 and 32), cross connect pins 3 and 7 (use header #18-000008-001 if externally-fused and #18-000008-002 if internally-fused): DO 1 (in controller)
1.0 Amp
8
7
6
5
1
2
3
4
96 TB11 97 + –
Internally Fused 24 Volt Output
J B 3
1.0 Amp
DO 3 (in controller)
8
7
6
5
1
2
3
4
To use the power source selected by JB9, connect the 20 mA transmitter across that input’s 24 V+ and CH+ terminals and leave its JB8 jumper intact.
24 Vdc (from JB9)
DO 2 (in controller)
24 Vdc
In the more likely event that a 4-to-20 mA transmitter is used, you can convert its signal to the required voltage by installing a 250 Ω dropping resistor in the corresponding position of RH1 or RH2. If it includes its own power source, the circuit should be connected across the CH+ and CH– terminals and its JB8 connection should be severed.
Finally, you can include a DCS input in an internallypowered 4-to-20 mA input circuit by severing the corresponding JB8 connection.
Externally Fused 24 Volt Output
(on-board)
sponding resistor from configuration block RH1 or RH2 and severing the corresponding JB8 connection. The transmitter is then connected across that input’s CH+ and CH– terminals on TB7, TB8, or TB9.
J B 4
24 Vdc (from JB9)
CH 1 (in controller) 50 mA
42
+
CH 5 (in controller)
–
43
44
45
24 Vdc
(on-board)
46
1.0 Amp
7
1
2
6
3
100 TB11 101 + –
5
4
J B 5
Externally Fused Dry Contact Output
50 mA
67 8
Internally Fused Dry Contact Output
1.0 Amp
1
7
2
6
3
102 TB11 103 + –
5
4
J B 6
24 Vdc
(on-board)
Analog Input Circuits Each analog input can be set up for either a 20 mA or 5 Vdc signal and can include its o wn power supply or use the onboard source selected by JB9. Special provisions ha ve also been made f or including a second device (such as a DCS input) in the 20 mA circuits. When used with an FIOM, the controller’s analog inputs are internally configured for 5 Vdc signals. Voltage inputs can thus be set up by omitting the correPage 2 of 4
+ Xmtr –
66
Shield
24 Vdc (from JB9) CH 3 (in controller) 50 mA
RH2-2 JB8-6
69
65
Xmtr
–
68
64
20 mA Transmitter, Externally Powered
DO 4 (in controller)
24 Vdc
(on-board)
– RH2-1 JB8-5
63 –
CH 6 (in controller) +
+
+
5 Volt Transmitter 24 Vdc (from JB9)
8
62
Shield
+ Xmtr – 98 TB11 99 + –
50 mA
RH1-1 JB8-1
70
71
Shield + DCS –
20 mA Transmitter, Internally Powered, with DCS
52
+
– RH1-3 JB8-3
53
54
55
56
Shield
+ Xmtr –
20 mA Transmitter, Internally Powered
Serial Port Connections Serial por ts 1 through 4 of the controllers in an y one panel can be connected via the ser ial b us. Terminal Blocks TB1 through TB4 should be used to connect controllers in different panels. TB5 Port 5 is not used. The serial bus is wired by using ribbon cables to connect each FTA’s Bus Output (J5) connector to the next FTA’s Bus Input (J4). However, do not create a loop by connecting the last FTA’s J5 to the first’s J4. Removing a given port’s configuration header (for example, JB10 for Port 1) disconnects that port from April 2010
Field Input/Output Module 4.3" 10.9 cm
Field Wiring Terminals 7 8 9 10 11 12
Port 2 TX + Port 2 TX – Port 2 Common Port 2 RX + Port 2 RX – Port 2 Shield
19 20 21 22 23 24
Port 4 TX + Port 4 TX – Port 4 Common Port 4 RX + Port 4 RX – Port 4 Shield
31 32 33 34 35 36
24 Vdc In + 24 Vdc In – Shield Ground Shield Ground 24 Vdc Out + 24 Vdc Out –
52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
Analog In 3, 24V + CH 3 + CH 3 – Analog In 3, 24 V – Analog In 3, Shield Analog In 4, 24V + CH 4 + CH 4 – Analog In 4, 24 V – Analog In 4, Shield Analog In 5, 24V + CH 5 + CH 5 – Analog In 5, 24 V – Analog In 5, Shield
67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
Analog In 6, 24V + CH 6 + CH 6 – Analog In 6, 24 V – Analog In 6, Shield Analog In 7, 24V + CH 7 + CH 7 – Analog In 7, 24 V – Analog In 7, Shield Analog In 8, 24V + CH 8 + CH 8 – Analog In 8, 24 V – Analog In 8, Shield
94 95 96 97 98 99 100 101 102 103 104 105
Discrete In 7 Fuse Discrete In 7 Discrete Out 1 + Discrete Out 1 – Discrete Out 2 + Discrete Out 2 – Discrete Out 3 + Discrete Out 3 – Discrete Out 4 + Discrete Out 4 – Discrete Out 5 + Discrete Out 5 –
TB4
TB6
TB8
TB1
SW1
1 2 3 4 5 6
Port 1 TX/RX + Port 1 TX/RX – Port 1 Common No Connection No Connection Port 1 Shield
13 14 15 16 17 18
Port 3 TX + Port 3 TX – Port 3 Common Port 3 RX + Port 3 RX – Port 3 Shield
JB10
TB5
JB12
25 26 27 28 29 30
Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Analog Out I1 + Analog Out I1 – Shield Analog Out I2 + Analog Out I2 – Analog In 1, 24V + CH 1 + CH 1 – Analog In 1, 24 V – Analog In 1, Shield Analog In 2, 24V + CH 2 + CH 2 – Analog In 2, 24 V – Analog In 2, Shield
TB3
J2: J3: J4:
JB2 J4
J5:
JB1
J6:
Port 3 (DB-9) Port 4 (DB-9) Serial Bus In (20-pin ribbon) Serial Bus Out (20-pin ribbon) Signal Cable (CPC-23/63)
Switches for Serial Port Termination Resistors
Jumper Blocks
J5
JB11
JB13
JB1: JB2: JB3: JB4: JB5: JB6: JB7: JB8: JB9: JB10: JB11: JB12: JB13:
J2
TB7
Serial Bus Other Serial Bus Master Discrete Output 1 Discrete Output 2 Discrete Output 3 Discrete Output 4 Discrete Output 5 Analog Inputs 24 Vdc Power Serial Port 1 Serial Port 2 Serial Port 3 Serial Port 4
J3
17.2" 43.7 cm
TB2
Service Connectors
JB9
Fuses for 24 VDC Power Fuses for Analog Inputs
TB9
TB11
J6
If shields are used, ground terminals 33 and 34. Common for Port 5 and returns for current loop outputs (I1–/I2–) are tied to the controller's internal ground. Commons for Ports 1 to 4 are isolated.
82 83 84 85 86 87 88 89 90 91 92 93
JB8 RH1 RH2
TB10
Discrete In 1 Fuse Discrete In 1 Discrete In 2 Fuse Discrete In 2 Discrete In 3 Fuse Discrete In 3 Discrete In 4 Fuse Discrete In 4 Discrete In 5 Fuse Discrete In 5 Discrete In 6 Fuse Discrete In 6
250W Resistor Headers for 4-to-20 mA Analog Inputs: RH1-1: CH 1 RH1-2: CH 2 RH1-3: CH 3 RH1-4: CH 4 RH2-1: CH 5 RH2-2: CH 6 RH2-3: CH 7 RH2-4: CH 8 Fuses for Discrete Outputs
JB3 JB4 JB5 JB6 JB7 Fuses for Discrete Inputs
DS300/T (6.0.6)
Page 3 of 4
Data Cable Conductors and Pins
Extended I/O Back Panel
The FIOM connects to the Extended I/O Back Panel using a High-Density Interconnect Cable (HDIC) with CPC-23/63 connectors on both ends. For controllers ordered with the Extended I/O Back but not the FIOM, the HDIC is supplied with a CPC plug on one end and unterminated, color-coded AWG 24 (0.2 mm 2) conductors on the other.
MADE IN USA
1
4
INPUTS/ OUTPUTS (J1) 60
Input Signal
+ Color
+ Pin
– Color
– Pin
Analog Input 1
Blue/White
22
White/Blue
23
Analog Input 2
Orange/White
24
White/Orange
25
Analog Input 3
Green/Gray
26
Brown/Black
34
Analog Input 4
Orange/Violet
28
Violet/Orange
29
Analog Input 5
Red/Green
30
Green/Red
31
Analog Input 6
Brown/Yellow
32
Black/Brown
33
Analog Input 7
Blue/Gray
35
Gray/Blue
36
Analog Input 8
Brown/Red
37
Red/Brown
38
Analog Output 1
Blue/Green
19
Gray/Green
27
Analog Output 2
Violet/Blue
20
Blue/Violet
21
Discrete In 1
Yellow/Gray
12
Brown/Green
11
63
Discrete In 2
Gray/Yellow
13
Brown/Green
11
Discrete In 3
Red/Orange
14
Brown/Green
11
Discrete In 4
Orange/Red
15
Brown/Green
11
Discrete In 5
Black/Gray
16
Brown/Green
11
Discrete In 6
Gray/Black
17
Brown/Green
11
Discrete In 7
Green/Blue
18
Brown/Green
11
Discrete Out 1
Yellow/Green
1
Green/Yellow
2
Discrete Out 2
Yellow/Orange
3
Orange/Yellow
4
H
Discrete Out 3
Yellow/Brown
5
Red/Blue
6
96-264 VAC
Discrete Out 4
Blue/Red
7
Yellow/Blue
8
Discrete Out 5
Blue/Yellow
9
Green/Brown
10
Gray/Red
47
21-32 VDC
N
G
35 W max the bus output connector (J5), thus dividing its portion of the bus into independent segments. This means, for example, that controllers sharing a single Port 2 network can be divided into several Port 1 networks. On each FIOM, enable the terminating resistor for each port whose bus segment begins or ends there. For systems utilizing Port 2, the master controllers (one per bus segment) must be identified by placing an intact header in jumper block JB2. All other controllers must have a header in JB1. Installing headers in both JB1 and JB2 will damage the controller! Host connections for the RS-485 Modbus ports can be made via terminal blocks TB3 and TB4 or DB-9F connectors J2 and J3. The DB-9 pinouts are: Common: Pin 1 Rx+: Pin 4 Tx+: Pin 8 Rx–: Pin 5 Tx–: Pin 9 DS300/T (6.0.6)
L Printed in U.S.A.
Serial Port 1 Tx/Rx
Violet/Green
46
Port 1 Isolated Ground
Green/Violet
45
Serial Port 2 Tx
Red/Gray
48
Green/White
49
Serial Port 2 Rx
White/Green
50
Black/Green
51
Port 2 Isolated Ground Brown/Orange
59
Serial Port 3 Tx
White/Brown
42
Orange/Green
43
Serial Port 3 Rx
Green/Orange
44
Green/Black
52
Port 3 Isolated Ground
Brown/White
41
Serial Port 4 Tx
Violet/Brown
53
Black/Blue
54
Serial Port 4 Rx
Blue/Black
55
Black/Orange
56
Port 4 Isolated Ground
Orange/Black
57
Serial Port 5 Tx
Orange/Blue
60
Blue/Orange
61
Serial Port 5 Rx
Orange/Gray
62
Gray/Orange
63
Gray/White
40
24 Vdc Out
White/Gray
39
Instrument Ground
Orange/Brown
58
Pin 11 (Brown/Green) is a shared return for Discrete Inputs 1 to 7
Page 4
April 2010
COMPRESSOR CONTROLS CORPORATION 4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
DS307/T
Series 3 Plus Turbine Controllers Field Termination Assemblydata sheet
Series 3 Plus
U
Turbine Controllers Field Termination Assembly
Standard Series 3 Plus Turbine Controllers have two rail-mounted Field Termination Assemblies (FTAs) that connect to the controller via High-Density Interconnect Cables (HDICs) with CPC-23/63 connectors.
Mounting Options 3.25" (82 mm)
3.0" (76 mm)
DIN EN 50 035 (TS 32)
DIN EN 50 022 (TS 35)
The Field Input Module (FIM) provides terminals for the analog, discrete, frequency, and position inputs, while those for the discrete and analog outputs and serial communication channels are located on the Field Output Module (FOM). This document describes those modules and their I/O circuit wiring options. Turbine Controllers can also be ordered without the FTAs. In that case, the HDICs are supplied with CPC plugs on one end and unterminated, color-coded AWG 24 (0.2 mm 2) conductors on the other (see DS307/H for pinouts).
Specifications Jumper Blocks Jumper blocks use soldered-in AWG 22 jumper wires. Fuses Plug-in, 125 V microfuses (Littel Fuse PN 273-XXX or equiv.). Field Terminals Compression terminals accepting AWG 18 (0.8 mm2) to AWG 12 (3.3 mm2) wire. Weight Field Output Module: 2.0 lb (0.9 kg). Field Input Module: 2.5 lb (1.1 kg).
In contrast, the FIM can be configured to obtain its 24 Vdc onboard power from either the controller’s transmitter power output or an external source. This choice can be made by selectively installing diodes and jumpers in its 24 Vdc Jumper Block. In practice, however, it’s simpler to install the diodes and jumpers for both power sources and remove the fuse for the one you’re not using: 24 VDC
A C E G
24 Vdc Power Options The FOM includes an onboard po wer circuit that can be connected to an y of its discrete output circuits . To utilize this f eature, y ou m ust connect an e xternal 24 Vdc power source to terminals 29 and 30:
B D F H
(to I/O circuits)
A
C
E
G
B
D
F
H
1.0 Amp
1.0 Amp
1
2
(in controller)
24 VDC
24 VDC
(from controller)
26
27
Analog Input Options
(to I/O circuits)
28
29
30
Note that the controller’s transmitter power output (available on terminals 26 and 27) does not have sufficient capacity to drive the control relay circuits and should not be used for this purpose. DS307/T (6.0.4)
Each standard analog input circuit includes a jumper block that provides maximum fl xibility in matching the controller’s analog input (AI in these diag rams) to the needs of your application. Five terminals (designated as B, C/E, D/F, H, and Shield) are provided for each input. The controller is internally configured to read the voltage drop across terminals C/E and D/F. Thus, the simplest application
Page 1 of 4
April 2010
is to connect an externally-powered 5 Vdc transmitter to those terminals (62 and 63, for example): B
A C E G 24 VDC
A
B D F H
E
C 50 mA
61 62
F
63
D
64
H
65
DI
Xmtr
B 24 VDC
A
B D F H
E
C 50 mA
66 67
Shield
–
F
68
D
–
+
+
69
H
70
Shield
To use the onboard 24 Vdc to power a 4-to-20 mA transmitter, jumper pin A to B and G to F, then connect the transmitter across the B and C/E terminals: B
A C E G 24 VDC
A
B D F H
E
C 50 mA
81 82
AI (in controller) G
F
+
Xmtr
B 24 VDC
B D F H
C 50 mA
91 92
AI (in controller) G H
F
D
E
C
F 50 mA
93 94 95
–
Terminal Block Connectors
24 Vdc
A
D
B
E
C
F 50 mA
D E F
–
Terminal Block Connectors
Discrete Output Options The discrete output circuits are designed to pro vide maximum fl xibility in matching the controller’ s output relays (CR in these diag rams) to the needs of y our application. Each such circuit includes an onboard fuse to protect the discrete output contacts. If your circuit includes other fuses, this one can be bypassed by installing a jumper between pins A and B of the jumper block: B
A 1.0 A
CR
Shield
+
Xmtr –
B D F H
C
H
D
G
–
Terminal Block Connectors
24 Vdc
You can configure one of these circuits to utilize the FTA’s onboard 24 Vdc by installing jumpers between pins C and D and pins G and H: A C E G
B
A 1.0 A
+ CR
DCS –
Shield
No onboard fuses or wiring options are provided for the analog position (auxiliary or AI9) input. It can be converted to a bipolar 20 mA current-loop circuit only by installing an external 250 Ω dropping resistor.
Discrete Input Options The discrete input circuits can use either the FIM’ s onboard 24 Vdc or a separ ate e xternal source to power each of the controller’ s discrete inputs (DI in these diagrams). To configure one of these circuits t use the onboard 24 Vdc, install jumpers between pins
Page 2 of 4
DI
84 85
E
A B C
A C E G
–
To include a DCS input in such a 4-to-20 mA circuit, jumper pin G to H (instead of F) and connect the DCS input across the D/F and H terminals: A
B
83
D
H
A C E G
D
To configure a discrete input circuit to use a separate external power source, install jumpers between pins A and E and pins B and F:
Xmtr
AI (in controller) G
24 Vdc
A
D E F
–
In the more-likely event that a 4-to-20 mA transmitter is used, you can convert its signal to the required voltage by installing a 250 Ω dropping resistor across pins C and D of the jumper block: A C E G
A B C
+
AI (in controller) G
A and D, B and E, and C and F:
B D F H
C
H
D
G
–
Terminal Block Connectors
24 Vdc
Alternately, if the circuit includes a separate 24 Vdc power source, you should bypass the onboard source by installing a jumper between pins C and H: A C E G
B
A 1.0 A
CR
B D F H
C
H
D
G
–
Terminal Block Connectors
24 Vdc
April 2010
Field Input Module
4.3" 10.9 cm
Field Wiring Terminals Discrete Input 7 + Discrete Input 7 – Discrete Input 8 + Discrete Input 8 – Discrete Input 9 + Discrete Input 9 – Discrete Input 10 + Discrete Input 10 – Discrete Input 11 + Discrete Input 11 – Discrete Input 12 + Discrete Input 12 – Discrete Input 13 + Discrete Input 13 – Unused
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Unused Unused Unused Do Not Use Do Not Use LVDT 1 Exc + LVDT 1 Exc – LVDT 1 Ret + Do Not Use LVDT 1 Ret – MPU 5 – MPU 5 + MPU 4 – MPU 6 + MPU 4 +
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Analog Input 7 B Analog Input 7 C/E Analog Input 7 D/F Analog Input 7 H Shield Analog Input 8 B Analog Input 8 C/E Analog Input 8 D/F Analog Input 8 H Shield Auxiliary Input – Auxiliary Input + Shield LVDT 1 Common Earth Ground
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
Analog Input 4 B Analog Input 4 C/E Analog Input 4 D/F Analog Input 4 H Shield Analog Input 5 B Analog Input 5 C/E Analog Input 5 D/F Analog Input 5 H Shield Analog Input 6 B Analog Input 6 C/E Analog Input 6 D/F Analog Input 6 H Shield
TB4
TB1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
24 VDC In + 24 VDC In – Discrete Input 1 + Discrete Input 1 – Discrete Input 2 + Discrete Input 2 – Discrete Input 3 + Discrete Input 3 – Discrete Input 4 + Discrete Input 4 – Discrete Input 5 + Discrete Input 5 – Discrete Input 6 + Discrete Input 6 – Unused
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Discrete Input 14 + Discrete Input 14 – Discrete Input 15 + Discrete Input 15 – Discrete Input 16 + Discrete Input 16 – MPU 1 + MPU 1 – Shield MPU 2 + MPU 2 – Shield MPU 3 + MPU 3 – Shield
DS307/T (6.0.4)
2 4
The Shield terminals are tied to the Earth Ground terminal, which should be connected to an external earth ground. MPU 6 – is on Field Output Module.
1 3 50 mA
6 8
5 7 50 mA
10 12
TB3
TB5
TB7
50 mA
9 11 50 mA
14 16
13 15 50 mA
1.0 Amp
24 Vdc Jumpers
1.0 Amp
16.0" 40.7 cm
TB2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Discrete Input Jumpers and Fuses
Analog Input Jumpers and Fuses 50 mA
2
1 50 mA
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
TB6
Analog Input 1 B Analog Input 1 C/E Analog Input 1 D/F Analog Input 1 H Shield Analog Input 2 B Analog Input 2 C/E Analog Input 2 D/F Analog Input 2 H Shield Analog Input 3 B Analog Input 3 C/E Analog Input 3 D/F Analog Input 3 H Shield
4
3 50 mA
6
5 50 mA
8
7
Page 3 of 4
Field Output Module
Field Wiring Terminations Port 4 Tx + Port 4 Tx – Port 4 Common Port 4 Rx + Port 4 Rx –
16 17 18 19 20
Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used Port 5 - Not Used
26 27 28 29 30
+ 24 VDC (Out) – 24 VDC (Out) Unused + 24 VDC (In) – 24 VDC (In)
TB4
TB6
TB7
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Current Output 2 + Current Output 2 – Shield Current Output 3 + Current Output 3 – Shield Current Output 1 + Current Output 1 – Shield Voltage Output 2 + Voltage Output 2 – Shield Voltage Output 3 + Voltage Output 3 – Shield
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Discrete Output 8 + Discrete Output 8 – Discrete Output 9 + Discrete Output 9 – +15 VDC Ground – 15 VDC MPU 6 – Spare – Shield Diagnostic Port + Diagnostic Port – Shield Earth Ground Earth Ground
TB9
DS307/T (6.0.4)
L Printed in U.S.A.
TB1
1 2 3 4 5
Port 1 Tx/Rx + Port 1 Tx/Rx – Port 1 Common Unused Unused
11 12 13 14 15
Port 2 Tx + Port 2 Tx – Port 2 Common Port 2 Rx + Port 2 Rx –
21 22 23 24 25
Port 3 Tx + Port 3 Tx – Port 3 Common Port 3 Rx + Port 3 Rx –
TB3
TB5
Discrete Output Jumpers and Fuses 1.0 Amp
The Shield terminals are tied to the Earth Ground terminals, which should be connected to an external earth ground.
12.8" 32.5 cm
TB2
6 7 8 9 10
4.3" 10.9 cm
The Ground terminals are tied to the controller digital ground.
1 1.0 Amp
3
2 1.0 Amp
Commons for Ports 1 to 4 are isolated.
5
4 1.0 Amp
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
TB8
7
Discrete Output 1 + Discrete Output 1 – Discrete Output 2 + Discrete Output 2 – Discrete Output 3 + Discrete Output 3 – Discrete Output 4 + Discrete Output 4 – Discrete Output 5 + Discrete Output 5 – Discrete Output 6 + Discrete Output 6 – Discrete Output 7 + Discrete Output 7 – Unused
6 1.0 Amp
9
Page 4
8
April 2010
COMPRESSOR CONTROLS CORPORATION 4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
DS300/R
U
Series 3 Plus Redundant Control Selectordata sheet
Series 3 Plus
Redundant Control Selector
In many turbomachinery applications, uninterrupted control and protection are so important that on-line, back-up controllers are installed as a hedge against single-point failures. To be most effective, such an approach requires an independent device that can sense when the main controller has failed and automatically transfer control to its back-up.
This scheme assumes the controllers’ normally-energized fault relay contacts will be closed when the controller is working properly. Thus, those relays must be set for normally-open operation by setting the faultrelay jumpers on their CPU PCBs (and Auxiliary PCBs, if so equipped) to the NO position.
For Series 3 Plus Control Systems, the Redundant Control Selector (RCS) provides the perfect answer to this need. In addition to providing isolated switching circuits for as many as sixteen process and control signals, this unit also dovetails perfectly with the controllers’ methods of signaling failure and switching between their active and tracking modes. Each Series 3 Plus Controller is equipped with at least one fault relay that is normally energized. An external device can thus determine when to activate a back-up controller by sensing the state of the main controller’s fault relay. In addition, a Series 3 Plus Controller will operate in a redundant tracking mode when its D1 discrete input is asserted.
REDUNDANT CONTROL SELECTOR
Thus, the RCS provides discrete inputs for sensing the status of both controllers’ fault relays and uses one of its switching circuits to control their D1 inputs: • It maintains a 24 Vdc potential across each of its fault-relay sensing circuits. If no current flow is detected in one of these circuits, the corresponding controller is assumed to have faulted. • The D1 input for the deselected controller is energized, thus causing it to operate in the tracking mode. The D1 input of the selected controller is deenergized, so that it will operate in its active mode.
MAIN Switch to Back-Up
If the main controller faults, the RCS will automatically transfer control of your process to the back-up, provided that its fault-relay circuit is closed. You may also manually select either controller using the push-button switches on the Switching Unit or a Remote Control Panel, again provided its fault-relay circuit is closed. Note that the RCS will never transfer control of your compressor to a controller that appears to have failed (that is, one whose fault-relay circuit is open). This restriction applies to manual as well as automatic operation — any attempt to manually select a failed controller is rejected. Also note that it will not automatically return control of your process to the main controller following a fault — this must be done manually.
BACK-UP Switch to Main GREEN ACTIVE
RED TRACK
Remote Control Panel DS300/R (6.0.4)
Page 1 of 4
October 2007
The RCS uses a primary (or master) relay to control four secondary (or slave) switching relays. When the main controller is selected, the slave relays are deenergized. The COMMON terminal for each signal is then connected to the corresponding RUN terminal. Selecting the back-up controller connects these signals to the TRACKING terminals.
Note that in such an installation, the batteries will not recharge when their voltage is less than that of the primary power input. We recommend against using the 24 Vdc output circuit of a Series 3 Plus Controller to power the Redundant Control Selector. Although the capacity of those circuits is marginally adequate for that use, it would preclude powering any other device (such as your field transmitters) from the 24 Vdc terminals of either the controller or the switching unit.
The Redundant Control Selector also has several reliability features of its own. If it loses power, all four secondary relays will de-energize. Both controllers will then select their active operating mode (assuming they have not also lost power), but only the main controller will be connected to your final control elements.
For more information on setting up and operating redundant controllers, please see Chapter 8 of the Series 3 Plus Hardware Reference manual [IM300/H].
When power is subsequently restored, the magnetically latched primary relay will restore the previous state of the control system by reselecting whichever controller was active when power was lost. The switching unit also has two parallel power input circuits that can be connected to independent sources. We generally recommend connecting one of these inputs to a regulated 24 Vdc power supply and the other to a back-up battery pack. The power supply should then be adjusted to provide a voltage slightly above that of the battery pack, so that the batteries will discharge only when the power supply fails.
Control Panel Mounting Dimensions
.63 16
5.25 133.4 6.0 152.4
24V Pos Trip Reset
1.25 31.8
Backup Main 24V Gnd
.875 22.2
.375 9.5 0.48 12.2
2.00 50.8 2.96 75.2
1.0 25.4 (min.)
1.0 25.4 1.3 33.0
Dimensions given in inches and millimeters. Page 2 of 4
October 2007
Switching Unit Mounting Dimensions
7.25 184
6.75 171
4.25 108
2.8 71
8.75 222
Dimensions given in inches and millimeters.
Major Components of Switching Unit Power Cord Connectors Fuses
Manual Selection Switches
Terminal Block TB5
Relay 1
24V Pos Trip Reset Backup Main 24V Gnd
TB4
Pass-Through 24V Gnd Spares (tied together) Pass-Through 24V Pos
Terminal Blocks TB1 through TB4 ABCD
Relay 2
TB3
ABCD
Control Panel Connections
Fault Relay from Main Controller
Relay 3
Spares (tied together)
ABCD
Terminal Block TB6
TB2
COMMON Terminals (to Process) TRACK Terminals (to Back-Up Controller) RUN Terminals (to MAIN Controller)
TB1
Fault Relay from Back-Up Controller
Relay 4
MAIN LED
Back-Up LED
Wiring Diagram for 24 Vdc Power Cables 24V Gnd (Black or Brown)
Cable Connector
End-Panel Connector
Chassis Ground (White) 24V Pos (Red or Orange)
DS300/R (6.0.4)
Page 3 of 4
Specifications Switching Four 4PDT electro-mechanical Relays slave relays controlled by a magnetically-latched master relay. Slave relay contacts are rated at: 3 A., 28 Vdc (resistive) 3 A., 120 Vac Automatic Unit will select Back-Up Controller Operation when Main Controller’s fault relay opens, provided the Back-Up Controller’s fault relay is closed. The Main Controller can only be reselected manually. Manual Unit will select Back-Up Controller Operation when Control-Panel SWITCH TO BACK-UP button or Switching-Unit TRIP button is pressed, provided the Back-Up Controller’s fault relay is closed. Unit will select the Main Controller when Control-Panel SWITCH TO MAIN button or Switching-Unit RESET button is pressed, provided the Main Controller’s fault relay is closed. Status Bi-color Main and Back-Up LEDs Indicators on both the Control Panel and the Switching Unit are green when the corresponding controller is active and red when it is deselected. The Switching Unit also has five red LEDs (one each for the master and slave relays) that light when the associated relay is energized. Control Panel Momentary-contact, push-button Switches switches for selecting the Main or Back-Up Controller are shrouded to prevent inadvertent operation.
Power Inputs 24 Vdc (± 10%) Two independent power sources can be connected — switching unit circuitry selects source with highest voltage. Each power input is equipped with a 2.0 A., slow-blow fuse and arcsuppression circuitry. Maximum power consumption is 7 W, excluding loads connected to pass-through power outputs. Pass-through Two 24 Vdc pass-through power Power circuits are provided on terminal block TB5. Total load should not exceed 5 W. Power Failure Switching unit automatically selects Protection power source with highest voltage, so unit will continue to function if either power source fails. If both power sources fail, slave relays will de-energize (thus selecting the Main controller) until at least one power source is restored. Magnetically-latched master relay then restores previous controller selection. Nameplate 0.42 x 2.56 in. (10.7 x 65 mm) label that can accommodate one line of 14 point type (about 17 characters) or two lines of 10 point type (about 22 characters each). Maximum Cable connecting Control Panel to Separation Switching Unit can be up to 300 feet in length. Weight Switching Unit: 2.75 lb (1.25 kg) Control Panel: 0.25 lb (0.11 kg)
Wiring Removable compression terminals Terminals accept AWG 18 (1.0 mm) to AWG 14 (1.6 mm) wire.
DS300/R (6.0.4)
L Printed in U.S.A.
Page 4
October 2007
COMPRESSOR CONTROLS CORPORATION 4725 121st Street, Des Moines, IA 50323, USA Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com
FM73
Documentation Feedback Form Publication Title: Series 3 Plus Hardware Reference Manual Publication No.: IM300/H (6.2.4)
Publication Date: April 2010
If you have questions or comments concerning the information provided in this user manual or in any of our technical documents please contact CCC’s Technical Documentation Department: E-mail:
[email protected] Which Series of Controllers do you have, and are you using our TrainTools software? Series 3P/3++ Series 4 Series 5 TrainTools Vibrant Vantage Guardian Air Miser ❒
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