Professional Documents
Culture Documents
278596 Rev. A1
Refer to this publication for complete and accurate information that helps you better operate and service Metso Automation equipment. Your comments and suggestions are welcome. Metso Automation 1180 Church Road Lansdale, PA 19446 Attention: Manager, Technical Publications
Copyright 2004 by Metso Automation MAX Controls, Inc. Printed in the United States of America All Rights Reserved
Contents
PREFACE ............................................................................................................................III CHAPTER 1 ...................................................................................................................... 1-1
maxPAC Input/Output Subsystem ............................................................................................................................1-1 Overview ...................................................................................................................................................................1-1 Model IOP I/O Subsystem.....................................................................................................................................1-1 Cabinet...............................................................................................................................................................1-1 Chassis Assembly ..............................................................................................................................................1-2 DPU Mounting ..................................................................................................................................................1-4 I/O Modules.......................................................................................................................................................1-4 I/O Module Types..............................................................................................................................................1-5 Power Supply.........................................................................................................................................................1-6 Field Termination Options.....................................................................................................................................1-7 Local Terminations (standard)...........................................................................................................................1-7 Remote Terminations (option)...........................................................................................................................1-7 Termination Assemblies ....................................................................................................................................1-7 Installing Model IOP I/O Equipment ....................................................................................................................1-8 Sequence of Mounting Operations ........................................................................................................................1-8 Mounting I/O Chassis Assemblies.........................................................................................................................1-9 Cabling, Power, and Ground Wiring .....................................................................................................................1-9 Supplying 24V Power to the I/O Modules ......................................................................................................1-10 Interconnecting Adjacent I/O Chassis .............................................................................................................1-11 Module Mounting Considerations .......................................................................................................................1-12 I/O Modules .....................................................................................................................................................1-12 DPU Modules ..................................................................................................................................................1-12 Module Addressing .............................................................................................................................................1-13 Backup Configuration Options............................................................................................................................1-14 Shared Configuration.......................................................................................................................................1-14 Redundant Configuration ................................................................................................................................1-15 Mixed Configuration .......................................................................................................................................1-15 Remote I/O ..........................................................................................................................................................1-16 Specifications.......................................................................................................................................................1-18 Environment ....................................................................................................................................................1-18 I/O Bus.............................................................................................................................................................1-18 Inputs/Outputs .................................................................................................................................................1-18
Contents
Analog Output Modules 4-20 mA Output Module IOP320.....................................................................................6-1 LED Indication ......................................................................................................................................................6-1 Bus Address...........................................................................................................................................................6-2 Jumper Configuration ............................................................................................................................................6-2 Module Operation..................................................................................................................................................6-3 Diagnostics ............................................................................................................................................................6-4 Module Specifications ...........................................................................................................................................6-5 Field Wiring...........................................................................................................................................................6-6 Field wiring for redundant modules with common end element ...........................................................................6-7
Contents
Termination Field Connections Channels 1-2 ...................................................................................................12-11 Termination Field Connections Channels 3-4 ...................................................................................................12-12 Group1 Analog I/O Configuration ....................................................................................................................12-13 Group2 Analog I/O Configuration ....................................................................................................................12-14 Digital I/O Configuration Channels 1-2 ............................................................................................................12-15 Digital I/O Configuration Channels 3-4 ............................................................................................................12-16 Digital I/O Configuration - DC Power Switches ...............................................................................................12-17 Specifications.....................................................................................................................................................12-18
vii
Preface
This publication, which describes the installation and operation of maxPAC, assumes familiarity with the DPU and its configuration. For additional information on related topics, refer to the following publications:
Book No. 278590 278705 278561 Book Title Model PDP Series 200 maxDPU4E Hardware Guide Model PDP Series 400 maxDPU4F Hardware Guide System Power and Grounding
Chapter 1
maxPAC Input/Output Subsystem
Overview
The maxPAC Input/Output System links the maxDNA Distributed Control System to real world process control inputs and outputs. The Input/Output system uses a compact design to provide the system with greatly enhanced I/O capacity in relatively little space. A close relationship exists, in turn, between this I/O system and the maxDNA Distributed Processing Unit (DPU) which it serves. The DPU and the I/O modules mount in an I/O chassis assembly. The backplane in the chassis assembly provides the I/O bus connection between the DPU and the I/O modules. It also provides the system power and field power connections to the modules. Multiple I/O chassis that share the I/O bus can be installed in a cabinet.
Chassis Assembly
Three chassis assembly types are available for the installation of the I/O module as follows: IOP382 Eight-pack assembly to accommodate up to eight maxPAC I/O modules. The DPU4F can also reside in this chassis. IOP383 Six-pack assembly to accommodate a DPU4E or a Model 564 I/O module in the right most position along with six maxPAC I/O modules; the DPU4E takes up the equivalent of two maxPAC I/O module positions. IOP381 Four-pack assembly to accommodate four maxPAC or Model 564 I/O modules.
1-2
System 24V
Field 24V
1-3
Description 4-wide frame assembly 8-wide rack assembly 6-wide rack assembly maxPAC Chassis used with IOP381 Model 564 Chassis used with IOP381
DPU Mounting
DPU4E mounts in the right most position of the six-pack chassis assembly. It occupies the equivalent of two I/O modules. Refer to Publication 278590 for DPU4E information. DPU4F mounts mounts in the left most position of the eight-pack chassis assembly. It occupies the equivalent of one I/O module. Refer to Publication 278705 for DPU4F information.
I/O Modules
The I/O modules are rugged enclosed printed circuit board assemblies. The edge connection at the rear of each module provides the interface to the backplane and the I/O bus. System power and field power, when applicable, is also available through this connection. While I/O modules vary by type, they may include one or more of the following: A color bar on the module faceplate identifies the module type. Each module type has a unique color. Euro-style terminal connector blocks for field wiring; each block contains 16 connectors; Rotary address switch; Light Emitting Diodes (LED) for module status indication; All the modules that require field power include a front mounted fuse disconnect and a LED fuse status indication; All discrete modules include front mounted LEDs for input/output logic state; The TC module includes front-end connectors with thermistors to measure the junction temperature for cold junction compensation. The I/O modules may be inserted and withdrawn safely with 24 Vdc and field power applied.
1-4
1-5
Analog Output
Part Number IOP320 Description 4-20 mA common output, 8 channels
Other
Part Number IOP371 IOP336 IOP341 IOP345 Description Optical bus extender QuadPAT, 4 channels Turbine Valve Positioner Turbine Overspeed
Power Supply
The maxDNA Input/Output System uses the Model APS Power Supply Assembly, which provides 24V dc power for Distributing Processing Units and I/O. This Power Supply Assembly consists of a 19-inch rack mount or flush mount chassis accommodating up to six independent 10 amp power supply modules. Metso Automation typically installs the power supply modules in an N + 1 redundancy configuration. Because each module is individually isolated, the chassis can be split to provide both system power and loop power. Power supply features consists of the following: Redundant AC power inputs 250 Watt power supply modules Hot replaceable Current Sharing Power factor correction Front panel indicators on each module AC input Output voltage status Output current level External status signals
1-6
Termination Assemblies
Termination Assemblies
Part Number IOP337 IOP342 IOP346 CTO301 CTO302 CTO303 Description QuadPAT Termination Assembly Turbine Valve Termination Assembly Turbine Overspeed QuadPAT Module to Termination Asembly Cable Turbine Valve Module to Termination Asembly Cable Turbine Overspeed Module to Termination Asembly Cable
1-7
1-8
1-9
1-10
For I/O bus connections to a cabinet outside the cabinet group, use a 7-foot cable (CPO307), a 15-foot cable (CPO315), or a special length cable. The maximum number of modules supported by the DPU4E or DPU4F within a cabinet or cabinet pairs is 60 maxPAC modules. This number of modules is reduced when the I/O bus is extended to other cabinets. A bus terminator (CPO402) must be installed at the end of the I/O bus connection. For applications that require I/O bus connections between Model 564 I/O racks and maxPAC racks, the following cables are available: Part Number Description CPO504 CPO507 CPO515 13 inches - 2 rack units between racks 7 feet 15 feet
1-11
P11
P9 P10
P11
P9 P10 Terminator
P11
P9 P10
P11
P9 P10
P11
P9 P10
P11
P9 P10
P11
P9 P10
P11
P9 P10
DPU Modules
The DPU4E requires the use of the six-wide chassis and is mounted in the right most position. DPU4F is mounted in the left most position of the 8wide chassis to take advantage of the airflow. Likewise, when using a second DPU for backup, it is mounted on a second chassis beneath the primary DPU. Before mounting I/O modules, you should complete power and grounding and field wiring and any I/O module preparation and adjustment. See appropriate chapters in this publication to check correct addressing and jumper selection on the modules. Before installing an I/O module in the right-most position of a chassis assembly, make sure the +24 Vdc is connected to the chassis assembly as well as the I/O bus cable. Additionally, connect the cabinet frame ground to the Model IOP I/O chassis assembly before installing an I/O module in the extreme left position of a chassis assembly. Refer to "Cabling, Power, and Ground Wiring."
1-12
Module Addressing
You must set addresses for each I/O module using rotary switches mounted in the lower or upper right corner of the printed circuit board of the module, depending on module type. These hexadecimal switches permit 255 logical addresses (hexadecimal FF is not available). The lower switch is the low order address and the upper switch is the high order address. maxPAC modules use one, two, four or eight addresses. The address set on the module is its base address. For the eight-address module the base address is the address of channel 1. The module will automatically occupy an address for each of its channels, starting with its base address. To convert the hexadecimal address to the equivalent logical (decimal) address: 1. Multiply the low order switch setting by 1 to get the decimal equivalent, where switch positions A to F correspond to 10 to 15, respectively. 2. Multiply the high order switch setting by 16 to get the decimal equivalent, where switch positions A to F correspond to 10 to 15, respectively. 3. Add the two decimal equivalents for logical (decimal) module address.
1-13
Shared Configuration
A shared I/O configuration uses a primary DPU, a secondary DPU, and one set of Model IOP parallel modules. See Figure 1-6. Both DPUs share the I/O bus but only the active DPU (primary or secondary) receives data from, and sends data to, the set of common I/O modules.
Redundant network
D P U
D P U
I/O Bus
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
1-14
D P U
D P U
I/O B us
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
C P O 3 09
Mixed Configuration
A mixed configuration uses a primary DPU, a secondary DPU, a Y adapter, two identical sets of redundant Model IOP parallel modules, and various other common Model IOP modules. See Figure 1-8. The primary and secondary DPUs receive data from, and send data to, the redundant modules. The active DPU (primary or secondary) also receives data from, and sends data to, the common set of I/O modules. The output-enable signal to the modules is handled internally by the mixed backup adapter; Part No. CPO401. In redundant or mixed configurations, the inactive DPU polls its redundant modules for hardware failures when it is not performing control actions. No transfer of control will occur if a failure is detected by the inactive DPU. The
1-15
D P U
D P U
I/O Bus
I/O Bus
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
Remote I/O
A Bus Expander Module (BEM) permits the I/O bus to be extended up to 2,000 meters using highly reliable and noise immune fiber optic cables. BEMs, configured in pairs, support both locally and remotely mounted I/O cards. In a typical configuration using redundant Distributed Processing Units (DPUs), an I/O cabinet installed locally in a control room contains I/O modules, a DPU pair, and a BEM pair. This is connected via I/O optical cable to a ruggedized remote cabinet containing I/O modules, and a second BEM pair. The optical link is established between the local and remote expander modules. Any DPU or redundant pair of DPUs, can communicate
1-16
D P U
Y ADAPTER
D P U
B E M
backplane
B E M
backplane
Control Room
I O
I O
I O
I O
Optical Cable
I O
I O
I O
I O
B E M
I O
I O
I O
B E M
I O
Remote location
I O
I O
I O
I O
I O
I O
I O
I O
I O
I O
1-17
Specifications
Environment
The Model IOP I/O operates in the temperature range of 0C to 60C at a relative humidity range of 0 to 90%, noncondensing.
I/O Bus
The Model IOP I/O uses an 8-bit parallel asynchronous I/O bus, capable of 10 microsecond transfers. The I/O bus interface uses LSI circuitry for better reliability. Parity checks are performed on all inputs and outputs, with additional security provided for outputs using a check-before-execute control strategy. To further enhance reliability, I/O incorporates module address verification and multiple module detection checks. Bus fault detection is also performed by automatic confirmation of input data on every module.
Inputs/Outputs
All modules, both analog and digital types, withstand the normal or common mode connection (IEEE-472, ANSI c37.90) and still maintain correct operation. Common mode transients are bypassed to chassis metal work. All points are optically isolated from the maxDNA I/O bus. Channel to channel isolation allows series or parallel connection between channels or external relay systems. All digital modules have logic state indication on the front panel, one indication per point. In addition to logic state indication, digital output modules contain fused outputs and a front-panel blown fuse indicator. Each output also has a deadman timer (approximately 1 second) that can be optionally used to freeze or drop out all outputs if the module is not updated by the DPU.
1-18
Chapter 2
Analog Input Modules Isolated Input Module IOP301
Overview
This module, featuring 16 isolated input channels, can be configured for any mix of voltage or current inputs. The current loop can be powered from a field supply or from a system loop supply provided via the backplane edge connector. For current inputs, this module is pin and function compatible with the IOP302 input module.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Metso Automation 278596
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers, located near the address switches. Refer to the following table for jumper setting information.
Jumper W1 W6
Installed
50 Hz
Model 564
In addition, five jumpers per channel determine the type of input connected to the channel.
Input Type 4-20 mA powered by Metso Automation 4-20 mA powered by user Voltage input A IN IN OUT B IN IN OUT C IN OUT OUT D IN OUT OUT E OUT IN IN
Program Resistors
Jacks are provides at the front of the module for the installation of a pair of resistors per channel. These resistors can be used to scale a voltage input to the 2.4V span of the A/D measurement. These resistors are identified as follows:
Channel Series R Shunt R 1 1 3 2 7 10 3 26 29 4 32 35 5 51 53 6 57 60 7 78 80 8 85 88 9 113 115 10 120 123 11 142 144 12 148 151 13 175 177 14 193 196 15 211 215 16 233 234
The input circuit configuration for each type of input is shown in the following sketch. An electronic fuse protects the 24-volt loop power to the transmitter. A 200-Ohm thermistor in series with the 4-20 mA input provides current limiting for voltages up to 100 Volts. The 24-volt loop supply is
2-2
200
1A
1B
24V(-)
From backplane
2
Rs
100
A/D
Xmitter
1
24V
Rp
1D
1E
1C
4-20 ma powered by system
200
1A
1B
2
+
Rs
100
A/D
Voltage
-
Rp
1
1D
1E
1C
Voltage input
200
1A
1B
2
+
Rs
+
Rp
1
100
A/D
Xmitter
-
1D
1E
1C
Module Operation
This microprocessor-based module supports up to 16 isolated high level inputs. A sigma delta A/D and precision reference is provided for each pair of inputs. The A/D reads the voltage generated by the selected input and converts the differential measurement to a 15-bit plus sign binary value
2-3
2-4
Regulator
24V
FLASH
OPTO A/D 1
Channel 2
uC
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on)
2-5
Module specifications
Resolution Scan Rate Temperature Sensitivity Accuracy Source Impedance Effect Conversion method Span Calibration Input Impedance - 4-20 mA input - voltage input Normal Mode Voltage Normal Mode Rejection Common Mode Voltage Common Mode Rejection Isolation Input Power (from 24V system supply) 15 bits plus sign 100 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of full scale at 25oC 10 MOhm operational, 20K Ohms on loss of power Sigma Delta oversampling. Single A/D per channel 4 to 20 mA, 0-2.4V Self-calibration on power up. Periodically on line to compensate for temperature effects 300 Ohms 1 Mohm 50 Volts 60db @ 50/60 Hz 500 Volts dc or peak ac 120db @ 50/60 Hz, 100 Ohm imbalance 1500 Vac (field to logic) 500 Vac (channel to channel) 400 mA
2-6
Field Wiring
P2
1 1
P3 24V,In(-)
2
24V,In(-)
2
Channel 1
Channel 9
In(+)
3
In(+)
3
24V,In(-)
4
Channel 10
In(+) 24V,In(-)
6
Channel 11
In(+) 24V,In(-)
8
Channel 12
In(+) 24V,In(-)
10
Channel 5
24V,In(-)
10
Channel 13
In(+)
11
In(+)
11
24V,In(-)
12
Channel 14
In(+) 24V,In(-)
14
Channel 15
In(+) 24V,In(-)
16
Channel 16
In(+)
2-7
Twisted pair (-) 4 wire Transmitter thermistor 100 (+) Primary IOP301 AI Module
(-)
2-8
2-9
Chapter 3
Analog Input Modules 4-20 mA Input Module IOP302 Voltage Input Module IOP305
Overview
The IOP302 module features sixteen 4-20 mA common input channels. The IOP305 module features 16 voltage input (not current input) channels. Transmitter loop power is available to the module via the backplane, providing individually fused 24V transmitter power for each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains two jumpers. Refer to the following table for jumper setting information.
Jumper W1 W6 Installed 50 Hz Model 564 Not Installed 60Hz maxPAC
Module Operation
This microprocessor-based module supports up to 16 4-20 mA inputs, all powered from a local 24V loop supply. A sigma delta A/D and reference are provided for each input. Each A/D constantly reads the voltage generated by the input and converts the differential measurement to a 15-bit plus sign binary value, which is read by the microcontroller. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. Immediately following each measurement, open input and over range conditions are checked. A DC/DC converter provides isolated power to the A/D measuring circuit. Communication between the microcontroller and the A/D is serial at 100kHz. Optical isolators provide the isolation between the A/D and the serial logic circuits. The microprocessor provides the input data to the DPU on demand via the bus FPGA. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. Module calibration is done automatically at power up following startup diagnostics. Calibration is repeated periodically online to compensate for temperature effects.
3-2
Analog Input Modules 4-20mA Input Module IOP302 Voltage Input Module IOP305
5V - field DC/DC 5V - logic Regulator 24V
FLASH
Channel 1
A/D
OPTO
uC
Channel 16
A/D
The input circuit for each channel of the 4-20 mA input module is shown in the following sketch. An electronic fuse protects the 24V loop power to the transmitter. A 200-Ohm thermistor in series with the input provides current limiting for overvoltage conditions up to 100 Volts. The 24-volt supply is available to the module from the backplane.
Current Limit 200 100 A/D
The following sketch shows the input circuit for the voltage-input module.
3-3
A/D
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on) Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Module Specifications
Resolution Scan Rate Temperature Sensitivity Accuracy Source Impedance Effect Conversion method Span Calibration Input Impedance Normal Mode Voltage Normal Mode Rejection Common Mode Voltage Common Mode Rejection Isolation Input Power (from 24V system supply) 15 bits plus sign 20 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of full scale at 25oC 10 Mohm operational, 20K Ohms on loss of power Sigma Delta oversampling. Single A/D per channel 4 to 20 mA, 0-2.4V. Self-calibration on power up. Periodically on line to compensate for temperature effects IOP302, 300 Ohms; IOP305, 1mOhm IOP302, 50 Volts; IOP305, 24 Volts 60db @ 50/60 Hz 100 volts dc or peak ac for the group 120db @ 50/60 Hz, 100 Ohm imbalance 1,500 Vac field to logic 125 mA
3-4
Analog Input Modules 4-20mA Input Module IOP302 Voltage Input Module IOP305
P3 1
Channel 1
24V
Transmitter
Channel 9
2 Iin 3 24V
2 Iin 3 24V
Transmitter
4 Iin 5 24V
Channel 2
Transmitter
4 Iin 5 24V
Channel 10
Transmitter
6 Iin 7 24V
Channel 3
Transmitter
6 Iin 7 24V
Channel 11
Channel 4
Channel 12
Transmitter
8 Iin 9 24V
Transmitter
8 Iin 9 24V
Transmitter
10 Iin 11 24V
Channel 5
Transmitter
10 Iin 11 24V
Channel 13
Transmitter
12 Iin 13 24V
Channel 6
Transmitter
12 Iin 13 24V
Channel 14
Transmitter
14 Iin 15 24V
Channel 7
Transmitter
14 Iin 15 24V
Channel 15
Transmitter
16 Iin
Channel 8
Transmitter
16 Iin
Channel 16
3-5
P2 1 (-)
0-2.4V
P3 1 (-)
Channel 1
2 (+) 3 (-)
0-2.4V
Channel 9
2 (+) 3 (-)
0-2.4V
4 (+) 5 (-)
Channel 2
0-2.4V
4 (+) 5 (-)
Channel 10
0-2.4V
6 (+) 7 (-)
Channel 3
0-2.4V
6 (+) 7
Channel 11
0-2.4V
Channel 4
(-)
0-2.4V
Channel 12
8 (+) 9 (-)
8 (+) 9 (-)
0-2.4V
10 (+) 11 (-)
Channel 5
0-2.4V
10 (+) 11 (-)
Channel 13
0-2.4V
12 (+) 13 (-)
Channel 6
0-2.4V
12 (+) 13 (-)
Channel 14
0-2.4V
14 (+) 15 (-)
Channel 7
0-2.4V
14 (+) 15 (-)
Channel 15
0-2.4V
16 (+)
Channel 8
0-2.4V
16 (+)
Channel 16
3-6
Analog Input Modules 4-20mA Input Module IOP302 Voltage Input Module IOP305
(-)
3-7
Chapter 4
Analog Input Modules 3 Wire RTD Module IOP303
Overview
This module features 8 isolated 3-wire RTD input channels.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU. It is also used to display errors detected by diagnostics.
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 8 bus addresses and provides 7 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 8 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains three jumpers. Refer to the following table for jumper setting information.
Jumper Installed Not Installed W2 Common I/O Redundant I/O W3 50 Hz 60 Hz W4 Not used W6 Model 564** maxPAC ** For version B or earlier, W7 must be installed for model 564 operation
Module Operation
This microprocessor-based module supports up to 8 RTD inputs, which can be independently configured. A reference excitation current is provided for each input. A sigma delta A/D reads the voltage generated by one of the eight inputs and converts the differential measurement to a 15-bit plus sign binary value representing the millivolt input, which is read by the microcontroller. Multiple readings are done for each channel to compensate for the error introduced by the field wiring in 3-wire RTDs. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. The A/D also provides a variable gain amplifier function. Prior to starting each conversion, the microcontroller sets the gain required in the A/D and selects the RTD excitation current based on the configuration for that input. It also selects the input channel by means of four solid-state optically coupled relays. The inputs are multiplexed with optical relays to provide channel to channel isolation. Immediately following each measurement, open RTD and over range conditions are checked. A DC/DC converter provides isolated power to the field side of the measuring circuit. Communication between the microcontroller and the A/D is serial at 100kHz.
4-2
Regulator
24V
FLASH
Channel 1
REF
A/D
OPTO
uC
I/O Bus
Channel 8
optical isolation field to logic
4-3
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on)
Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Module Specifications
Resolution Scan Rate Input Type Input Range Temperature Sensitivity Accuracy Input Multiplexer Conversion method Linearization Calibration Maximum Lead Resistance Compensation Backup Conformity Error Normal Mode Rejection Common Mode Rejection Common Mode Voltage Input Power (from 24V system supply) 15 bits plus sign 8 points converted in 1.6 seconds 10 ohm Cu, 10 ohm Pt, 25 ohm Pt, 100 ohm Cu, 100 ohm Pt, 100 ohm Ni, 1000 ohm Pt 0 1000 ohms 0.004% of reading/oC 1.5uv/oC RTI 0.15% of reading 0.5oC Solid-state FET, optical isolation Sigma Delta oversampling Digital in DPU. RTD ranges may be randomly mixed. Self-calibration on power up. Periodically on line to compensate for temperature effects. 5 Ohms each lead Conversions disabled if common RTD is connected to redundant modules. 0.3oC, 0.5oF 60db @ 50/60 Hz 120db @ 50/60Hz, 100 Ohm imbalance 240V rms, 350V dc peak 125 mA
4-4
Field Wiring
P2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 16 Channel 4 15 11 16 Channel 3 Channel 2 Channel 1 1 2 3 4 5 6 7 8 9 10 11 Channel 7 12 13 14 Channel 8 Channel 6 Channel5 P3
4-5
Twisted pair,
same length
(+)
(+)
(-)
4-6
Chapter 5
Analog Input Modules TC Module IOP304
Overview
This module features 16 isolated thermocouple of emf input channels
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off at a constant rate when the module is not being scanned by the DPU.
Bus Address
This module supports two modes of operation selected by jumper setting. For use as a replacement for a Model 564 module this module requires 16 bus addresses and provides 15 channels. The addressing rules specified in the Model 564 manuals still apply. When used as a maxPAC module, the module only requires two bus addresses and provides 16 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains three jumpers. These jumpers are located at the rear of the module above the edge connector. Refer to the following table for jumper setting information.
Jumper W3 W2 W6 Installed 50 Hz Common I/O Model 564 Not Installed 60Hz Redundant I/O maxPAC
Module Operation
This microprocessor-based module supports up to 16 TC or emf inputs, which may be independently configured. A sigma delta A/D reads the voltage generated by one of the 16 TC or emf inputs and converts the differential measurement into a 15 bit plus sign binary value representing the millivolt input which is read by the microcontroller. The microcontroller initiates the conversion and waits for the conversion to complete. The digital filter in the oversampling A/D provides excellent 50/60 Hz normal mode rejection. The A/D also provides a variable gain amplifier function. Prior to starting each conversion, the microcontroller sets the gain required in the A/D for each configured input measurement, and selects the input channel by means of two solid state, optically coupled relays.
5-2
Regulator
24V
FLASH
Channel 1
REF
A/D
OPTO
uC
OPEN
TC
Channel 16
optical isolation field to logic
Diagnostics
5-3
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition A/D send fault A/D receive fault A/D self calibration failure Bad A/D communication A/D does not complete conversion RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) Code 0x12 0x13 0x14 0x15 0x16 0x22 0x23 0x24 0x25 0x26 0x32
Module Specifications
Resolution Scan Rate Input Type Input Range Temperature Sensitivity Accuracy Input Multiplexer Conversion method Linearization Calibration RJ Compensation Open TC Detection Backup Conformity Error Reference Junction Error Normal Mode Rejection Common Mode Rejection Common Mode Voltage Input Power (from 24V system supply) 15 bits plus sign 16 points converted in 1 seconds Types B, D, E, G, J, K, N, R, S, T, Platinell II +/-10mv, +/-25mv, +/-60mv, +/-100mv, +/-250mv, +600/-250mv 0.004% of reading/oC 1.5uv/oC RTI 0.15% of reading 0.5oC Solid-state FET, optical isolation Sigma Delta oversampling Digital in DPU. RTD ranges may be randomly mixed. Self-calibration on power up. Periodically on line to compensate for temperature effects Digital in module Performed each reading (1,000 0hm threshold) Conversions disabled if common TC is connected to redundant modules 0.3oC, 0.5oF 0.25oC 60db @ 50/60 Hz 120db @ 50/60 Hz, 100 Ohm imbalance 240V rms, 350V dc peak 125 mA
5-4
Field Wiring
P2 1 + 2 3 + 4 5 + 6 7 + 8 9 + 10 11 + 12 13 + 14 15 + 11 16 Channel 8 11 16 Channel 7 14 15 + Channel 16 Channel 6 12 13 + Channel 15 Channel 5 10 11 + Channel 14 Channel 4 8 9 + Channel 13 Channel 3 6 7 + Channel 12 Channel 2 4 5 + Channel 11 Channel 1 2 3 + Channel 10 1 + Channel 9 P3
5-5
(+)
TC extension wire
W2 not installed
(+)
5-6
Chapter 6
Analog Output Modules 4-20 mA Output Module IOP320
This module, featuring eight 4-20 mA output channels, receives power from the 24V-system supply via the backplane edge connector. Loop power is also available to the module via the backplane and is individually fused 24V for each channel.
LED Indication
A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU. A second green LED provides the status of the loop power fuse disconnect.
Bus Address
This module requires eight bus addresses and provides eight channels. Each module address must be on a 0 or eight boundary (i.e. 32, 38, 50, etc.) in the range of 32 to 240. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
The module contains four jumpers. Refer to the following table for jumper setting information.
Jumper W1 W2 W3 W4 W6 Installed Run Mode Hold Output Secondary Common I/O 8 addresses Not Installed Calibrate Mode Reset Output Primary Redundant I/O
Note: the W6 switch setting shown in the above table applies to modules with two rotary switches installed. For modules with only one rotary switch, use the following definition: W6 base address = x8 (hexadecimal) W7 base address = x0 (hexadecimal) Where x is the rotary switch setting. Refer to the following table:
6-2
S1 Setting 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 A A B B C C D D E E
W6 Setting out in out in out in out in out in out in out in out in out in out in out in out in out in out in
W7 Setting In Out In Out In Out In Out In Out In Out In Out In Out In Out In Out In Out In Out In Out In Out
Base Address 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160 168 176 184 192 200 208 216 224 232
Module Operation
This microprocessor-based module supports up to eight 4-20 mA output channels. Communication between the microcontroller and each output is serial. The output request received from the I/O bus is translated by the microcontroller into a pulse width modulated signal, which is transmitted to each output circuit via a high-speed optical isolator. This optical isolator provides the isolation between the logic and the field. The duty cycle of the serialized output is proportional to the output level. The output circuit converts this signal into 4-20 mA. Open load is detected and reported to the DPU. The FPGA provides the I/O bus interface logic; its program is loaded from the FLASH on power up. A watchdog timer function is included to monitor communications on the I/O bus. The watchdog timers will timeout if there is no communications on the I/O bus for longer than 0.7 seconds. When this occurs, the outputs will either
6-3
Channel 1
D/A 1
OPTO
uC
Channel 8
4-20 ma out
D/A 8
OPTO
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
6-4
Module Specifications
Resolution Rise Time Temperature Sensitivity Accuracy Span Calibration Load Impedance Input Power (from 24V system supply) 12 bits 750 msec. 0.004% of reading/oC 1.5uv/oC RTI 0.1% of reading .05% of span at 25oC 4 to 20 mA. Self-calibration on power up with calibration jumper set 0 800 Ohms 175 mA
6-5
Field Wiring
P2 1 Iout
Load
Channel 1
2 Return 3 Iout
Load
4 5 Iout
Channel 2
Return
Load
6 7 Iout
Load
8 Return 9 Iout
Load
10 11 Iout
Channel 5
Return
Load
12 Return 13 Iout
Channel 6
Load
14 Return 15 Iout
Channel 7
Load
16
Channel 8 Return
6-6
(+)
(-) Primary IOP320 AO Module W2 not installed W3 not installed W4 - not installed
(+)
(-) Secondary IOP 320 AO Module W2 not installed W3 installed W4 not installed
6-7
Chapter 7
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331
Overview
These modules feature 16 digital common inputs.
LED Indication
Individual red front-panel LEDs provide the input status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being
Bus Address
This module requires one bus address. The address range for digital input modules is 0 to 31 (0 1F). The address range for digital input modules configured as slow DIs is 32 to 254.
Module Operation
The following is a simplified sketch of the circuit for one channel. The signal-conditioning block provides filtering, current limiting circuit, and an input threshold. It also includes the input status LED. The optical isolator provides isolation between the field circuits and the logic circuits. The input status is buffered and latched in the I/O bus interface circuit. The data is presented to the I/O bus as a 16-bit word when the module is scanned by the DPU. A watchdog timer in the I/O bus interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds. The 24V/48V(+) and 24V/48V(-) loop power signals are connected to all the channels. They are routed to the module from the backplane via a fuse disconnect which is accessible from the front of the module.
24V/48V(-)
24V/48V(+)
Fuse disconnect
To other channels
7-2
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331
Module specifications
Rated Input Voltage Input current per point On-State Voltage Isolation User input to logic Indicators IOP 330 24V IOP331 48V 24Vdc nominal, 40 Vdc 48Vdc nominal, 60V dc maximum maximum 5 mA @ 24 Volts 5 mA @ 48 Volts 8.5 Volts 22 Volts 250 VAC continuous, 1,500 VAC for 1 minute 1 LED per point provides status indication. LED provides power and communication indication. LED provides loop power disconnect status One address 50 mA
7-3
Field Wiring
P2 1 2 3 4 5 6 7 8 9 10 11 12 Channel 6 13 14 15 11 16 Channel 8 Channel 7 Channel 5 Channel 4 8 9 10 11 12 Channel 14 13 14 15 11 16 Channel 16 Channel 15 Channel 13 Channel 3 Channel 2 Channel 1 2 3 4 5 6 7 Channel 12 Channel 11 Channel 10 1 Channel 9 P3
7-4
Digital Input Modules 24V Common Input Module IOP330 48V Common Input Module IOP331
(+)
(+)
7-5
Chapter 8
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333
Overview
These modules provide16 isolated digital inputs
LED Indication
Individual red front-panel LEDs provide the input status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating
Metso Automation 278596
Bus Address
This module requires one bus address. The address range for digital input modules is 0 to 31 (0 1F). The address range for digital input modules configured as slow DIs is 32 to 254.
Jumper Configuration
For IOP332 and IOP333, jumpers (W1W16) must be installed for AC inputs. Note: IOP334 does not include jumpers.
Module Operation
The following is a simplified sketch of the circuit for one channel. The signal-conditioning block provides filtering, current limiting circuit, and an input threshold. It also includes the LED. The optical isolator provides isolation between the field circuits and the logic circuits. The input status is buffered and latched in the I/O bus interface circuit. The data is presented to the I/O bus as a 16-bit word when the module is scanned by the DPU. A watchdog timer in the interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds.
Input Voltage
8-2
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333
Module Specifications
IOP 332 120V 120 Volts ac/dc nom. Rated Input Voltage 180 Volts max Input current per 5 mA @ 120 Volts point On-State Voltage 48 Volts dc Isolation User input to logic Isolation Channel to channel Indicators IOP333 240V 240 Volts ac/dc nom. 280 Volts max 5 mA @ 240 Volts IOP334 24V 24V dc nominal, 40V dc max 5 mA @ 24Volts
70 Volts dc 8.5 Volts dc 100 Volts ac 60 VAC; 250 VAC continuous, 125 VAC; 1500 VAC for 1 minute
1 LED per point provides status indication LED provides power and communication indication LED provides the status of the loop power fuse disconnect One address 50 mA
8-3
Field Wiring
P2 1 AC/DC 2 3 AC/DC 4 5 AC/DC 6 7 AC/DC 8 9 AC/DC 10 Channel 5 11 AC/DC 12 Channel 6 13 AC/DC 14 15 AC/DC 11 16 Channel 8 AC/DC Channel 7 AC/DC AC/DC AC/DC Channel 4 AC/DC Channel 3 AC/DC Channel 2 AC/DC Channel 1 AC/DC 1 2 3 4 5 6 7 8 9 10 Channel 13 11 12 Channel 14 13 14 15 11 16 Channel 16 Channel 15 Channel 12 Channel 11 Channel 10 Channel 9 P3
8-4
Digital Input Modules 24V DC Isolated Input Module IOP334 120V AC/DC Isolated Input Module IOP332 240V AC/DC Isolated Input Module IOP333
(-)
AC/DC
Primary DI Module
(+)
8-5
Chapter 9
Digital Input Modules Counter Timer Module IOP335
This module provides eight isolated digital input channels. Each channel provides a pair of digital inputs, which can be individually programmed to support 24, or 48 Volt inputs.
Features Software stored in FLASH Low Power Dissipatioin Configuration per channel
LED Indication
A red status LED is provided for each input. A green LED, labeled Active on the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module only requires two bus addresses and provides 8 channels. Each module address must be on an even boundary (i.e. 32, 34 50 etc.) in the range of 32 to 252. Addresses 0 to 31 are reserved for digital input modules. This module is compatible with DPU4E and DPU4F only.
Jumper Configuration
A two-position jumper is used to select the input voltage for each input. The input number identifies the jumpers. The two positions are A and B as follows:
Jumper W1A - 16A Installed 24 V Not Installed 48V
This microprocessor-based module supports up to eight pulse input channels. Each channel can be independently configured for both function type and debounce time. The functions supported are: Mode 1 Frequency Input Frequency in counts per second in input1. Input 2 is not used. The Pulse I/O Buffer in DPU4E supports the following timebase mode selections for frequency measurement: 20 msecs, 50 msecs, 100 msecs, 250 msecs, 500 msecs, and 1 second. For the selected timebase, the Pulse I/O module measures frequency for the specified duration and normalizes each measurement to cycles per second. The measurement is updated at the end of each interval and the counts read by the DPU when the module is scanned represent the average of the last four measurements in cycles/second. The scan rate of the DPU is asynchronous from the scan rate by the module. The accuracy of the frequency measurement is +/-1 count for the one-second timebase. The accuracy for the other timebases is approximately the normalizing multiplier divided by 4. Thus for the shortest timebase (20 msecs), the accuracy is reduced to approximately +/-12 counts. In applications requiring fast frequecy measurements, a period measurement (mode 7) can also be used to measure frequency. Since each count in the period measurement corresponds to 0.5 microseconds, the inverse of the period will yield a fast frequency measurement with an accuracy of 0.1% for a 2000Hz input and 0.25% for a 5000Hz. Mode 2 Simple Event Counter (default configuration)
9-2
Module Operation
This microprocessor based module supports up to 16 digital inputs. As shown in the functional block diagram, the field circuits are used to detect and optically isolate the digital inputs. High-speed optical isolators support higher frequency inputs. The processor circuits implement the configured timing functions and provide the interface to the I/O bus FPGA. The Time Processor Unit (TPU) included in the 68332 processor is used to process the timing functions. The TPU operates from microcode masked in 68332 ROM. The 16 DI inputs are debounced in an FPGA and are available individually to the processor TPU inputs.
9-3
Diagnostics
The module executes diagnostics on power up. To indicate any errors detected during power-up or on-line operation the LED labeled active blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation this LED stays on or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power on) Code 0x22 0x23 0x24 0x25 0x26 0x32
Module specifications
Input voltage Input thresholds Debounce Accuracy Maximum frequency Minimum Pulse Width Common Mode Voltage Input Power (from 24V system supply) 24V, 48V jumper selectable 24V 10 Volts 48V 20 Volts 0-255 msec dynamically configured per channel 1 cycle or 0.15%, whichever is greater 32KHz 10 usecs 240Vac rms, 350V dc peak 150 mA
9-4
Field Wiring
P2 1 + 2 Channel 1 + 5 + 6 Channel 2 + 9 + 10 Input 5 Channel 3 + 13 + 14 Channel 4 + 15 11 16 Input8 Input 7 Channel 8 + 11 16 Input 16 15 + 14 Input 15 11 12 Input 6 13 Channel 7 + 11 12 Input 14 + 10 Input 13 7 8 Input 4 Input 3 Channel 6 + 9 + 6 7 8 Input 12 Input 11 3 4 Input 2 5 Input 1 + 2 Channel 5 + 3 4 Input 10 1 Input 9 P3
9-5
Chapter 10
Digital Output Modules Form A/B Relay Module IOP351 Form C Relay Module IOP350
Overview
These modules provide 16 Form A relays or 10 form C relays. The form A outputs can be converted to form B via on-board jumpers.
LED Indication
Individual red front-panel LEDs provide the output status indication for each channel. A green LED, labeled Active at the bottom of the module front panel, is on when system power is present and the module is communicating with the DPU. This LED blinks on and off when the module is not being scanned by the DPU.
Bus Address
This module requires one I/O one bus address. This module requires one bus address. The address range for digital output modules is 32 to 254. Addresses 0 to 31 are reserved for digital input modules.
Jumper Configuration
Jumper W1 configures all the outputs to either reset or fail in place when there is no communications in the I/O Bus for more than 0.7 seconds. Configuration is as follows:
Jumper W1 Position 2-2 Reset Output Position 1-2 Hold Output
For the IOP351 module, each channel can be strapped in the printed circuit assembly for form A or form B operation per the following table. The default configuration is form A for all channels.
Channel Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Form A R100 R103 R106 R108 R111 R114 R116 R119 R122 R124 R127 R130 R132 R135 R138 R140 Form B R101 R104 R107 R109 R112 R115 R117 R120 R123 R125 R128 R131 R133 R136 R139 R141
Module Operation
The following is a simplified sketch of the circuit for one channel. The relay drivers energize the relay coils and control the operation of the output LEDs to correspond to the data in the I/O bus interface circuit. A watchdog timer in the interface circuit controls the operation of the active LED, causing it to blink when the module is not scanned for 0.7 seconds. It also controls the state of the outputs on loss of communications.
10-2
Digital Output Modules Form A/B of Relay Module IOP351 Form C Relay Module IOP350
5V
Reg
24V
Channel 1
BUFFER
I/O Bus
Channel 16 PROM
optical isolation field to logic
Module Specifications
Maximum Switching Capacity Number of Channels Expected Relay Life Maximum Operating Speed Operating Time Release Time LED Indication I/O Bus Address Input Power (from 24V system supply) IOP 350 Form C IOP351 Form A/B 5 amps @ 250 VAC 3 amps @ 30 VDC 0.3 amps @ 110 VDC 10 16 Mechanical @ 180cpm - 5X10^6 Electrical @ 20cpm (resistive load) 10^5 20cpm 15 msec. Maximum (excluding bounce) 5 msec. Maximum (excluding bounce) 1 LED per point provides output status indication active LED provides power and communication indication One address 400 mA
10-3
5V
Reg
24V
Channel 1
BUFFER
I/O Bus
Channel 16 PROM
optical isolation field to logic
10-4
Digital Output Modules Form A/B of Relay Module IOP351 Form C Relay Module IOP350
10-5
Wiring IOP350
P2 1 Channel 1 2 Channel 6 3 4 5 Channel 2 6 7 8 Channel 3 9 10 11 Channel 4 12 13 14 Channel 5 15 11 16 Channel 10 15 11 16 Channel 9 12 13 14 Channel 8 9 10 11 Channel 7 6 7 8 3 4 5 1 2 P3
10-6
Digital Output Modules Form A/B of Relay Module IOP351 Form C Relay Module IOP350
(+)
W1 installed
(+)
W1 installed
10-7
Chapter 11
Bus Extender Unit Module IOP371
Overview
The Bus Extender Unit (BEM) provides a flexible way to distribute the system throughout the plant, resulting in reduced cabling costs and installation time. Placing I/O in remote cabinets closer to a given process typically reduces tray loading and the number of required junction boxes since remote I/O cabinets are substituted. It also shortens wiring distances to field devices, such as thermocouples and RTDs.
LED Indication
Individual green front-panel LEDs provide status indication for each channel. The lower LED, labeled Active at the bottom of the module front panel, is on when the BEM and its associated DPU are active. The LEDs labeled link1 and link2 indicate which optical link is operational.
Link Test
A link test pushbutton is provided to switch operation between the two optical links. This can be used to verify that the two links are operational.
Bus Address
This module does not require a bus address.
Jumper Configuration
The module contains two jumpers located in the bottom right corner of the board. Refer to the following table for jumper setting information.
Jumper W1 W3
Bus Extender Modules, configured in pairs, support both locally and remotely mounted I/O cards. The local BEM installed with the DPU, plugs into the I/O backplane to access the DPU's parallel I/O bus. Locally mounted I/O can share the I/O bus with the BEM. The remote BEM receives the bus data over the optical link and establishes the I/O bus at the remote location. A single DPU, or redundant pair of DPUs, can communicate with I/O modules that are locally and/or remotely mounted. In a typical configuration
11-2
B E M
B E M
I / O
I / O
Figure 10-1. Optical Link between Local and Remote Extender Modules
Multiple BEMs can be connected to the I/O bus to allow multiple remote locations for I/O. When multiple BEM modules are connected to different parts of the system, all BEMs connected to a DPU must share the same I/O bus as the DPU, as shown in figure 10-2. See also, "Redundant Configuration Approaches."
11-3
I / O
I / O
B E M
B E M
B E M
D P U
Figure 10-2. The DPU Supports up to 60 Modules per Location, the locally, remotely, or both.
In addition to the configuration described in Figure 10-1, BEMs may be nonredundant, and configured with redundant or non-redundant DPUs. All options are possible. See " Redundant Configuration Approaches."
DPU Compatibility
The Extender is compatible with 4A, 4B and 4E DPUs, but is not compatible with the earlier DPU3, DPU4 or controller file models. To use a bus Extender with DPU 4A and 4B, firmware EPLD may need to be updated. Contact Metso Automation Customer Care for assistance.
11-4
BEM Operation
Each Extender module is packaged in a Model IOP I/O style printed circuit board. Each board contains a chipset that includes a transmitter, receiver and an optical transceiver. The transmitter converts the parallel data into serial data, appends encoded error checking bits and sends the data serially over a very fast fiber optic link (160 MBaud). The receiver decodes the serial data, does error checking and converts the data back to the original parallel form. The Extender also includes the buffers/darlingtons associated with the Model IOP bus, bosfet switches to disconnect the backup DPU Extender from the bus, and a CPLD to provide some small additional logic required to support the operation of the chip set. The MACK condition (multiple modules on the bus) is detected by the remote Extender transmitted over the link and simulated locally for interpretation by the DPU. Figure 10-3 shows a functional block diagram of the Bus Extender Module. Operation is as follows: I/O Bus Interface Buffers to duplicate both the DPU and I/O module bus interface. The ACK signal from the module is detected at the remote end transmitted by the link and simulated at the DPU end. CPLD provides all the logic resources required by the link. This includes latching and synchronizing the bus data to the frame clock, error detection and link failover. Transmitter (Serializer) Converts a snapshot of the parallel bus data into 160Mb TTL level serial stream. Receiver (Serializer) Converts the received TTL level serial stream into parallel data. Frame Clock 8 MHz clock initiates the serial conversion of the I/O bus data. Thus a snapshot of the Model IOP bus is sent every 125 nsecs. This corresponds to a serial speed of 160Mb of the optical transceivers.
11-5
Local Area
Primary DPU
OUT/IN LO/HI ADDR DATA LATCH INT
Remote area
Fiber
B u f f e r s
M A C K
CPLD
DATA[8..0]
CPLD
M A C K Transmitter
Fiber
Receiver
ACK XACK
B u f f e r s
ALT_IN LATCH
INT
Fiber
B u f f e r s
M A C K
Transmitter
B u f f e r s
CPLD
CPLD
M A C K
DATA[8..0]
Fiber
Transmitter
Receiver
Status
Optical Transceivers Convert the TTL level transmit serial data into an optical signal and the received optical signal into a TTL level serial data. A second transceiver supports redundant links for single DPU applications. The transmitter/receiver chip pair detects the operational state of the active link. On power-up transceiver 1 is selected. If a failure is detected, the circuit will switch the link to transceiver 2, a digital output will be set and an LED will
11-6
Optical Cabling
The two front-accessible optical transceivers, designated Link 1 (top link) and Link 2 (bottom link), each have two ST type connectors, one to transmit (Tx) and the other to receive (Rx). The fiber optic cable connects the transmit output of one BEM to the receive input of the other BEM. Multimode 62.5-micron cable is used to connect the local and remote Extender modules. Cable is run between the redundant optical transceivers to support redundant optical cable pairs. If redundant cables are provided, one cable pair is always active while the second pair serves as a hot standby link. See "Ensuring Link Availability.
Termination Requirements
In an I/O configuration using BEMs, an additional terminator is required at the remote BEM I/O bus location. This is in addition to the terminator assembly usually installed at the end of the I/O bus. For model 564 I/O installations, use CPO102 terminator assembly. For maxPAC applications, use CPO402 terminator assembly.
11-7
11-8
D P U B E M
backplane
Y CABLE
D P U B E M
backplane
Control Room
I O
I O
I O
I O
Optical Cable
I O
I O
I O
I O
B E M I O I O I O
B E M I O I O
Remote location
I O
I O
I O
I O
I O
I O
I O
I O
I O
Figure 10-4. Redundant DPUs with local common and remote common I/O configuration using Y cable.
11-9
backplane
D P U B E M I O I O Control Room B E M
To other Locations
Optical Cable
I O
I O
I O
I O
B E M
I O
I O
I O
Remote location
I O
I O
I O
I O
Figure 10-6. Single DPU with common and remote I/O configuration. The redundant optical cables shown in this illustration are optional but recommended.
11-10
11-11
Cabling Recommendations
To augment cable reliability, Metso Automation recommends the following cabling practices: For configurations using either single or redundant pairs of BEMs, use two separate, four-fiber optical cables (Part No. CON064-LLLL). Attach one cable to Link 1 and the other cable to Link 2. As noted, route cables separately to minimize the possibility of damage to both cables. For each link connect two of the four available connector ends to the optical transceiver connectors. The two extra, unused fibers in each cable serve as spares in the event that the active fibers are cut or damaged.
11-12
Specifications
Model: IOP371 Bus Extender Module (Part No. 181500) Distance: Up to 2000 meters Speed: Maintain Model IOP I/O bus communications I/O addresses: Up to 255 unique I/O addresses per DPU Link bus loading: One of up to 60 I/O nodes Approval Bodies and Standards The product meets SAMA PMC33.1 EMI/RFI specs at three different frequencies, and is designed to meet IEC 801-2 static specification (8,000 Volts). Power Requirements 24 Volts @0.5 amps Environment The module operates in the temperature range of 0oC to 60oC at a relative humidity range of 0 to 90%, noncondensing. Optical cable 62.5/125 m multimode fiber optic cable CON062-LLLL Two- fiber optical cable CON064-LLLL Four-fiber optical cable Operating wavelength 1300 nm.
11-13
Chapter 12
QuadPAT Module IOP336 QuadPAT Termination Module IOP337
Overview
The maxPAC Quad Position Adjusting (QuadPAT) module in combination with the maxPAC Quad PAT termination assembly produces PAT increase and decrease outputs (120V or open collector) for single phase AC drive units or three-phase power switches. The module accommodates 1000-ohm slidewires or two-wire rotary position sensors. In addition, the maxPAC Quad PAT termination includes the DI circuits for sensing the drive unit limit switches.
Front Panel
The QuadPAT front panel contains bicolor LEDs to report the status of the increase and decrease outputs and limit switch for each channel and also LEDs for module status indication. It also includes the two I/O connectors. The top connector includes all the digital I/O and the analog signals are available at the bottom connector.
LED Indication
A pair of bi-color LEDs provides I/O state indication for each QuadPAT channel. The DO is the first LED of the pair and the DI is the second LED. For normally closed limit switches (open at a limit) the LED indication for each digital input and digital output pair is as follows:
LED Output Output Limit Limit Limit Limit Color Green Red Green Red Amber OFF Description Decrease Increase Decrease Limit Increase Limit No limit No Power
12-2
In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
Jumper Configuration
Refer to the following table for the jumper setting information that is applicable to this module. Bold indicates the default position of the jumper.
Jumper W1 W2 W3 W4 W5 W6 Installed Backup Ignore Limit Common I/O QuadPAT Not Installed Not Used Primary Not Used Stop on Limit Redundant Other
Channel 1
Jumper W11 W12 W13 W14 W15 W16 W17 Slidewire A C A Installed A Installed Not Installed Rotary sensor B A,B B Not Installed Not Installed Not Installed Installed
Channel 2
Jumper W21 W22 W23 W24 W25 W26 W29 Slidewire A C A Installed Installed Not Installed A Rotary sensor B A,B B Not Installed Not Installed Installed Not Installed
12-3
Channel 4
Jumper W41 W42 W43 W44 W45 W46 W49 Slidewire A C A Installed Installed Not Installed Installed Rotary sensor B A,B B Not Installed Not Installed Installed Not Installed
Bus Address
This module requires four bus addresses and provides four channels. Each module address must be a multiple of 4 (i.e. 32, 36, 40, 44, 56, etc.) in the range of 32 to 248. Addresses 0 to 31 are reserved for digital input modules. The two address rotary switches can be found at the upper right hand corner of the module above the edge connector as follows:
Most Significant Less Significant
DPU Compatibility
This module is only compatible with DPU4E and DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes eight analog inputs, four analog outputs, 8 digital inputs and eight digital outputs. Successive approximation 14-bit A/D converters digitize the
12-4
12-5
+/-15V 24V
DC/DC
24V
5V
DC/DC
24V +/-15V
FLASH 2Mbit
5V
DC/DC
CLOCK
I/O Bus
DO1 DOI8
QuadPAT Termination
The IOP346 QuadPAT Termination interfaces with the QuadPAT module via cable CTO301. It is a DIN rail mounted assembly with two 16-point Eurostyle plugs providing the interface for the field connections. The QUADPAT module provides 24-volt power for the Termination circuits. The termination assembly provides the following functions: It provides four optically isolated TRIAC circuits. Each circuit includes a pair of TRIACs for the increase and decrease signals as well as the output suppression circuits
12-6
Feedback Options
Slidewire: The bottom of the slidewire is connected to ground through a 100-ohm resistor to allow detection of an open slidewire. A reference current of 2 ma produces an approximate voltage range of 0.5 to 2 volts for the slidewire. Open wipers are detected through a pulldown resistor on the slidewire input. If a high or low signal reading is detected when the module is scanned by the DPU, outputs to the module from the DPU will be suspended. Rotary Sensor: Power to the sensor is supplied from the field 24V. The sensor 4-20ma signal results in a 0.4 to 2V signal across the internal 100 ohm sensing resistor. Overvoltage protection is provided for the 100 shunt. If a shorted sensor or an open circuit is detected by the DPU, outputs to the module are suspended.
Output Options
Single-Phase and Three-Phase Drive Units TRIAC outputs require the use of the termination assembly. DC Power Switch Open collector outputs are wired directly from the module, and the termination assembly is not required. A commoning strip is required for the ground connections to the individual power switches. No IEEE surge suppression is available for the open collector outputs.
12-7
Redundant Configuration
Standby Mode Standby mode is activated when a QUAD PAT module is one of a redundant pair in a backup configuration and its DPU is inactive. All outputs from the module will be suspended while in the standby mode. The slidewire reference is also disabled in the standby mode.
12-8
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Error FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x33 0x35 0x36 0x37 0x38 0x39
12-9
12-10
12-11
12-12
AO01(4-20ma) 1 W15
A B
AO01(4-20ma) 1 W15
A B
AO01(+/-10V) W11
A
AO01(+/-10V) W11
A
AuxAI01
B
AuxAI01
B
F1
W16 24VF1
W17
W16
F1
W17
24VF1 2 AI01
A C
A C
W12
B 100K
W12 AI01
B 100K
A B
A B
F1
F1
W29
W29
AO02(4-20ma)
W25
A
W26
W21
AuxAI02 24VF1
F1
F1 A
AI02 W22 C
B
100K
A B
W23 7
A B
therm
W24
F1
shunt
8
F1
shunt
F1
12-13
P3
Rotary Sensor
P3
AO03(4-20ma)
W15
AO03(4-20ma)
W35
AO03(+/-10V)
AO03(+/-10V)
W11
AuxAI03
B
W31
AuxAI03
B
F2
W36
W37
W36
F2
W37
24VF2
10
A
24VF2
W12
C
10
AI03
B
100K
A
C
W32
AI01
B
100K
11
W13
W14
therm
shunt
F2
11
W33
W34
therm
shunt
F2
12
12
F2
F2
13
W49
AO02(4-20ma)
13
W45
W49
AO04(4-20ma)
W46
A
W45
W46
W41
AuxAI04
W41
AuxAI04
24VF1
F2
F2
24VF2
14
AI04
14
W42
AI04
W22 C
B
15
W43
A
100K
B
W43
15
A
100K
B
therm
W44
F2
therm
W44
F2
16
shunt
16
F2
shunt
F2
12-14
Termination
P1
P2
Module
1 2 3
DEC1
HI LIM 1
6 7 8 4 4
DIO2
LO LIM 1 9 H 120 AC N 10 11
M INC2 12
5
DEC2 13
5 DO03
HI LIM 2 14 15 16 LO LIM 2
6 7
6 7
DO04 DI03
8 17 18
8 17 18
12-15
P3 120 AC H N
INC1
Termination
P1
P2
Module
1 2 3
DEC1
12
N 10 11
INC1
DEC1
13
14 15 16
15
16
12-16
DIO5 DIO6
DIO3 DIO4
24V
12-17
Specifications
TRIAC Outputs 120VAC: Maximum Voltage: 200 VAC Continuous on-state current: 2A On-state voltage: 1.6 VAC Off-state current: 3.5 mA Hold Current: 50 mA Open Collector Outputs Maximum Current: 100mA Maximum Voltage: 28VDC Maximum on-resistance: 0.2 ohms Power 24Vdc system supply Temperature Humidity Surge (TRIAC Outputs only) 400 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
12-18
Chapter 13
Turbine Valve Positioner Module IOP341 Turbine Valve Termination Module IOP342
Overview
The Turbine Valve Positioner module implements the logic for real-time closed loop control of a single turbine valve. The module provides two independent and electrically isolated channels. Each channel includes a coil drive output and a position feedback input normally receiving inputs from position transducers. Each channel also includes auxiliary inputs for loopback measurement of the output signal. In addition, a turbine speed input is provided as a service with the intent of bringing back three speed signals, one on each of three Turbine Valve Positioner modules for triple redundancy of speed input. The product consists of a maxPAC Positioning Module and a Turbine Valve Termination card. The Termination card provides both current and voltage outputs for characterizing the output for different coil types. It also provides signal conditioning for the frequency input. The logic shown in the following sketch is programmed in the maxDPU4F Atom Compiler language and may be modified by a trained engineer via tools provided. It is one of up to nine personalities that can be downloaded to the module and stored in flash memory. A cable is provided for downloading the configuration. Personality selection, the configuration Tuning constants for the PI loop, I/O status, and other signals are accessible via the maxDPU4F.
Pos
>
Pos
4-20 ma
Servo Amp
K+
Pos Err Coil(s) Status
Servo Amp
Turbine Speed
Freq
Speed
13-2
Features Self-calibration on power-up Software stored in FLASH Field to logic isolation Channel-to-channel isolation Fast Scan Time Fast slew rate Full complement of I/O Frequency inputs On-line diagnostics Downloadable personality
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip output and frequency input. Two bicolor LEDS, Stat 1 and Stat 2 provide diagnostic indication In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the module. The upper green LED at the bottom of the front panel indicates that loop power is turned on.
13-3
Jumper Configuration
The Turbine Valve Positioner module uses a multi-purpose-positioning module with multiple jumper options as its base. The base module has four AI/AO and eight DI/DO. Not all the jumpers are used for this application. Jumpers W1-W4 at the rear of the module are for factory test only and must not be installed. Refer to the following table for the jumper setting information that is applicable to this module. Bold indicates the default position.
Channel 1
Jumper W11 W12 W13 W14 W15 W16 W17 Position 4-20ma +/-10V B A, B B Not Installed A B OUT IN OUT IN
Channel 2
Jumper W21 W22 W23 W24 W29 W25 W26 Position 4-20ma +/-10V A C B Not Installed Not Installed OUT IN OUT IN
Channel 3
Jumper W31 W32 W33 W34 W35 W36 W37 Position 4-20ma +/-10V B A, B B Not Installed A B OUT IN OUT IN
Channel 4
Jumper W41 W42 W43 W44 W49 W45 W46 Position 4-20ma +/-10V A C B Not Installed Not Installed OUT IN OUT IN
13-4
function Wetting Voltage Frequency Voltage Channel 1 Series R Channel 2 Series R V/I Out V/I Out
and +/-10V
+/- 40 ma +/- 40 ma
100 ohms or 4-20ma 100 ohms or 4-20ma +/-10 volts or 4-20ma +/-10 volts or 4-20ma
Bus Address
This module consumes two bus addresses. The two address rotary switches can be found at the upper right hand corner of the module above the edge connector as follows:
Most Significant Less Significant
DPU Compatibility
This module is only compatible with maxDPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes four analog inputs, four analog inputs, 8 digital inputs and eight digital outputs. Four auxiliary analog inputs are also included for diagnostic use. Successive approximation 14-bit A/D converters digitize the input signals in microseconds.
13-5
+/-15V 24V
DC/DC
24V
5V
DC/DC
24V +/-15V
FLASH 2Mbit
5V
DC/DC
CLOCK
FPGA
RS232
I/O Bus
DO1 DOI8
The analog I/O is separated into two electrically isolated groups as shown in the functional sketch. There is also optical isolation between the field circuits and the logic. DC/DC converters provide isolated power to the A/D converters and analog output circuits. The microprocessor communicates serially with the field circuits via optical isolators. Each of the four analog output circuits provides 4-20 ma. Two of the circuits provide 10 to +10 volt outputs. The A/D in each group has four inputs. Two of the inputs are used as auxiliary inputs for diagnostic monitoring of the analog outputs.
13-6
Configuration
The Turbine Valve Module provides a serial port for downloading the configuration programs that are generated and compiled with the maxPAC Positioning Module Compiler Tool. Up to nine programs (personalities) can reside in the module FLASH. The interpreter code running in the module executes any one of the nine personalities selected via the DPU. A module personality typically defines an exchange of variable data between the DPU POS Buffer and the module I/O and other parameters defined in the module shell; it also includes the logic sequence that implements the required application. See the maxPAC Positioning Module Programming Guide.
Calibration
The Turbine Valve Module can be configured via on-board jumper selection to provide either a current or voltage output. The module is factory calibrated for 4-20 ma current outputs and the calibration constants are stored in FLASH. Calibration is only required when the FLASH program is upgraded.
13-7
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x35 0x36 0x37 0x38 0x39
The turbine valve module can also execute on line diagnostics to verify the integrity of the loop. This test must be defined in the personality program. The module shell includes four AOs (AO01-AO04), four AIs (AI01-AI04), four Auxiliary AIs (AuxAI01- AuxAI04), eight DIs (DI01-DI08) and eight DOs (DO01 DO08). These shell variables are associated with I/O signals at the module I/O connector. The bipolar analog outputs generated by the module are converted at the termination assembly to a 0-2V plus sign signal. As shown in the Group1 Analog I/O configuration sketches at the end of the chapter, the analog output from the module is buffered by the termination and fed back to AuxAI02. The coil current is fed back to AI02, while the sign is available as status DI02 (1 is negative). The personality program must define the input types to be 0-2V. Also the analog value read at those inputs must be sign adjusted. For example, the configuration program includes the following code to define the input types and adjust the sign.
13-8
= = = =
1 3 3 1
;4-20ma AI ;0-2V AI
13-9
1 DO1 2 DO2 3 DI1 4 DI2 5 DO3 6 DO4 7 DI3 8 DI4 9 DO5 10 DO6 11 DI6 12 DI7 13 DO7 14 DO8 15 DI7 16 DI8 17 24V 11 18 GND Voltage Feedback Voltage Feedback Ch 3-4 field Ground 4-20 ma input Ch 3-4 Field Power 4-20 ma or +/-10V out Voltage Feedback Voltage Feedback Ch 1-2 Field Ground 4-20 ma input Ch 1-2 Field Power 4-20 ma or +/-10V out
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
13-10
13-11
P2
P1
P3
W13
+/- 40 ma AO01(4-20ma)
50 62 50
50
W15
A B
AO01(+/-10V)
Current Sense W11
W11
AuxAI01
B
2
F1
Sign 1
Buffer
F1
A C
W12 AI01
B 100K
4
F1
F1
4 Output voltage
W29
AO02(4-20ma)
W21
AuxAI02 24VF1
F1
Output current
100K
A B
therm
W24
F1
shunt
F1
13-12
P2
P1
P3
W14
+/- 40 ma AO03(4-20ma)
50 62 50
50
W35
A B
AO03(+/-10V)
Current Sense W12
W31
AuxAI03
B
7
F2
Sign 2
Buffer
F1
10
A C
W32 AI03
B 100K
10
12
F2
F2
10 Output voltage
13
W49
AO04(4-20ma)
W41
AuxAI04 24VF2
F2
Output current
11
14
15
100K
A B
therm
W44
F2
16
shunt
F2
13-13
P2
W1
P1
P2
24VF2 12 13
W2
15
DIO1
Sign 1
13
7 DIO3
16 17 18 17 17 16 2 DO02
24V
18
18 GND
13-14
Specifications
Turbine valve Outputs Analog +/- 10 VDC at 40 ma. or +/- 40 ma at 200 ohms max 4-20 ma (isolated 24V supplied from the system) Accuracy: 0.25% Resolution: 16 bits Slew Time: 5 msecs Digital Form C Relay 5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC Turbine valve Inputs Analog: 4-20 ma (isolated 24V supplied from the system) Accuracy: 0.15% Resolution: 14 bits Scan Time: 5 msecs
Frequency:
Frequency: 0 -10KHz Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz 50Kz. Input voltage: 200 mv. to 10V or 24V. Isolation Galvanic isolation between two analog I/O groups. Common mode between groups: 350V dc or peak ac Galvanic isolation between field and logic: 500V
RS232 Port: 9600 baud Power 24Vdc system supply Temperature Humidity Surge 500 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
13-15
Chapter 14
Overspeed Trip Module IOP345 Overspeed Termination Module IOP346
Overview
The Overtrip module measures and processes turbine speed from three separate tachometers based speed inputs without intervention from the DPU. If the overspeed logic determines that two out of the three inputs exceed a defined threshold, Trip contacts are energized to protect the turbine from an overspeed condition.
Raw Speed3
F
Raw Speed2
F
Raw Speed1
F
DPU
Median
Field
>
Runback Output
>
Trip Output
The product consists of a maxPAC Overspeed Positioning Module and an Overspeed Termination card. The Termination card provides signal conditioning and isolation for the frequency inputs and also two form C relays.
The logic shown in the sketch is programmed in the maxDPU4F Atom Compiler language and may be modified by a trained engineer via tools provided. It is one of up to nine personalities that can be downloaded to the module and stored in flash memory. A cable is provided for downloading the configuration. Personality selection, the configuration, I/O status, and other signals are accessible via the maxDPUF.
Features Software stored in FLASH Field to logic isolation Fast scan time Fast frequency measurements On-line diagnostics Downloadable personality
LED Indication
Individual bicolor front-panel LEDs provide I/O state indication for Trip outputs and frequency inputs. Two bicolor LEDS, Stat 1 and Stat 2 provide diagnostic indication In addition, the lower green LED, labeled Active at the bottom of the front panel, is on when power is on and the DPU is communicating with the
14-2
Jumper Configuration
The Overspeed module uses a multi-purpose-positioning module with multiple jumper options. Not all the jumpers are applicable for this application because the analog I/O is not used. Refer to the following table for the jumper setting information that is applicable to this module.
Position B Not Installed Not Installed Installed Installed Installed Not Installed
Position B Not Installed Not Installed Installed Not Installed Installed Installed
Position B Not Installed Not Installed Installed Not Installed Installed Installed
Refer to the following table for the Turbine Valve Termination jumpers.Bold indicated the default positions:
Jumper W1 W2 W3 W4 W5 W6
function Wetting 1 Voltage Frequency 1 Voltage Wetting 2 Voltage Wetting 2 Voltage Wetting 3 Voltage Wetting 3 Voltage
Installed Local 0.2 10V Local 0.2 10V Local 0.2 10V
14-3
Bus Address
This module consumes two bus addresses.
Most Significant Less Significant
DPU Compatibility
This module is only compatible with DPU4F
Module Operation
This microprocessor-based module provides a full complement of I/O. It includes four analog inputs, eight analog inputs, 8 digital inputs and eight digital outputs. The turbine overspeed application utilizes only the digital I/O portion of the module. The unused analog portion is shown with dashed lines in the functional sketch. The microprocessor circuit includes a 25Mhz 68332 processor and associated memory. The Time Processor Unit (TPU) included in the 68332 processor is used to process the frequency measurements. A FPGA provides support logic including parity and the I/O bus control logic.
14-4
DC/DC
24V
5V
DC/DC
24V +/-15V
FLASH 2Mbit
5V
DC/DC
CLOCK
FPGA
RS232
I/O Bus
DO1 DOI8
14-5
Diagnostics
The module executes diagnostics on power up. When an error is detected on power-up or during online operation, the front-panel green LED, labeled Active, blinks the first digit at a slower rate and the second digit at a faster rate. During normal operation the active LED is on continuously or flashes at a steady one-second rate when the module is not being scanned. The diagnostic codes are as follows:
Error Condition ADC Serial Transmit Fault ADC Serial Transmit Fault ADC Sanity Test Failed RAM Test Failure (power-on) CPU Stack Error (power-on) CPU Error (power-on) Checksum Error (power-on) Interrupt Error (power-on) FPGA Download Error (power-on) FLASH Erase Error FLASH Programming Error FPGA Error Serial I/O Failure Parity Error
Code 0x12 0x13 0x15 0x22 0x23 0x24 0x25 0x26 0x32 0x35 0x36 0x37 0x38 0x39
14-6
14-7
14-8
P2
P1
P3
AO01(4-20ma) 1 W15
A B
AO01(+/-10V) W11
A
AuxAI01
B
F1
24VF1 2 24VF1 2
A C B 100K
W12 AI01
3 3
A B
F1
F1
W29
AO02(4-20ma)
W21
AuxAI02 24VF1
F1
100K
A B
therm
W24
F1
shunt
F1
14-9
AO03(4-20ma) 9 W35
A B
AO03(+/-10V) W31
A
AuxAI01
B
F2
24VF2 10
A C B 100K
W32 AI03
11
A B
12
F2
13
W49
AO04(4-20ma)
W41
AuxAI04 24VF2
F2
14
15
100K
A B
therm
W44
F2
16
shunt
F2
14-10
Termination 24VF2
P1
P2
Module
12 13
W2
3 DIO1
14 15 Conditioning Circuit
W3
24VF2 7 7 DIO3
12 13
W4
14 15 Conditioning Circuit
W5
12 13
W6
24VF2 9 11 DIO5
14
6 DO04
14-11
Specifications
Frequency Input: Frequency: 0 -10KHz Accuracy: 0.1% for frequency up to 5KHz, 0.25% for 5KHz 10KHz. Input voltage: 200 mv to 10V or 24V. Digital Output Form C Relay 5A @ 250VAC, 3A @ 30VDC, 0.3A @110VDC RS232 Port: 9600 baud Power 24Vdc system supply Temperature Humidity Surge 500 ma 0-60 degrees C 0-90% no-condensing IEEE-472-1974
14-12