Remote Automation Solutions Bristol DPC 3335 Distributed Process Controller Owner's Manual
광고
광고
Instruction Manual
CI-3335
Jan., 2007
DPC 3335 & RIO 3331
Distributed Process Controller DPC 3335
& Remote I/O Unit RIO 3331
www.EmersonProcess.com/Bristol
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, failsafe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional in-formation is required, the purchaser is advised to contact Bristol .
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol and save Bristol harmless from any liability or damage which Bristol may incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 at the back of this manual for proper care and handling of ESD-sensitive components.
Bristol 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
WARRANTY
A. Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing.
B. Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited to the terms of the warranties given by the manufacturer of such goods.
D. All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without Bristol's consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by Bristol, or (iv) worn, injured or damaged from abnormal or abusive use in service time.
E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
F. No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.
REMEDIES
A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
B. Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation, from use of the information herein or from the purchase or use by Buyer, its em-ployees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com) and sending it via E-Mail to [email protected]
. A Bristol Repair Dept. representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Inc.
Repair
1100 Buckingham Street
Watertown, CT 06795
A Bristol Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.
Bristol
Repair Authorization Form
(off-line completion)
(Providing this information will permit Bristol to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH
Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
•
Evaluate / Test / Verify Discrepancy
•
Repair / Replace / etc. in accordance with this form
•
Return to Customer
Line No.____________
Please be aware of the Non warranty standard charge:
•
There is a $100 minimum evaluation charge, which is applied to the repair if applicable (
√
in “returned”
B,C, or D of part III below)
Part I Please complete the following information for single unit or multiple unit returns
Address No.
Bill to :
Purchase Order:
Phone:
(office use only) Address No.
Ship to:
Fax:
(office use only)
Contact Name: ____________________________________
E-Mail:
Model No./Part No. Description
Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1.
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3. What is the Firmware revision? _____________________ What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A.
If product is within the warranty time period but is excluded due to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B.
If product were found to exceed the warranty period, would you like the product:
C.
If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?
D.
If Bristol is unable to verify the discrepancy, would you like the product: returned replaced *see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: ______________________________ phone_____________________
If we are unable to contact this person the backup person is: _________________________ phone_____________________
Special Requests: ____________________________________________________________________________________
____________________________________________________________________________________________________
Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
A Few Words About Bristol Inc.
For over 100 years, Bristol ® has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Inc. instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about Control Wave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865 or e-mail: [email protected]
For technical questions regarding ACCOL products, OpenBSI Utilities , UOI and all other software except for Control Wave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/
For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464 .
You can e-mail the Communication Technology Group at: [email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
Questions of a non-technical nature (product orders, literature requests, price and delivery information, etc.) should be directed to the nearest sales office (listed on the rear cover of this manual) or to your Bristol-authorized sales representative.
Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office covers your particular area.
Visit our Site on the World Wide Web
For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com
Training Courses
Bristol’s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown, Connecticut headquarters, and at selected Bristol regional offices, throughout the year. Contact our Training Department at (860) 945-2343 for course information, enrollment, pricing, and scheduling.
CI-3335 - TABLE OF CONTENTS
Page
PRODUCT DESCRIPTION ..................................................................................................................... 1-1
OVERVIEW OF MODULES AND PC BOARDS .................................................................................... 1-4
System Interconnect (SI) Board ........................................................................................................ 1-5
System Monitor Module..................................................................................................................... 1-5
Power Supply Module (DC-DC Converter) ....................................................................................... 1-5
CPU Module........................................................................................................................................ 1-5
Enhanced Communication Engine Module (ECE Module).............................................................. 1-8
I/O Modules......................................................................................................................................... 1-8
HAZARDOUS AREA CLASSIFICATION............................................................................................. 1-10
Equipment
Class
MODEL NUMBER ANALYSIS ............................................................................................................. 1-11
Section 1A APPLICATION SOFTWARE
CATEGORIES OF APPLICATION SOFTWARE................................................................................ 1A-1
ACCOL TOOLS SOFTWARE ............................................................................................................... 1A-1
SUPERVISORY SOFTWARE ............................................................................................................... 1A-4
OPEN BSI UTILITIES SOFTWARE.................................................................................................... 1A-4
SYSTEM APPLICATIONS ................................................................................................................... 1A-5
Unit............................................................................................................................. 1A-6
Local Area Network (LAN) ........................................................................................................... 1A-6
Wide Area Network (WAN) ............................................................................................................ 1A-8
IP Network Using Ethernet and Open BSI 3.0 ............................................................................. 1A-9
UNPACKING THE DPC .......................................................................................................................... 2-1
SELECTING A LOCATION..................................................................................................................... 2-1
Combined Equipment Temperature Effects ..................................................................................... 2-1
Radio Frequency Interference (RFI) ................................................................................................. 2-1
Electrical Interference ....................................................................................................................... 2-1
INSTALLING THE DPC.......................................................................................................................... 2-2
REMOVING AND INSTALLING OPTIONAL COVERS....................................................................... 2-3
INSTALLING PC BOARDS & I/O MODULES ...................................................................................... 2-4
Identification............................................................................................................................... 2-4
Module
WIRING AND CABLING PRACTICES .................................................................................................. 2-4
Preparation .............................................................................................................................. 2-4
Shielded Wiring for AI and HSC Inputs .......................................................................................... 2-5
Harnesses............................................................................................................................... 2-5
PERFORMING FIELD WIRING CONNECTIONS ............................................................................... 2-6
Plug-In Terminal Blocks.................................................................................................................... 2-6
Labels ................................................................................................................................. 2-7
GENERAL NOTES................................................................................................................................... 3-1
DESCRIPTION OF POWER SYSTEM ................................................................................................ 3A-1
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Section 3A - DC POWER SYSTEM (Continued)
Power Supply Module (DC-DC Converter) .................................................................................... 3A-1
Monitor Module.................................................................................................................. 3A-1
System
WIRING AND SETUP........................................................................................................................... 3A-1
Terminals ............................................................................................................................. 3A-2
Watchdog
Auto/Man Transfer Terminals........................................................................................................ 3A-4
Grounding
Section 3B - 80186 CPU MODULE ( Series 391369-XX-X )
DESCRIPTION ...................................................................................................................................... 3B-1
SWITCH AND JUMPER CONFIGURATION..................................................................................... 3B-3
Switch SW1 (Mode) ......................................................................................................................... 3B-4
Switch SW2 (Node Address) ........................................................................................................... 3B-6
Jumpers - Memory Board ............................................................................................................... 3B-6
Jumpers - Processor Board ............................................................................................................. 3B-6
LEDS AND RESET BUTTON .............................................................................................................. 3B-6
Status LEDs .................................................................................................................................... 3B-6
Watchdog & Idle LEDs ................................................................................................................... 3B-7
Reset Button (SW3)......................................................................................................................... 3B-7
INSTALLATION OF RAM OR EPROM LOAD SET........................................................................... 3B-7
Low Byte and High Byte Matched Set........................................................................................... 3B-8
Changing a Load Set....................................................................................................................... 3B-8
PART NUMBER ASSIGNMENT.......................................................................................................... 3B-9
Section 3BA - 32-Bit CPU ENGINE ASSEMBLY - Real Mode (Series 395358-01-9)
DESCRIPTION ....................................................................................................................................3BA-1
Overview ...........................................................................................................................3BA-1
I/O INTERFACE..................................................................................................................................3BA-4
SWITCH AND JUMPER CONFIGURATION...................................................................................3BA-4
Memory & Peripheral Board Switch SW1 (Mode).......................................................................3BA-4
Memory & Peripheral Board Switch SW1-1 - System Firmware Flash Download...................3BA-5
Memory & Peripheral Board Switches SW1 -2, -3, -4 - Cold Download Baud Rate..................3BA-5
Memory & Peripheral Board Switches SW1 -5, -6 - ACCOL FLASH Lock/ACCOL
Load
Memory & Peripheral Board Switch SW2 (Node Address).........................................................3BA-6
CPU Board Switches SW3 & SW4 ...............................................................................................3BA-7
Memory & Peripheral Board Reset Button SW5.........................................................................3BA-7
Memory & Peripheral Board Jumper W1 (RAM Battery) ..........................................................3BA-7
LED ASSIGNMENTS..........................................................................................................................3BA-8
Memory & Peripheral Board Status LEDs DS1-DS6 .................................................................3BA-8
Memory & Peripheral Board Watchdog and Idle LEDs DS7 & DS8 .........................................3BA-8
CPU Board Communication Port LEDs DS9-1 through DS9-4 .................................................3BA-8
Section 3BB - 32-Bit CPU ENGINE ASSEMBLY - Protected Mode Series 396029-XX-X
DESCRIPTION ....................................................................................................................................3BB-1
Overview ...........................................................................................................................3BB-1
PROTECTED MODE 32 BIT CPU ENGINE I/O INTERFACE .......................................................3BB-4
SWITCH AND JUMPER CONFIGURATION...................................................................................3BB-5
Memory & Peripheral Board Switch SW1 - (Mode) ....................................................................3BB-5
Memory & Peripheral Board Switch SW1-1 System Firmware FLASH Download..................3BB-6
Memory & Peripheral Board Switches SW1 -2, -3, -4 Cold Download Baud Rate ....................3BB-6
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Section 3BB - 32-Bit CPU ENGINE ASSEMBLY - Protected Mode
Series 396029-XX-X (Continued)
Memory & Peripheral Board Switches SW1-6 - ACCOL Load Storage
Page
& SW1-4 - ACCOL FLASH Lock ..................................................................................................3BB-7
Memory & Peripheral Board Switch SW2 - (Node Address)......................................................3BB-7
32-Bit CPU Engine Board Switches SW3 & SW4 .......................................................................3BB-7
Memory & Peripheral Board Reset Button SW5.........................................................................3BB-8
Memory & Peripheral Board Jumper W1 (Ram Battery)...........................................................3BB-8
Extended Memory Board Jumpers W1, W2 & W3 ......................................................................3BB-8
Extended Memory Board Jumper W4..........................................................................................3BB-8
Memory & Peripheral Board Status LEDs DS1-DS6 .................................................................3BB-9
Memory & Peripheral Watchdog and Idle LEDs DS7 & DS8 ....................................................3BB-9
CPU Board Communication Port LEDs DS9-1 through DS9-4.................................................3BB-9
Section 3BC - 32-Bit CPU PROTECTED MODE ENGINE ASS'Y. with Ethernet
DESCRIPTION ....................................................................................................................................3BC-1
Overview ...........................................................................................................................3BC-1
PROTECTED MODE 32-BIT CPU ENGINE I/O INTERFACE.......................................................3BC-5
SWITCH AND JUMPER CONFIGURATION...................................................................................3BC-5
Memory & Peripheral Board Switch SW1 (Mode).......................................................................3BC-6
Memory & Peripheral Board Switch SW1-1 System Firmware FLASH Download..................3BC-6
Memory & Peripheral Board Switches SW1 -2, -3, -4 Cold Download Baud Rate....................3BC-6
Memory & Peripheral Board Switches SW1-6 - ACCOL Load Storage
& SW1-4 - ACCOL FLASH Lock ..................................................................................................3BC-7
Memory & Peripheral Board Switch SW2 (Node Address) ....................................................3BC-7
Ethernet CPU Board Switches SW3 & SW4 ...............................................................................3BC-8
LED Board (CPU) Reset Button SW5..........................................................................................3BC-8
Memory & Peripheral Board Jumper W1 (RAM Battery) ..........................................................3BC-9
Extended Memory Board Jumpers W1, W2 & W3 ......................................................................3BC-9
Extended Memory Board Jumper W4..........................................................................................3BC-9
ETHERNET ASSEMBLY LEDs.........................................................................................................3BC-9
LED Board Status LEDs DS1-DS6..............................................................................................3BC-9
LED Board Watchdog and Idle LEDs DS7 & DS8......................................................................3BC-9
CPU Board Communication Port LEDs DS9-1 through DS9-4 ................................................3BC-9
Ethernet CPU Engine Ethernet Status LEDs DS100-1 through DS100-4 .............................3BC-10
Ethernet CPU Engine Board Ethernet Ports ............................................................................3BC-10
Ethernet CPU Engine 10Base-T Connector P2.........................................................................3BC-10
Ethernet CPU Engine Attachment Unit Interface Connector J3 ............................................3BC-12
Section 3C - 4 & 2 PORT ENHANCED COMMUNICATION BOARDS
GENERAL.............................................................................................................................................. 3C-1
CONFIGURATION NOTES.................................................................................................................. 3C-1
SETTING DIP SWITCHES................................................................................................................... 3C-4
SETTING JUMPERS ............................................................................................................................ 3C-5
RS-485 AND RS-423 PORT CONNECTIONS ..................................................................................... 3C-6
LED INDICATORS................................................................................................................................ 3C-7
LOOPBACK TESTING ......................................................................................................................... 3C-7
Section 3D - ANALOG INPUT MODULE (Four AI Type)
GENERAL.............................................................................................................................................. 3D-1
TERMINAL DESIGNATIONS.............................................................................................................. 3D-1
SIGNAL GROUNDING OPTIONS....................................................................................................... 3D-6
0-10 V TYPE MODULES ...................................................................................................................... 3D-7
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Section 3D - ANALOG INPUT MODULE (Four AI Type) (Continued)
1-5 V / 4-20 mA TYPE MODULES ....................................................................................................... 3D-8
1-5 V dc Isolated Input.................................................................................................................... 3D-8
4-20 mA Transmitter Using +24 V DPC Power Source ................................................................ 3D-9
4-20 mA Transmitter Using Auxiliary +24 V Power Supply...................................................... 3D-10
SPECIFICATIONS .............................................................................................................................. 3D-11
Analog Input Specifications.......................................................................................................... 3D-11
Environmental Specifications..................................................................................................... 3D-12
Section 3DA - ANALOG INPUT MODULE (Eight AI Type)
GENERAL............................................................................................................................................3DA-1
TERMINAL DESIGNATIONS............................................................................................................3DA-1
SELECTING 1-5V OR 4-20 mA INPUTS...........................................................................................3DA-3
1-5 Vdc Isolated Inputs .................................................................................................................3DA-3
4-20 mA Transmitter Using +24 V DPC Power Source .............................................................3DA-4
4-20 mA Transmitter Using Aux. +24V Power Supply...............................................................3DA-5
Section 3DB - HIGH DENSITY ANALOG INPUT MODULE (Four or Eight AI Type)
GENERAL............................................................................................................................................3DB-1
TERMINAL DESIGNATIONS............................................................................................................3DB-1
SELECTING 1-5V OR 4-20 mA INPUTS...........................................................................................3DB-4
1-5 Vdc Isolated Inputs .................................................................................................................3DB-4
4-20 mA Transmitter Using +24V DPC Power Source...............................................................3DB-5
4-20 mA Transmitter Using Auxiliary +24V Power Supply.......................................................3DB-6
SPECIFICATIONS ..............................................................................................................................3DB-7
Analog Input Specifications..........................................................................................................3DB-7
Specifications.......................................................................................................3DB-8
Section 3E - ANALOG OUTPUT MODULE (Two AO Type)
GENERAL.............................................................................................................................................. 3E-1
TERMINAL DESIGNATIONS.............................................................................................................. 3E-1
SIGNAL GROUNDING OPTIONS....................................................................................................... 3E-4
0-10 V TYPE MODULES ...................................................................................................................... 3E-4
1-5 V / 4-20 mA TYPE MODULES ....................................................................................................... 3E-5
1-5 Vdc Output ................................................................................................................................ 3E-5
4-20 mA Output............................................................................................................................... 3E-6
SPECIFICATIONS ................................................................................................................................ 3E-7
Analog Output Specifications ......................................................................................................... 3E-7
Environmental
Section 3EA - HIGH DENSITY ANALOG OUTPUT MODULE (Two & Four AO Type)
GENERAL............................................................................................................................................3EA-1
TERMINAL DESIGNATIONS............................................................................................................3EA-1
SELECTING 1-5 V OR 4-20 mA OUTPUTS......................................................................................3EA-3
1-5 Vdc Output ..............................................................................................................................3EA-3
4-20 mA Output.............................................................................................................................3EA-4
JUMPERS & ADJUSTMENTS...........................................................................................................3EA-5
SPECIFICATIONS ..............................................................................................................................3EA-5
Analog Output Specifications .......................................................................................................3EA-5
Specifications.......................................................................................................3EA-6
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Section 3F - DISCRETE INPUT MODULE (Four or Eight DI Type)
GENERAL...............................................................................................................................................3F-1
Locations .............................................................................................................................3F-6
LED On-Off Option ..........................................................................................................................3F-6
TERMINAL DESIGNATIONS...............................................................................................................3F-6
APPLICATIONS FOR 5, 12 & 24 V TYPE MODULES .......................................................................3F-7
Bi-State Voltage Signal as Input.....................................................................................................3F-7
Relay Contact or PDM Xmtr. as Input ...........................................................................................3F-8
Dry Contact Powered by DPC Supply.............................................................................................3F-8
APPLICATIONS FOR 120 V TYPE MODULES ..................................................................................3F-9
SPECIFICATIONS ...............................................................................................................................3F-10
Discrete Input Specifications.........................................................................................................3F-10
Environmental
Section 3FA - HDDI BOARD (Sixteen DI Type)
GENERAL............................................................................................................................................3FA-1
LED On-Off OPTION - Jumper W17 ...........................................................................................3FA-3
TERMINAL DESIGNATIONS............................................................................................................ 3FA-3
INTERNALLY-SOURCED RELAY CONTACT OR
OPEN COLLECTOR DI ...................................................................................................................... 3FA-4
SINGLE-ENDED DRIVEN RELAY CONTACT DI .........................................................................3FA-4
DRIVEN DIFFERENTIAL RELAY CONTACT DI ..........................................................................3FA-5
MODULE RESTRICTIONS................................................................................................................ 3FA-6
SPECIFICATIONS ..............................................................................................................................3FA-6
Section 3G - DISCRETE OUTPUT MODULE (Four or Eight DO Type)
GENERAL.............................................................................................................................................. 3G-1
Applications........................................................................................................................ 3G-1
Jumper
LED On-Off Option ......................................................................................................................... 3G-5
TERMINAL DESIGNATIONS.............................................................................................................. 3G-5
OPEN COLLECTOR/OPEN DRAIN TYPE MODULES ..................................................................... 3G-6
RELAY-CONTACT TYPE MODULES................................................................................................. 3G-6
SPECIFICATIONS ................................................................................................................................ 3G-8
Discrete Output Specifications ...................................................................................................... 3G-8
Specifications......................................................................................................... 3G-9
Section 3GA SOLID STATE DC RELAY DO MODULE (Eight SSDCRDO Type)
GENERAL............................................................................................................................................3GA-1
Applications......................................................................................................................3GA-1
Jumper
LED On-Off Option .......................................................................................................................3GA-1
TERMINAL DESIGNATIONS............................................................................................................3GA-3
THE EXTERNAL CIRCUIT................................................................................................................3GA-4
SPECIFICATIONS ..............................................................................................................................3GA-4
Section 3GB - HIGH DENSITY DISCRETE OUTPUT MODULE
GENERAL............................................................................................................................................3GB-1
TYPICAL APPLICATIONS ................................................................................................................3GB-1
LED ON-OFF OPTION .......................................................................................................................3GB-1
TERMINAL DESIGNATIONS............................................................................................................3GB-1
OPEN DRAIN OUTPUT REQUIREMENTS .....................................................................................3GB-3
SPECIFICATIONS ..............................................................................................................................3GB-4
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Section 3H HIGH SPEED COUNTER MODULE Series 392008 & 392028
GENERAL.............................................................................................................................................. 3H-1
Locations ........................................................................................................................... 3H-1
LED On-Off Option ......................................................................................................................... 3H-1
TERMINAL DESIGNATIONS.............................................................................................................. 3H-2
SIGNAL GROUNDING OPTIONS.......................................................................................................3H-3
HSC INPUT CONFIGURATIONS .......................................................................................................3H-4
Configurations for Self-Powered Devices (Isolated)..................................................................... 3H-4
Configurations for HSC-Powered Devices (Non-Isolated) .......................................................... 3H-5
SPECIFICATIONS .............................................................................................................................. 3H-10
High Speed Counter Specifications .............................................................................................. 3H-10
Specifications...................................................................................................... 3H-10
Section 3HA HIGH SPEED COUNTER MODULE Series 400018
GENERAL........................................................................................................................................... 3HA-1
Locations ......................................................................................................................... 3HA-1
LED On-Off Option ...................................................................................................................... 3HA-1
TERMINAL DESIGNATIONS........................................................................................................... 3HA-2
SIGNAL GROUNDING OPTIONS.................................................................................................... 3HA-4
HSC INPUT CONFIGURATIONS .................................................................................................... 3HA-5
Configurations for Self-Powered Devices (Isolated) ................................................................... 3HA-6
Configurations for HSC-Powered Devices (Non-Isolated) ......................................................... 3HA-6
SPECIFICATIONS ........................................................................................................................... 3HA-11
High Speed Counter Specifications ........................................................................................... 3HA-11
Specifications.................................................................................................... 3HA-11
Section 3I LOW LEVEL ANALOG INPUT MODULE (Four LLAI Type)
GENERAL............................................................................................................................................... 3I-1
WIRING TERMINALS........................................................................................................................... 3I-1
FOUR-WIRE RTD INPUT ..................................................................................................................... 3I-3
THREE-WIRE RTD INPUT................................................................................................................... 3I-4
THERMOCOUPLE OR MILLIVOLT INPUT....................................................................................... 3I-5
SPECIFICATIONS ................................................................................................................................. 3I-5
Low level Analog Input Specifications ............................................................................................ 3I-5
Environmental
Section 3J HIGH SPEED ANALOG INPUT MODULE & SYSTEM
GENERAL............................................................................................................................................... 3J-1
HSAI Module Pressure Application ................................................................................................ 3J-1
HSAI Module Operating Overview ................................................................................................. 3J-1
HSAI MODULE TERMINAL DESIGNATIONS .................................................................................. 3J-3
HSAI MODULE SIGNAL GROUNDING OPTIONS ........................................................................... 3J-4
Grounding.................................................................................................................................... 3J-5
DI Grounding.................................................................................................................................... 3J-6
HSAI MODULE ANALOG INPUT WIRING........................................................................................ 3J-6
1-5 V dc Isolated Input..................................................................................................................... 3J-6
4-20 mA Transmitter Using +24 V DPC Power Source ................................................................. 3J-6
4-20 mA Transmitter Using Auxiliary +24 V Power Supply......................................................... 3J-7
HSAI MODULE DISCRETE INPUT WIRING..................................................................................... 3J-8
HSAI SYSTEM OVERVIEW.................................................................................................................. 3J-9
HSAI PANEL TERMINAL DESIGNATIONS & MAJOR COMPONENTS........................................ 3J-9
HSAI Panel Jumpers & LEDs ....................................................................................................... 3J-11
HSAI Panel Terminal Blocks......................................................................................................... 3J-12
SPECIFICATIONS ............................................................................................................................... 3J-14
Requirements ...................................................................................................................... 3J-14
Contents / 6 CI-3335
CI-3335 - TABLE OF CONTENTS
Page
Section 3J HIGH SPEED ANALOG INPUT MODULE & SYSTEM (Continued)
HSAI Module Inputs............................................................................................................................. 3J-14
HSAI Module Input Types............................................................................................................. 3J-14
HSAI Module Accuracy.................................................................................................................. 3J-14
HSAI Module Input Impedance..................................................................................................... 3J-15
HSAI Module Signal Conditioning................................................................................................ 3J-15
HSAIM Common Mode Rejection Ratio ...................................................................................... 3J-15
HSAIM Common Mode Voltage .................................................................................................... 3J-15
Surge
HSAI Panel Inputs ......................................................................................................................... 3J-15
HSAI Panel Input Types................................................................................................................ 3J-15
HSAI Panel Input Impedance ....................................................................................................... 3J-15
HSAI Panel Signal Conditioning................................................................................................... 3J-15
HSAI Panel Common Mode Voltage ............................................................................................. 3J-16
Suppression.......................................................................................................................... 3J-16
HSAI Panel Outputs ...................................................................................................................... 3J-16
Environmental
Section 3L - REMOTE I/O UNIT - 3331
PRODUCT DESCRIPTION ...................................................................................................................3L-1
TYPICAL APPLICATIONS ...................................................................................................................3L-4
INSTALLATION.....................................................................................................................................3L-5
RIO Unit Enclosure..........................................................................................................................3L-5
Communication Ports ......................................................................................................................3L-5
Board Configuration & Field Wiring...............................................................................................3L-5
CONFIGURING RIO-TYPE CPU MODULE (PT.NO. 395212-01-5)................................................3L-6
Function of Switch SW1...................................................................................................................3L-6
Address,
Jumpers ............................................................................................................................................3L-9
GENERAL STARTUP NOTES ..............................................................................................................3L-9
PART NUMBER ASSIGNMENT.........................................................................................................3L-11
Section 3M - REMOTE TERMINATION MODULES
DESCRIPTION ......................................................................................................................................3M-1
Host Module Requirements ............................................................................................................3M-1
MECHANICAL INSTALLATION ........................................................................................................3M-1
STANDARD ANALOG INPUT RT MODULE .....................................................................................3M-3
POWERED ANALOG INPUT RT MODULE.......................................................................................3M-5
ANALOG OUTPUT RT MODULE .......................................................................................................3M-6
EXTERNALLY-POWERED DISCRETE INPUT.................................................................................3M-8
Standard & Fused, DIO-RT Modules.............................................................................................3M-8
Powered DIO-RT Module..............................................................................................................3M-10
OPEN COLLECTOR DISCRETE OUTPUT ......................................................................................3M-10
Standard & Fused Type DIO-RT Module ....................................................................................3M-10
Powered DIO-RT Module..............................................................................................................3M-12
RELAY CONTACT DISCRETE OUTPUT.........................................................................................3M-12
SPDT Relay DO-RT Module .........................................................................................................3M-12
DPDT Relay DO-RT Module.........................................................................................................3M-14
Section 3N - ISOLATED REMOTE TERMINATION MODULES
DESCRIPTION ...................................................................................................................................... 3N-1
Power and Indication ...................................................................................................................... 3N-2
Requirements ......................................................................................................................... 3N-2
MECHANICAL INSTALLATION ........................................................................................................3N-2
CI-3335 Contents / 7
CI-3335 - TABLE OF CONTENTS
Page
Section 3N - ISOLATED REMOTE TERMINATION MODULES (Continued)
ANALOG INPUT & RT-TYPE IRT MODULE .................................................................................... 3N-3
THERMOCOUPLE (TC) TYPE IRT MODULE................................................................................... 3N-6
ANALOG OUTPUT IRT MODULES.................................................................................................... 3N-6
DISCRETE INPUT IRT MODULES .................................................................................................... 3N-8
Externally-Powered
Locally-Powered
DI ................................................................................................................... 3N-8
DI ......................................................................................................................... 3N-9
240 Vac DI ..................................................................................................................................... 3N-10
Section 3P - CHECK BEFORE OPERATE SYSTEM
DESCRIPTION .......................................................................................................................................3P-1
CONFIGURATION OF CBO MODULE ...............................................................................................3P-5
CONFIGURATION OF CBO RELAY BOARD .....................................................................................3P-5
BOARD WIRING ....................................................................................................................................3P-5
Cable
Connections for Relay-Type Termination Boards ..........................................................................3P-5
Connections for Open Collector Termination Boards ....................................................................3P-6
Wiring of +24 V Supply Terminals..................................................................................................3P-7
SERVICE.................................................................................................................................................3P-8
CBO SPECIFICATIONS ........................................................................................................................3P-8
GENERAL................................................................................................................................................. 4-1
PRELIMINARY CHECKS ....................................................................................................................... 4-1
STARTING THE DPC .............................................................................................................................. 4-2
SHUTDOWN PROCEDURE.................................................................................................................... 4-5
SERVICE NOTES..................................................................................................................................... 5-1
Equipment .................................................................................................................................. 5-1
DC POWER SYSTEM .............................................................................................................................. 5-1
Monitor Module..................................................................................................................... 5-1
Calibration of Supply Reference Voltage (4.7 Vdc) .......................................................................... 5-4
Hints ....................................................................................................................... 5-4
CPU ENGINE BOARD CHECKS............................................................................................................ 5-6
Backup
Watchdog & Idle LEDs .................................................................................................................... 5-10
LEDs ..................................................................................................................................... 5-11
Ethernet CPU Engine Ass'y. Ethernet Port Loopback Test ......................................................... 5-15
COMMUNICATION ENGINE BOARD TESTS .................................................................................. 5-15
CE Board Loopback Test ................................................................................................................. 5-16
TXD and RXD LEDs ........................................................................................................................ 5-17
DI AND DO MODULES......................................................................................................................... 5-17
HIGH SPEED COUNTER MODULE.................................................................................................... 5-17
DIAGNOSTICS....................................................................................................................................... 5-18
GENERAL NOTES................................................................................................................................. 5-18
Extent of Field Repairs .................................................................................................................... 5-18
Disconnecting RAM Battery ............................................................................................................ 5-18
Maintaining Backup Files ............................................................................................................... 5-18
32-Bit CPU Assembly Battery......................................................................................................... 5-19
PHYSICAL SPECIFICATIONS............................................................................................................... 6-1
Contents / 8 CI-3335
CI-3335 - TABLE OF CONTENTS
Page
Section 6 - SPECIFICATIONS (Continued)
PERFORMANCE SPECIFICATIONS .................................................................................................... 6-1
Power Supply Module (DC-DC Converter) ....................................................................................... 6-1
System
CPU Engine Module........................................................................................................................... 6-2
Enhanced Communication Engine (ECB) Board.............................................................................. 6-3
Analog Input Modules........................................................................................................................ 6-3
Analog Output Modules ..................................................................................................................... 6-4
Discrete Input Modules...................................................................................................................... 6-4
Discrete Output Modules................................................................................................................... 6-5
High Speed Counter Modules............................................................................................................ 6-6
Low Level Analog Input Modules...................................................................................................... 6-6
High Speed Analog Input Module ..................................................................................................... 6-8
Solid State DC Relay Discrete Output Board................................................................................... 6-8
Optional Display & Keyboard Assembly........................................................................................... 6-8
ENVIRONMENMTAL SPECIFICATIONS ............................................................................................ 6-9
POWER REQUIREMENTS ..................................................................................................................... 6-9
APPENDICES
REFERENCED SUPPLEMENTAL CUSTOMER INSTRUCTION MANUALS
Bristol 1200 bps - PL & PSTN Modems ..........................................................................................CI-1200
Bristol 1200 bps - PL Modem .....................................................................................................CI-1200-PL
Bristol 9600 bps - PSTN Modem......................................................................................................CI-9600
Bristol 9600 bps - PSTN Modem................................................................................................... CI-9600A
WINDIAG - Windows Diagnostics for Bristol Controllers .............................................................D4041A
SUPPLEMENTAL INSTRUCTION MANUALS
Guidelines for System Grounding.......................................................................................................S1400
Care and Handling of PC Boards and ESD-Sensitive Components ...............................................S14006
CI-3335 Contents / 9
BLANK PAGE
Section 1
INTRODUCTION
This section describes the Series 3335 Distributed Process Controllers and Data Concentrators. Details on the Series 3331 Remote Input/Output Unit are covered in Section 3L.
1.1 PRODUCT DESCRIPTION
Series 3335 Distributed Process Controllers (DPC) are microprocessor-based units that can function as stand-alone devices or as nodes of a complex NETWORK 3000 tm system. Each
DPC monitors a number of process-related I/Os, maintains and analyzes real-time data, executes control algorithms based on the user's software configuration, and communicates with the network as required.
Although compact in size, the DPC provides a high degree of versatility and flexibility. A general overview of its features follows:
● Universal CPU Engine
The CPU Engine Assembly is a two board set consisting of a CPU Board and a Memory
& Peripheral Board.
80186-Based CPU Engine Assembly
This assembly contains the Central Processing Unit (CPU), memory subsystem, watchdog timer, real-time clock, LED status logic, and the input/output bus. RAM data is backed by a 4000-hour lithium battery.
80186-Based CPU Engine Assemblies are available with either a 12 MHz or 20 MHz processor. A variety of RAM sizes and ACCOL Load EPROMS options are available (see
Section 3B and Table 1-B).
80386EX-Based CPU Engine Assemblies
A 32-bit embedded microprocessor functions as the CPU. This fully static microprocessor features low power and low voltage capabilities, and utilizes either a 16bit (Real Mode) or 32-bit (Protected Mode) programming architecture. These assemblies are furnished with two asynchronous serial ports (BIP1 & BIP2) which are switch configurable for RS-562 or RS-485 operation.
The Protected Mode (32-bit) version of the 80386EX-based CPU Engine Assembly has a piggyback mounted Extended Memory Board (EMB) which is equipped with 2MB of
FLASH Memory and accommodates up to 4MB of RAM (see Table 1-B and Section 3BB).
A description of the Real Mode (16-bit) version of the 80386EX-based CPU Engine
Assembly is provided in Section 3BA.
CI-3335 Introduction / 1-1
A description of the 80386EX-based CPU with Ethernet is provided in Section 3BC.
● Flexible I/O Subsystem
Plug-in modules may be added or changed in the field to meet the needs of future applications. The modules offered are AI, AO, DI, DO, HSC, LLAI and HSAI types. For details, see OVERVIEW OF MODULES AND PC BOARDS on page 1-4.
Figure 1-1 - DPC with Optional Front Cover
● Communications
The DPC provides two RS-423/RS-485 ports as standard, with up to six additional ports available as options (maximum of eight). Communication rates are selectable from 110
Baud (Bd) to 38.4 KiloBaud (KBd) asynchronous, or up to 187.5 KBd synchronous.
Other optional communication formats offered are internal Private Line Modems,
Switched Network Modems, Redundant Automatic Switchover Communication Link
(RASCL) Boards, and Fiber Optic Interface (FOI) Boards. Appendices on these communication op-tions are provided in the rear of this manual.
● ACCOL Software
The ACCOL Interactive Compiler (AIC program) is used to configure and execute the
ACCOL load. This load, which contains the user's process configuration data, is stored in RAM or optional EPROM memory. RAM-type memory is backed by a lithium battery to retain the load data during power shutdowns or failures. EPROM-type memory is hard configured and its ACCOL load data is retained with or without power. See
ACCOL TOOLS SOFTWARE in Section 1A.
● BSAP Network
Series 3335 DPCs can function as nodes of a Bristol-Babcock Synchronous
Asynchronous Protocol (BSAP) Network along with other distributed controller models such as the DPC 3330, RDC 3350 and UCS 3380. These nodes can be used in wide area networks, local area networks, or combinations of both. See Section 1A for details.
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Introduction CI-3335
CI-3335
Figure 1-2 - Front View Showing PC Board and Module Layout
Introduction / 1-3
● Optional LCD Display with Keypad
This option provides local user interface via an LCD numeric display and entry keypad.
It features a 4-line x 20-character LCD screen and a 25-key function keypad. This assembly is furnished in a separate housing that connects to the DPC through a 10-foot rib-bon cable.
● Data Concentrator
A 3335 provides the capability to operate as a data concentrator in the Network 3000 hierarchy. Network schemes are discussed in Section 1A Application Software.
● Enclosures
DPC 3335s are offered in rack-mount enclosures designed to meet NEMA-1 specifications. These enclosures provide either ten or nine I/O slots, depending upon the presence of a second Communication Module.
● Sources
The DPC's Power Supply Module operates from a 24 Vdc regulated power source and provides outputs of +15, -15 and +5 Vdc.
● Ambient Temperature o C (-40 to 158 o F). The DPC operates over an ambient temperature range of -40 to +70
1.2
OVERVIEW OF MODULES AND PC BOARDS
The DPC contains a number of hardware modules and PC boards as shown in Figure 1-2.
The modules are plug-in assemblies, while boards are fixed assemblies. Figure 1-3 shows a typical plug-in module.
The module and board assemblies contained in the DPC are as follows:
System Interconnect Board (SI Board)........................................1 ea.
System Monitor Module ...............................................................1 ea.
Power Supply Module...................................................................1 ea.
CPU ..............................................................1
Communications Module (Comm Module) ...............................2 max.
I/O Modules (13 types) * .........................................................10 max.
Optional Communication Boards **.........................................1 max.
* Limited to 9 I/O modules if #2 Comm Module is specified.
** Private Line (PL) Modems, Switched (SN) Network Modems and a combination
(SN/PL) modem are described in Customer Instruction Manuals (in the rear of this manual), RASCL and Fiber Optic options are described in appendices RM and FB respectively.
1-4
/
Introduction CI-3335
An overview of the DPC circuitry is shown in the block diagrams of Fig. 1-4 and Fig. 1-5.
The subtopics that follow provide a brief description of each module and board assembly.
Figure 1-3 - Typical Plug-In I/O Module
System Interconnect (SI) Board
This board provides the socket connections for each plug-in module and also contains the
I/O, communications, and DC power busses.
System Monitor Module
This module provides field wiring terminals for the +24 Vdc input, watchdog alarm contacts, and auto/manual transfer contacts. It contains a detector logic circuit and output transistor to drive the watchdog alarm relay, and a logic and open collector circuit that provides an Auto/Man transfer function. It also includes Power Fail (PF) and Master Clear
(MC) LED circuitry to monitor the power status. A fuse provides +24 power circuit protection.
Power Supply Module (DC-DC Converter)
This module operates from either a nominal +24Vdc power source (22-28 Vdc for the enclosed type DC-DC Converter) or a bulk 9-30 Vdc power source (for open frame type DC-
DC Convereter) and provides outputs of +15, -15 and +5 V to power the DPC circuitry.
CPU Module
80C186-Based CPU Engine
This module contains the Central Processing Unit, memory subsystem, watchdog timer, real-time clock, LED status logic, and the input/output buss.
An 80C186 16-bit, high-integration, microprocessor chip functions as the CPU. It provides a clock generator, two DMA high-speed channels, an interrupt controller, three 16-bit timers, a wait state generator, and a memory and peripheral chip-select logic. The CPU addresses
CI-3335 Introduction / 1-5
up to 1 M-byte of memory and 64 k-bytes of I/O.
The CPU Module can be furnished with configurable RAM or EPROM. RAM versions are backed by a battery located on the board. The battery provides approximately 4000 hours of cumulative backup time. EPROM versions retain the application load without battery backup.
EPROMs may be furnished as pre-configured factory units or as field configurable units.
The latter type require a PROM Programmer to perform field configuration.
Figure 1-4 - Block Diagram of 186-based DPC
80386EX-Based CPU Engine Boards
A 32-Bit embedded microprocessor functions as the CPU. This fully static microprocessor features low power and low voltage capabilities, and utilizes either a 16-bit (Real Mode) or
32-bit (Protected Mode) programming architecture. These boards may be furnished with
1-6
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Introduction CI-3335
510 k-bytes of Base RAM, 512 k-bytes of Base FLASH Memory, and 128 k-bytes of
Load/Boot Code FLASH Memory. These boards are furnished with two asynchronous serial ports (BIP1 & BIP2) which are switch configurable for RS-562 or RS-485 operation.
Figure 1-5 - Block Diagram of 386EX-based DPC
A description of the Real Mode (16-Bit) version of the 80386EX-based CPU Engine
Assembly is provided in Section 3BA.
The protected Mode (32-bit) version of the 80386EX-based CPU Engine Assembly has a piggyback mounted Extended Memory Board (EMB) which is equipped with 2MB of FLASH memory and accommodates up to 4MB of RAM (see Section 3BB).
CI-3335 Introduction / 1-7
Back-up power is provided to RAM by a Lithium battery. The battery provides a cumulative back-up period of six months (4500 Hours worst case) for Base RAM. With the addition of the EMB the back-up period diminishes as follows:
EMB with 1M RAM - 3490 Hours worst case
EMB with 2M RAM - 2830 Hours worst case
EMB with 4M RAM - 2050 Hours worst case
ENHANCED COMMUNICATION ENGINE MODULE (ECE Module)
The ECE Module contains serial communication controllers, interface drivers and receivers, and LED signal status indicators. DPC models with 10 I/O slots provide one slot for an ECE
Module, while models with 9 I/O slots provide two.
ECE Modules provide two or four serial ports which can be configured independently for use with either RS-423 or RS-485 communication formats via switch selection. These ports consist of 9-pin, D-type connectors which are compatible with Bristol Babcock’s 3350 and
3380 equipment lines.
Communication ports may be assigned for use as master or slave through the AIC program.
With the AIC, the user can implement MASTER and SLAVE Modules to develop the BSAP network hierarchical scheme. In a BSAP network, these ports interface with other distributed controllers or personal computers (PC compatibles). The communication rates of each port can be independently set via the AIC program; rates of 110, 300, 600, 1200, 2400,
4800, 9600, 19.2K and 38.4K baud are presented on a communication menu.
Ports may be configured for an RS-485 or RS-232 interface. The former is required for
BSAP network communications, while the later is required for devices such as a PC or printer. However, these ports can also be configured for other applications. For example, port A may be configured as LOGGER to provide an ASCII interface with a printer or display device while ports B, C D, etc. can be configured for use with options such as modem boards. It should be noted that neither the 2PECB or the 4PECB will support use with a
Hand held terminal. It should also be noted that only the 2PECB (ports B/D) will support piggyback modems and RASCL.
I/O MODULES
I/O Modules plug into the I/O assemblies as noted in Figure 1-4. The various types of modules are described as follows:
Analog Input (AI) Module
4 or 8 AIs: 10Vdc type or 1-5Vdc/4-20mA type
Versions with 250 V dc common mode are optional.
The Analog Input Module contains signal conditioning circuits, instrumentation amplifiers, an analog-to-digital converter, and an I/O bus interface. Surge suppression is also provided for each AI channel
1-8
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Introduction CI-3335
Analog Output Module
2 or 4 AOs 0-10Vdc type and 1-5Vdc/4-20mA type. Latter type is field configurable for either range.
The Analog Output Module utilizes a digital-to-analog converter chip set and I/O bus interface circuitry. Surge suppression is also provided for each AO channel.
Discrete Input Module
16 DIs: 12 V or 24 V ac/dc input types
8 DIs: 5 V, 12 V or 24 V ac/dc input types
4 DIs: 120 V ac/dc input type only
The Discrete Input Module provides opto-isolation and signal conditioning circuitry for each
DI. The DI processing circuitry consists of storage registers, "change-of-state" detect circuitry, interrupt generation circuitry, and bus interface and on-line test select circuitry.
Surge suppression is also provided for each DI channel.
Discrete Output Module
16 DOs: Open drain output type
8 DOs: Open collector output type
4 DOs: Relay contact output (24Vdc @ 10.0mA) type
The Discrete Output Module contains an I/O bus interface, output status buffer and control circuitry. Surge suppression is also provided for each DO channel.
Solid State DC Relay Discrete Output Module
8 DOs: Normally Open/Normally Closed "opto-isolated" output - 3A, 38Vdc (Max) type
SSDCRDO Modules provide 8 outputs which can be discretely configured (via on board jumper) for normally open or normally closed operation. SSDCRDO Modules can be used to operate devices or to actuate control loops that require a higher drive capability than that which could be supported by the Discrete Output Module. Surge suppression is provided for each channel.
High Speed Counter Module
4 HSC Inputs: 5, 12, and 24Vdc types.
The High Speed Counter Module contains four independent input conditioning circuits that provide opto-isolation and debouncing. Each input may be sourced from either dry contact or a differential signal source. Surge suppression is also provided for all HSC channels.
Low Level Analog Input Module
4 LLAIs: Differential - Thermocouple, RTD sensor or 10mV inputs.
Each analog input of a Low Level Analog Input Module contains amplifiers and interface cir-cuitry for the low level millivolt inputs. Each input also contains a low pass filter to
CI-3335 Introduction / 1-9
block noise and provide a degree of current limiting. A reference junction temperature sensor is also included to compensate for changes in ambient temperature. Types are available with and without high common mode isolation.
High Speed Analog Input Module
The HSAI Module is a specialized data acquisition module for gas pipeline compressor/engine pumping stations. Four AIs applied to the module measure pressure parameters, while two DIs provide synchronized sampling periods based on degree rotation and top dead
The DO Module is available with 8 or 4 DOs. The 8 DO version provides open collector outputs, while the 4 DO version provides relay contact outputs. These modules contain an I/O bus interface, output status buffer, and control circuitry. Surge suppression is also provided for each DO channel.
1.3 HAZARDOUS AREA CLASSIFICATION
Equipment Approval
FM-Approved models are designated for use in nonincendive Class I, Division 2, Groups A,
B, C and D hazardous locations. These models can be identified by the "FM-Approved" mark appearing on the DPC's instrument data plate. The plug-in modules used with DPCs have separate approvals and will carry a separate FM marking. When replacing or adding modules to an "FM-Approved" DPC model, verify that an FM mark is also present on the module. Do not use unapproved modules in these models.
Class Definitions
The National Electric Code, Article 500, defines several classes of hazardous environments as follows:
Atmospheres:
Class I Contains flammable gases or vapors.
Class II Contains combustible dust particles.
Class III Contains ignitable fibers or flyings.
Divisions:
Div. 1
Div. 2
Where there is a continuous threat of fire or explosion under normal conditions, or may exist because of frequent repair operations, or because of leakage.
Where threat of fire or explosion is not normally present and not likely to result from abnormal occurrence.
Groups:
A through D Cover various flammable gases and liquids such as ethyl-ether vapor, gasoline, acetone, etc.
1-10
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Introduction CI-3335
E through G Cover various combustible dusts such as dust from metalworking, coal, coke car-bon black, grain, etc.
1.4 MODEL NUMBER ANALYSIS
The model number is stamped on a data plate affixed to the unit. The DPC's general features can be identified by comparing its model number to Table 1-A.
A DPC can include one or more attachments. The attachment numbers, which only appear in the sales order, identify the type and characteristics of the I/O modules furnished with the DPC. The attachment number codes are given in Tables 1-B and 1-C.
TABLE 1-A - MODEL NUMBER BREAKDOWN
Figure 1-6 Sample Model Number
# = BASE MODEL NUMBER
A = PACKAGING
1 = 10 I/O slots (with 1 Comm. slot)
2 = 9 I/O slots (with 2 Comm. slots)
B = FRONT COVER
0 = Without
1 = With
C = NOT APPLICABLE
D = CERTIFICATION
0 = None
1 = FM Approved **
E = HIGH RESOLUTION
0 = With
* Attachment numbers appended to a model number represent additional features and options not covered here. See Tables 1-B and 1-C for inter- preting attachment codes.
** See topic titled, HAZARDOUS AREA CLASSIFICATION for details.
Note: This table is only provided for identifying product features and not for sales ordering purposes.
CI-3335 Introduction / 1-11
Figure 1-7 - Sample Model Attachments for Basic Features
Using Table 1-B
Attachment numbers for basic features will have an "A" group prefix followed by a seven character spaces filled with digits (example: A nnnnnnn). Identify the attachment code num-ber assigned to each numerical position and reference to the list below.
TABLE 1-B - ATTACHMENTS FOR BASIC FEATURES
Note: This table is only provided for identifying product features and not for sales ordering purposes.
A = ATTACH. PREFIX (A) FOR BASIC
FEATURES
A B = UNIVERSAL CPU MODULE
12 MHz 80186 CPU
2 0 128K RAM
1 1
3 0
3 1
5 0
4 1
6 0
7 1
7 2
7 3
64K RAM ACL EPRM
256K RAM
192K RAM ACL EPRM
20 MHz 80186 CPU
128K RAM
64K RAM W/64K ACL EPRM
24 MHz 80386 CPU
REAL MODE
0MB EXT RAM - PROTECTED MODE
1MB EXT RAM - PROTECTED MODE0
2MB EXT RAM - PROTECTED MODE
4MB EXT RAM - PROTECTED MODE 7 4
A B D = PROTECTED MODE W/ETHERNET
8 1 0 1MB RAM
8 2 0 2MB RAM
8 3 0 3MB RAM
8 4 0 4MB RAM
8 5 0 6MB RAM
A C = FLOATING POINT PROCESSOR
0 NONE
* 1 WITH (Note 4
6 1 WITH
7 1 WITH
A D = COMM. MODULE #1 (Note 5)
Port A Port B
? 0 None
* 1 RS232/485
* 2 RS232/485
* 3 RS232/485
* 5 RS232/485
* 6 RS232/485
* 7 RS232/485
* 8 RS232/485
*
* A RS232/485 TIB
None
RS232/485
1200 BAUD MODEM
9600 BAUD MODEM
F/O MODEM
RS485 & NIB
RASCL (Notes 1 & 3)
RASCL (Notes 2 & 3)
E = COMM. MODULE #2
0
1
2
Port C
N/A
RS232/485
RS232/485
Port D
N/A
RS232/485
RS232/485 (Note 6)
NOTES
1 Redundant
2
3
4
5
6
Single Comm. Highway
LIB to LIB Cable Not Supplied
* = 1,2,3,4,5 (0 - 60 C) Op. Temp.
* = 1 through 7 & ? = 6, 7 or 8
Comm. Ports C,D,I,J (4-Port ECB)
1-12
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Introduction CI-3335
TABLE 1-C - ATTACHMENT 3335-BCDE FOR I/O MODULE ATTACHMENT
CODES
Figure 1-8 - Sample Model Attachments for I/O Modules
Using Tables 1-C1 through 1-C10
The I/O attachment numbers are contained in suffix groups: B, C, D and E. Groups B, C and D provide space for six characters each, while group provides space for two characters.
A module slot corresponds to two spaces of a suffix. A module slot is coded with alphanumeric characters (example: B2, C3, A1, etc.) identified in the list below. A pair of zeroes appearing in any slot indicates a vacant slot.
Note: These tables only provided for product identity and not for sales ordering purposes. Italicized items are no longer available
TABLE 1-C1 - ANALOG INPUT MODULES:
Att. Sig. Amt. Input Surge 250V Com
Code Type Signals Input Range Imped. Filt. Suppr. Mode Part Number
Local Termination - Right Angle Term. Block
A1 AI 4 0-10 Vdc 150K yes yes no 392029-02-2
A2 AI 4 1-5 Vdc & 150K yes yes no 392544-12-0
4-20 mA 250
AA AI 8 1-5 Vdc & 150K yes yes no 392544-02-4 mA 250
A3 AI 4 0-10 Vdc 2M yes yes yes 392029-03-0
A4 AI 4 1-5 Vdc & 2M yes yes yes 392544-11-1
4-20 250
AB AI 8 1-5 Vdc & 2M yes yes yes 392544-01-6
4-20
Remote Mass Termination (Non-Isolated) - Without Term. Module
A5 AI 4 0-10 Vdc 150K yes yes no 392029-12-0
A6 AI 4 1-5 Vdc & 150K yes yes no 392544-14-6
4-20 mA 250
A7 AI 4 0-10 Vdc 2M yes yes yes 392029-13-8
A8 AI 4 1-5 Vdc & 2M yes yes yes 392544-13-8
4-20 mA 250
A9 AI 8 1-5 Vdc & 150K yes yes no 392544-04-0 mA 250
AC AI 8 1-5 Vdc & 2M yes yes yes 392544-03-2
CI-3335 Introduction / 1-13
TABLE 1-C1 - ANALOG INPUT MODULES: (Continued)
Att. Sig. Amt. Input Surge 250V Com. 1 st P.N. = Ckt. Bd.
P.N. = Term. Mod. Code Type Signals Input Range Imped. Filt. Suppr. Mode 2 nd
Remote Mass Termination (Isolated) - Without Term. Module
H1* AI 4 1-5 Vdc & 150K yes yes no 392086-12-3 = 1 st mA 250 391250-01-9 nd
H2** AI 4 1-5 Vdc & 150K yes yes no 392086-12-3 = 1 st
4-20 nd
Remote Mass Termination (Non-Isolated) - With Term. Module
J1 AI 4 0-10 Vdc 150K yes yes no 392029-12-0 = 1 st
390994-01-4 nd
J2 AI 4 1-5 Vdc & 150K yes yes no 392544-13-8 = 1 st
4-20 nd
J3 AI 4 0-10 Vdc 2M yes yes yes 392029-13-8 = 1 st
390994-01-4
4-20
=
J4 AI 4 1-5 Vdc & 2M yes yes yes 392544-13-8 = 1 st mA 250 390994-01-4 nd
Remote Mass Termination (Non-Isolated), (Powered) - With Term. Module
J5 AI 4 0-10 Vdc 150K yes yes no 392029-12-0 = 1 st
390994-02-2 nd
J6 AI 4 1-5 Vdc & 150K yes yes no 392544-13-8 = 1 st
4-20 mA 250 390994-02-2 nd
J7 AI 4 0-10 Vdc 2M yes yes yes 392029-13-8 = 1 st
390994-02-2
J8 AI 4 1-5 Vdc & 2M yes yes yes 392544-13-8 = 1 st
4-20 mA 250 390994-02-2 nd
Note: * = RTD, ** = Thermocouple
TABLE 1-C2 - ANALOG OUTPUT MODULES:
Att. Sig. Amt. Surge
Code Type Signals Output Range Protection Part Number
Local Termination - Right Angle Term. Block
B1 AO 2 0-10 Vdc @ 5 mA max. yes 392027-02-0
B2 AO 2 1-5 Vdc @ 5 mA max. & yes 392547-02-3
4-20 into
BB AO 4 1-5 Vdc @ 5 mA max. & yes 392547-01-5
4-20
Remote Mass Termination (Non-Isolated) - Without Term. Module
B3 AO 2 0-10 Vdc @ 5 mA max. yes 392027-12-7
B4 AO 2 1-5 Vdc @ 5 mA max. & yes 392547-04-0
4-20 into
B5 AO 4 1-5 Vdc @ 5 mA max. & yes 392547-03-1
4-20
1-14
/
Introduction CI-3335
TABLE 1-C2 - ANALOG OUTPUT MODULES: (Continued)
Att. Sig. Amt. Surge 1 st P.N. = Ckt. Bd.
P.N. = Term. Mod. Code Type Signals Output Range Protection 2 nd
Remote Mass Termination (Isolated) - Without Term. Module
H3 AO 2 1-5 Vdc @ 5 mA max. & yes 392547-04-0 = 1 st mA ohm load
Remote Mass Termination (Non-Isolated) - With Term. Module
K1 AO 2 0-10 Vdc @ 5 mA max. yes 392027-12-7
K2 AO 2 1-5 Vdc @ 5 mA max. & yes 392547-04-0
4-20 into ohm load
TABLE 1-C3 - LOW LEVEL ANALOG INPUT MODULES:
Att. Sig. Amt. Input Input Surge Com.
Code Type Signals Input Range Imped. Filt. Suppr. Mode Part Number
Local Termination. - Right Angle Term. Block
C1 LLAI 4 RTD, TC, mV 1 Mohm yes yes yes 389927-12-0
TABLE 1-C4 - DISCRETE INPUT MODULES:
Att. Sig Amt. Input Optical Surge
Code Type Signals Input Range Filter Isolation Prot. Part Number
Local Termination - Right Angle Term. Block
D1 DI 8 5V ac/dc 1 ms yes yes 392087-07-3
DB DI 8 12V ac/dc 1 ms yes yes 400092-07-7
392087-08-1
D2 DI 8 24V ac/dc 1 ms yes yes 400092-05-0
392087-02-2
D3 DI 8 12V ac/dc 30 ms yes yes 392087-01-4
D4 DI 8 24V ac/dc 30 ms yes yes 400092-06-9
392087-03-0
D5 DI 4 120V ac/dc 30 ms yes yes 392502-01-1
DD DI 16 24V ac/dc 1 ms yes yes 392557-01-0
DE DI 16 24V ac/dc 30 ms yes yes 392557-02-9
Remote Mass Termination (Non-Isolated) - Without Term. Module
D6 DI 8 5V ac/dc 1 ms yes yes 392087-17-0
DC DI 8 12V ac/dc 1 ms yes yes 392087-18-9
D7 DI 8 24V ac/dc 1 ms yes yes 392087-12-0
D8 DI 8 12V ac/dc 30 ms yes yes 392087-11-1
D9 DI 8 24V ac/dc 30 ms yes yes 400092-03-4
392087-13-8
DG DI 16 24V ac/dc 1 ms yes yes 392557-03-7
DH DI 16 24V ac/dc 30 ms yes yes 392557-06-1
CI-3335 Introduction / 1-15
TABLE 1-C4 - DISCRETE INPUT MODULES: (Continued)
Att. Sig Amt. Input Optical Surge 1 st P.N. = Ckt. Bd.
P.N. = Term. Mod. Code Type Signals Input Range Filter Isolation Prot. 2 nd
Remote Mass Termination (Isolated) - Without Term. Module
H4 DI 8 24V dc 30 ms yes yes 392087-13-8 = 1 st
391253-01-8 nd
H5 DI 8 48V dc 30 ms yes yes 392087-13-8 = 1 st
391253-02-6
Remote Mass Termination (Isolated) - Without Term. Module
=
H6 DI 8 120V ac 30 ms yes yes 392087-13-8 = 1 st
391253-03-4 nd
H7 DI 8 220V ac 30 ms yes yes 392087-13-8 = 1 st
=
Remote Mass Termination (Non-Isolated) (8 Pt. - With Term. Module
L1 DI 8 5V ac/dc 1 ms yes yes 392087-17-0 = 1 st
390997-01-3 nd
L2 DI 8 12V ac/dc 1 ms yes yes 392087-18-9 = 1 st
390997-01-3 =
L3 DI 8 24V ac/dc 1 ms yes yes 392087-12-0 = 1 st
390997-01-3
L4 DI 8 12V ac/dc 30 ms yes yes 392087-11-1 = 1 st
390997-01-3 =
L5 DI 8 24V ac/dc 30 ms yes yes 392087-13-8 = 1 st
=
Remote Mass Termination (Non-Isolated) (8 Pt. (Powered) - With Term. Module
L6 DI 8 5V ac/dc 1 ms yes yes 392087-17-0 = 1 st
390997-02-1 nd
L7 DI 8 12V ac/dc 1 ms yes yes 392087-18-9 = 1 st
390997-02-1 =
L8 DI 8 24V ac/dc 1 ms yes yes 392087-12-0 = 1 st
390997-02-1
L9 DI 8 12V ac/dc 30 ms yes yes 392087-11-1 = 1 st
390997-02-1 =
LA DI 8 24V ac/dc 30 ms yes yes 392087-13-8 = 1 st
=
Remote Mass Termination (Non-Isolated) (8 Pt. (Feed Thru) - With Term. Module
LB DI 8 5V ac/dc 1 ms yes yes 392087-17-0 = 1 st
390997-03-0 nd
LC DI 8 12V ac/dc 1 ms yes yes 392087-18-9 = 1 st
=
LD DI 8 24V ac/dc 1 ms yes yes 392087-12-0 = 1 st
=
LE DI 8 12V ac/dc 30 ms yes yes 392087-11-1 = 1 st
=
1-16
/
Introduction CI-3335
TABLE 1-C4 - DISCRETE INPUT MODULES: (Continued)
Att. Sig Amt. Input Optical Surge 1 st P.N. = Ckt. Bd.
P.N. = Term. Mod. Code Type Signals Input Range Filter Isolation Prot. 2 nd
Remote Mass Termination (Non-Isolated) (8 Pt. (Feed Thru) - With Term. Module
LF DI 8 24V ac/dc 30 ms yes yes 392087-13-8 = 1 st
390997-03-0 nd
TABLE 1-C5 - DISCRETE OUTPUT MODULES:
Att. Sig. Amt. Surge Relay Coil 1 st P.N. = Ckt. Bd.
Code Type Signals Output Type Prot. Voltage 2 nd P.N. = Term. Mod.
Local Termination - Right Angle Term. Block
E1 DO 8 Open Collector yes -- 392076-02-0 yes V 392076-04-7
E4 DO 8 Solid State Relay yes -- 392567-02-4
E6 DO 16 Open Drain yes -- 392586-01-0
E8 DO 8 Open Drain yes -- 400091-02-0
Remote Mass Termination (Non-Isolated) - Without Term. Module
E3 DO 8 Open Collector yes -- 392076-12-8
E7 DO 16 Open Drain yes -- 392586-02-9
E9 DO 8 Open Drain yes -- 400091-03-8
Remote Mass Termination (Non-Isolated) - With Term. Module
M1 DO 8 Open Collector yes -- 392076-12-8 = 1 st
Pt. 390997-01-3 nd
M2 DO 8 Open Collector yes -- 392076-12-8 = 1 st
390997-02-1 =
M3 DO 8 Open Collector yes -- 392076-12-8 = 1 st
390997-03-0
M4 DO 8 Open Collector yes -- 392076-12-8 = 1 st
Relays 390998-01-0 nd
M5 DO 8 Open Collector yes -- 392076-12-8 = 1 st
Relays 390998-02-8 nd
M6 DO 8 Open Collector yes -- 392076-12-8 = 1 st
Relays 390998-02-8 nd
M7 DO 8 Open Collector yes -- 392076-12-8 = 1 st
Relays 390998-04-4 nd
TABLE 1-C6 - HIGH SPEED COUNTER MODULES:
Att. Sig. Amt. Debounce Surge
Code Type Signals Range Circuit Prot. Part Number
Local Termination - Right Angle Term. Block
F1 HSC 4 +24V yes yes 400018-02-0
392028-04-2
F2 HSC 4 +12V yes yes 400018-04-7
392028-02-6
CI-3335 Introduction / 1-17
TABLE 1-C6 - HIGH SPEED COUNTER MODULES: (Continued)
Att. Sig. Amt. Debounce Surge
Code Type Signals Range Circuit Prot. Part Number
F3 HSC 4 +5V yes yes 400018-06-3
392028-05-0
F7 HSC 8 +24V yes yes 400018-01-2
F8 HSC 8 +12V yes yes 400018-03-9
F9 HSC 8 +5V yes yes 400018-05-5
Remote Mass Termination (Non-Isolated) - Without Term. Module
F4 HSC 4 +24V yes yes 400018-12-8
392028-14-0
F5 HSC 4 +12V yes yes 400018-13-6
392028-12-3
F6 HSC 4 +5V yes yes 400018-14-4
392028-15-8
TABLE 1-C7 - HIGH SPEED ANALOG INPUT MODULE
Att. Sig. Amt.
Code Type Signals Application
Local Term. - Right Angle Term. Block
G1 AI 4 Pressure 390827-02-9
TABLE 1-C8 - HONEYWELL SMARTLINE TRANSMITTER INTERFACE MODULE
Att. Amt.
Code Signals Signal Type Part number
R1 8 BIDI Comm. 395205-01-8
TABLE 1-C9 - CHECK BEFORE OPERATE MODULE
Att. Amt. Type
Code Outputs Output Part Number PN Description
T1 8 CBO Relay 392514-01-0 CBO Module (Plugs into I/O Slot)
392513-01-3
391399-01-2 (Module Term.
T2 8 CBO Relay 392514-01-0 CBO Module (Plugs into I/O Slot)
Board).
392513-01-5
391399-01-2 (Module Term.
T3 8 CBO Relay 392514-01-0 CBO Module (Plugs into I/O Slot)
Board).
392513-01-7
391399-01-2 (Module Board).
1-18
/
Introduction CI-3335
TABLE 1-C10 - BRISTOL BABCOCK TELETRANS INTERFACE SYSTEM
Att. Amt. Type
Code Inputs Input Part Number Qty. PN
U1 4 3308 Teletrans 392535-01-7 1 BBTI I/O Board
392536-01-3 Field
395334-01-2 10’ Cable
U2 4 3308 Teletrans 392535-01-7 1 BBTI I/O Board
392536-01-3
395334-02-0 20’ Cable
U3 8 3308 Teletrans 392535-01-7 1 BBTI I/O Board
392536-01-3
395335-01-9
Field
10’
U4 8 3308 Teletrans 392535-01-7 1 BBTI I/O Board
392536-01-3
395335-02-7
Field
20’
CI-3335 Introduction / 1-19
BLANK PAGE
Section 1A
APPLICATION SOFTWARE
1A.1 CATEGORIES OF APPLICATION SOFTWARE
There are basically three categories of application software used with the DPC 3335:
1) ACCOL Tools and related software which are used to program your DPC 3335 controller for its intended application (pump control, pipeline monitoring, etc.). In general, this type of software is used by the System Engineer or ACCOL programmer.
2) Supervisory Software which is used to allow operator interaction with the controller via graphical displays, trending, and printed reports. In general, this type of software is used by the Process Operator, or Technician.
3) Open BSI Utilities Software which facilitates communication between the DPC
3335 and certain types of Supervisory software. In general, this software is configured by the System Engineer.
Each of these application software categories will be discussed briefly in this section.
Additional information on these subjects is found in documents referenced within the text.
1A.2 ACCOL TOOLS SOFTWARE
ACCOL stands for Advanced Communications and Control-Oriented Language, and is
Bristol Babcock's proprietary language for programming Network 3000-series controllers, such as the DPC 3335. The ACCOL compilers and related software are collectively referred to as the ACCOL Tools. Each of these tools will be discussed later in this section.
The ACCOL language includes a large set of pre-programmed software modules and control statements which can perform various mathematical, logical, process control, or communication functions.
For example, the PID3TERM module allows proportional, integral, and derivative control over a process input value; the AGA3ITER module computes natural gas volume flow rates, and the DIFFERENTIATOR module calculates the rate of change of an input. There are over 100 modules and control statements to choose from. For more detailed information on particular modules or statements, see the ACCOL II Reference Manual (document #
D4044).
These modules and control statements are organized by the ACCOL programmer into individual tasks. Each task is specified to execute at a specific rate, and with a specific priority, relative to other tasks. One or more tasks are then combined by the ACCOL programmer into an ACCOL program. This program must be tailored for the particular use of this controller, for example, measuring and controlling natural gas flows, monitoring pressure of a pump, etc.
Depending upon which ACCOL Tools you are using, your ACCOL program is initially created as ASCII text in an ACCOL source file (.ACC file).
CI-3335 Application Software / 1A-1
When editing of the ACCOL program has been completed, it must be compiled and linked to generate an ACCOL object file (.ACO) and an ACCOL load file (.ACL). The ACCOL load file contains the original programming instructions in a machine-readable format which can be executed by the DPC 3335 control-ler. In order to get the load file into the controller, the file is downloaded into the DPC 3335, which then executes the programming instructions in the load file.
The Windows™-based ACCOL Tools set consists of ACCOL Workbench 7.0 (or newer), together with the WINDIAG diagnostic program. Note: Windows diagnostics are detailed in the WINDIAG Diagnostics Manual - Document # D4041A.
ACCOL allows you to create, modify, compile, link, and document an
ACCOL source file, all using a single integrated tool. Workbench allows direct editing of an ACCOL source file, without the need for a separate ASCII text editor, and allows the user to call up a pre-defined template of any ACCOL module or statement. The user can then edit the template to conform to the requirements of the intended application. An on-line debugging facility is also provided. See the ACCOL Workbench User Manual
(document # D4051) for more information. Note: On-line debugging is NOT supported for 186-based units .
NOTE: All Workbench on-line communication, debugging, and downloading is facilitated via Open BSI Utilities software, discussed later in this chapter.
NOTE: If you are using older DOS-based ACCOL Tools, or older ACCOL Workbench RM or PM versions (prior to version 7.0) please see the table, below.
To do the following: If you have 186-based
Controllers, or 386EX Real
Mode Controllers:
DOS-based ACCOL Tools
Version 5.13
Firmware: AL.02, RMS04, or newer
If you have 186-based
Controllers, or 386EX Real
Mode Controllers:
Windows™-based ACCOL
Workbench (RM) Version 1.1
(or newer RM version) or
ACCOL Workbench 7.0 (or newer)
Firmware: AL.02, RMS04, or newer
If you have 386EX
Protected Mode
Controllers:
Windows™-based
ACCOL Workbench
(PM) Version 6.3 or
ACCOL Workbench
7.0 (or newer)
Firmware:
PLS03/PLX03/PES03/
PEX03 or newer
Create / edit an ACCOL source (.ACC) file.
Generate an ACCOL object (.ACO) file.
Link the ACO file to generate the ACL file.
Download the ACL file.
View live data coming from the controller.
Make on-line edits to the
Use any text editor. NOTE:
Not all modules are supported in DOS-based tools.
Use the AIC program or use a text editor, and the ABC program.
Run the ACLINK program on the ACO file.
Use AIC in on-line mode,
Toolkit, Taskspy, or the Open
BSI Downloader.
Use AIC in on-line mode,
Toolkit, Taskspy, or the Open
BSI DataView program.
Use AIC in on-line mode.
Use ACCOL Workbench (RM) or any text editor.
Use ACCOL Workbench to edit the .ACC file, then use the
Workbench "Build" command to generate the ACO.
Linking is performed by the
ACCOL Workbench "Build" command.
Use the Open BSI Downloader
(accessible via Workbench in online mode)
Use the Open BSI DataView program.
On-line edits to certain ACCOL
Use ACCOL
Workbench (PM) or any text editor.
Use ACCOL
Workbench to edit the
.ACC file, then use the
Workbench "Build" command to generate the ACO.
Linking is performed by the ACCOL
Workbench "Build" command.
Use the Open BSI
Downloader (accessible via Workbench in online mode)
Use the Open BSI
DataView program.
On-line edits to certain
1A-
2
/ Application Software CI-3335
To do the following:
ACL file running in the unit.
Generate required network files.
Reverse compile an ACO file to generate an ACC file.
Download diagnostic loads and perform diagnostic tests.
If you have 186-based
Controllers, or 386EX Real
Mode Controllers:
DOS-based ACCOL Tools
Version 5.13
Firmware: AL.02, RMS04, or newer
Edits to signal and data array values may be made using
Toolkit, Taskspy, or the Open
BSI DataView program.
For Open BSI 2.3 or older, use
NETTOP or NETBC and
NETREV compilers
For Open BSI 3.0 or newer, use NetView.
Use the REV compiler.
Use the DIAG5 program.
If you have 186-based
Controllers, or 386EX Real
Mode Controllers:
Windows™-based ACCOL
Workbench (RM) Version 1.1
(or newer RM version) or
ACCOL Workbench 7.0 (or newer)
Firmware: AL.02, RMS04, or newer structures available via ACCOL
Workbench (RM). (NOT
SUPPORTED FOR 186-based units with firmware earlier than
AM).
Edits to signal and data array values may be made via the
Open BSI DataView program.
For Open BSI 2.3 or older, use
NETTOP or NETBC and
NETREV compilers
For Open BSI 3.0 or newer, use
NetView.
Use the File Reverse command in
ACCOL Workbench (RM).
Use the DIAG5 program.
If you have 386EX
Protected Mode
Controllers:
Windows™-based
ACCOL Workbench
(PM) Version 6.3 or
ACCOL Workbench
7.0 (or newer)
Firmware:
PLS03/PLX03/PES03/
PEX03 or newer
ACCOL structures available via ACCOL
Workbench (PM).
Edits to signal and data array values may be made via the Open
BSI DataView program.
For Open BSI 2.3 or older, use NETTOP or
NETBC and NETREV compilers
For Open BSI 3.0 or newer, use NetView.
Use the File Reverse command in ACCOL
Workbench (PM).
Use the DIAG6 program.
Table 1A-1 - Software Tools/Firmware Version Usage Guide
CI-3335
Figure 1A-1 - Files Created by Windows™-based ACCOL Workbench
Application Software / 1A-3
1A.3 SUPERVISORY SOFTWARE
Supervisory software allows operator interaction with the Bristol Babcock controllers via graphical displays, trends, and reports of historical data. Generally, the supervisory software requires a customized communication driver in order to communicate with the
Bristol devices. In some cases this is provided via Open BSI Utilities. The following types of supervisory software are currently supported:
1) OpenEnterprise software is Bristol Babcock's own supervisory system.
OpenEnterprise utilizes a Windows™ server and one or more PC client workstations.
Communication with the controller network is supported via Open BSI.
OpenEnterprise provides large real time and historical data bases, which may be displayed, logged, or exported.
2) Iconics Inc. Genesis software is a popular PC-based supervisory package which is suitable for systems with smaller numbers of ACCOL signals. Genesis, and the Bristol driver may be purchased from Bristol Babcock (see "Local Area Network").
1A.4 OPEN BSI UTILITIES SOFTWARE
The Open Bristol System Interface (Open BSI) is a layer of communications software which provides access to a network of Bristol Babcock remote process controllers.
Above this communications layer are a group of applications (programs) which are collectively known as the Open BSI Utilities . These utilities interact with the communications layer to:
• Download ACCOL load files to 3xxx controllers in the network
• Collect and display data from the 3xxx controllers
• Monitor and control Open BSI communications
Figure 1A-2 - Open BSI Interface Diagram
1A-
4
/ Application Software CI-3335
Third-party supervisory software can also use Open BSI communications, and data files generated by Open BSI utilities, to access the Bristol network in order to display and report information from field instrumentation about a running process. An operator then uses this information to monitor and/or interact with the process.
The standard set of Open BSI utilities is accessed from within a Windows program group on the PC; some of the major utilities are described, briefly, below. Full details on each utility are included in the Open BSI Utilities Manual (document # D5081).
Downloader transfers a linked ACCOL load file (*.ACL) from the PC to the DPC 3335.
DataView collects and displays several types of process data from the DPC 3335-series controller, including signal values, data array values, signal lists, archive data, and audit trail information. In addition, it allows the user to search for signals based on various criteria.
Remote Communication Statistics Tool allows additional monitoring of Open BSI communication information. Details on buffers, communication ports, and custom protocols are accessible via this tool. Some of the information collected via this tool is primarily of interest to Bristol Babcock support personnel.
SigWrite reads ASCII files containing ACCOL signal values, and writes those values to corresponding signals or signal lists in the DPC 3335 controller. SigWrite scans for such files at a user-definable interval. allows the user to define communication network characteristics, define details about individual RTUs, and to change these characteristics on-line. NetView supports existing BSAP networks, as well as the Internet Protocol (IP) (Available with
Open BSI 3.0 and newer).
LocalView is used for flash downloading of 'cold download' port parameters at the DPC
3330, for programming IP addresses, and for performing field upgrades of system firmware.
In addition to the standard set of Open BSI Utilities, just described, there are other utilities, available from Bristol Babcock as add-ons to the standard utilities, which provide capabilities for scheduled data collection, and file export. These utilities include the Open
BSI Harvester and the Data File Conversion utility (see the Ooen BSI Harvester manual
(document # D5120) for details.
For more information on these packages, consult the manuals accompanying them, or contact Bristol Babcock's application support group for assistance.
1A.5 SYSTEM APPLICATIONS
A DPC can operate as an independent, stand-alone unit, or as a node in a local or wide area network. These applications are described in sections 1A.5.1 through 1A.5.4.
CI-3335 Application Software / 1A-5
1A.5.1 Stand-Alone Unit
Figure 1A-3 shows a DPC used as a stand-alone unit in a non-network application. This arrangement is ideal for small local systems requiring a limited number of monitoring and control points. The PC for this application runs Bristol Babcock's ACCOL Workbench
Software and Open BSI Utilities. Data stored in the DPC can be observed or edited via the
PC.
Figure 1A-3 - Basic Stand-Alone Application
Once on line, the DPC executes the ACCOL load and performs its configured tasks.
Although the PC is attached to the DPC in Figure 1A-3, it can be disconnected and removed once the DPC has been loaded and made operational.
1A.5.2 Local Area Network (LAN)
LANs typically support the communications requirements of computers and equipment in one or more buildings at a site or plant complex. A local area network requires a PC with extended graphics capability. This PC will typically run the Iconics GENESIS software package to display process parameters, real time or historical process data, and graphical displays, etc.
An example of a local area network is shown in Figure 1A-4. This network can communicate directly through RS-485 cable connections for short distances (1000 feet max. from master to most distant slave) or over longer distances via phone line modems, fiber modems or broadband/carrier band modems (on coaxial cable).
Figure 1A-4 shows a network that contains a PC as the network master and a DPC 3335 at the first level of the network hierarchy. The data concentrator, which functions as a communications traffic director, communicates upward with the PC through a slave (S) port and downward with the second level through a master (M) port. This pattern repeats through each descending level. The second level contains two controllers; one communicates with three other controllers at the third level, while the other communicates with two at the third level. Each port configured as a master has the capability of supporting up to 127 slaves.
1A-
6
/ Application Software CI-3335
The communication ports of each controller require both hardware and software configuration. The hardware part is performed using board switches of the DPC, while software configuration is performed using ACCOL Workbench. Netview is used to configure the hierarchy of the network.
The PC, which runs the network monitoring software (FIX or Genesis, etc.), oversees the activities of the local area network. It displays process parameters, real-time data, and historical process information in both tabular and graphic formats. Journaling and system configuration utilities can also be employed as required.
The Bristol Babcock NETWORK 3000 BSAP system supports a maximum of five levels starting with the master device at level 1. Slave nodes at each descending level communicate upward through its preceding master node. Each master node stores data from its slaves until polled.
A local area network can also include printers and/or display terminals. Figure 1A-4 shows a printer connected directly to a PC port; however, a controller port could have been configured as a logger and used in the same manner.
CI-3335
Figure 1A-4 - Local Area Network
Application Software / 1A-7
1A.5.3 Wide Area Network (WAN)
WANs typically support the communications requirements of computers and equipment at numerous geographical locations and may encompass many local and remote sites. A Network 3000 system can also be constructed as a wide area network encompassing many local area networks. This application places a dedicated “Area Operator” computer at the top of the hierarchy as shown in Figure 1A-5. The central system includes all the interface, monitoring and data recording equipment necessary to operate all the subservient networks. The central system employs Open BSI software to provide the on-line network interface.
The Area Operator computer running Open BSI software provides the operator with realtime communications with remotes. Depending on the associated Human Machine Interface
(HMI) software package (such as OpenEnterprise, Genesis, etc.), various features such as real-time management, historical data, alarm logging, event journaling, color graphics,
CRT trending, report logging, process modeling, supervisory control, and high-level language support may be employed. The Area Operator PC of Figure 1A-5 communicates with the local area networks and discrete remote BBI RTUs, Flow Computers and a Smart
Transmitter through a DPC 3330. Depending on the configuration of the DPC 3330, four or more asynchronous channels for use with phone line or modem applications, as-well-as a single, redundant channel for data highway applications may be utilized.
Figure 1A-5 - An Example of a Wide Area Network
1A-
8
/ Application Software CI-3335
1A.5.4 IP Network Using Ethernet and Open BSI
IP is a communications protocol for transmitting data over a computer network. It also allows computers on different networks to exchange information with one another. IP is also the standard communication protocol used on the Internet, a constantly changing set of computer networks that millions of people around the world use for business, government, and educational purposes. The 'IP', in fact, stands for Internet Protocol.
Bristol Babcock controllers have traditionally used a proprietary Bristol protocol, called
BSAP (Bristol Synchronous/Asynchronous Protocol) in order to communicate. While, BSAP is still commonly used in Bristol networks, certain customers, may prefer to use a more
'industry standard' method of communication.
As a result, certain DPC 3335s with PES03/PEX03 (or newer firmware) now support communication via IP. (Open BSI 3.0 or newer is required, as well). This allows a customer to connect Bristol controllers together using Ethernet, a standard type of local area network
(LAN) originally developed by Xerox Corporation. (Other types of LANs may be supported in the future, however, Ethernet is currently the only choice available.)
A Bristol Babcock network using only IP nodes is somewhat different from the other applications discussed previously. There is no hierarchical structure enforced at the network level. For certain applications, this is a significant advantage over BSAP, because all nodes in a given section of the network are essentially on the same level, therefore, peer-to-peer communication is simplified; there is no need to use more than a single pair of IP Client / IP
Server modules to get a message from one node to any other node because all nodes are
'siblings' on the same level.
Figure 1A-6 - Ethernet LAN using Internet Protocol (IP) and Open BSI
CI-3335 Application Software / 1A-9
If an IP node or an Open BSI workstation needs to communicate with another IP node or
Open BSI workstation, and it doesn't know the address of the IP Port for that node or workstation, it obtains the necessary addresses and routing information from the NETDEF file at the NHP.
It is also possible to treat an existing BSAP network as a sub-network of an IP network.
The BSAP network is connected either to the Network Host PC (NHP), or to an IP node which is connected to the NHP.
The figure below shows a typical configuration which mixes both IP nodes, and BSAP network(s).
Open BSI
Workstation
Open BSI
Workstation
Open BSI
Workstation
Serving as a
Network Host PC
(NHP)
Open BSI
Workstation
Serving as a
Network Host PC
(NHP)
BSAP Node
IP Node IP Node IP Node
BSAP Node
BSAP Node BSAP Node BSAP Node BSAP Node
Legend:
Ethernet cable Pre-existing BSAP nodes
RS 485 cable
Figure 1A-7 - Ethernet LAN using Internet Protocol (IP) and Open with a BSAP
Sub-network underneath
1A-
10
/ Application Software CI-3335
Section 2
INSTALLATION
UNPACKING THE DPC
Unpack the equipment carefully. Your shipment may include items such as PC boards, mounting brackets and hardware (where applicable). Carefully inspect all cardboard inserts and cushioning material for any concealed items. Do not discard any packing material until all pieces of the shipment have been identified and sorted.
SELECTING A LOCATION
When choosing a location for the DPC, select one that is protected from the effects of dust, grime and corrosive vapors. You should avoid areas subject to extreme levels of temperature, moisture, vibration or shock. Although your DPC will operate satisfactorily over many extreme conditions, its accuracy, performance and reliability can be maintained by adhering to the environmental conditions contained in Section 7 Specifications.
Combined Equipment Temperature Effects
If you intend to install one or more DPCs in a confined area along with other equipment, special consideration should be given to their combined heating effect. If the combined temperature exceeds the equipment rating, a blower-driven, filtered air supply will be required for cooling.
However, this arrangement may not be adequate for installations where the ambient room temperature exceeds the DPC's environmental specifications. For these situations, an enclosure or room having a controlled heating and air conditioning system will be required.
Radio Frequency Interference (RFI)
Interference from high-power radio-frequency transmitters operating near the your control site can sometimes affect the operation of a DPC or its associated equipment. In general, interference from commercial radio stations will be of a constant nature, while that from a private station will tend to be intermittent.
You can often reduce RFI by returning the chassis ground connection of each DPC, along with the associated mounting racks, cabinets and consoles to a single ground point or system grounding buss. Shielding certain signal wires can also help but be sure that you only ground the shield at the DPC input. In extreme cases, your entire equipment area may require a grounding cage. See “Supplement S1400 - Guidelines For System Grounding” for grounding information.
Electrical Interference
Any electrical device that radiates energy or generates intermittent or continuous sparks can be a potential source of interference. Incandescent light bulbs, fluorescent lights, defective switches, pitted relay contacts, defective transformers and open grounds are typical sources.
You will find that interference is best controlled at the source of origin. Typically this involves checking shielding and grounding of the equipment. Repairing or replacing defective devices will
CI-3335 Installation / 2-1
often cure the problem but obstinate cases may require that you install special line filters.
Figure 2-1 - Overall Dimensions for Series 3335 Rack
INSTALLING THE DPC
The DPC is designed to meet EIA-310-C specifications for indoor rack or panel installations. The overall mounting dimensions for enclosure is given in Figure 2-1, while those for the cover are given in Figure 2-2.
1. For panel-mounted DPCs, initially provide the proper size cutout.
2. Remove the front cover (if so equipped) as previously described.
3.
Position the DPC against the rack or panel and align the DPC's mounting holes with those in the support structure. Install screws finger tight.
4. Re-align DPC as required and tighten the screws until the enclosure is rigid and selfsupporting.
5. Replace front cover.
6.
Mounting is complete.
WARNING
When an DPC is installed in a rack along with other equipment, check that the rack's weight load is properly distributed. A top heavy load may cause some types of racks to tip and fall over, causing possible injury to persons and damage to equipment.
2-2 / Installation CI-3335
REMOVING AND INSTALLING OPTIONAL COVER
If an optional cover (Figure 2-2) has been specified, it will be held in place by interlocking snapin fittings. To remove the cover, grasp each side and pull it out.
When installing the cover, line up the snaps on the cover with the proper slots in the DPC chassis and push in firmly at each corner. Before pushing in the cover, make sure that the cable openings at each end fit over any wiring harnesses; otherwise it will not be possible to obtain the proper fit. When properly installed, the cover should fit flatly against the DPC.
CI-3335
Figure 2-2 - Overall Dimensions for Optional Cover
Installation / 2-3
INSTALLING PC BOARDS & I/O MODULES
Unless otherwise specified, DPC units will be shipped with all function and I/O modules installed in their proper slots. If the modules are not installed or are removed for any reason, it is essential that they be inserted in the correct slots.
Slot Identification
Although I/O modules mate with any slot in an I/O assembly, it is essential that modules be installed in their original slots that correspond to their configured application. Each DPC shipped from the factory will be provided with an identification label affixed to the foil or solder side of each module, as well as a slot label on the DPC chassis. Both labels become visible when the module is unplugged. It is then an easy matter to match each module with its proper slot. If the user builds or modifies an I/O system, it becomes his responsibility to label each module and its slot.
Module Ejector
Above each module slot the DPC contains a built-in ejector to facilitate removal. To release a module from its socket, lift the ejector tab upward. Then grasp the front of the board and pull it out completely from its rail.
When replacing the module, make sure the ejector tab is up. Push the module into its rail until the upper notched edge of the module is under the ejector tab. Push the ejector tab down to force the module into its socket. The ejector tab must be fully down to lock the module in place.
WARNING
Never attempt to install or remove any modules (plug-in PC boards) from a DPC 3335 or an RIO 3331 while it is powered and running. Doing so can cause electrical transients or imbalances that are capable of damaging the module itself as well as other associated circuit boards. Always turn off the 24 V dc power, including any additional supply sources used for externally-powered
I/O circuits, before changing any modules.
WIRING AND CABLING PRACTICES
All field wiring should conform to standard industry practices and procedures. For Class I,
Division 2 Hazardous Locations, the wiring should be in accordance with Article 500 of the
National Electric Code.
Wire Preparation
The maximum wire size that can be inserted into the wiring terminals is 14 gauge. The minimum wire size is relative to the amperage rating of the circuit and is determined by the appropriate electrical code.
To prepare solid wire, trim off approximately 1/4 in. (7 mm) of insulation of wire ends. Remove
2-4 / Installation CI-3335
any protective coating present on the wire end before inserting it into a terminal. When inserting wires into terminals, make sure that no bare wire ends are visible outside the terminal block. Bare wire leads of excessive length can cause electrical shocks or short circuits.
Tighten each terminal screw to secure the wire leads. Do not overtighten screws as the terminals may be damage.
Multi-strand wire will require additional care. When stripping insulation from the wire ends, maintain sufficient cutting pressure on the stripper to remove insulation but not excessive enough to damage or remove strands. Clean and tin each wire end with solder before inserting them into a terminal. Use a low-power soldering iron to prevent insulation burn and shrinkage.
Shielded Wiring for AI and HSC Inputs
Shielded 2-wire cable is recommended for analog input signal wiring to minimize electrical interference. The shield is left open at the source end, and grounded at the input of the DPC.
Shield ends should be tinned with solder to prevent fraying and covered with shrink tubing to provide insulation.
Shielded 3-wire cable is recommended for High-Speed Counter (HSC) inputs when using a differential input (Set and Reset inputs). The rules for grounding and preparation are the same as noted for analog input wiring.
Wiring Harnesses
A DPC will typically have a great number of wires connected to the terminals of its modules.
These wires can become mixed and hard to identify if they are not properly coded and secured.
We recommend the use of wiring harnesses to contain wiring and improve the housekeeping appearance at the front of the DPC.
Wiring harnesses can consist of running lace or a flexweave sheath. If the harness is secured with a running lace, make the separation between each loop no greater than 1-1/2 in. (3.8 cm).
Put in a loop at each wire breakout to maintain harness integrity and appearance. Secure cables to running surfaces with cable clamps or support devices as required. If a wiring harness is encased in a flexweave sheath, protect each breakout with heatshrink tubing.
If cables feed through any holes, those holes must contain rubber or plastic grommets. This action will prevent chaffing of insulation, especially in areas where the equipment is subject to vibration or mechanical stress.
If the DPC is furnished with a front cover, position each harnesses so that they are under the slotted openings of the cover. If the harnesses are not aligned with these openings, it will not be possible to secure the cover.
WARNING
No wiring should be attempted while the unit is powered and operating. If any rewiring is required, the equipment power source, as well as power sources for external signals or accessories connected to the field wiring terminals, must be turned off to prevent electrical shock.
CI-3335 Installation / 2-5
PERFORMING FIELD WIRING CONNECTIONS
All signal and power wiring terminals are located at the front of the DPC. The terminal blocks are only present on those modules requiring field connections. On DPC models with housing covers, the terminals become accessible when the cover is removed.
The terminal block uses compression-type connections. You can make a connection by inserting the clean, bared end of a wire lead (1/4 inch max.) into the opening behind the screw and tightening the screw. No part of the bared lead should extend beyond the opening as it can cause shorts.
Plug-In Terminal Blocks
The field wiring terminals are typically dual assembly blocks much like that shown in Figure 2-
3. Each block is a separate connector assembly that allows you to disconnect the complete terminal strip without unwiring each signal lead. This arrangement speeds up module disconnects and troubleshooting procedures.
The terminal block connector fits very tightly in its socket. To unplug a connector, grip the block firmly at each side and twist it lightly back and forth to work it out of the socket. Remove the second connector (if so equipped) in the same manner.
WARNING
Some terminals may be wired to electrical potentials sufficiently high to cause dangerous electrical shocks. Do not attempt to perform any wiring, or unplug or re-connect any terminal blocks while the unit is powered and operating. Make sure that power applied to the DPC, as well as any powered I/O sources wired to the module terminals, are turned OFF before starting.
2-6 / Installation CI-3335
Figure 2-3 - Dual-Type Terminal Block Assembly
Each terminal block is keyed to prevent it from being plugged in incorrectly. However, the blocks are not keyed in a manner that prevents them from being plugged into the wrong module base connector. We recommend that you tag and label each terminal block to avoid any mistakes.
WARNING
An incorrect terminal block connection can, in some instances, cause damage to the DPC. In extreme cases, there could be a loss of control of an associated process which, in some cases, could result in property damage and injury to persons. Make sure that all terminal block connections are correct before applying power.
Terminal Labels
Labels are provided on the plug-in connector of each terminal block to identify the signals. The top label references each signal by number, while the front label identifies the signal type.
When a terminal block is of the dual type as shown in Figure 2-3, the left block will be designated by the letter "A," and the right by the letter, "B." Generally, the right terminals represent the + side of the signals, while the left terminals represents the corresponding - side or signal common. However, this is not a hard rule and the termination assignments can vary with certain modules.
CI-3335 Installation / 2-7
BLANK PAGE
Section 3
SETUP & WIRING
GENERAL NOTES
The DPC is an extremely versatile product that utilizes both operational and I/O modules to meet a specific user application. Operational modules are those that are furnished with all DPC models; modules in this category perform functions such as computing, controlling, communications, DC-DC conversion, etc. I/O modules are those that interface to real world signals such as AIs, AOs, DIs, DOs, etc.; the number and type of I/O modules furnished in a
DPC will a function of the system application.
Several operational modules and assemblies will require a preliminary setup. Nearly all I/O modules will require both setup and field wiring procedures. The setup procedures involve the selection of options using configuring switches and jumpers, while the wiring procedures involve the connections made to the module terminal blocks.
The associated sections contained in the list below identify the modules and assemblies offered for DPCs. Refer only to those sections that pertain to modules and assemblies contained in your DPC.
Associated Section General Content
Section 3A DC Power System
Section 3B Universal CPU Module
Section 3BA 32-Bit CPU Module - Real Mode
DC power & watchdog wiring
CPU setup
CPU setup
Section 3BB 32-Bit CPU Module - Protected Mode CPU setup
Section 3BC 32-Bit CPU Module - w/Ethernet CPU setup
Section 3C Communication Module Communications setup
Section 3D Analog Input Module (4 AI)
Section 3DA Analog Input Module (8 AI)
Section 3DB Analog Input Module (4 or 8 AI)
Section 3E Analog Output Module (2 AO)
Section 3EA Analog Output Module (2 & 4 AO)
Section 3F Discrete Input Module (4 or 8 DI)
Section 3FA Discrete Input Module (16 DI)
Section 3G Discrete Output Module (4 or 8 DO)
Section 3GA Solid State DC Relay
AI setup and wiring
AI setup and wiring
AI setup and wiring
AO setup and wiring
AO setup and wiring
DI setup and wiring
DI setup and wiring
DO setup and wiring
Discrete Output Module (8 SSDCRDO) DO setup and wiring
Section 3GB Discrete Output Module (8 or 16 DO) DO setup and wiring
Section 3H High Speed Counter Module
Section 3I Low Level AI Module
Section 3J High Speed AI Module
HSC setup and wiring
LLAI setup and wiring
HSAI setup and wiring
CAUTION
When we ship a DPC from our factory, it may not be configured for your application.
Do not attempt to power up a DPC until all modules and assemblies have been properly configured and wired for your application. A failure to do so could result in damage to equipment and property, and possible injury to persons.
CI-3335 Setup & Wiring / 3-1
BLANK PAGE
Section 3A
DC POWER SYSTEM
DESCRIPTION OF POWER SYSTEM
The dc power system consists of the Power Supply Module, System Monitor Module, and the System Interconnect Board. These assemblies provide the following functions:
Power Supply Module (DC-DC Converter)
This module operates from either a nominal +24 Vdc power source (22-28 Vdc for the enclosed type DC-DC Converter Pt. No. 390725-02-1) or a bulk 9-30 Vdc power source (for open frame type or a bulk 9-30 Vdc power source (for open frame type or a bulk 9-30 Vdc power source (for open frame type DC-DC Converter Pt. No. 396840-01-9) provides outputs of +15, -15 and +5 Vdc. This module obtains +24 V power via the System Monitor Module.
System Monitor Module
The System Monitor Module contains terminals for connection to a 24 vdc power source. It also includes terminals for the watchdog alarm and the auto-man transfer function. A
Power Fail and Master Clear LED on this module monitors the power status, while a fuse
(4 A fast-acting type) provides protection for the power circuitry.
A DPC will be furnished with either of the following module types:
System Monitor Module, Standard Type Pt. No. 392041-01-4
System Monitor Module, Heavy Duty Type Pt. No. 392041-02-2
The Heavy Duty type is only used with DPC models that include High Isolation Remote
Termination Modules. The standard type is used for all other models.
System Interconnect Board
The System Interconnect Board functions as a backplane for the DPC. It provides the dc power, I/O, control and communication busses, along with socket connectors that mate with the plug-in modules (see Figures 3A-7 and 3A-8).
WIRING AND SETUP
The System Monitor Module is illustrated in Figure 3A-1. This illustration identifies the location of the field wiring terminals, fuse, circuit jumpers and power LEDs.
The text that follows details the field wiring connections and the jumper options associated with the System Monitor Module. Information on electrical grounding is also included.
CI-3335 DC Power System / 3A-1
Figure 3A-1 - System Monitor Module - Surface Mount Version
Power Terminals
The supply connection terminals are labeled 24V and GND. These terminals are wired to a supply source as shown in Figure 3A-2.
It is recommended that the 3335 be used with a grounding system that provides a power grid ground and zero reference point return as shown in the illustration. Certain jumpers in
3A-2 / DC Power System CI-3335
the 3335 must be configured for this application. See the next subtopic, Grounding
Option , for details.
For the grounding system of Figure 3A-2, the enclosure of the 3335 must connect to the power grid ground of the facility and the -24 V supply terminal to the zero reference point of the facility. A chassis bonding bolt, located inside the left rear panel of the 3335, is provided for the power grid ground connection. Make sure that the ground conductor is free of any coating before forming it around the bolt. Install a washer and nut on the bolt and use a socket driver or wrench to secure the connection.
WARNING
Electrically powered equipment must be properly grounded to protect users from electrical shock and possible fatal injury. Grounding should be performed in accordance with the National Electrical Code, ANSI/ISA standard S82.01, S82.02 and S82.03 and local regulations.
The use of #14 AWG solid copper wire is recommended for grounding. Each end of the wire must be clean to provide a good, low-resistance connection to earth ground. Installations having two or more DPC units mounted in the same rack will require a connection to the earth grounding bolt of each enclosure. The GND terminal on the SM Module must terminate to the Zero Reference Point of the system. Details on grounding are contained in
Supplement Manual S1400 “Guidelines for System Grounding.”
Watchdog Terminals
Figure 3A-2 - DC Power Connections
The watchdog relay circuit is controlled by the CPU. When CPU operation is normal, the relay is energized. If a CPU failure occurs, the relay will de-energize.
The watchdog terminals provide single-pole, double-throw (SPDT) contacts. These contacts, identified as WDNO (Watchdog Normally Open) and WDNC (Watchdog Normally Closed), are in the states shown in Figure 3A-3 when the relay is in a de-energized watchdog condition. During normal operation, the relay is energized and the WDNO contacts are closed while the WDNC contacts are open.
These contacts can be wired to external load devices to indicate normal or alarm conditions.
Typical alarm load devices are bells, horns, lights and buzzers. The watchdog relay contact ratings are given in Section 6 - Specifications.
CI-3335 DC Power System / 3A-3
Auto/Man Transfer Terminals
The Auto/Man Transfer capability allows the DPC to send out a CPU failure signal to an external controller. This signal, identified as the A/MTRAN signal, occurs approximately 2 ms before the watchdog relay signal present at the WD terminals.
The A/MTRAN signal could be used to enable or inhibit an external control device when a watchdog condition occurs. In a typical application, the external device could be one or more single-loop analog controllers that are under control of the DPC. Three basic types of wiring configurations are shown in Figures 3A-4 to 3A-6.
Jumpers W3 shown in the illustrations allows the user to configure the A/MTRAN output as follows:
For position 1-2: High = Manual, Low = Auto
For position 2-3: High = Auto, Low = Manual
Figure 3A-3 - Watchdog Alarm Connections
Jumper W6 selects three operating modes of the output. In position 1-2, the collector is powered by an internal voltage (+5 Vdc) source so that a logical 0/5 V output is applied to the external device (Figure 3A-4). In position 3-2, the collector of the output transistor (Q2) is powered by an internal 24 V dc source so that a logical 0/24 V output is applied to the external device. With no jumper installed, the open collector output can be powered by an external voltage source (24 V dc @ 50 mA max.).
3A-4 / DC Power System CI-3335
Figure 3A-4 - A/MTRAN with 0/5 V Logic
Figure 3A-5 - A/MTRAN with 0/24 Logic
CI-3335
Figure 3A-6 - A/MTRAN with Open Collector Logic
DC Power System / 3A-5
Figure 3A-7 - System Interconnect (SI) Board
With Filters & 10 I/O (3335/3331)
3A-6 / DC Power System CI-3335
CI-3335
Figure 3A-8 - System Interconnect (SI) Board
With Filters & 9 I/O (3335)
DC Power System / 3A-7
Grounding Option
The System Interconnect Board provides two, pin-wire jumpers to set the internal ground reference point of the 3335. These jumpers, identified as W13-A and W13-B in Figures 3A-7 and 3A-8, are accessed by removing the backplate at the rear of the unit.
Jumpers W13-A and W13-B provide a choice of two grounding configurations to minimize noise or common mode error (see Figure 3A-9). When both jumpers are OUT, the supply
GROUND is isolated from chassis ground. When both jumpers are IN, the supply
GROUND is returned to chassis ground. It is essential that both jumpers be set to the same position when selecting a configuration.
The recommended grounding arrangement for the 3335 is shown in Figure 3A-2. For this arrangement the dc supply ground is connected to the "Zero Reference Point" of the facility and the chassis bonding bolt is connected to the "Power Grid Ground." This configuration requires that both jumpers be OUT (the jumpers may be stored by plugging them over a single pin).
Figure 3A-9 - Grounding Option
3A-8 / DC Power System CI-3335
Section 3B
80186 CPU Module
Series 391369-XX-X
WARNING!
The procedures described in this section apply to the CPU Module of a DPC
3335. Do not attempt to use them on the CPU Module of an RIO 3331. See
Section 3L for the proper RIO/CPU setup.
DESCRIPTION
The CPU Module is a dual-board assembly consisting of a Processor Board and Memory Board.
The board assemblies are illustrated in Figures 3B-1 and 3B-2.
The Processor Board, shown in Figure 3B-2, contains the Central Processing Unit, real-time clock, address latches, CPU gate array, peripheral control, watchdog timer, LED status logic, and the input/output buss. It uses an 80C186 12 or 20 MHz, 16-bit microprocessor chip that provides a clock generator, two DMA high-speed channels, an interrupt controller, three 16-bit timers, a wait state generator, and chip-select and ready generation logic. The chip can address 1 M-bytes of memory and 64 k-bytes of I/O.
The Memory Board, shown in Figure 3B-1, is furnished with 128 k-byte RAM backed by a 4000 hour lithium battery as the standard arrangement. Expanded versions with 192 k and 256 k RAM, as well as combination EPROM versions, are also available.
RAM or EPROM chip sets can be purchased separately for field expansion. The maximum memory capacity for any combination of chips is limited to 256 k-bytes.
CPU Modules may also be specified with an optional floating point processor. The processor provides arithmetic and transcendental instructions in hardware.
TABLE 3B-A LISTING OF MODULES (For Part Number 391369-XX-X)
CHIPS IN
POSITION
U5B, U7B
U1B, U3B
02-4
128K
RAM
20 MHz
32K x 8
RAMs
28 Pins
32K x 8
RAMs
28 Pins
03-2
64K RAM &
64K ACL PROM
20 MHz
32K x 8
RAMs
28 Pins
EPROMs
28 Pins
04-0
128K
RAM
12 MHz
32K x 8
RAMs
32 Pins
32K x 8
RAMs
32 Pins
05-9
64K RAM &
ACL EPROM
12 MHz
32K x 8
RAMs
32 Pins
EPROMs/
RAMs
28 Pins
06-7
256K
RAM
12 MHz
128K x 8
RAMs
32 Pins
None
07-5
192K RAM &
ACL EPROM
12 MHz
128K x 8
RAMs
32 Pins
EPROMs
28 Pins
The modules offered in this series are identified in Table 3B-A. The top row of this table lists the board part numbers, while the next row lists the RAM and EPROM capacities. The first column, labeled "Chips in Positions," identifies the chips that are installed in socket positions
CI-3335 (09/01) 80186 CPU Module / 3B-1
for the given features. The remainder of the columns describe the memory organization and processor speed.
This table also provides information to upgrade an existing board. Expansion RAM or EPROM chip sets cited in the table may be purchased separately and installed in the field. The maximum memory capacity for any combination of chips is limited to 128 k-bytes. The procedure for installing chip sets is described under, INSTALLATION OF RAM OR EPROM
LOAD SET.
Figure 3B-1 Memory/Peripheral Board Assembly
3B-2 / 80186 CPU Module CI-3335 (09/01)
Figure 3B-2 Processor Board Assembly
SWITCH AND JUMPER CONFIGURATION
Prior to placing a board in operation, its switches and jumpers must be checked for proper configuration. The location of these components are illustrated in Figure 3B-1. Table 3B-B and 3B-C itemize the respective switch and jumper positions.
CI-3335 (09/01) 80186 CPU Module / 3B-3
Switch SW1 (Mode)
SW1 is an eight-switch package that selects the operating modes listed in Table
3B-B. These switches have the following board labels:
Switch Board Label
SW1-1
SW1-2
SW1-3
SW1-4
SW1-5
SW1-6
SW1-7
SW1-8
128/64
SY/ASY
BR1
BR2
12/20
EP/RA
A/B
BSAP
The functions of these switches are as follows: o 128/64 RAM
Switch SW1-1 must always be set to the OFF position. This position is used with 128K, 192K and 256K RAM boards (boards with 64K RAM were discontinued). To determine the module's RAM capacity, check the board's part number against Table 3B-A.
TABLE 3B-B SETTINGS FOR SWITCHES SW1 & SW2
SWITCH
NUMBER
SW1-1
-4
-5
-2
-3
-6
-7
-8
SW2-1 to -7
SWITCH
SELECTION
ON
OFF see Note 1 see Note 1 see Note 1
ON
OFF
ON
OFF
ON/OFF
ON
OFF
ON
OFF
FUNCTION
64 k RAM (Not Used)
128-256 k RAM
SY/ASY Comm. Rate - MSD
BR1 - Comm. Rate
BR2 - Comm. Rate - LSD
20 MHz system clock - factory set
12 MHz system clock - factory set
RAM chips in U1B & U3B
EPROM chips in U1B & U3B
N/A
Standard BSAP Slave Comm.
Extended BSAP Slave Comm.
Seven-Bit Node Address:
Bit Value is 0
Bit Value is 1
SET
TO
OFF
AR
AR
AR
*'
*
-
AR
AR
Not Used -8
3B-4 / 80186 CPU Module
ON/OFF ON
CI-3335 (09/01)
DIP SWITCH CONVENTIONS FOR TABLE 3B-B
AR = As Required. Refer to text for details.
* Set at factory. Do not change position unless upgrading a chip set.
* ' Set at factory. Do not change position.
** Only used for Model 3332 redundancy application. Otherwise SW1-7 may be left in
either position.
Note 1: See Cold Download Baud Rate for Port B/D Only o Cold Download Baud Rate for Port B/D Only
A cold download is a condition whereby the DPC has successfully completed the startup diagnostics cycle and is standing by for a download. The cold download communication rates are selected by switches SW1-2, -3 and -4. These switches, which bear the legends
SY/ASY, BR1 and BR2, are set to provide the following rate selections:
Port B/D
Rate
1200 Bd
2400 Bd
4800 Bd
9600 Bd
19.2 kBd
38.4 kBd
Sync *
SY/ASY
SW1-2
ON
ON
OFF
ON
ON
OFF
OFF
BR1
SW1-3
ON
OFF
OFF
ON
OFF
OFF
ON
BR2
SW1-4
ON
ON
ON
OFF
OFF
OFF
ON
* Synchronous rates of 187.5 kBd or 1 Mbd are selected on the Comm. Module.
All baud rates in the above list apply to asynchronous communications. However, port B/D can also be configured for synchronous communications by setting the switches to the bottom selection (Sync). Synchronous rates, which are only provided for 187.5 kBd and 1 MBd, are selected by jumper blocks on the Comm. Module. See Section 3C for details.
If it is desire to use port A/C for a cold download, the Comm. rate will be fixed at 9600 baud.
o 12/20 (MHz)
Switch SW1-5 is factory-set for the specified processor speed.
o EP/RA (EPROM/RAM)
The DPC may be specified with EPROM or expanded RAM chips in sockets U1B and U3B.
SW1-6 is set OFF for EPROM memory and ON for RAM memory. This switch is factoryset and need not be changed unless EPROM or RAM alterations are made in the field.
CI-3335 (09/01) 80186 CPU Module / 3B-5
o Standard BSAP/Expanded BSAP Slave Communications
SW1-8 should be set to the "OFF" position only if communicating with an expanded Master and in group 1 or above.
Switch SW2 (Node Address)
Switches 1 through 7 of SW2 select a 7-bit node address for the DPC. When set to OFF, each switch provides the following binary values:
Switch
SW2-1
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
SW2-8
"OFF" Binary Value
1 (LSB)
2
4
8
16
32
64 (MSB
*
Notes
*
The maximum number of addreses available using SW2-1 to SW2-
7 is 127. SW2-8 is not used for addressing and must be set to the
"ON" position.
Jumpers - Memory Board (Figure 3B-1)
W1. Jumper W1 on the Memory Board (Figure 3B-1) disables the RAM battery circuit to prevent unnecessary drain during shipment or storage. To activate the backup battery circuit, plug W1 into pins 1 and 2 as noted in Table 3B-C.
W2,W10. The numeric processor option (NPX) performs floating point arithmetic and transcendental operations. It includes integrated circuit chip U12C which is shown in Figure
3B-1. When this option is present, W2 must be plugged in as noted in Table 3B-C. Jumper
W10 is factory-set for the proper clock speed and should not moved.
W3-W9. These jumpers are factory-set to correspond with the type and capacity of memory chips installed on the board (see Table 3B-C). These settings should not be disturbed unless chip additions are made in the field. See topic, INSTALLATION OF RAM OR EPROM LOAD
SET for details.
Jumpers - Processor Board (Figure 3B-2)
W1. This jumper is a four-pin header that is set at the factory to correspond with the type of processor chip installed. Table 3B-C identifies the selections. This jumper should not be tampered with in the field.
LEDS AND RESET BUTTON
Status LEDs
Six LEDs (DS1 to DS6) at the front of the Processor Board provide a diagnostic status indication (Figure 3B-2). The diagnostic failure patterns are given in Section 5 - Service.
3B-6 / 80186 CPU Module CI-3335 (09/01)
Watchdog & Idle LEDs
The WDOG LED (DS8) monitors the watchdog timer. This LED is normally OFF and turns
ON if a failure is detected. The IDLE LED (DS7) turns ON when the CPU has stopped or is idle, and turns OFF when the CPU is busy.
Reset Button (SW3)
When pressed, this button will initiate the "cold start" diagnostic test cycle which results in clearing of the RAM. A RAM-based DPC will then require a download (see "Section 4 -
Operation" for details).
TABLE 3B-C JUMPER SETTINGS
JUMPER
NUMBER
AVAILABLE
SELECTIONS
W1
W1
W2
W3 - W9
W10
-
1-2 & 3-4
2-3
1-2
2-3
IN
OUT
1-2/2-3
-
1-2
2-3
FUNCTION
PROCESSOR BOARD
Processor Type Installed in U10C:
Intel 80C186EA
AMD 80C186 or Intel 80C186XL
MEMORY BOARD
RAM Battery Circuit is ON
RAM Battery Circuit is OFF
Numeric Processor Installed in U12C
None
Memory Selection
Numeric Processor Clock Speed:
20 MHz
12 MHz
INSTALLATION OF RAM OR EPROM LOAD SET
The ACCOL load that contains the user's process configuration data is organized on two, 32 k x 8 RAM or EPROM chips. These chips are located at sockets U1B and U3B shown in Figure
3B-1.
CI-3335 (09/01) 80186 CPU Module / 3B-7
If the module contains RAM chips in positions U1B and U3B, the ACCOL configuration data must be loaded from a PC into the DPC via a defined port. Once the load is on line, it is protected during equipment or power failures by the backup battery.
If the module contains EPROM chips in positions U1B and U3B, no loading is required. These chips are configured with the ACCOL application load using an EPROM programming device.
EPROM-based loads, unlike RAM-based loads, automatically restart after an equipment or power failure. Once the self-test startup cycle has completed, process execution begins from the initial values programmed into the load.
CAUTION
RAM or EPROM chips can be damaged by static electric charges.
Before adding or changing any chips, refer to instruction supplement S14006 located at the end of this manual for proper handling procedures.
Low Byte and High Byte Matched Set
When an EPROM chip pair is programmed, the user will assign separate identities to each unit. Referring to Table 3B-D, one EPROM will be designated as the low-byte unit, and the other as the high-byte unit. The EPROM programmed with the "High Byte" code is inserted in socket U1B, while the one with the "Low Byte" code is inserted in socket U3B. Once programmed, the chip positions must not be reversed. This restriction does not apply to modules that use RAM chips. RAM chips may be inserted into either socket without consequence.
Changing a Load Set
A RAM or EPROM load set is changed or installed as follows:
1. Turn off power to the DPC.
2. Remove the CPU Module from its socket and turn it so that the Memory Board is face up as in Figure 3B-1.
3. Locate sockets U1B and U3B. Use a tool such as a chip puller to remove the current
RAM or EPROM set. Remove the chips carefully to prevent damage to the pins and socket connectors.
4. Before installing a replacement EPROM set only, identify the proper sockets for the low and high-byte units (see Table 3B-D). RAM replacement sets can be mixed.
TABLE 3B-D IDENTIFICATION OF EPROM/RAM CHIP SETS
Board
Socket
U1B
U3B
EPROM Chip
Part Number Byte
389164-09-7 High
389164-09-7 Low
RAM Chip
Part Number
390620-06-8
390620-06-8
3B-8 / 80186 CPU Module CI-3335 (09/01)
5. At this time the pin and socket connections should also be identified. If the chip is oriented so that the pins are facing away from observer and the notch is at the 12 o'clock position, pin 1 will be at the top left. Hole #1 on the mating socket will typically be marked with a dot or digit. However, pin 1 of the chip does not mate with hole 1.
Instead, it mates with hole 3 of the socket.
CAUTION
Even though the sockets for U1B and U3B have openings for 32 pins, some chips have only 28 pins. Be sure to position 28-pin chips so that pin #1 of the chip mates with hole #3 opening of the socket. Holes 1, 2, 31 and 32 are not used by these chips.
6. Align chip pins with proper socket connections and push the chip carefully into its socket. Apply pressure evenly to prevent bent pins. If any pins bend, stop and straighten them out.
7. After both chips are installed, check that switch SW1-6 on the memory board is set to its OFF position. This configures the CPU Module for EPROM operation.
TABLE 3B-E MEMORY JUMPER SETTINGS
Jumper
Header
W3
W4
W5
W6
W7
W8
W9
64K
RAM
128K
RAM
1 to 2 1 to 2
1 to 2 1 to 2
1 to 2 1 to 2
1 to 2 1 to 2
1 to 2 1 to 2
64K RAM
& EPROM
2 to 3
2 to 3
2 to 3
2 to 3
2 to 3
1 to 2 1 to 2 2 to 3 2 to 3
1 to 2 1 to 2 2 to 3 2 to 3
* Not Currently Avaliable
256K
RAM*
2 to 3
2 to 3
1 to 2
2 to 3
2 to 3
192K RAM
& EPROM*
2 to 3
2 to 3
1 to 2
2 to 3
2 to 3
2 to 3
2 to 3
8. Configure jumpers W3 to W9 for the desired configuration using Table 3B-E.
9. Replace the CPU Module in its socket and power up the system. The DPC will begin executing the ACCOL load starting from the initial values specified in the load.
PART NUMBER ASSIGNMENT
Series 391369-XX-X CPU Module and associated printed circuit board (PCB) part numbers are provided in Table 3B-F.
CI-3335 (09/01) 80186 CPU Module / 3B-9
TABLE 3B-F 80186 CPU MODULE BOARDS PART NUMBER IDENTIFICATION
CPU MODULE
PART NUMBER
391369-02-4
391369-03-2
391369-04-0
391369-05-9
391369-06-7
391369-07-5
CPU PCB
PART
NUMBER
392522-01-2
392522-01-2
395212-01-4
395212-01-4
395212-02-2
395212-02-2
MEM./PERIPH.
PCB
PART NUMBER
392507-02-1
392507-03-0
395218-02-0
395218-03-9
395218-04-7
395218-05-5
CONFIG.
NOTES
20MHz
20MHz
12MHz
12MHz
12MHz
12MHz
3B-10 / 80186 CPU Module CI-3335 (09/01)
Section 3BA
32-Bit CPU Engine Assembly - Real Mode
Series 395358-01-9
DESCRIPTION
The "Real Mode" 32-Bit CPU Engine Assembly is a two board set that is fully compatible with current 3335 boards and has been designed to provide the following enhancements:
• Two additional BSAP Asynchronous Serial Ports (BIP1 & BIP2).
• FLASH Memory - 512K Bytes of Asymmetrically Blocked FLASH Memory.
• 510K Bytes oof Static RAM.
• ACCOL application load storage in FLASH Memory.
• Utility Serial Port.
The 32- Bit CPU Engine Assembly boards mount back-to-back and reside in the CPU slot.
Circuit Overview
The Series 395358-01-9 CPU Engine Assembly is equipped with a 24 MHz Intel 386EX, 32bit embedded microprocessor that features low power and low voltage capabilities, and utilizes a 32-bit programming architecture. The CPU Engine Assembly may be furnished with 510K Bytes of Base RAM, 512K Bytes of Base FLASH Memory and 128K Bytes of
ACCOL Load/Boot Code FLASH Memory. The microprocessor utilizes the following integrated peripherals (Located in I/O Address Space):
• Clock Generation and Power Management Unit
• Chip Select Unit
• Interrupt Control Unit
• Timer/Counter Unit
• Watchdog/Bus Monitor Timer Unit
• Asynchronous Serial I/O Unit
• Parallel I/O Unit
• DMA Unit
• Numeric Processor Interface : Provides access to an 80387SX Numeric Processor.
• JTAG Boundary Scan Unit (For Test Only)
In addition to the Microprocessor, RAM and FLASH Memory, the following main items are included in the CPU Engine Assembly design: Battery, Node Address Switch, Function
Switch, Real-Time Clock, On-Board 85C30 SCC and 80387SX Numeric Processor:
• Battery : Back-up power is distributed to all RAM by a Lithium battery which provides a cumulative back-up period of six months (4,500 Hours worst case) for Base RAM.
• Node Address Switch (SW2) : An eight position DIP Switch (SW2) (on the Memory &
Peripheral Board) provides for node address assignment. SW2 is read from byte location 09F880 with the first switch set as the least significant bit. The open or OFF position is read as a 1 and the closed or ON position is read as a 0.
CI-3335 (09/2001) CPU Engine Board / 3BA-1
Figure 3BA-1
Memory & Peripheral Board
3BA-2 / CPU Engine Board
Figure 3BA-2
CPU Board
CI-3335 (09/2001)
Note: EMB Board not available on Real Mode CPU Engine Assembly
Figure 3BA-3 - 32-Bit Real Mode CPU Engine Assembly
• Function Switch (SW1): An eight-position switch (SW1) (on the Memory & Peripheral
Board) accommodates function assignment and is read from byte location 09F881 with the first switch set as the LSB. The open or OFF position is read as a 1. No hardware functions are controlled by SW1.
• Real-Time Clock : The CPU Board offers a Real-Time Clock with an accuracy of " 1
Second/Day over a 0 E to 50 E C temperature range.
• 85C30 SCC : An On-Board 85C30 SCC (on the CPU Board) provides two asynchronous serial channels.
- Each of the two on-board serial channels has a switch configurable EIA-562 or RS-485 interface. EIA-562 outputs swing approximately " 4.5 volts and may not meet older
RS-232 applications; however, the ports do accept all RS-232 levels as inputs.
• Numeric Processor : A socket is provided on the CPU Board for an optional 80387SX
Numeric Processor.
CI-3335 (09/2001) CPU Engine Board / 3BA-3
I/O INTERFACE
• Utility Port Interface : The CPU Engine's Memory & Peripheral Board provides an
RS-232 compatible 3-Wire interface (J5): J5-1 = TXD, J5-2 = RXD and J5-3 = GND.
This port is used for loading FLASH memory.
• Extended Memory Interface : The CPU Board includes a 70-pin connector (J1) to accommodate an optional extended memory board.
• RS-485/EIA-562 Port Interface : Built-in Port 1 (BIP1) and built-in Port 2 (BIP2)
(both on the CPU Board) are configured via SW3 & SW4 (on the CPU Board) respectively. On-board 10KV ESD protection is provided.
Table 3BA-1 - RS-485/EIA-562 Interface Ports
6
7
4
5
PIN# EIA-562 RS-485
1 /DTR TXD+
2
3
TXD
N/A
TXD-
RXD+
8
9
RXD
/RTS
/CTS
/DCD
/DTR
GND
RXD-
RTS+
CTS+
CTS-
RTS-
GND
• I/O Card Interface : The CPU Engine Assembly interfaces with up to 12 I/O cards via the dedicated 8-Bit Bus on the P1 Edge Connector of the CPU Board. The I/O Clock runs at 6MHz.
• Communications Board Interface BUS : The same data and address lines used for the I/O Cards are used to interface with up to two Communication Boards via the P1
Connector.
SWITCH & JUMPER CONFIGURATION
Prior to operation, the switches and jumpers of the 32-Bit CPU Engine Assembly must be checked.
Function switch SW1 and node address switch SW2 (both on the Mem. & Peripheral Bd.) define their OFF (open) positions as logic "1" and their ON (closed) positions as logic "0."
Memory & Peripheral Board Switch SW1 - (Mode)
Switch SW1 selects various board operating modes (see Tables 3BA-2 & 3BA-3).
3BA-4 / CPU Engine Board CI-3335 (09/2001)
Table 3BA-2 - Switch SW1 Mode Labels
Switch
#
SW1-1
Switch
Selection
ON
OFF
SW1-2 Table 3BA-3
SW1-3 Table 3BA-3
SW1-4 Table 3BA-3
SW1-5
ON
OFF
SW1-6
ON
OFF
SW1-7 ON/OFF
SW1-8
ON
OFF
Mode Label
FLASH Download
SY/ASY
BR1
BR2
Unlocked
Locked
RAM
FLASH
-
BSAP
Function
Normal
FLASH Download
Comm. Baud Rate - MSD
Comm. Baud Rate
Comm. Baud Rate - LSD
ACCOL FLASH Lock
ACCOL Load Storage
N/A
Standard BSAP
Expanded BSAP
Set To
AR
AR
AR
AR
AR
AR
-
AR*
Note: SW1-8 "BSAP" is set to OFF only if unit is communicating with an expanded master, and in Group 1 or above.
Mem. & Peripheral Bd. Switch SW1-1 - System Firmware FLASH Download
With SW1-1 set "OFF," the 32-Bit CPU Board waits for the system firmware to be downloaded into FLASH via the Utility Port. SW1-1 must be set to the "ON" position at the end of the FLASH Download.
Mem. & Peripheral Bd. Switches SW1 -2, -3, -4 - Cold Download Baud Rate
A "cold download" is a condition whereby the Distributive Process Controller has successfully completed startup diagnostics and is standing by for a download. The ports and communication rates are selected by switches SW1-2, -3 and -4. These switches correspond to respective board legends, SY/ASY, BR1, and BR2 (see Table 3BA-3).
All baud rates listed in Table 3BA-3 apply to asynchronous communications for ports B, D,
H, J & BIP2; however, ports B, D can also be configured for synchronous communications by setting the three switches in the last position (Sync). Synchronous rates, which are only provided for 187.5 KBd and 1 MBd, are selected by jumper blocks on the CE Board. Ports
A, C, G, I & BIP1 default to 9600 Baud.
Note:
Ports BIP2, H & J are strictly asynchronous Ports, i.e., when configured for normal communications or for a cold download. Port BIP1 is also strictly asynchronous.
CI-3335 (09/2001) CPU Engine Board / 3BA-5
Table 3BA-3 - Switch SW1 Baud Rate Settings
Selection
(Baud Rate)
1200
2400
4800
9600
19200
38400
Sync*
SY/ASY
SW1-2
ON
ON
OFF
ON
ON
OFF
OFF
BR1
SW1-3
ON
OFF
OFF
ON
OFF
OFF
ON
BR2
SW1-4
ON
ON
ON
OFF
OFF
OFF
ON
* Synchronous rates of 187.5K Baud or 1M Baud are selected on the Communications Board.
Mem. & Peripheral Board Switches SW1-5, 6 - ACCOL FLASH Lock/ACCOL
Load Storage
ACCOL loads can be stored in RAM or FLASH memory. With SW1-5 has no meaning unless SW1-6 has been set to the OFF position, i.e., set for ACCOL FLASH load storage.
When SW1-6 and SW1-5 are set to the OFF position, the unit will not accept a new ACCOL
FLASH download. Switch SW1-5 should not be set to the OFF position until SW1-6 has been set to the OFF position and a download has been completed.
Memory & Peripheral Board Switch SW2 (Node Address)
Switches 1 through 7 of SW2 select a 7-bit node address for the DPC in a network application. When set to OFF, the switch provides the binary values in Table 3BA-4.
Table 3BB-4 - Binary Values For Switch SW2
Switch Binary Value
SW2-1 1
SW2-2
SW2-3
2
4
SW2-4
SW2-5
SW2-6
SW2-7
SW2-8
8
16
32
64 (MSB)
0
3BA-6 / CPU Engine Board CI-3335 (09/2001)
Note:
The maximum number of addresses available using SW2-1 to SW2-7 is 127.
SW2-8 is not used for addressing and is normally set to the ON position.
CPU Board Switches SW3 & SW4
SW3 controls a Port 1 and SW4 controls Port 2. These 8-position dip switches have identical configurations (see Table 3BA-5). Switch positions -1, -5 & -6 are not used on both
SW3 and SW4. Switch positions -3 (+) and -4 (-) are transmit-to-receive loopback. Switch positions -7 (+) and -8 (-) are receive-to-send and clear-to-send loopback. When switch positions -3, -4, -7, or -8 are ON, the loopbacks are enabled; otherwise, they are OFF or disabled.
Table 3BA-5 - Switches SW3 & SW4 Configuration Settings
Switch Pos.
-1, -5 & -6
-2
-3
-4
-7
-8
Selection
N/A
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Function
N/A
EIA-562 Interface Enabled
RS-485 Interface Enabled
+ (Tx to Rx) Loopback Enabled
+ (Tx to Rx) Loopback Disabled
- (Tx to Rx) Loopback Enabled
- (Tx to Rx) Loopback Disabled
+ (RTS to CTS) Loopback Enabled
+ (RTS to CTS) Loopback Disabled
- (RTS to CTS) Loopback Enabled
- (RTS to CTS) Loopback Disabled
Memory & Peripheral Board Reset Button SW5
Reset Button (SW5) an SPST Momentary Switch will initiate the "cold start" diagnostic test cycle that clears RAM. A RAM-based DPC will then require a download (see "Section 4
- Operation" for details).
Memory & Peripheral Board Jumper W1 (RAM Battery)
Jumper W1 disables the RAM battery circuit to prevent unnecessary drain during shipment or storage. The RAM battery back-up is enabled by connecting Jumper W1 across
Pins 1 and 2. Disable the back-up battery by disconnecting the jumper wire from Pin 2, leaving it connected to Pin 1.
A Lithium battery (3.6 volts) that plugs into the back of the Memory & Peripheral Board, provides back-up voltage to all RAMs if the +5V supply fails. The cumulative back-up period last six months (4,500 hours maximum) for base RAM.
Jumper W2 (WARNING)
Jumper W2 should never be plugged in or have a jumper wire installed by the customer. It is for Bristol Babcock testing only.
CI-3335 (09/2001) CPU Engine Board / 3BA-7
LED ASSIGNMENTS
Memory & Peripheral Board Status LEDs DS1-DS6
LEDs DS1 to DS6 on the Memory & Peripheral Board (Figures 3BB-1 & 3BB-4) provide a diagnostic status indication.
Memory & Peripheral Board Watchdog and Idle LEDs DS7 & DS8
The IDLE LED (DS7) remains OFF when the CPU is busy and turns ON when the CPU is idle or has stopped. The WDOG LED (DS8) Monitors the watchdog timer. This LED is normally OFF and turns ON if a failure is detected.
CPU Board Communication Port LEDs DS9-1 through DS9-4
LEDs DS9-1 through DS9-4 provide information about the Communications Ports as follows:
Table 3BA-6 - Communication Port LEDs
LED ON
DS9-1
DS9-2
DS9-3
DS9-4
FUNCTION
Transmit Data on BIP1
Receive Data on BIP1
Transmit Data on BIP2
Receive Data on BIP2
3BA-8 / CPU Engine Board CI-3335 (09/2001)
Section 3BB
32-Bit CPU Engine Assembly - Protected Mode
Series 396029-XX-X
DESCRIPTION
The "Protected Mode" 32-Bit CPU Engine Assembly is a three board set which is fully compatible with current 3335 boards. The assembly consists of the 32-Bit CPU Engine
Board, the Memory & Peripheral Board and the Extended Memory Board (EMB). This assembly allows a user to field upgrade a 3335 system for 32-bit protected mode operation and has been designed to provide the following enhancements:
• Two on-board BSAP Asynchronous Serial Ports (BIP1 & BIP2). Supports up to eight
(8) serial communication ports.
• Asymmetrically Blocked FLASH Memory - 512K Bytes on CPU and 2M Bytes on EMB.
• Static RAM - 512K Bytes on CPU Board - up to 4M Bytes on EMB.
• ACCOL application load storage in FLASH Memory.
• Utility Serial Port.
• Protected Mode Operating System.
• Up to 4.5M Bytes of application memory.
The 32- Bit CPU Engine Assembly boards mount back-to-back and reside in the CPU slot.
Circuit Overview
The Series 396029-XX-X CPU Engine Ass’y. is equipped with a 24 MHz Intel 386EX, 32-bit embedded microprocessor that features low power and low voltage capabilities, and utilizes a 32-bit programming architecture. The CPU Engine Ass’y. may be furnished with 512K
Bytes of Base RAM, 512K Bytes of Base FLASH Memory and 128K Bytes of ACCOL Load/-
Boot Code FLASH Memory (112K for ACCOL, 4K for Soft Switches, 4K Spare & 8K for
Boot Code). The piggy-back mounted EMB accommodates up to 4M Bytes of RAM with 2M
Bytes of Flash Memory (1M for System, .5M Custom & .5M for ACCOL). The microprocessor utilizes the following integrated peripherals (Located in I/O Address Space):
• Clock Generation and Power Management Unit
• Chip Select Unit
• Interrupt Control Unit
• Timer/Counter Unit
• Watchdog/Bus Monitor Timer Unit
• Asynchronous Serial I/O Unit
• Parallel I/O Unit
• DMA Unit
• Numeric Processor Interface : Provides access to an 80387SX Numeric Processor.
• JTAG Boundary Scan Unit (For Test Only)
In addition to the Microprocessor, RAM and FLASH Memory, the following main items are included in the CPU Engine Assembly design: Battery, Node Address Switch, Function
Switch, Real-Time Clock, On-Board 85C30 SCC and 80387SX Numeric Processor:
CI-3335 (05/2003) CPU Engine Board / 3BB-1
Figure 3BB-1
Memory & Peripheral Board
Figure 3BB-2
CPU Board
• Node Address Switch (SW2) : An eight position DIP Switch (SW2) (on the Memory &
Peripheral Board) provides for node address assignment. SW2 is read from byte location 07F880 with the first switch set as the least significant bit. The open or OFF position is read as a 1 and the closed or ON position is read as a 0. SW2 controls no hardware functions.
3BB-2 / CPU Engine Board CI-3335 (05/2003)
• Battery : Back-up power is distributed to all RAM by a Lithium battery (3.6 volts) which provides a cumulative back-up period of six months (4,500 Hours worst case) for
Base RAM (if the +5V Supply fails). With the addition of RAM on the Extended
Memory Board (EMB) the back-up period diminishes as follows:
EMB with 1M RAM - 3490 Hours worst case
EMB with 2M RAM - 2830 Hours worst case
EMB with 4M RAM - 2050 Hours worst case
Figure 3BB-3 - Extended Memory Board for 32-Bit CPU
CI-3335 (05/2003)
Figure 3BB-4 - 32-Bit CPU Engine Assembly
CPU Engine Board / 3BB-3
• Function Switch (SW1) : An eight position switch (SW1) (on the Memory &
Peripheral Board) accommodates function assignment and is read from byte location
07F881 with the first switch set as the LSB. The open or OFF position is read as a 1.
No hardware functions are controlled by SW1.
• Real-Time Clock : The CPU Board offers a Real-Time Clock with an accuracy of " 1
Second/Day over a 0 E to 50 E C temperature range.
• 85C30 SCC : An On-Board 85C30 SCC (on the CPU Board) provides two asynchronous serial channels.
- Each of the two on-board serial channels has a switch configurable EIA-562 or RS-485 interface. EIA-562 outputs swing approximately " 4.5 volts and may not meet older
RS-232 applications; however, the ports do accept all RS-232 levels as inputs.
• Numeric Processor : A socket is provided on the CPU Board for an optional 80387SX
Numeric Processor.
The following main items are included on the Extended Memory Board (EMB):
• Static RAM Block - Eight 512Kbit x 8 CMOS Static RAM ICs.
• Flash Memory Block - One 1MBit x 16 CMOS FLASH Memory ICs.
• Control Programmable Logic Block - Two Zero Power PLDs.
PROTECTED MODE 32-BIT CPU ENGINE I/O INTERFACE
• Utility Port Interface : The CPU Engine's Memory & Peripheral Board provides an
RS-232 compatible 3-Wire interface (J5): J5-1 = TXD, J5-2 = RXD and J5-3 = GND.
This port is used for loading FLASH memory.
• Extended Memory Interface : The CPU Board includes a 70 pin connector (J1) to accommodate an optional extended memory board.
• I/O Card Interface : The CPU Board interfaces up to 9 or 10 I/O cards via the dedicated 8-Bit Bus on the P1 Edge Connector. The I/O Clock runs at 6MHz.
• Communications Board Interface BUS : The same data and address lines used for the I/O Cards are used to interface with up to two Communication Boards via the P1
Connector.
Table 3BB-1 - RS-485/EIA-562 Interface Ports
PIN# EIA-562 RS-485 PIN# EIA-562 RS-485 PIN# EIA-562 RS-485
1 /DTR TXD+ 4 RXD RXD7 /DCD CTS-
2 TXD
3 N/A
TXD-
RXD+
5
6
/RTS
/CTS
RTS+
CTS+
8
9
/DTR
GND
RTS-
GND
• RS-485/EIA-562 Port Interface : Built-in Port 1 (BIP1) and built-in Port 2 (BIP2)
(both on the CPU Board) are configured via SW3 & SW4 (on the CPU Board) respectively. On-board 10KV ESD protection is provided.
3BB-4 / CPU Engine Board CI-3335 (05/2003)
SWITCH & JUMPER CONFIGURATION
Prior to operation, the switches and jumpers of the 32-Bit CPU Engine Assembly must be checked.
Function switch SW1 and node address switch SW2 (both on the Memory & Peripheral
Board) define their OFF (open) positions as logic "1" and their ON (closed) as logic "0."
Configuration of Soft Switches is provided in Open BSI. Once configured, the Soft Switches have priority over the associated Hard Switches unless SW1-3 has been set to the OFF position. Soft Switches provide the following functions:
• Node Address
• Updump Enable/Disable
• EBSAP Group #
• Cold Download Rates (for any CPU Board port)
• Internet Protocol Configuration
It should be noted that Soft Switches don’t have to be configured.
Memory & Peripheral Board Switch SW1 - (Mode)
Switch SW1 selects various board operating modes (see Tables 3BB-2, 3BB-3 & 3BB-4).
Table 3BB-2 - Switch SW1 Mode Labels
Switch
#
Switch
Selection
SW1-1
ON
OFF
SW1-2 Table 3BB-3
SW1-3 Table 3BB-3
SW1-4 Table 3BB-3
SW1-5 ON/OFF
SW1-6
ON
OFF
SW1-7 ON/OFF
SW1-8
ON
OFF
Mode Label
FLASH Download
SY/ASY
BR1
BR2
MWS
RAM
FLASH
-
BSAP
Function
Normal
FLASH Download
Comm. Baud Rate - MSD
Comm. Baud Rate
Comm. Baud Rate - LSD
2 Memory Wait States for RAM Access
ACCOL Load Storage
N/A
Standard BSAP
Expanded BSAP
Set To
AR
AR*
AR*
AR*
*
AR
-
AR*
Note: SW1 -2, -3 & -4 - see Note 1 under Memory & Peripheral Board Switch SW1-
2, -3, -4 - Cold Download Baud Rate.
Note: SW1-5 "MWS" should be set as follows:
Set to the ON (closed) position (1 Wait State) if the Extended Mem. Board has 0 or 1MB of RAM and the unit is operating at or below 50 ° C (122 ° F).
Set to the OFF (open) position (2 Wait States) if the Extended Mem. Board has 2MB to 4MB of RAM or if the unit is operating above 50 E C (122 E F).
Note: SW1-8 "BSAP" is set to OFF only if unit is communicating with an expanded master, and in Group 1 or above.
CI-3335 (05/2003) CPU Engine Board / 3BB-5
Mem. & Peripheral Bd. Switch SW1-1 - System Firmware FLASH Download
With SW1-1 set "OFF," the 32-Bit CPU Board waits for the system firmware to be downloaded into FLASH via the Utility Port. SW1-1 must be set to the "ON" position at the end of the FLASH Download.
Mem. & Peripheral Bd. Switches SW1 -2, -3, -4 - Cold Download Baud Rate
Note 1
As of Firmware versions PLS03 and PLX03, these switches apply only if the Soft Switches of the DPC have not been configured. If configured, cold rates are contained within the Soft Switches and these switches are re-defined (see
Table 3BB-4).
A "cold download" is a condition whereby the Distributive Process Controller (DPC) has successfully completed startup diagnostics and is standing by for a download. The ports and communication rates are selected by switches SW1-2, -3 and -4. These switches correspond to respective board legends, SY/ASY, BR1, and BR2 (see Table 3BB-3).
Baud rates shown in Table 3BB-3 apply to asynchronous communications for ports B, D,
H, J & BIP2; however, ports B, D can also be configured for synchronous communications by setting the three switches in the last position (Sync). Synchronous rates, which are only provided for 187.5 KBd and 1 MBd, are selected by jumper blocks on the CE Board. Ports
A, C, G, I & BIP1 default to 9600 Baud.
Note:
Ports BIP2, H & J are strictly asynchronous Ports, i.e., when configured for normal communications or for a cold download. Port BIP1 is also strictly asynchronous.
Table 3BB-3 - Switch SW1 Baud Rate Settings
Selection
(Baud Rate)
1200
2400
4800
9600
19200
38400
Sync*
SY/ASY
SW1-2
ON
ON
OFF
ON
ON
OFF
OFF
BR1
SW1-3
ON
OFF
OFF
ON
OFF
OFF
ON
BR2
SW1-4
ON
ON
ON
OFF
OFF
OFF
ON
* Synchronous rates of 187.5K Baud or 1M Baud are selected on the
Communications Board.
Note: With Soft Switches configured and SW1-3 set to the OFF position, all ports default to 9600 BSAP and the Node Address and updump features are redefined by Hard Switches. Additionally, the Internet Protocol (IP) for
Asynchronous Ports is disabled.
3BB-6 / CPU Engine Board CI-3335 (05/2003)
Table 3BB-4 - Switch SW1 Definitions with Configuration FLASH Loaded
Switch
SW1-2
SW1-3
SW1-4
Selection
OFF
ON
OFF
ON
OFF
ON
Function
Soft Switches can’t be changed
Soft Switches can be changed
Read from Hard Switches (Override Soft Switches)
Use Soft Switches
ACCOL is FLASH Locked
Unlocked
Set To
AR
AR
AR
Memory & Peripheral Board Switches SW1-6 - ACCOL Load Storage &
SW1-4 - ACCOL FLASH Lock
ACCOL loads can be stored in RAM or FLASH memory. With SW1-6 set in the OFF position, i.e., set for ACCOL FLASH load storage, Switch SW1-4 can be configured to accept a new ACCOL FLASH download or the ACCOL Load can be locked, i.e., cannot be overwritten. When SW1-6 and SW1-4 are set to the OFF position, the unit will not accept a new ACCOL FLASH download. Switch SW1-4 should not be set to the OFF position until
SW1-6 has been set to the OFF position and a download has been completed. Note: The
ACCOL FLASH Lock option (see Table 3BB-4) is not enabled until switches SW1 -2,
-3 and -4 have been re-defined by configuration of soft switches.
Memory & Peripheral Board Switch SW2 - (Node Address)
Switches 1 through 7 of SW2 select a 7-bit node address for the DPC in a network application. When set to OFF, the switch provides the binary values in Table 3BB-4.
Switch SW2-8 disables the updump feature when it is set to the ON position. When set to the OFF position, SW2-8 disables the Watch Dog Timer and enables a core memory dump.
With the Watch Dog Timer disabled, the Reset Button (SW5) should be pressed twice
(within 2 seconds). This will cause a menu to be posted at 19.2K baud on BIP1. This menu is used to dump the CPU memory.
Table 3BB-5 - Binary Values For Switch SW2
Switch Binary Value
SW2-1
SW2-2
SW2-3
SW2-4
1
2
4
8
Switch Binary Value
SW2-5 16
SW2-6
SW2-7
SW2-8
32
64 (MSB)
0
Note:
The maximum number of addresses available using SW2-1 to SW2-7 is 127.
SW2-8 is not used for addressing and is normally set to the ON position.
32-Bit CPU Engine Board Switches SW3 & SW4
SW3 controls a Port 1 and SW4 controls Port 2. These 8-position dip switches have identical configurations (see Table 3BB-6). Switch positions -1, -5 & -6 are not used on both
SW3 and SW4. Switch positions -3 (+) and -4 (-) are transmit-to-receive loopback. Switch
CI-3335 (05/2003) CPU Engine Board / 3BB-7
positions -7 (+) and -8 (-) are receive-to-send and clear-to-send loopback. When switch positions -3, -4, -7, or -8 are ON, the loopbacks are enabled; otherwise, they are OFF or disabled.
Table 3BB-6 - 32-Bit CPU Board Switches SW3 & SW4 Configuration Settings
Switch Pos.
-1, -5 & -6
-2
-3
-4
-7
-8
Selection
N/A
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Function
N/A
EIA-562 Interface Enabled
RS-485 Interface Enabled
+ (Tx to Rx) Loopback Enabled
+ (Tx to Rx) Loopback Disabled
- (Tx to Rx) Loopback Enabled
- (Tx to Rx) Loopback Disabled
+ (RTS to CTS) Loopback Enabled
+ (RTS to CTS) Loopback Disabled
- (RTS to CTS) Loopback Enabled
- (RTS to CTS) Loopback Disabled
Memory & Peripheral Board Reset Button SW5
Reset Button (SW5) an SPST Momentary Switch will initiate the "cold start" diagnostic test cycle, which clears RAM. A RAM-based DPC will then require a download (see "Section
4 - Operation" for details).
Memory & Peripheral Board Jumper W1 (RAM Battery)
Jumper W1 disables the RAM battery circuit to prevent unnecessary drain during shipment or storage. The RAM battery back-up is enabled by connecting Jumper W1 across
Pins 1 and 2. Disable the back-up battery by disconnecting the jumper wire from Pin 2, leaving it connected to Pin 1.
Jumper W2 (WARNING)
Jumper W2 should never be plugged in or have a jumper wire installed by the customer. It is for Bristol Babcock testing only.
Extended Memory Board Jumpers W1, W2 & W3 (Factory Installed)
Jumpers W1 through W3 are used to set the FLASH RAM and Static RAM memory configuration.
Extended Memory Board Jumper W4 (Factory Installed) (see Table 3BB-7)
Jumper W4 provides Hardware FLASH write protection. An installed Jumper equals a
"0."
3BB-8 / CPU Engine Board CI-3335 (05/2003)
Jumper Position
W4 0
W4 1
Table 3BB-7 - EMB Jumpers W4 Settings
FLASH Write Protection Assoignment
First two Megabytes of FLASH Memory Unwritable
First two Megabytes of FLASH Memory Writable (Factory Default)
Memory & Peripheral Board Status LEDs DS1-DS6
LEDs DS1 to DS6 on the Memory & Peripheral Board (Figures 3BB-1 & 3BB-4) provide a diagnostic status indication.
Memory & Peripheral Board Watchdog and Idle LEDs DS7 & DS8
The IDLE LED (DS7) remains OFF when the CPU is busy and turns ON when the CPU is idle or has stopped. The WDOG LED (DS8) Monitors the watchdog timer. This LED is normally OFF and turns ON if a failure is detected.
CPU Board Communication Port LEDs DS9-1 through DS9-4
LEDs DS9-1 through DS9-4 provide information about the Communications Ports as follows:
Table 3BB-8 - Communication Port LEDs
LED ON
DS9-1
DS9-2
FUNCTION
Transmit Data on BIP1
Receive Data on BIP1
LED ON
DS9-3
DS9-4
FUNCTION
Transmit Data on BIP2
Receive Data on BIP2
CI-3335 (05/2003) CPU Engine Board / 3BB-9
BLANK PAGE
Section 3BC
32-Bit CPU Protected Mode Engine Ass’y. - with Ethernet
Series 392762-XX-X
DESCRIPTION
The 32-Bit CPU Protected Mode Engine Assembly (with Ethernet) is a three or four board set which is fully compatible with current 3335 systems. An assembly (with extended memory) includes the 32-Bit CPU Engine Board, the Memory & Peripheral Board, the LED
Board and the EMB. The EMB is not provided unless extended memory has been specified.
This assembly allows a user to field upgrade a 3335 system for 32-bit protected mode operation with Ethernet communications capability providing the following enhancements:
• Two on-board BSAP Asynchronous Serial Ports (BIP1 & BIP2). Supports up to six (6) serial communication ports.
• Symmetrically Blocked FLASH Memory - 2M Bytes on CPU and 2M Bytes on EMB.
• Static RAM - 1 or 2 M Bytes on CPU Board - up to 4M Bytes on EMB.
• ACCOL application load storage in FLASH Memory.
• Utility Serial Port.
• Protected Mode Operating System.
• Up to 6M Bytes of application memory.
• 10M Baud Ethernet communications via one of two on-board connectors (10Base-T -
Shielded 8-pin RJ45) & (Attachment Unit Interface (AUI) 15-pin female D-Type).
The 32- Bit CPU Engine Assembly boards mount back-to-back and reside in the CPU slot.
Circuit Overview
Series 392762-XX-X CPU Engine Assemblies are equipped with a 24 MHz Intel 386EX, 32bit embedded microprocessor. This microprocessor features low power and low voltage capabilities, and utilizes a 32-bit programming architecture. The CPU Engine Assembly may be furnished with 1M or 2M Bytes of Base RAM, 2M Bytes of Base FLASH Memory
(1M for System Firmware, .5M Custom, & .5M ACCOL) and 128K Bytes of ACCOL
Load/Boot Code FLASH Memory (112K for ACCOL, 4K for Soft Switches, 4K Spare & 8K for Boot Code). The piggy-back mounted Extended Memory Board (EMB) accommodates up to 4M Bytes of RAM with 2M Bytes of Flash Memory optional. The microprocessor utilizes the following integrated peripherals (Located in I/O Address Space):
• Clock Generation and Power Management Unit
• Chip Select Unit
• Interrupt Control Unit
• Timer/Counter Unit
• Watchdog/Bus Monitor Timer Unit
• Asynchronous Serial I/O Unit
• Parallel I/O Unit
• DMA Unit
• Numeric Processor Interface : Provides access to an 80387SX Numeric Processor.
• JTAG Boundary Scan Unit (For Test Only)
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-1
Figure 3BC-1 Figure 3BC-2
Memory & Peripheral Board CPU Board
In addition to the Microprocessor, RAM and FLASH Memory, the following main items are included in the CPU Engine Assembly design: Battery, Node Address Switch, Function
Switch, Real-Time Clock, On-Board 85C30 SCC, 80387SX Numeric Processor, and
AM79C961A PCnet Controller.
3BC-2 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
• Node Address Switch (SW2) : An eight position DIP Switch (SW2) (on the Memory &
Peripheral Board) provides for node address assignment. SW2 is read from byte location 07F880 with the first switch set as the least significant bit. The open or OFF position is read as a 1 and the closed or ON position is read as a 0. SW2 controls no hardware functions.
Figure 3BC-3 - Extended Memory Board for 32-Bit CPU
• Battery : Back-up power is distributed to all RAM by a Lithium battery (3.6 volts) which provides a cumulative back-up period of six months (4,500 Hours worst case) for
Base RAM (if the +5V Supply fails). With the addition of RAM on the Extended
Memory Board (EMB) the back-up period diminishes as follows:
EMB with 1M RAM - 3490 Hours worst case
EMB with 2M RAM - 2830 Hours worst case
EMB with 4M RAM - 2050 Hours worst case
• Function Switch (SW1) : An eight position switch (SW1) (on the Memory & Peripheral
Board) accommodates function assignment and is read from byte location 07F881 with the first switch set as the LSB. The open or OFF position is read as a 1. No hardware functions are controlled by SW1.
• Real-Time Clock : The CPU Board offers a Real-Time Clock with an accuracy of " 1
Second/Day over a 0 E to 50 E C temperature range.
• 85C30 SCC : An On-Board 85C30 SCC (on the CPU Board) provides two asynchronous serial channels.
- Each of the two on-board serial channels has a switch configurable EIA-562 or RS-485 interface. EIA-562 outputs swing approximately " 4.5 volts and may not meet older
RS-232 applications; however, the ports do accept all RS-232 levels as inputs.
• Numeric Processor : A socket is provided on the CPU Board for an optional 80387SX
Numeric Processor.
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-3
Figure 3BC-4 - Card Edge End View of Ethernet CPU Engine Assembly
• PCnet Controller : The AMD AM79C961A PCnet Controller is a highly integrated
132-pin VLSI device that supports the IEEE 802.3 Ethernet standard. The PCnet configuration and Ethernet address are loaded on power-up from EEPROM. Two interfaces are provided; 10Base-T and AUI. Four Ethernet Status LEDs are provided.
The following main items are included on the Extended Memory Board (EMB):
• Static RAM Block - Two to Eight 512Kbit x 8 CMOS Static RAM ICs.
• Flash Memory Block - One 1MBit x 16 CMOS FLASH Memory ICs.
• Control Programmable Logic Block - Two Zero Power PLDs.
3BC-4 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
PROTECTED MODE 32-BIT CPU ENGINE I/O INTERFACE
• Utility Port Interface : The LED Board provides an RS-232 compatible 3-Wire interface (J5): J5-1 = TXD, J5-2 = RXD and J5-3 = GND. This port is used for loading
FLASH memory.
• Extended Memory Interface : The CPU Board includes a 70 pin connector (J1) to accommodate an optional Extended Memory Board (EMB).
• I/O Card Interface : The CPU Board interfaces up to 9 or 10 I/O cards via the dedicated 8-Bit Bus on the P1 Edge Connector. The I/O Clock runs at 6MHz.
• Communications Board Interface BUS : The same data and address lines used for the I/O Cards are used to interface with either a 2-Port or 4-Port Communication
Boards via the P1 Connector. Note: When the Ethernet CPU Board is installed, an
Interrupt Bypass Board (391938-01-0) must be installed in Comm. Slot #1. Ports A, B, G and H will not be available.
Table 3BC-1 - RS-485/EIA-562 Interface Ports
PIN# EIA-562 RS-485 PIN# EIA-562 RS-485 PIN# EIA-562 RS-485
1 /DTR TXD+ 4 RXD RXD7 /DCD CTS-
2 TXD
3 N/A
TXD-
RXD+
5
6
/RTS
/CTS
RTS+
CTS+
8
9
/DTR
GND
RTS-
GND
• RS-485/EIA-562 Port Interface : Built-in Port 1 (BIP1) and built-in Port 2 (BIP2)
(both on the CPU Board) are configured via SW3 & SW4 (on the CPU Board) respectively. On-board 10KV ESD protection is provided.
SWITCH & JUMPER CONFIGURATION
Prior to operation, the switches and jumpers of the 32-Bit CPU Engine Assembly must be checked. Function switch SW1 and node address switch SW2 (both on the Memory &
Peripheral Board) define their OFF (open) positions as logic "1" and their ON (closed) as logic "0." Two eight-position DIP switches (SW3 & SW4) (both on the CPU Board) accommodate BIP1 & BIP2 configuration.
Configuration of Soft Switches is provided in Open BSI, Once configured, the Soft Switches have priority over the associated Hard Switches unless SW1-3 has been set to the OFF position. Soft Switches provide the following functions:
•
•
Node Address
Updump Enable/Disable
• EBSAP Group #
• Cold Download Rates (for any CPU Board port)
• Internet Protocol Configuration
It should be noted that Soft Switches don’t have to be loaded unless Ethernet communications are required, i.e., for Ethernet operation the Soft Switches MUST BE configured.
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-5
Memory & Peripheral Board Switch SW1 - (Mode)
Switch SW1 selects various board operating modes (see Tables 3BC-2, 3BC-3 & 3BC-4).
Table 3BC-2 - Switch SW1 Mode Labels
Switch
#
SW1-1
Switch
Selection
ON
OFF
SW1-2 Table 3BC-3
SW1-3 Table 3BC-3
SW1-4 Table 3BC-3
SW1-5 -
SW1-6
ON
OFF
SW1-7 ON/OFF
SW1-8
ON
OFF
Mode Label
FLASH Download
SY/ASY
BR1
BR2
-
RAM
FLASH
-
BSAP
Function
Normal
FLASH Download
Comm. Baud Rate - MSD
Comm. Baud Rate
Comm. Baud Rate - LSD
-
ACCOL Load Storage
N/A
Standard BSAP
Expanded BSAP
Set To
AR
AR*
AR*
AR*
-
AR
-
AR*
Note: SW1 -2, -3 & -4 - see Note 1 under Memory & Peripheral Board Switch SW1-
2, -3, -4 - Cold Download Baud Rate.
Note: SW1-8 "BSAP" is set to OFF only if unit is communicating with an expanded master, and in Group 1 or above.
Mem. & Peripheral Bd. Switch SW1-1 - System Firmware Flash Download
With SW1-1 set "OFF," the 32-bit CPU board waits for the system firmware to be downloaded into FLASH via the Utility Port. SW1-1 must be set to the "ON" position at the end of the FLASH Download.
Mem. & Peripheral Bd. Switches SW1 -2, -3, -4 - Cold Download Baud Rate
Note 1
These switches apply only if the Soft Switches of the DPC have not been configured. If configured, cold rates are contained within the Soft Switches and switches SW1-2,
SW1-3 and SW1-4 are re-defined (see Table 3BC-4).
A "cold download" is a condition whereby the Distributive Process Controller (DPC) has successfully completed startup diagnostics and is standing by for a download. The ports and communication rates are selected by switches SW1-2, -3 and -4. These switches correspond to respective board legends, SY/ASY, BR1, and BR2 (see Table 3BB-3).
Baud rates shown in Table 3BC-3 apply to asynchronous communications for ports D, J &
BIP2; however, port D can also be configured for synchronous communications by setting the three switches in the last position (Sync). Synchronous rates, which are only provided for 187.5 KBd and 1 MBd, are selected by jumper blocks on the CE Board. Ports C, I &
BIP1 default to 9600 Baud.
3BC-6 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
Note:
Ports BIP2 & J are strictly Async. Ports, i.e., when configured for normal communications or for a cold download. Port BIP1 is also strictly asynchronous.
Table 3BC-3 - Switch SW1 Baud Rate Settings
Selection
(Baud Rate)
1200
2400
4800
SY/ASY
SW1-2
ON
ON
OFF
BR1
SW1-3
ON
OFF
OFF
BR2
SW1-4
ON
ON
ON
9600
19200
38400
Sync*
ON
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
ON
* Synchronous rates of 187.5K Baud or 1M Baud are selected on the Comm.
Board. When set for synchronous operation, BIP1 defaults to 9600 Baud.
Table 3BC-4 - Switch SW1 Definitions with Configuration FLASH Loaded
Switch
SW1-2
SW1-3
SW1-4
Selection
OFF
ON
OFF
ON
OFF
ON
Function
Soft Switches can’t be changed
Soft Switches can be changed
Read from Hard Switches (Override Soft Switches)
Use Soft Switches
ACCOL is FLASH Locked
Unlocked
Set To
AR
AR
AR
Note: With Soft Switches configured and SW1-3 set to the OFF position, all ports default to 9600 BSAP and the Node Address and updump features are redefined by Hard Switches. Additionally, the Internet Protocol (IP) for
Asynchronous Ports is disabled.
Memory & Peripheral Board Switches SW1-6 - ACCOL Load Storage &
SW1-4 - ACCOL FLASH Lock
ACCOL loads can be stored in RAM or FLASH memory. With SW1-6 set in the OFF position, i.e., set for ACCOL FLASH load storage, Switch SW1-4 can be configured to accept a new ACCOL FLASH download or the ACCOL Load can be locked, i.e., cannot be overwritten. When SW1-6 and SW1-4 are set to the OFF position, the unit will not accept a new ACCOL FLASH download. Switch SW1-4 should not be set to the OFF position until
SW1-6 has been set to the OFF position and a download has been completed. Note: The
ACCOL FLASH Lock option (see Table 3BC-4) is not enabled until switches SW1 -2,
-3 and -4 have been re-defined by configuration of soft switches.
Memory & Peripheral Board Switch SW2 - (Node Address)
Switches 1 through 7 of SW2 select a 7-bit node address for the DPC in a network application. When set to OFF, the switch provides the binary values in Table 3BC-5.
Switch SW2-8 disables the updump feature when it is set to the ON position. When set to the OFF position, SW2-8 disables the Watchdog Timer and enables a core memory dump.
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-7
With the Watchdog Timer disabled, the Reset Button (SW5) should be pressed twice
(within 2 seconds). This will cause a menu to be posted at 19.2K baud on BIP1. This menu is used to dump the CPU memory.
Table 3BC-5 - Binary Values For Switch SW2
Switch
SW2-1
SW2-2
SW2-3
Binary
Value
1
2
4
Switch
SW2-4
SW2-5
SW2-6
Binary
Value
8
16
32
Switch
Binary
Value
SW2-7 64 (MSB)
-
-
Note:
The maximum number of addresses available using
SW2-1 to SW2-7 is 127. SW2-8 is not used for addressing and is normally set to the ON position.
Ethernet CPU Board Switches SW3 & SW4
SW3 controls a Port 1 and SW4 controls Port 2. These 8-position dip switches have identical configurations (see Table 3BB-6). Switch position -1, is not used on both SW3 and
SW4. Switch positions -3 (+) and -4 (-) are transmit-to-receive loopback. Switch positions -7
(+) and -8 (-) are receive-to-send and clear-to-send loopback. When switch positions -3, -4, -
7, or -8 are ON, the loopbacks are enabled; otherwise, they are OFF or disabled.
Table 3BC-6 - Ethernet CPU Board Switches SW3 & SW4
Configuration Settings
Switch Pos.
-1
-2
-3
-4
-5
-6
-7
-8
Selection
N/A
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Function
N/A
EIA-562 Interface Enabled
RS-485 Interface Enabled
+ (Tx to Rx) Loopback Enabled
+ (Tx to Rx) Loopback Disabled
- (Tx to Rx) Loopback Enabled
- (Tx to Rx) Loopback Disabled
RS-485 Rx- Termination Enabled
RS-485 Rx- Termination Disabled
RS-485 Rx+ Termination Enabled
RS-485 Rx+ Termination Disabled
+ (RTS to CTS) Loopback Enabled
+ (RTS to CTS) Loopback Disabled
- (RTS to CTS) Loopback Enabled
- (RTS to CTS) Loopback Disabled
LED Board (CPU) Reset Button SW5
Reset Button (SW5) an SPST Momentary Switch will initiate the "cold start" diagnostic test cycle that clears RAM. A RAM-based DPC will then require a download (see "Section 4
- Operation" for details).
3BC-8 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
Memory & Peripheral Board Jumper W1 (RAM Battery
)
Jumper W1 disables the RAM battery circuit to prevent unnecessary drain during shipment or storage. The RAM battery back-up is enabled by connecting Jumper W1 across
Pins 1 and 2. Disable the back-up battery by disconnecting the jumper wire from Pin 2, leaving it connected to Pin 1.
CPU Board Jumper W2 (WARNING)
Jumper W2 should never be plugged in or have a jumper wire installed by the customer. It is for Bristol Babcock testing only.
Extended Memory Board Jumpers W1, W2 & W3 (Factory Installed)
Jumpers W1 through W3 are used to set the Flash RAM and Static RAM memory configuration.
Extended Memory Board Jumper W4 (Factory Installed)
(see Table 3BC-7)
Jumper W4 provides Hardware FLASH write protection. An installed Jumper equals a "0."
Table 3BC-7 - EMB Jumpers W4 Settings
Jumper Position
W4 0
W4 1
FLASH Write Protection Assoignment
First two Megabytes of FLASH Memory Unwritable
First two Megabytes of FLASH Memory Writable (Factory Default)
ETHERNET ASSEMBLY LEDs
LED Board Status LEDs DS1-DS6
LEDs DS1 to DS6 on the LED Board (Figure 3BB-4) provide a diagnostic status indication
(see Section 5 - Service).
LED Board Watchdog and Idle LEDs DS7 & DS8
The IDLE LED (DS7) remains OFF when the CPU is busy and turns ON when the CPU is idle or has stopped. The WDOG LED (DS8) Monitors the watchdog timer. This LED is normally OFF and turns ON if a failure is detected.
CPU Board Communication Port LEDs DS9-1 through DS9-4
LEDs DS9-1 through DS9-4 provide information about the Communications Ports as detailed in Table 3BC-8 (see Figure 3BC-4).
Table 3BC-8 - Communication Port LEDs
LED ON
DS9-1
DS9-2
FUNCTION
Transmit Data on BIP1
Receive Data on BIP1
LED ON
DS9-3
DS9-4
FUNCTION
Transmit Data on BIP2
Receive Data on BIP2
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-9
Ethernet CPU Engine Ethernet Status LEDs DS100-1 through DS100-4
LEDs DS100-1 through DS100-4 provide information about the Ethernet Port as follows
(see Figure 3BC-4):
Table 3BC-9 - Ethernet Communication Port LEDs
LED NAME
DS100-1
DS100-2
DS100-3
DS100-4
FUNCTION
Link Integrity
Receive Data
Collision Detection
Transmit Data
STATUS
ON = Link O.K.
OFF = Link Down or No Connection
ON = Receiving Data
OFF = Not Receiving Data
ON = Collision Detected
OFF = O.K.
ON = Transmitting Data
OFF = Not Transmitting Data
Ethernet CPU Engine Ethernet Ports
Connection to the Ethernet can be established via one of two on-board Ethernet Ports. Port
Connector P2 is a 10Base-T RJ45 modular connector that typically provides a twisted pair interface to an Ethernet Hub. Connector J3 is a 15-pin D-Type Connector that serves as an
Attachment Unit Interface (AUI) to an Ethernet Media Access Unit (MAU). Note: Use of an “off the shelf” MAU is limited to devices that draw 120mA @ 12Vdc (Maximum) from the
AUI Port.
Ethernet CPU Engine 10Base-T Connector P2
8-pin 10Base-T Connector P2 typically provides connection to a twisted pair Ethernet via an Ethernet Hub. Both ends of the Ethernet cable are equipped with modular RJ45 connectors. A typical hub provides eight (8) 10Base-T RJ45 ports (with port 8 having the capability to link to another hub or to an Ethernet communication port. The cable used between CPU Board Ethernet 10Base-T connector and the Ethernet Hub has a one-to-one wiring configuration as shown in Figure 3BC-6. Table 3BC-10 provides the assignment and definitions of the 8-pin 10Base-T Connector P2.
It is possible to connect two nodes in a point-to-point configuration without the use of a
Hub. However; the cable used must be configured such that the TX+/- Data pins are connected to the RX+/- Data pins (swapped) at the opposite ends of the cable (see Figure
3BC-5).
Table 3BC-10 - Ethernet 10Base-T Connector P2 Pin Assignments
Pin #
1TX+
2TXTransmit Data-
3RX+ Receive Data+
4
Description
Transmit Data+ 5
Pin #
Not Connected
6RX-
7
8
Description
Not Connected
Receive Data-
Not Connected
Not Connected
Note: TX & RX are swapped at Hub’s .
3BC-10 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
The maximum length of one segment (CPU to Hub) is 100 meters (328 feet). The use of
Category 5 shielded cable is recommended.
Figure 3BC-5 - Point-to-Point 10Base-T Ethernet Cable
Figure 3BC-6 - Standard 10Base-T Ethernet Cable (CPU Board to Hub)
Figure 3BC-7 - 10Base-T Connector (P2) with Cable Configured for Loopback
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-11
Ethernet CPU Engine Attachment Unit Interface Connector J3
15-pin D-Type Attachment Unit Interface (AUI) Connector J3 provides connection to an
Ethernet Media Access Unit (MAU). The MAU must draw less than 120mA at 12Vdc.
Table 3BC-11 provides the assignment and definitions of the 15-pin AUI Connector J3.
Figure 3BC-8 shows the BBI MAU with cover removed. Connection to the thin-wire
Ethernet is made via the MAU’s BNC connector J1.
Figure 3BC-8 - BBI Media Attachment Unit
Table 3BC-11 - Ethernet AUI Connector J3 Pin Assignments
Pin #
7
8
5
6
3
4
1
2
9
10
11
12
13
14
15
Description
Collision Shield
Collision +
Xmit (DO) +
Rx Shield
Rx (DI) +
Not Connected
Not Connected
Shield
Collision -
Xmit (DO) -
Xmit Shield
Rx (DI) -
Not Connected
Not Connected
Not Connected
3BC-12 / Ethernet CPU Engine Ass’y.
CI-3335 (05/2003)
The BBI MAU is a stand-alone unit that interfaces BBI model 3330/3335 products with
Ethernet 10BASE2 networks.
An AUI transceiver cable can be a maximum length of 45 meters (150 feet). The use of a cable manufactured for industrial environments is recommended.
Connection to the 10BASE2 Ethernet as well as Network and Interface requirements are provided as follows:
• Maximum length of one 10BASE2 Ethernet segment is 185 meters (607 feet).
• Maximum network length is 925 meters (3000 feet).
• RG-58 A/U type BNC connector
• Minimum distance between Tee connectors is 0.5 meters (1.6 feet).
• Maximum number of connectors per segment is 30.
• First and last device on each segment must be terminated on one side of their Tee connector with a 50-ohm resistor.
• Tee connectors must be plugged directly into the MAU. No cable (stub) is allowed between the Tee.
CI-3335 (05/2003) Ethernet CPU Engine Ass’y. / 3BC-13
BLANK PAGE
Section 3C
4 & 2 PORT ENHANCED COMMUNICATION BOARDS
GENERAL
This section covers both Four Port and Two Port versions of the Enhanced Communication
Board (4PECB & 2PECB). The Four Port version of the Enhanced Communication Board
(ECB) must be used in conjunction with a "Protected Mode" 32-Bit CPU Engine Board (see
Section 3BB); however, the Two Port version can be used with Protected or Real Mode versions of the 32-Bit CPU Engine Board as well as 16-Bit CPUs. Up to two ECBs can be installed in a DPC 3335.
Enhanced Communication Boards provide either four or two (depopulated version of Four
Port ECB) communication ports which are 9-pin, D-Type, female connectors. These ports are labeled as follows:
2PECB - Contains Ports A & B (in CE Socket #1). Note: Socket #1 only supports 2PECBs.
2PECB - Contains Ports C & D (in CE Socket #2).
4PECB - Contains Ports C, D, I & J (Board resides in Communication Socket #2).
Enhanced Communication Boards are available in two versions which are listed as follows:
Model Number 392589-01-0 - 4 Port Enhanced Comm. Board
Model Number 392589-02-8 - 2 Port Enhanced Comm. Board
Note: When an Ethernet CPU assembly is installed, an Interrupt Bypass Board
(391938-01-0) MUST BE INSTALLED in Socket #1.
Standard 9-Pin D-Type Connectors are used in the two port version of the ECB and dual stacked D-Type Connectors are used on four port versions. A maximum of eight (8) ports are available (two on the 2PECB, four on the 4PECB and two on the 32-Bit CPU Engine Board).
When two 2PECBs are installed in a DPC 3335, a maximum of 6 ports are available (2 on each board including the 32-Bit CPU Engine Board).
The ports can be configured for an RS-485 or RS-232 interface. The former is required for
BSAP network communications, while the latter is required for devices such as a PC or printer. However; these ports can also be configured for other applications. For example, port A can be configured to interface with a PC while ports B, C, D, etc. can be configured for use with options such as modems and printers. The selected option board plugs directly into the upper accessory slot of the DPC 3335 backplane. It should be noted that use with a Hand
Held Terminal is supported on Port A only. It should also be noted that only the 2PECB (Port
B) will support Modems/RASCL.
CONFIGURATION NOTES
The CE Board contains switches and jumpers that must be checked before placing the DPC into operation. The location of these items are shown in Figures 3C-1 and 3C-2. It will be necessary to power-down the DPC and remove the board to access these components. The procedure for removing and installing the board is described in Section 2 - Installation.
CI-3335 (11/99) CE Board / 3C- 1
Figure 3C-1 - Four Port Enhanced Communication Board (4PECB)
3C-2 / CE Board (11/99) CI-3335
Figure 3C-2 - Two Port Enhanced Communication Board (2PECB)
CI-3335 (11/99) CE Board / 3C- 3
SETTING DIP SWITCHES
The procedure for setting DIP switches is identical for the two different board versions except that the 4 Port Enhanced Communication Board contains four DIP switches while the
2PECB contains two DIP switches. When an individual switch (toggle) is pressed to the right it is set to its ON position (see Figure 3C-3). Switches SW1 through SW4 control port configuration and are assigned as follows:
SW1 - Controls Port A/C
SW2 - Controls Port I
SW3 - Controls Port B/D
SW4 - Controls Port J
Switch functions are provided for RS-485 and RS-232 operation, in Tables 3C-1 & 3C-2.
Table 3C-1 - SW1 - SW4 RS-485 DIP Switch Configuration Selections
SW1-SW4
1
Function
SW3 Only. ON = RS-4XX Enable
OFF = Modem Interface Enable
2
3
4
ON = TXD+ to RXD+ Loopback
ON = TXD- to RXD- Loopback
5
6
ON = RS-485 RX- Termination Enabled
OFF = RS-485 RX- Termination Disabled
ON = RS-485 RX+ Termination Enabled
OFF = RS-485 RX+ Termination Disabled
ON = RTS+ to CTS+ Loopback * 7
8 ON = RTS- to CTS- Loopback *
Note: For an Internal Modem, SW3-2 must be set for RS-232 operation, i.e., (ON).
* Note: For RS-485 enabled, these switches must be set ON if no jumpers are present on the corresponding Port Cable, i.e., RTS-CTS jumpers, and RTS-
CTS is not utilized by the device connected to the port.
3C-4 / CE Board
Figure 3C-3 - Enlarged View of SW1-SW4
(11/99) CI-3335
Table 3C-2 - SW1 - SW4 RS-232 DIP Switch Configuration Selections
SW1-SW4
1
2*
5
6
3
4
Function
SW3 Only. ON = RS-4XX Enable
OFF = Modem Interface Enable
ON = RS-232
N/A
ON
OFF
OFF
= TXD to RXD Loopback
7 ON = RTS to CTS Loopback
8 ON = DTR DCD
Note: For an Internal Modem, SW3-2 must be set for RS-232 operation, i.e., (ON).
Setting switches SW1 through SW4 does not complete the set-up configuration. The jumpers listed in Table 3C-3 must also be set to complete the procedure.
Note: When the DPC is specified with an internal 1200 bps Private Line (PL) Modem Ass’y.,
9600 bps Publicly Switched Telephone Network (PSTN) Modem Ass’y., or a 1200 bps
PL/PSTN Modem Ass’y., refer to the appropriate Customer Instruction Manual, i.e., CI-1200-
PL, CI-9600 (PSTN), CI-9600A (PSTN) or CI-1200 (PL/PSTN). For details on the Fiber Optic
Interface, refer to Appendix FB.
SETTING JUMPERS
The 4PECB/2PECB Board contains up to twenty-three jumpers to set various communication parameters. The location of these jumpers is shown in Figure 3C-1 and 3C-2. The jumpers are set according to Table 3C-3.
Table 3C-3 - Configuration Jumper Settings
Jumper
W1
Description
Port A/C RXD LED Control
W2
W3
W4
W5
Port B/D RXD LED Control
Port G/I RXD LED Control
Port H/J RXD LED Control
Port A/C RTXC Selection
Setting
OUT
IN
OUT
IN
OUT
IN
OUT
IN
1 to 2
2 to 3
Configuration
RXD LED qualified by RTS Not
RXD LED Always enabled
RXD LED qualified by RTS Not
RXD LED Always enabled
RXD LED qualified by RTS Not
RXD LED Always enabled
RXD LED qualified by RTS Not
RXD LED Always enabled
RTXC = 6 MHz (187.5KB)
RTXC = 16 MHz (1MB)
CI-3335 (11/99) CE Board / 3C- 5
Table 3C-3 - Configuration Jumper Settings (Continued)
Jumper
W6
W7
W8
W9
W10
W11
W12/W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
Description
Port B/D RTXC Selection
Port B/D Receive Clock
Port I RTXC Selection
Port J RTXC Selection
Serial Communication
Controller #1 PCLK Selection
Serial Communication
Controller #2 PCLK Selection
1 or 2 DMA Controllers
Port B/D Transmit Clock
Debug Only
RASCL Present (2PECB)
1 or 2 Serial Communication
Controllers (*)
1 or 2 DMA Controllers (*)
Number of Ports Detected (*)
Hand Held Terminal (HHT)
(Available only on Port A)
Rev. S (and Earlier) Firmware
Support (*)
RASCL Option (2PECB)
RASCL Option (2PECB)
Note: * = Factory (Hardwired) Configured
Setting
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
Configuration
RTXC = 6 MHz (187.5KB)
TXC = 16 MHz (1MB)
With RASCL
Without RASCL
RTXC = 6 MHz (187.5KB)
RTXC = 16 MHz (1MB)
RTXC = 6 MHz (187.5KB)
RTXC = 16 MHz (1MB)
PCLK = 6 MHz (187.5KB)
PCLK = 16 MHz (1MB)
PCLK = 6 MHz (187.5KB)
PCLK = 16 MHz (1MB)
1 DMA Controller (2PECB)
2 DMA Controllers (4PECB)
1 to 2
2 to 3
With RASCL
Without RASCL
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2 Factory Hardwired
IN
OUT
RASCL installed
RASCL not installed
IN
OUT
IN
OUT
1 SCC (2PECB)
2 SCCs (4PECB)
2 DMA Controllers (4PECB)
1 DMA Controller (2PECB)
2-Port Detection
4-Port Detection
Without HHT Option
With HHT Option
Disabled
Enabled
RASCL Installed
RASCL Not Installed
RASCL Installed
RASCL Not Installed
3C-6 / CE Board (11/99) CI-3335
RS-485 AND RS-423 PORT CONNECTIONS
Ports configured for an RS-423 interface are RS-232 compatible and may be used with a PC or printer. The RS-485 interface is required for BSAP network communications. Details on wiring communication ports are covered in Appendix CP. The Female "D" Connector "Pin
Assignment" is provided in Figure 3C-4.
Figure 3C-4 - Female "D" Connector Pin Assignment
LED INDICATORS
The ECB Boards provide either two (2) or four (4) bi-color LEDs (TX and RX indicators) (one for each communication channel). An LED will light (red) when the associated channel is transmitting data, and lights (green) when the channel is receiving data. Depending upon the data activity, the light may blink or appear continuously lit during communication activity. The lights will be out when there is no activity (see Figures 3C-1 and 3C-2).
LOOPBACK TESTING
The loopback configuration (controlled by Switches - see Tables 3C-1 & 3C-2) feeds the output of the ECB Board back to the input (TXD to RXD & RTS to CTS, internally, i.e., prior to the D-Type Connector. This configuration is used for testing the board via the diagnostic test program described in the User Manual D4041 - Diagnostics.
CI-3335 (11/99) CE Board / 3C- 7
BLANK PAGE
Section 3D
ANALOG INPUT MODULE
(Four AI Type)
Series 392009-XX-X, 392029-XX-X & 392086-XX-X
GENERAL
Analog Input Modules with four AIs are available with the ranges and features given in the
Table 3D-A. Modules having 1-5 V and 4-20 mA input ranges can be configured for either range by jumper arrangement. Modules with a 0-10 V input are factory set and cannot be field-converted to other ranges.
TERMINAL DESIGNATIONS
In the case of “local terminations,” the AI signal connections are made to terminal block
TB1 which is a dual-block assembly as shown in Figures 3D-1, 3D-2B, 3B-2C & 3B-2D. The upper terminals of TB1 represent the + signal connections, while the corresponding lower terminals represent the - signal connections. The AI shields may be connected to any available shield terminal since these terminals are internally wired to the same point. Plus
(+) terminals are located on the top and the minus (-) terminals are located on the bottom of
TB1.
Figure 3D-1 - Terminal Block TB1 Signal Designations
When connecting to an Analog Input Board which has been supplied with a mass termination connector (J1), the field circuits must be properly connected to a mating 30-pin mass termination connector plug (see Table 3D-B and Figures 3D-2A, 3D-2C and 3C-2D).
CI-3310/30/35 (08/2006) AI Module / 3D-1
Figure 3D-2A - AI Module (1-5 V / 4-20 mA Type Shown w / Mass Term. Connector)
(w/o Common Mode - left diagram - w / Common Mode - right diagram )
(For 3330s, 3331s & 3335s)
3D-2 / AI Module CI-3310/30/35 (08/2006)
Figure 3D-2B - AI Module (0-10 V Type Shown w / Straight Term. Connector)
(w / Common Mode - left diagram - w/o Common Mode - right diagram )
(For 3310s & 3330s)
CI-3310/30/35 (08/2006) AI Module / 3D-3
Figure 3D-2C - AI Module (0-10 V Type Shown w / Common Mode)
(w / Right Angle Connector - left diagram for 3331 & 3335)
(w / Mass Term. Connector - right diagram for 3330, 3331 & 3335)
3D-4 / AI Module CI-3310/30/35 (08/2006)
Figure 3D-2D - AI Module (0-10 V Type Shown w/o Common Mode)
(w / Right Angle Connector - left diagram for 3331 & 3335)
(w / Mass Term. Connector - right diagram for 3330, 3331 & 3335)
CI-3310/30/35 (08/2006) AI Module / 3D-5
TABLE 3D-A - AI MODULE PART NUMBERS
I nput
Range
#AIs Impedance
Input
Filter
180V
Com. Mode
Part
Number
33XX
Use
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
0-10 V DC
0-10 V DC
0-10 V DC
0-10 V DC
0-10 V DC
0-10 V DC
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
150 Ω
250
2
250
150 Ω
250
150 Ω
250
2
250
2
250
150 Ω
2
K Ω
K Ω
M Ω
2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
392004-02-0*
No
392004-03-8*
Yes
392086-02-6*
No
392086-12-3*
No
392086-03-4*
Yes
392086-13-1*
Yes
No
Yes
No
392009-02-1*
392009-03-0*
392029-02-2*
No
Yes
392029-13-8
2
2
2
2
1,2
2
2
2
1,2
2
1,2
1,2
* = These modules are field configurable for 1-5 V or 4-20 mA signals.
1 = Remote, Mass Termination, Non-Isolated, Without Termination Module
2 = Discontinued (No Longer Available) Part Number
SIGNAL GROUNDING OPTIONS
The presence of noise or common mode error on the line can affect the stability or accuracy of the signal. These effects can very often be minimized or eliminated by modifying the reference points used for signal grounding within the DPC. Jumper W5 provides a choice of three grounding modes as noted in Figure 3D-3.
When jumper W5 is connected to position A as shown in Figure 3D-3-2, the signal shield terminals of TB1 are connected to the chassis. In position B (Figure 3D-3-3), the shield terminals are connected to the analog common buss, while in position C (Figure 3D-3-4), they are connected to the power common buss. Unless the desired grounding point is known, it may be necessary to experiment with all three positions to determine which one yields the best results.
10/30
10/30
31/35
30/31/35
31/35
30/31/35
10/30
10/30
31/35
30/31/35
31/35
30/31/35
3D-6 / AI Module CI-3310/30/35 (08/2006)
Figure 3D-3 - Shield Grounding Jumper
0-10 V TYPE MODULES
Modules specified with 0-10 V inputs provide isolated inputs for all four channels. The source for these inputs may be a transmitter or device that generates the appropriate voltage signal.
The signal source for each input connects to the input terminals through shielded wiring as shown in Figure 3D-4. The shield floats at the signal source and returns to ground through the "S" terminal of the module.
CI-3310/30/35 (08/2006) AI Module / 3D-7
In order to achieve accurate measurements, the 0-10 V signal source must be referenced to power common of the system. This leakage path can be provided by a resistor (0 to 1 M ) connected to the negative side of the signal source as shown in the illustration.
Figure 3D-4 - Input Wiring for 0-10 V Type Module
1-5 V / 4-20 mA TYPE MODULES
Each of the Analog Inputs on these modules may be independently configured to accept a range of 1-5 V dc or 4-20 mA. Selection of the desired input range for AI1 to AI4 is accomplished via corresponding jumper clusters W1 to W4. A discussion of each range application follows:
1-5 V dc Isolated Input
The jumper clusters are arranged as shown at the top of Figure 3D-5 to configure the module for a 1-5 V input. The 1-5 V signal is typically obtained from a recorder, controller, transducer, or similar device.
The 1-5 V signal source connects to the module input terminals through a shielded cable as shown in the illustration. The shield floats at the signal source and returns to ground through the "S" terminal of the module.
The 1-5 V signal source must be referenced to power common of the system in order to achieve accurate measurements. This leakage path can be provided by a resistor (0 to 1
M ) connected to the negative side of the signal source as shown in the illustration.
3D-8 / AI Module CI-3310/30/35 (08/2006)
Figure 3D-5 - Input Wiring for 1-5 V Type Module
4-20 mA Transmitter Using +24 V DPC Power Source
For this application the input signal is generated by a transmitter or transducer that operates in a 4-20 mA current loop as shown in Figure 3D-6. The +24 V power required to operate this loop is obtained from the DPC's 24 V power supply. The module jumpers are ar-ranged as shown to accept the 4-20 mA input.
This configuration places a precision 250-ohm resistor in the transmitter current loop. The voltage drop across this resistor presents a 1-5 V signal to the module input circuitry.
When using this arrangement to power a number of current loops, it is important to consider the total maximum current drain of all the AIs. If this value exceeds the rated output of the DPC supply source, inaccurate AI readings will result. Use a separate supply to power cur-rent loops exclusively whenever a heavy current load is anticipated.
Shielded wiring is required between the transmitter and the AI Module. The shield floats at the transmitter and returns to ground through the "S" terminal of the module.
NOTE This wiring configuration cannot be used with DPC's that operate from +12 V dc power sources. For these models, an external +24 V power source will be required. See "4-20 mA
Transmitter Using Auxiliary 24 V Power Supply" on page 3D-10 for details.
CI-3310/30/35 (08/2006) AI Module / 3D-9
Figure 3D-6 - 4-20 mA Transmitter Loop Powered by DPC +24 V Supply
4-20 mA Transmitter Using Auxiliary +24 V Power Supply
In situations where +24 V power from the DPC is insufficient to drive the desired number of transmitter loops, an auxiliary power supply must be used. For this mode of operation, the jumper clusters are connected as shown in Figure 3D-7.
The transmitter and supply shown in Figure 3D-7 are wired in series with a 250 loop resistor; the voltage drop across the resistor provides a 1-5 V signal for the module input.
The supply used in this application should be capable of powering all the 4-20 mA signal loops wired to it.
This arrangement is also recommended for DPC's that operate from +12 V dc sources since
+24 V power is required for the transmitter current loops.
The external DC supply that is used to power the transmitter must be must be referenced to power common of the system in order to achieve accurate measurements. This leakage path can be provided by a resistor (0 to 1 M Ω ) connected to the negative side of the signal supply source as shown in the illustration.
Shielded wiring is required between the transmitter and the AI Module. The shield floats at the transmitter and returns to ground through the "S" terminal of the module.
3D-10 / AI Module CI-3310/30/35 (08/2006)
Figure 3D-7 - 4-20 mA Transmitter Loop Powered by Auxiliary +24 V Supply
SPECIFICATIONS
Analog Input Specifications
Number of Inputs:
Input Ranges:
4 Differential
0-10 VDC
VDC
4-20 mA DC
24 VDC to power 2-wire transmitter/4-20 mA
Accuracy at Room Temperature (+25°C / +77°F):
Accuracy at -20°C to +70°C (-4°F to +158°F):
0.1% of Span 0-10 VDC
0.1% of Span 4-20 mA
0.1% of Span 1-5 VDC
0.2% of Span 0-10 VDC
0.2% of Span 4-20 mA
0.2% of Span 1-5 VDC
CI-3310/30/35 (08/2006) AI Module / 3D-11
Input Filtering - Single Pole (50 msec time constant): 300 msec to .1% of input value
Common Mode Rejection Ratio DC to 60 Hz;
Input Impedance:
110dB
1-5V, 0-10V - 150K
1-5V, 0-10V - 2M
4-20 mA - 250 Ω
Ω
Ω (w/o H.C.M.)
(with High C.M.)
Analog Input Wiring: see Table 3D-B & all Figures
TABLE 3D-B - INPUT CONNECTOR PIN ASSIGNMENTS
J1 PIN # TB1A/B - PIN # MNEMONIC DESCRIPTION
29 TB1A-1 AI1+ Field Term. (+)
30
25
26
21
TB1B-1
TB1A-2
TB1B-2
TB1A-3
AI1-
AI2+
AI2-
AI3+
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
22
17
TB1B-3
TB1A-4
AI3-
AI4+
Field Term. (-)
Field Term. (+)
18 TB1B-4 AI4- Field Term. (-)
13 TB1A-6 S Shield
14 TB1B-6 S Shield
9 TB1A-5 S Shield
10 TB1B-5 S Shield
J1 Pins 1, 2, 3, 4, 5, 6, 7, 8, 11, 12, 15, 16, 19, 20, 23, 24, 27 & 28 are not used.
Environmental Specifications
Operating Temperature:
Storage Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
-20°C to +70°C (-4°F to +158°F)
-40°C to +85°C (-40°F to +185°F)
0-95% Non-condensing
1g for 10-150 Hz
.5g for 150-2000 Hz
10 V/Meter - 10MHz to 500MHz
3D-12 / AI Module CI-3310/30/35 (08/2006)
Section 3DA
ANALOG INPUT MODULE
(Eight AI Type)
Series 395315-XX-X & 395316-XX-X
Note: The Analog Input Modules discussed herein, i.e., 395315-XX-X and 395316-XX-X are no longer available.
GENERAL
Analog Input Modules of this group utilize high density construction and accept eight analog inputs. These modules can be specified with or without common mode inputs and each AI can be configured for 1-5 V or 4-20 mA inputs. See table below for module part numbers.
TABLE 3DA-A - AI MODULE PART NUMBERS
Input
Range
#AIs Impedance
Input
Filter
180V
Common Mode
Part
Number
33XX
Use
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
8
8
8
8
8
8
150 K
6
250 6
150 K 6
250 6
150 K 6
250 6
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
395316-01-4
395316-02-2
395316-03-0*
10/30
31/35
30/31/35
1-5 V DC or
4-20 mA
8
8
2 Meg
250
6
Yes
Yes
Yes
Yes
395315-01-8 1
10/30
1-5 V DC or
4-20 mA
8
8
2 Meg
250
6
Yes
Yes
Yes
Yes
395315-02-6
1
31/35
1-5 V DC or
4-20 mA
8
8
2 Meg
250
6
Yes
Yes
Yes
Yes
395315-03-4*
1
Notes: 1 = High Common Mode
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
30/31/35
TERMINAL DESIGNATIONS
The AI signal connections are made to terminal block TB1 which is a dual-block assembly as shown in Figure 3DA-2. The upper terminals of TB1 represent the + signal connections, while the corresponding lower terminals represent the -signal connections. Plus (+) terminals are located on the top and minus (-) terminals are located on the bottom of TB1.
CI-3310/30/35 (02/99) AI Module / 3DA- 1
Figure 3DA-1 - Analog Input Module Jumper & Misc. Components Location
3DA-2 / AI Module CI-3310/30/35 (02/99)
Figure 3DA-2 - Terminal Block (TB1) Signal Designations
SELECTING 1-5 V OR 4-20 mA INPUTS
Each of the Analog Inputs on these modules may be independently configured to accept a range of 1-5 V dc or 4-20 mA. Selection of the desired input range for AI1 to AI8 is accomplished via corresponding jumper clusters W1 to W8. A discussion of each range application follows:
1-5 V dc Isolated Input
The jumper clusters are arranged as shown at the top of Figure 3DA-3 to configure the module for a 1-5 V input. The 1-5 V signal is typically obtained from a recorder, controller, transducer, or similar device.
If the module is furnished without common mode (pt. no. 395316-01-4), the 1-5 V signal return must be referenced to power common of the system in order to achieve accurate measurements. This path can be provided by a jumper or resistor (0 to 1 M 6 ) connected to the negative side of the signal source as shown in the illustration. This path is not required for the AI Module with 180 V common mode.
CI-3310/30/35 (02/99) AI Module / 3DA- 3
Figure 3DA-3 - Input Wiring for 1-5 V Type Module
4-20 mA Transmitter Using +24 V DPC Power Source
For this application the input signal is generated by a transmitter or transducer that operates in a 4-20 mA current loop as shown in Figure 3DA-4. The +24 V power required to operate this loop is obtained from the DPC's 24 V power supply. The module jumpers must be configured as shown in the illustration for the isolated 4-20 mA input.
This configuration places a precision 250-ohm resistor in the transmitter current loop. When using this arrangement to power a number of current loops, it is important to consider the total drain of all AIs when they are at maximum current (20 mA each). If this value exceeds the rated current output of the DPC supply source, inaccurate AI readings will result. Use a separate supply to power current loops exclusively whenever a heavy current load is anticipated. See "4-20 mA Transmitter using Auxiliary +24 V Power Supply" on next page for details.
NOTE
This wiring configuration cannot be used with DPC's that operate from +12 V dc power sources. For these models, an external +24 V power source will be required. See next page for details.
3DA-4 / AI Module CI-3310/30/35 (02/99)
Figure 3DA-4 - 4-20 mA Transmitter Loop Powered by DPC +24 V Supply
4-20 mA Transmitter Using Auxiliary +24 V Power Supply
In situations where +24 V power from the DPC is insufficient to drive the desired number of transmitter loops, an auxiliary power supply must be used as shown in Figure 3D-5.
The transmitter and supply shown in Figure 3DA-5 are wired in series with a 250
6
loop resistor. The supply used in this application should be capable of powering all the 4-20 mA signal loops wired to it.
This arrangement is also recommended for DPC's that operate from +12 V dc sources since
+24 V power is required for the transmitter current loops.
If the module is furnished without common mode (pt. no. 395316-XX-X), the signal-supply return must be referenced to power common of the system in order to achieve accurate measurements. This path can be provided by a jumper or resistor (0 to 1 M 6 ) connected as shown in the illustration. This path is not required for the AI Module with 180 V common mode.
CI-3310/30/35 (02/99) AI Module / 3DA- 5
Figure 3DA-5 - 4-20 mA Transmitter Loop Powered by Auxiliary +24 V Supply
3DA-6 / AI Module CI-3310/30/35 (02/99)
Section 3DB
HIGH DENSITY ANALOG INPUT MODULE
(Four or Eight AI Type)
Series 392544-XX-X
GENERAL
Analog Input Modules of this group utilize high density construction and depending on part number accept either four or eight analog inputs. These HDAI modules can be specified with either low or high common mode inputs (but not both) and each AI can be configured for 1-5 V or 4-20 mA inputs. See Table 3DB-A below for HDAI module part numbers.
TABLE 3DB-A - HDAI MODULE PART NUMBERS
Input
Range
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
1-5 VDC or
4-20 mA
#AIs Impedance
8
8
8
8
8
8
8
8
4
4
4
4
4
4
4
4
2 Meg. Ω
250 Ω
2 Meg. Ω
250 Ω
150 K Ω
250 Ω
150 K Ω
250 Ω
2 Meg. Ω
250 Ω
2 Meg. Ω
250 Ω
150 K Ω
250 Ω
150 K Ω
250 Ω
Common Mode
(HCM/LCM)
High
High
High
High
Low
Low
Low
Low
High
High
High
High
Low
Low
Low
Low
Part
Number
Model
Assignment
392544-01-6 3310/30/31/35
392544-03-2* 3330/31/ 35
392544-02-4 3310 / 30 / 31 / 35
392544-04-0* 3330 / 31 / 35
392544-11-1 3310/30/31/35
392544-13-8* 3330/ 31 / 35
392544-12-0 3310 / 30 / 31 / 35
392544-14-6* 3330 / 31 / 35
Note: * = Remote, Mass Termination, Without Termination Module
Note: HDAI Numbers associated with BOLDED Model Assignments are no longer available!
TERMINAL DESIGNATIONS
In the case of “local terminations,” the AI signal connections are made to terminal blocks
TB1 & TB2 as shown in Figure 3DB-3. The upper terminals (TB1) represent the + signal connections, while the corresponding lower terminals (TB2) represent the - signal connections. Terminals labeled 9 through 12 are not utilized.
When connecting to a High Density Analog Input Board which has been supplied with a mass termination connector (J1), the field circuits must be properly connected to a mating
30-pin mass termination connector plug (see Table 3DB-B).
CI-3310/30/35 (11/05) HDAI Module / 3DB-1
Older Units
New Units
Figure 3DB-1 - 8 & 4 Channel LCM-HDAI Module Misc. Components Location
[Left figure fully populated (8AI) / Right figure depopulated (4AI)]
3DB - 2 / HDAI Module CI-3310/30/35 (11/05)
Older Units
New Units
Figure 3DB-2 - 8 & 4 Channel HCM-HDAI Module Misc. Components Location
[Left figure fully populated (8AI) / Right figure depopulated (4AI)]
CI-3310/30/35 (11/05) HDAI Module / 3DB-3
Figure 3DB-3 - Terminal Blocks (TB1 & TB2) Signal Designations
SELECTING 1-5 V OR 4-20 mA INPUTS
Each of the Analog Inputs on these modules may be independently configured to accept a range of 1-5 V dc or 4-20 mA. Selection of the desired input range for AI1 to AI8 is accomplished via corresponding jumper clusters W1 to W8. A discussion of each range application follows:
1-5 V dc Isolated Input
The jumper clusters are arranged as shown at the top of Figure 3DB-4 to configure the module for a 1-5 V input. The 1-5 V signal is typically obtained from a recorder, controller, transducer, or similar device.
If the module is furnished without common mode (see Table 3DB-A), the 1-5 V signal return must be referenced to power common of the system in order to achieve accurate measurements. This path can be provided by a jumper or resistor (0 to 1 M Ω ) connected to the negative side of the signal source as shown in the illustration. This path is not required for AI Modules with 180 V common mode, i.e., high common mode.
3DB - 4 / HDAI Module CI-3310/30/35 (11/05)
Figure 3DB-4 - Input Wiring for 1-5 V Type Module
4-20 mA Transmitter Using +24 V DPC Power Source
For this application the input signal is generated by a transmitter or transducer that operates in a 4-20 mA current loop as shown in Figure 3DB-5. The +24 V power required to operate this loop is obtained from the DPC's 24 V power supply. The module jumpers must be configured as shown in the illustration for the isolated 4-20 mA input.
This configuration places a precision 250-ohm resistor in the transmitter current loop.
When using this arrangement to power a number of current loops, it is important to consider the total drain of all AIs when they are at maximum current (20 mA each). If this value exceeds the rated current output of the DPC supply source, inaccurate AI readings will result. Use a separate supply to power current loops exclusively whenever a heavy current load is an-ticipated. (See Figure 3DB-6 “4-20 mA Transmitter Using Auxiliary +24
V Power Supply” for details).
NOTE
This wiring configuration cannot be used with DPC's that operate from +12 V dc power sources. For these models, an external +24 V power source will be required. See next page for details.
CI-3310/30/35 (11/05) HDAI Module / 3DB-5
Figure 3DB-5 - 4-20 mA Transmitter Loop Powered by DPC +24 V Supply
4-20 mA Transmitter Using Auxiliary +24 V Power Supply
In situations where +24 V power from the DPC is insufficient to drive the desired number of transmitter loops, an auxiliary power supply must be used as shown in Figure 3DB-6.
The transmitter and supply shown in Figure 3DB-6 are wired in series with a 250 Ω loop resistor. The supply used in this application should be capable of powering all the 4-20 mA signal loops wired to it.
This arrangement is also recommended for DPC's that operate from +12 V dc sources since
+24 V power is required for the transmitter current loops.
If the module is furnished without common mode (see Table 3DB-1), the signal-supply return must be referenced to power common of the system in order to achieve accurate measurements. This path can be provided by a jumper or resistor (0 to 1 M Ω ) connected as shown in the illustration. This path is not required for the AI Module with 180 V common mode.
3DB - 6 / HDAI Module CI-3310/30/35 (11/05)
Figure 3DB-6 - 4-20 mA Transmitter Loop Powered by Auxiliary +24 V Supply
SPECIFICATIONS
Analog Input Specifications
Number of Inputs:
Input Ranges:
4/8 Differential
1-5 VDC
4-20 mA DC
24 VDC to power 2-wire transmitter/4-20 mA
Accuracy at Room Temperature (+25 ° C / +77 ° F):
Accuracy at -20 ° C to +70 ° C (-4 ° F to +158 ° F):
Accuracy at -40 ° C (-40 ° F)
0.1% of Span 4-20 mA
0.1% of Span 1-5 VDC
0.2% of Span 4-20 mA
0.2% of Span 1-5 VDC
0.3% of Span
Input Filtering - Single Pole (50 msec time constant): 300 msec to .1% of input value
Common Mode Rejection Ratio 47 to 63 Hz; 100 dB
CI-3310/30/35 (11/05) HDAI Module / 3DB-7
Normal Mode Rejection at 60 Hz: 26 dB
Input Impedance:
Isolation & Surge Suppression:
Rugged AI - w/o High Common Mode:
1-5V - 150K
1-5V - 2M Ω
Ω (w/o High C.M.)
(with High C.M.)
4-20 mA - 250 Ω
1-5V/4-20 mA AI
Common Mode 5.75V, -9.5V
Surge Suppression - Input & Common Mode to RMS
Rugged AI - with High Common Mode: 1-5V/4-20 mA AI
Common Mode Isolation to 180VDC
Surge Suppression - Input & Common Mode to 130V RMS
Analog Input Wiring: see Table 3DB-B & all Figures
TABLE 3DB-B - INPUT CONNECTOR PIN ASSIGNMENTS
J1 PIN # TB1/TB2 - PIN # MNEMONIC DESCRIPTION
13
14
9
10
5
6
1
2
21
22
17
18
29
30
25
26
TB1-1
TB2-1
TB1-2
TB2-2
TB1-3
TB2-3
TB1-4
TB2-4
TB1-5
TB2-5
TB1-6
TB2-6
TB1-7
TB2-7
TB1-8
TB2-8
AI5+
AI5-
AI6+
AI6-
AI7+
AI7-
AI8+
AI8-
AI1+
AI1-
AI2+
AI2-
AI3+
AI3-
AI4+
AI4-
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Environmental Specifications
Operating Temperature:
Storage Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
-40°C to +70°C (-40°F to +158°F)
-40°C to +85°C (-40°F to +185°F)
0-95% Non-condensing
1g for 10-150 Hz
.5g for 150-2000 Hz
10 V/Meter - 10MHz to 500MHz
3DB - 8 / HDAI Module CI-3310/30/35 (11/05)
Section 3E
ANALOG OUTPUT MODULE
(Two AO Type)
Series 392007-XX-X & 392027-XX-X
Note: The Analog Output Modules discussed herein, i.e., 392007-XX-X , 392027-XX-X,
392005-XX-X and 392080-XX-X are no longer available.
GENERAL
Analog Output Modules with two AOs are available with the ranges given in Table 3E-A. It will be noticed in the table that modules having a 1-5 V / 4-20 mA output range are field con-figurable by the user for either range. Modules with 0-10 V outputs are factory set for this range and cannot be converted to other ranges.
Figure 3E-2 shows the 1-5 V/ 4-20 mA type and the 0-10 V type AO Modules. Switch SW1 and jumper W1 are used to configure the 1-5V/4-20 mA type module for either range.
Modules with 0-10 V ranges are somewhat similar in appearance but do not have a DIP switch.
TABLE 3E-A - AO MODULE PART NUMBERS
Output Range
0-10 Vdc @ 5 A Max
0-10 Vdc @ 5 A Max.
0-10 Vdc @ 5 A Max.
1-5 Vdc @ 5 mA Max. &
4-20 mA dc into 0-650 load
1-5 Vdc @ 5 mA Max. &
4-20 mA dc into 0-650 load
1-5 Vdc @ 5 mA Max. &
4-20 mA dc into 0-650 load
AOs
2
2
2
2
2
2
Part Number
392007-02-9
33XX Use
392027-02-0
392027-12-7 1
392005-02-6* 2
392080-02-8* 2
392080-12-5* 1,2
10/30
31/35
30/31/35
10/30
31/35
30/31/35
1
* Field configurable for 1-5 V or 4-20 mA
Remote, Mass Term., Non-Isolated, w/o Term. Module
2 Discontinued - Replaced by 392547-XX-X (see Section 3EA)
TERMINAL DESIGNATIONS
AO signal connections are made to either a 30-pin mass termination connector (J1) or to a pair of 3-position terminal blocks (TB1A & TB1B). The AO terminal connector signal designations are shown in Figure 3E-1, 3E-2 &and 3E-3. The upper terminals represents the + signal connection, while the corresponding lower terminals represent the - signal connection. The AO shields may be connected to either shield terminal since they are internally wired to the same point. Terminal designations for the 30-pin mass termination connector (j!) are shown in Figure 3E-3.
CI-3310/30/35 (11/05) AO Module / 3E-1
Figure 3E-1 - Terminal Block Signal Designations
3E-2 / AO Module
Figure 3E-2 - Two AO Modules
(1-5 V / 4-20 mA & 1-10 V Types Shown)
CI-3310/30/35 (11/05)
CI-3310/30/35 (11/05)
Figure 3E-3 - Two AO Type Modules
(1-10 V Types Shown)
AO Module / 3E-3
SIGNAL GROUNDING OPTIONS
The presence of noise or common mode error on the line can affect the stability or accuracy of the signal. These effects can very often be minimized or eliminated by changing the reference points used for signal grounding within the DPC. Jumper W1 provides a choice of three grounding modes as noted in Figure 3E-4.
When jumper W1 is connected to position A as shown in Figure 3E-4-2, the signal shield terminals of TB1 are connected to the chassis. In position B (Figure 3E-4-3), they are connected to the analog common buss, while in position C (Figure 3E-4-4) they are connected to the power common buss. Unless the desired grounding point is known, it may be necessary to experiment with all three positions to determine which yields the best results.
Figure 3E-4 - Shield Grounding Jumper
0-10 V TYPE MODULES
Modules specified with 0-10 V outputs can be used to drive an external high-impedance device as shown below. Since the output range is fixed on these modules, no field configuration is required. The external device used in this application may be a recorder, indicator, control element, etc. The load drain is limited to a maximum of 5 mA.
The output leads to the load are shielded as shown in the illustration. The shield floats at the load end and returns to ground through the "S" terminal.
3E-4 / AO Module CI-3310/30/35 (11/05)
Figure 3E-5 - Output Wiring for 0-10 V Type Module Output
1-5 V / 4-20 mA TYPE MODULES
Each of the Analog Outputs on these modules may be independently configured to provide an output range of 1-5 V dc or 4-20 mA. Selection of the desired output range for AO1 and
AO2 is accomplished via DIP switch S1. The method of setting these switches is described in the applications that follow.
1-5 V dc Output
When used for this application, the module provides a 1-5 V dc output referenced to analog common. Figure 3E-6 illustrates a portion of the AO circuitry and the external load. The proper switch positions are also shown.
Figure 3E-6 - Output Wiring for 1-5 V Type Module
CI-3310/30/35 (11/05) AO Module / 3E-5
The load current of the external device must be limited to 1-5 V @ 5 mA max. for this application.
The output leads to the load are shielded as shown in the illustration. The shield floats at the load end and returns to ground through the "S" terminal.
4-20 mA Output
A simplified presentation of an AO Module driving an external load is shown in Figure 3E-
7. This wiring application is only usable with DPC models specified for +24 V supplies.
Note that the external load device is wired into an open collector output which is sourced to an internal +19 V dc supply source. The load impedance for this circuit must not exceed 650 ohms.
This arrangement is not suitable for DPC models that operate from a +12 V dc supply. The decreased supply voltage on these models prevents the output signal from swinging over its full current range.
The output leads to the load are shielded as shown in the illustration. The shield floats at the load end and returns to ground through the "S" terminal.
Figure 3E-7 - 4-20 mA Module Driving Low-Impedance Load
(For DPCs w/24 V Supply)
3E-6 / AO Module CI-3310/30/35 (11/05)
SPECIFICATIONS
Analog Output Specifications
Number of Outputs:
Output Range:
2 or 4 (see Table 3EA-1)
Accuracy:
Setting Time:
Surge Suppression:
Environmental Specifications
Temperature:
@ +25°C (+77°F) = 0.1% of Span
(-20° to +85°)C (-4° to 185°)F = 0.2% of Span
1-5V, 4-20 mA - 100 milliseconds to .1%
0-10V - 65 microseconds to .1%
Meets ANSI/IEEE C37.90-1978
Operating = (-20° to +70°)C (-4° to 158°)F
Storage = (-40° to +85°)C (-40° to 185°)F
Relative Humidity:
Vibration:
1-5V dc @ 5mA
4 - 20 mA (into 0 to 650 ohm load)
0-10V dc @ 5mA
5-95% Non-condensing
1g for 15-150 Hz
.5g for 150-2000 Hz
RFI Susceptibility: 10 V/M from 10 MHz to 500 MHz
CI-3310/30/35 (11/05) AO Module / 3E-7
BLANK PAGE
Section 3EA
HIGH DENSITY ANALOG OUTPUT MODULE
(Two & Four AO Type)
Series 392547-XX-X
GENERAL
The Analog Output Module utilizes high density construction and has a capacity of up to four analog outputs. These modules can be configured via switches for 1-5 V or 4-20 mA outputs. The location of the switch is shown in Figure 3EA-2 (see Table 3EA-1).
TABLE 3EA-1 - FOUR AO MODULE PART NUMBERS
Output
Range
1-5 V DC or
4-20 mA
1-5 V DC or
4-20 mA
#AOs Impedance
4
4
5 mA Source
0-650 Ohms
2
2
5 mA Source
0-650 Ohms
Surge
Protection
Yes
Yes
Yes
Yes
Part Number
392547-01-5
392547-02-3
Model
Assignment
310/30/31/35
310/30/31/35
1-5 V DC or
4-20 mA
2
2
5 mA Source
0-650 Ohms
Yes
Yes
392547-04-0* 3330/31/35
1-5 V DC or
4-20 mA
4
4
5 mA Source
0-650 Ohms
Yes
Yes
392547-03-1* 3330/31/35
Note: * = Remote, Mass Termination, Non-Isolated, Without Termination Module.
Figure 3EA-1 - Terminal Block Signal Designations
TERMINAL DESIGNATIONS
AO signal connections are made to either a 30-pin mass termination connector (J1) or to a
12-position terminal block (TB1). The AO terminal block signal designations are shown in
Figure 3EA-1. From left to right, the terminals are assigned with odd numbered terminals
CI-3310/30/35 (06/04) High Density AO Module / 3EA-1
representing (+) signal connections and even numbered terminals representing (-) signal connections. The last four terminals, i.e., terminals 9 through 12 are used for shield connections. The AO shields may be connected to any shield terminal since they are internally wired to the same point. Terminal designations for the 30-pin mass termination connector (J1) are provided in Table 3EA-2.
392547-01-5
392547-01-5
Older Units
392547-03-1
Figure 3EA-2 - 4 Output High Density AO Modules
3EA-2 / High Density AO Module CI-3310/30/35 (06/04)
TABLE 3EA-2- CONNECTOR J1 DESIGNATIONS
J1 PIN # MNEMONIC J1 PIN # MNEMONIC
1 +24V 16 -
2
3
AGND
+24V
17
18
AO3+
AO3-
6
7
8
4
5
AGND
+24V
AGND
-
-
19
20
21
22
23
-
AO Shield
AO Shield
-
-
13
14
15
9
10
11
12
AO Shield
AO Shield
-
-
AO4+
AO4-
-
28
29
30
24
25
26
27
-
AO2+
AO2-
-
-
AO1+
AO1-
SELECTING 1-5 V OR 4-20 mA OUTPUTS
Each AO on this module may be independently configured to provide an output range of 1-5
V dc or 4-20 mA. Selection of the desired output range for AO1 through AO4 is accomplished via DIP switch S1 as described below.
TABLE 3EA-3 - SWITCH SW1 CHANNEL & CONFIGURATION ASSIGNMENT
CHANNEL
A01
A02
A03
A04
1-5 V OUT
1, 2 'ON'; 3 'OFF'
4, 5 'ON'; 6 'OFF'
4-20 mA OUT
1, 2 'OFF'; 3 'ON'
4, 5 'OFF'; 6 'ON'
7, 8 'ON'; 9 'OFF' 7, 8 'OFF'; 9 'ON'
10, 11 'ON'; 12 'OFF' 10, 11 'OFF'; 12 'ON'
1-5 V dc Output
When used for this application, the module provides a 1-5 V dc output referenced to analog common. Figure 3EA-3 illustrates a portion of the AO circuitry and the external load. The proper switch positions are also shown.
The load current of the external device must be limited to 1-5 V @ 5 mA maximum for this application. This arrangement is not suitable for DPC models that operate from a +12 V dc supply. The decreased supply voltage on these models prevents the output signal from swinging over its full current range.
The output leads to the load are shielded as shown in the illustration. The shield floats at the load end and returns to ground through the "S" terminal.
CI-3310/30/35 (06/04) High Density AO Module / 3EA-3
Figure 3EA-3 - 1-5 V Output Configuration
(For DPCs w/24 V Supply)
4-20 mA Output
A simplified presentation of an AO Module driving an external load is shown in Figure 3EA-
4. This wiring application is only usable with DPC models specified for +24 V supplies.
Figure 3EA-4 - 4-20 mA Output Configuration
(For DPCs w/24 V Supply)
Note that the external load device is wired into an open collector output which is sourced to an internal +19 V dc supply source. The load impedance for this circuit must not exceed 650 ohms.
3EA-4 / High Density AO Module CI-3310/30/35 (06/04)
This arrangement is not suitable for DPC models that operate from a +12 V dc supply. The decreased supply voltage on these models prevents the output signal from swinging over its full current range.
The output leads to the load are shielded as shown in the illustration. The shield floats at the load end and returns to ground through the "S" terminal.
JUMPERS & ADJUSTMENTS
The High Density Analog Output Board contains three jumpers. Jumpers W2 and W3 are factory configured. Jumper W1 is used to connect the cable shields to chassis, analog common, or power ground, by selecting position A, B, or C respectively (see Figure 3EA-2).
There are up to eight (8) potentiometers on the High Density Analog Input Module which are identified in Table 3EA-4.
TABLE 3EA-4 - POTENTIOMETER ASSIGNMENT
POT. # ADJUSTMENT
R2
R12
R24
R35
R7
Span of AO1
Span of AO2
Span of AO3
Span of AO4
Offset of AO1
R20
R31
R45
Offset of AO2
Offset of AO3
Offset of AO4
SPECIFICATIONS
Analog Output Specifications
Number of Outputs:
Output Range:
Accuracy:
Setting Time:
Surge Suppression:
2 or 4 (see Table 3EA-1)
1-5V dc @ 5mA
4 - 20 mA (into 0 to 650 ohm load)
@ +25°C (+77°F) = 0.1% of Span
(-20° to +70°)C (-4° to 158°)F = 0.2% of Span
(-40° to +85°)C (-40° to 185°)F = 0.3% of Span
1-5V, 4-20mA - 100 milliseconds to .1%
Meets ANSI/IEEE C37.90-1978
CI-3310/30/35 (06/04) High Density AO Module / 3EA-5
Environmental Specifications
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Operating = (-20° to +70°)C (-4° to 158°)F
Storage = (-40° to +85°)C (-40° to 185°)F
5-95% Non-condensing
1g for 15-150 Hz
.5g for 150-2000 Hz
10 V/M from 20 MHz to 500 MHz
3EA-6 / High Density AO Module CI-3310/30/35 (06/04)
Section 3F
DISCRETE INPUT MODULE
(Four or Eight DI Type)
Series 392000-XX-X, 392010-XX-X, 392087-XX-X, 392502-XX-X & 400092-XX-X
GENERAL
Discrete Input Modules (DI Modules) are offered with input ranges of 5 V, 12 V, 24 V and
120 V. Modules having input ranges of 5 V, 12 V and 24 V provide eight DI channels, while those having a 120 V input range provide four DI channels. Opto-isolation is provided for each DI on all DI Modules.
A minimum input voltage equivalent to 90% of the input range is necessary to change a DI channel from an OFF to ON state. Conversely, the voltage level necessary to turn a DI channel from ON to OFF is 10% (max.) of the input range.
Each DI channel contains a LED for visual indication of the signal status. A LED will light when its corresponding input is in an ON state. For DC or very low frequency signals, the
ON-OFF excursions of the LED can be followed by the eye; for higher frequencies, the LED will appear to be continuously lit.
TABLE 3F-A - DI MODULE TYPES
Input Range No.
DIs
Input
Filter
Surge
Protection
Part Number
33XX
Use
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
120 V ac/dc
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
120 V ac/dc
5 V ac/dc
12 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
24 V ac/dc
24 V ac/dc
24 V ac/dc
12 V ac/dc
24 V ac/dc
24 V ac/dc
12 V ac/dc
1 ms
1 ms
30 ms
1 ms
30 ms
30 ms
1 ms
1 ms
30 ms
1 ms
30 ms
30 ms
1 ms
1 ms
30 ms
1 ms
30 ms
1 ms
30 ms
30 ms
1 ms
1 ms
30 ms
1 ms
8
8
8
8
8
4
8
8
8
8
8
4
8
8
8
8
8
8
8
8
8
8
8
8
10 V rms
30 V rms
30 V rms
30 V rms
30 V rms
130 V rms
10 V rms
30 V rms
30 V rms
30 V rms
30 V rms
130 V rms
10 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
30 V rms
392000-07-5
392000-08-3
392000-01-6
392000-02-4
392000-03-2
392010-02-0
392087-07-3
392087-08-1
392087-01-4
392087-02-2
392087-03-0
392502-01-1
392087-17-0*
392087-18-9*
392087-11-1*
392087-12-0*
392087-13-8*
400092-01-8
400092-02-6
400092-03-4*
400092-04-2
400092-05-0
400092-06-9
400092-07-7
10/30
10/30
10/30
10/30
10/30
10/30
31/35
31/35
31/35
31/35
31/35
31/35
30/31/35
30/31/35
30/31/35
30/31/35
30/31/35
10/30
10/30
30/31/35
10/30
31/35
31/35
31/35
• = Remote, Mass Termination, Non-Isolated, Without Termination Module
Note: Only Series 400092 DI Modues are currently available.
CI-3310/30/35 (11/05) DI Module / 3F-1
DI Modules contain low-pass input filters to control the bandwidth. Modules with 30 millisecond filters are intended for 50/60 Hz AC and DC type input signals, while those with 1 millisecond filter are intended for pulsed input signals ranging from dc to 400 pulses-persecond. Those modules having 1 millisecond filters are also suitable for use with 5 or 15 second PDM (Pulse Duration Modulation) transmission loops.
Figure 3F-1 Figure 3F-2
5, 12 & 24 V ac/dc Type 120 V ac/dc Type
With Vertical Term. Block With Vertical Term. Block
3F-2 / DI Module CI-3310/30/35 (11/05)
Figure 3F-3 Figure 3F-4
5, 12 & 24 V ac/dc Type 120 V ac/dc Type
With Right Angle Term. Block With Right Angle Term. Block
CI-3310/30/35 (11/05) DI Module / 3F-3
3F-4 / DI Module
Figure 3F- 5
5, 12 & 24 V ac/dc Type
With Mass Termination Connector
CI-3310/30/35 (11/05)
All DI Modules are furnished with surge protection circuitry. The surge protection rating varies with the input range of the module. Table 3F-A lists the input ranges, input filter values, surge values, and part numbers
CI-3310/30/35 (11/05)
Figure 3F- 6
Series 400092 DI Modules
12 & 24 V ac/dc Type
DI Module / 3F-5
Jumper Locations
Figures 3F-1, 3F-3 & 3F-5 illustrate typical 5, 12, or 24 V type DI Modules while Figure 3F-
6 shows series 400092 12 & 24 V type DI Modules. These illustrations show the location of jumpers W1 to W8 that are used to configure inputs DI1 to DI8. The 120 V type module shown in Figures 3F-2 and 3F-4 provide inputs DI1 to DI4 and, therefore, only jumpers W1 to W4 are present. On series 400092 DI Modules Jumper W9 is used to enable or disable the LEDs.
Jumper settings for various input configurations should be checked prior to startup to insure proper selection of options.
LED On-Off Option
If power consumption is critical, the LED status indicators (DS1-DS8) can be disabled. On earlier units (series 392000, 392010, 392087 & 392505 DI Modules) this is accomplished by unplugging resistor pack R4 whose location is shown in Figures 3F-1 through 3F-5. On series 400092 DI Modules Jumper W9 (see Figure 3F-6) is used to enable (position 1-2) or disable (position 2-3) the LEDs. On the earlier units, it is recommended that the resistor pack be stored in a cloth bag affixed to the DPC should it be desired to restore LED operation for testing.
TERMINAL DESIGNATIONS
In the case of “local terminations,” the DI connections are made to terminal blocks TB1A and TB1B as shown in Figures 3F-1 through 3F-4. The upper terminals TB1A represent the
+ signal connections, while the corresponding lower terminals TB1B represent the - signal connections.
When connecting to a Discrete Input Board which has been supplied with a mass termination connector (J1 or P2), the field circuits must be properly connected to a mating
30-pin mass termination connector plug (see Table 3F-B).
Each DI has an opto-isolated circuit that permits dc signals to be connected to the terminal block in either polarity configuration. However, to maintain wiring consistency, it is recommended that modules used with dc inputs be wired according to the polarity conventions shown in Figure 3F-6. It is also recommended that modules intended for use with 120 V ac inputs have their "hot" and "neutral" leads connected as shown in the illustration.
The sixteen terminals (8 DIs) identified in Figure 3F-7 (also see Figures 3F-1, 3F-3 & 3F-6) will appear on 5 V, 12 V and 24 V type modules. Modules specified with 120 V inputs will have eight terminals (4 DIs) that follow same numeric sequence (see Figures 3F-2 and 3F-
4).
3F-6 / DI Module CI-3310/30/35 (11/05)
Figure 3F-7 - Terminal Block Signal Designations
APPLICATIONS FOR 5, 12 & 24 V TYPE MODULES
Modules specified with 5, 12 or 24 V ac/dc input ranges provide jumper clusters W1 to W8 to configure DI1 to DI8. Each DI may be independently configured for voltage or relaycontact inputs. The various configuration and wiring arrangements that can be used with
DI Modules are described in the applications that follow.
Figure 3F-8 - Externally-Powered DI (5, 12 or 24 V)
Bi-State Voltage Signal as Input
For this application DI1 is a bi-state voltage signal (5, 12 or 24 V) typically obtained from the open collector output of an external device. The circuit arrangement of Figure 3F-8 is
CI-3310/30/35 (11/05) DI Module / 3F-7
achieved by setting the W1 jumpers to their "B" position. This arrangement applies the signal voltage to a bidirectional, opto-isolator circuit that isolates the module input from the signal source and also eliminates polarity restrictions. However, it is recommended that the same polarity conventions be applied to all DIs to maintain wiring consistency.
Relay Contact or PDM Xmtr. as Input
An externally-powered relay contact or PDM transmitter can function as an input to a 12 or
24 V DI Module. For this application the W1 jumpers are set to the "B" configuration as shown at the top of the Figure 3F-9. The opto-isolator circuit provides input isolation and eliminates polarity restrictions. However, it is recommended that the same polarity conventions be applied to all DIs to maintain wiring consistency. This configuration is not recommended for 5 V DI Modules.
Figure 3F-9 - Externally-Powered Relay Contact or PDM Xmtr. Input
Dry Contact Powered by DPC Supply
An external dry contact circuit can be powered by the DI Module's internal power source.
For this application, the W1 jumpers are set to the "A" configuration as shown in Figure 3F-
10. This allows the 24 V or 12 V power source of the DPC to complete the opto-isolator circuit through the dry contact (not recommended for 5 V input modules). Although modules with 24 V or 12 V inputs can be used with either 24 V or 12 V supplies, certain restrictions will apply as follows:
24 V Input Modules.
This type of module can be used with either a 24 V or 12 V powered DPC. If it is used with a 24 V powered DPC, the circuit of Figure 3F-10 can
3F-8 / DI Module CI-3310/30/35 (11/05)
be used as shown. If it is used with a 12 V powered DPC, the circuit of Figure 3F-10 cannot be used since the opto-isolator will not function properly. For this situation it will be necessary to provide external 24 V power as shown in Figure 3F-8.
12 V Input Modules. This type of module can also be used with either a 12 V or 24 V powered DPC. If it is used with 12 V powered DPC, the circuit of Figure 3F-10 can be used as shown. If it is used with a 24 V powered DPC, the circuit of Figure 3F-10 cannot be used since the opto-isolator will be overdriven, resulting in erratic operation. For this situation it will be necessary to provide external 12 V power as shown in Figure 3F-8.
Figure 3F-10 - Internally-Powered Relay Contact as DI
APPLICATIONS FOR 120 V TYPE MODULES
Modules specified for this application will accept 120 V ac or dc signals as inputs. For this mode of operation, the jumpers of W1 are set to the "B" configuration as shown in Figure
3F-11.
CI-3310/30/35 (11/05) DI Module / 3F-9
Figure 3F-11 - High Voltage Signal (120 V) as DI
If the DI is an on/off dc signal, it can be wired to the input terminals without any consideration for polarity. However, in order to maintain system wiring conventions, it is recommended that the upper terminal (A) be positive and the lower terminal (B) be negative. If the DI is an ac signal, it is recommended that the hot lead (L1) be connected to the upper terminal (A) and the neutral lead (L2) to the lower terminal (B).
SPECIFICATIONS
Discrete Input Specifications
Number of Inputs:
Signal Conditioning:
Surge Suppression:
4 - for 120 V, or 8 - for 5, 12 or 24 V
30 msec delay for DC & 50/60 Hz AC Inputs
1 msec delay for PDM Inputs, low Speed Counters
Rugged - Surge Suppression
(Meets ANSI/IEEE C37.90-1978)
Discrete Input Wiring:
@ 10V RMS for 5V Input
@ 30V RMS for 12V & 24V Inputs
@ 130V RMS for 120V Input see Table 3F-B & all Figures
3F-10 / DI Module CI-3310/30/35 (11/05)
TABLE 3F-B - INPUT CONNECTOR PIN ASSIGNMENTS
J1 PIN # TBA/TBB - PIN # MNEMONIC DESCRIPTION
29 TBA-1 DI1+ Field Term. (+)
30
25
TBB-1
TBA-2
DI1-
DI2+
Field Term. (-)
Field Term. (+)
26
21
22
17
TBB-2
TBA-3
TBB-3
TBA-4
DI2-
DI3+
DI3-
DI4+
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
10
5
6
1
18
13
14
9
TBB-4
TBA-5
TBB-5
TBA-6
TBB-6
TBA-7
TBB-7
TBA-8
DI4-
DI5+
DI5-
DI6+
DI6-
DI7+
DI7-
DI8+
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
2 TBB-8
VCC = J1, Pins 15, 16, 19, 20 = +24Vdc
PGND = J1, Pins 23, 24, 27, 28
Environmental Specifications
Operating Temperature:
DI8- Field Term. (-)
-20 ° C to +70 ° C (-4 ° F to +158 ° F)
Storage Temperature: -40 ° C to +85 ° C (-40 ° F to +185 ° F)
Relative Humidity:
RFI Susceptibility:
Vibration:
0-95% Non-condensing
10V/Meter 10MHz - 500MHz
1g for 15-150 Hz
.5g for 150-2000 Hz
CI-3310/30/35 (11/05) DI Module / 3F-11
BLANK PAGE
Section 3FA
HDDI Module
(Sixteen DI Type)
Series 392557-XX-X
GENERAL
The High Density Discrete Input (HDDI) boards (DI Modules, for short) in this series provide 16 DI channels which receive 12/24V inputs. Figure 3FA-1, "High Density Discrete
Input Modules", provides illustrations of the boards. This illustration identifies the location of jumpers W1 through W16 ("JUMPER PLUGS") which are used to configure 16 respective
DIs. Jumper positions should be checked prior to startup for the correct configuration (see
Figures 3FA-4 through 3FA-6).
Figure 3FA-1 - High Density Discrete Input Modules
CI-3310/30/35 (11/2005) HDDI Module / 3FA-1
Each input is opto-isolated so that the signal supply source is isolated from the DI circuitry.
Opto-isolated DIs will function regardless of input supply polarity.
Sixteen LEDs indicate the DI signal status (see Figure 3FA-2). An LED will light when its corresponding input is in an ON state. For DC or very low frequency signals, the ON-OFF excursions of the LED can be followed by the eye; for higher frequencies, the LED will appear to be continuously lit. The LEDs may be turned off by jumper arrangement to conserve power.
Figure 3FA-2 - High Density Discrete Input Modules LED Assignment
A minimum input voltage equivalent to 90% of the input range is necessary to change a DI channel from an OFF to an ON state. Conversely, the voltage level necessary to turn a DI channel from ON to OFF is 10% (max.) of the input range.
DI Modules will be furnished with 30 or 1-millisecond filters to suppress noise superimposed on the signal. Modules with 30-millisecond filters are intended for 50/60 Hz
AC and DC-type inputs, while those with a 1-millisecond filter are intended for pulsed input signals ranging from dc to 400 pulses-per-second. Those modules having 1-millisecond filters are also suitable for use with 5 or 15-second pulse duration modulation (PDM) transmission loops.
TABLE 3FA-1 - MODULE TYPES
Input Range
24 V ac/dc
24 V ac/dc
12 V ac/dc
24 V ac/dc
No.
DIs
16
16
16
16
Input
Filter
1 ms
30 ms
1 ms
30 ms
Surge
Protection
30 V rms
30 V rms
30 V rms
30 V rms
Part Number
392557-01-0
392557-02-9
392557-11-8
392557-06-1*
Model
Assignment
3310/30/31/35
3310/30/31/35
3310/31/35
3330/31/35
* = Remote, Mass Termination, Non-Isolated, Without Termination Module.
Note: HDDI Modules with 16 inputs must not be located in slot 10 of a DPC 3335.
3FA-2 / HDDI Module CI-3310/30/35 (11/2005)
All DI Modules are furnished with surge protection circuitry. Table 3FA-1 lists the input ranges, input filter values, surge values, and part numbers of currently available HDDI
Boards
LED On-Off Option - Jumper W17
If power consumption is critical, the sixteen LED status indicators (DS1-DS4) can be disabled. This is accomplished by unplugging jumper W17, mounted next to U9 and U10 on the board (Figure 3FA-1); in this situation it is recommended that jumper-plug be installed on only one pin for storage.
TERMINAL DESIGNATIONS
DI wiring connections are made to a single 40-pin mass termination connector (J1) or two
12-position terminal blocks, TB1 and TB2. The terminal designations for TB1 and TB2 are shown in Figure 3FA-3, "HDDI Terminal Block Labels". Terminal designations for the 40pin mass termination connector (J1) are provided in Table 3FA-2.
TABLE 3FA-2 – 40-PIN MASS TERMINATION CONNECTOR J1
PIN ASSIGNMENTS
J1 PIN # MNEMONIC J1 PIN # MNEMONIC
1 DI-16+ 21 DI-8+
2 DI-16- 22 DI-8-
3 DI-15+ 23 DI-7+
4 DI-15- 24 DI-7-
5 DI-14+ 25 DI-6+
6 DI-14- 26 DI-6-
7 DI-13+ 27 DI-5+
8 DI-13- 28 DI-5-
9
DI-14/16COM
DI-13/15COM
29
+12/24V
Term. Module Pwr.
10
DI-10/12COM
DI-9/11COM
30
+12/24V
Term. Module Pwr.
11 DI-12+ 31 DI-4+
12 DI-12- 32 DI-4-
13 DI-11+ 33 DI-3+
14 DI-11- 34 DI-3-
15 DI-10+ 35 DI-2+
16 DI-10- 36 DI-2-
17 DI-9+ 37 DI-1+
18 DI-9- 38 DI-1-
19
20
+12/24V
Term. Module Pwr.
+12/24V
Term. Module Pwr.
39
40
DI5/7COM
DI6/8COM
DI1/3COM
DI2/4COM
When connecting DIs to these terminals, note that various DI circuits share a single common return (-) (see Figure 3FA-3 for wiring to terminal blocks TB1 & TB2 or Table 3FA-
2 for mass termination connector J1 signal assignments).
CI-3310/30/35 (11/2005) HDDI Module / 3FA-3
Modules are furnished with 12/24V ac/dc input voltage ratings. Be sure that the external
DIs connected to the module wiring terminals coincides with the input rating of the module.
Each DI has an opto-isolated circuit that permits dc signals to be connected to the terminal block in either polarity configuration. However, we suggest that the polarity of each signal follow the same polarity convention to minimize wiring errors.
Figure 3FA-3 – HDDI Terminal Block Labels
All HDDI modules support connection to Internally-Sourced (Relay Contact or Open
Collector) and Externally-Powered (Single-ended Driven Relay Contact) DIs (see Figures
3FA-4 and 3FA-5). HDDI modules equipped with a mass termination connector also support connection to Externally-Powered Differential Driven Relay Contact DIs (see
Figure 3FA-6).
INTERNALLY-SOURCED RELAY CONTACT OR
OPEN COLLECTOR DI
A DI will accept an internally-sourced relay contact or open collector signal when its jumper block is plugged in for the "IS" (internally-sourced) configuration as shown in the illustration below. For this example, DI-1 is wired for a relay contact, obtaining power from the DPC's power supply. DI-3 is wired for an open collector and also derives power from the
DPC's supply. Note that DI-1 and DI-3 share the same common return i.e., 1/3-. This pattern is repeated for each DI signal pair.
The opto-isolator circuit shown provides electrical isolation for each DI and eliminates polarity restrictions for relay contacts. However, polarity restrictions must be observed for open collector DIs as shown in Figure 3FA-4, "Internally-Sourced Configuration".
SINGLE-ENDED DRIVEN RELAY CONTACT DI
To use a single-ended driven DI with an externally-powered or self-powered bi-state signal, the appropriate jumper block must be plugged into its "DSE" (driven, single-ended) configuration as shown in Figure 3FA-5.
Signals DI-1+ and DI-3+ shown in the illustration share the same common return, i.e., 1/3-.
This pattern is repeated for each DI signal pair (see Figure 3FA-5 "Single-ended Driven DIs
Powered by External Supply").
3FA-4 / HDDI Module CI-3310/30/35 (11/2005)
Figure 3FA-4 - Internally-Sourced Configuration
Figure 3FA-5 - Single-ended Driven DIs Powered by External Supply
DRIVEN DIFFERENTIAL RELAY CONTACT DI
To use a driven differential DI with an externally-powered or self-powered bi-state signal, the appropriate jumper block must be plugged into its "DD" (driven, differential) configuration as shown in Figure 3FA-6. This configuration is only available on modules with a mass termination connector.
CI-3310/30/35 (11/2005) HDDI Module / 3FA-5
Figure 3FA-6 - Differentially Driven DIs Powered by External Supply
MODULE RESTRICTIONS
24V HDDI Modules are furnished for use with 24V input levels only. A 24V HDDI Module should only be used in conjunction with a DPC equipped with a 24V power supply.
12V HDDI Modules are furnished for use with 12V input levels only. A 12V HDDI Module should only be used in conjunction with a DPC equipped with a 12V power supply.
SPECIFICATIONS
Temperature:
Number of Inputs:
Types of Voltage Inputs:
Input Isolation:
-20 ° C to +70 ° C (-4 ° F to +158 ° F)
16 DI channels
24 Vac/Vdc, +10% @ 5 mA.
12 Vac/Vdc, +10% @ 5 mA
1500 V common mode isolation protection
(With Remote Terminations Only)
Surge Suppression: Input and common mode at 39V input voltage. Meets
IEEE 472-1974.
Signal Conditioning: 30 ms delay for dc and 50/60 Hz ac inputs.
1 ms for PDM (pulse duration modulation input signal).
3FA-6 / HDDI Module CI-3310/30/35 (11/2005)
Section 3G
DISCRETE OUTPUT MODULE
(Four or Eight DO Type)
Series 392006-XX-X, 392076-XX-X & 400091-XX-X
GENERAL
Discrete Output Modules (DO Modules) are offered as open collector, open drain and relay contact types. Open collector and open drain types provide eight DO channels, while relay types provide four. DO Module types supported in Section 3G are listed in Table 3G-A.
Each DO channel contains one LED for each DO to indicate the signal status. LEDs will be lit when their corresponding outputs turns ON. For DC or very low input frequencies, the
ON-OFF excursions of the LED can be followed by the eye; for high frequencies, the LED will appear to be continuously lit.
Typical Applications
DO Modules can be used to operate external alarm devices, actuate external on-off control loops, or drive a pulse duration (PD) signal communication loop. These applications are achieved by implementing the appropriate ACCOL II software modules.
When used in a PD application, the DO Module can output a 5 or 15-second pulse signal to a PD receiver. Note that an open collector/drain type DO Module can, in some cases, be used for short-distance, indoor PD loops. However, a relay contact type module is required for long-distance, outdoor loops.
TABLE 3G-A - DO MODULE TYPES
Module Type
(Output)
No.
DOs
Load/Coil Current
Surge
Suppression Part Number
33XX
Use
Open Collector
Relay Contact
Relay Contact
Open Collector
Open Collector
Relay Contact
Open Drain
Open Drain
Open Drain
8
4
4
8
8
4
8
8
8
Load: 100 mA @ 35 Vdc
Coil: 24 V dc @ 10.0 mA
Coil: 12 V dc @ 26.7 mA
Load: 100 mA @ 35 Vdc
Load: 100 mA @ 35 Vdc
Coil: 24 V dc @ 10.0 mA
Load 100mA @ 35 Vdc
Load 100mA @ 35 Vdc
Load 100mA @ 35 Vdc
30 V rms
130 V rms
130 V rms
30 V rms
30 V rms
130 V rms
30 V rms
30 V rms
30 V rms
392006-02-2
392006-04-9
392006-05-7
392076-12-8*
392076-02-0 1
392076-04-7 1
400091-01-1
400091-02-0 1
400091-03-8*
10/30
10/30
10/30
30/31/35
31/35
31/35
10/30
31/35
30/31/35
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
1 = Right Angle Terminal Block
Note: Series 392006 and 392076 DO Modules are no longer available
Jumper Locations
Physical layouts for the open collector and relay contact type module are shown in Figures
3G-1 and 3G-2 respectively. Figure 3G-3 provides an illustration of the mass terminated open collector type DO Modules and Figure 3G-4 shows a simplified layput of the open
CI-3310/30/35 (11/05) DO Module / 3G-1
drain type DO Modules. Open collector and open drain DO Modules are provided with one configuration jumper (W1) that is used to enable or disable poer to the LEDs. Relay contact type DO Modules are provided with five configuration jumpers (W1, W4, W7, W10 and
W13).
Jumper settings for various output configurations should be checked prior to a power-up to insure proper selection of options. Jumpers W2, W5, W8, W11 and W14 on the open collector and relay contact DO Modules are factory set.
Figure 3G-1 - Open Collector Type Figure 3G-2 - Relay Contact Type
3G-2 / DO Module CI-3310/30/35 (11/05)
Figure 3G-3 - Open Collector / Mass Terminated Type
CI-3310/30/35 (11/05) DO Module / 3G-3
Figure 3G-4 - Open Drain DO Modules - Series 400091
3G-4 / DO Module CI-3310/30/35 (11/05)
LED On-Off Option
If power consumption is critical, the LED status indicators (DS1-DS8) associated with open collector or relay contact type DO Modules can be disabled by unplugging jumper W1 whose location is shown in Figures 3G-1, 3G-2 and 3G-3. For open drain DO Modules LED power is enabled when jumper W1 is set in position 1 to 2 and is disabled when W1 is set in position 2 to 3. For open collector or relay contact type DO Modules, it is recommended that the jumper plug be plugged into pin 1 or 2 of W1 so that it is easily accessible should it be desired to restore LED operation for testing.
TERMINAL DESIGNATIONS
In the case of
“ local terminations,
”
the DO signal connections are made to terminal block
TB1 which is a dual-block assembly (see Figures 3G-1, 3G-2 and 3G-4). The upper terminals of TB1 represent the + signal connections, while the corresponding lower terminals represent the - signal connections. The DO assignments associated with local termination are shown in Figure 3G-5. The grouping of the signal leads for DO1 at the left establishes the wiring pattern for the remaining DOs.
The dc polarity must be carefully checked when making connections to open-collector type modules. Although relay contact type modules do not have polarity restrictions, it is recommended that the polarity conventions shown in Figure 3G-5 be applied to all DOs to maintain wiring consistency.
The sixteen terminals (8 DOs) identified in Figure 3G-5 will only appear on open collector and open drain type modules (see Figure 3G-1). Modules specified with relay contact outputs will have eight terminals (4 DOs) that follow the same numeric sequence shown for the first four DOs in Figure 3G-5 (also see Figure 3G-2).
NOTE: The dc polarity (+ or -) must be observed for open collector and open drain type modules. The recommended conventions for ac outputs (Load/-
Neutral) are shown at DO1.
Figure 3G-5 - Terminal Block Signal Designations
CI-3310/30/35 (11/05) DO Module / 3G-5
When connecting to a Discrete Output Module which has been supplied with a mass termination connector (J1), the field circuits must be properly connected to a mating 30-pin mass termination connector plug (see Table 3G-B).
OPEN COLLECTOR/OPEN DRAIN TYPE MODULES
For this application the open collector/drain output must be driven by an external dc supply which is wired in series with the load device as shown in Figure 3G-6 below. The load current for each DO should not exceed 100 mA and the supply voltage should not exceed 35
V dc. Observe dc polarity when making connections.
NOTE
When using inductive loads such as relay coils, the user is required to place a diode across the load as shown in the illustration.
Figure 3G-6 - Open Collector Type Output
RELAY-CONTACT TYPE MODULES
Relay-contact type modules provide four outputs (DO1-DO4) that can be independently configured as Normally Open (NO) or Normally Closed (NC) contacts. Figure 3G-7 shows the configuration of jumper W4 (used with DO#1) for either mode of operation.
3G-6 / DO Module CI-3310/30/35 (11/05)
The load device wired to the DO1 terminals may be powered by an ac or dc power source.
The module's relay-contacts are rated at 2 Ampere resistive, 0.6 Ampere inductive, and 0.4
Ampere motor (all applications assume 50 V dc max. or 120 V ac max. @ 50/60 Hz).
DO Modules with relays are furnished as 12 V or 24 V types. Be sure that the module type is correctly matched with the supply voltage to prevent erratic operation or relay coil burnout.
The external circuit may be a controlled load, an alarm device, or a PD transmission loop.
In all cases, the external voltage source and load current must not exceed the specified ratings of the relay-contacts given above.
CI-3310/30/35 (11/05)
Figure 3G-7 - Relay Contact Type DO
DO Module / 3G-7
SPECIFICATIONS
Discrete Output Specifications
Number of Outputs: 4 - Relay Outputs,
8 - Open Collector Outputs or
8 - Open Drain Outputs
Configuration: Open Collector/Drain - 100mA@ 35 VDC
(Customer is required to place diode across load for
Relay
2.0A Resistive - 50 VDC or 120 VAC 50/60 Hz
0.6A Inductive - 50 VDC or 120 VAC 50/60 Hz
0.4A Motor - 50 VDC or 120 VAC 50/60 Hz
0.2A Lamp - 50 VDC or 120 VAC 50/60 Hz
Note: For load voltages above 30 VDC and 24 VAC, the load and the neutral side of the power source should only be connected to the customer connect terminals and the relay case must be connected to chassis Gnd.
Surge Suppression:
Discrete Output Wiring:
Rugged - Surge Suppression
(Meets ANSI/IEEE C37.90-1978)
@ 30V RMS for Open Collector
@ 130V RMS for Relay see Table 3G-B & all Figures
TABLE - 3G-B - DISCRETE OUTPUT CONNECTOR PIN ASSIGNMENT
J1/P2 PIN # TB1A/B - PIN # MNEMONIC DESCRIPTION
10
5
6
1
18
13
14
9
29
30
25
26
21
22
17
TB1A-1
TB1B-1
TB1A-2
TB1B-2
TB1A-3
TB1B-3
TB1A-4
TB1B-4
TB1A-5
TB1B-5
TB1A-6
TB1B-6
TB1A-7
TB1B-7
TB1A-8
DO1+
DO1-
DO2+
DO2-
DO3+
DO3-
DO4+
DO4-
DO5+
DO5-
DO6+
DO6-
DO7+
DO7-
DO8+
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
Field Term. (-)
Field Term. (+)
2 TB1B-8 DO8- Field Term. (-)
J1 Pins 3, 4, 7, 8, 11, 12, 15, 16, 19, 20, 23, 24, 27 & 28 are not used.
3G-8 / DO Module CI-3310/30/35 (11/05)
Environmental Specifications
Operating Temperature:
Storage Temperature:
Relative Humidity:
RFI Susceptibility:
Vibration:
-20
º
C to +70
º
C (-4 ° F to +158 ° F)
-40
º
C to +85
º
C (-40 ° F to +185 ° F)
0-95% Non-condensing
10V/Meter 10MHz - 500MHz
1g for 15-150 Hz
.5g for 150-2000 Hz
CI-3310/30/35 (11/05) DO Module / 3G-9
BLANK PAGE
Section 3GA
SOLID STATE DC RELAY DO MODULE
(Eight SSDCRDO Type)
Series 392567-XX-X
GENERAL
Solid State DC Relay Discrete Output Boards (SSDCRDO board) provide 8 outputs which can be discretely configured (via on board jumpers) for normally open or normally closed contacts. When configured for normally closed operation, the "opto-isolated" Discrete Outputs will not remain ON without power to the SSDCRDO board.
Each DO channel contains an LED to indicate the signal status. An LED will light when its corresponding output turns ON (provided that Jumper W9 has been installed.
Typical Applications
Solid State DC Relay Discrete Output Boards can be used to operate external alarm/annunciator devices or to actuate external on-off control loops (valves, motors, pumps, etc.) which require the higher drive capability of the Solid State DC Relay Discrete Output
Board. These applications are achieved by implementing the appropriate ACCOL II software modules.
Jumper Locations
The physical layout of the SSDCRDO board is shown in Figure 3GA-1.
Jumper settings for various output configurations should be checked prior to a power-up to insure proper selection of options.
Jumpers W1 through W8 affect DO1 through DO8 respectively, i.e., W1 sets DO1 and W8 sets DO8. Jumper positions A & B affect solid state relay operation as follows:
When set to the A position, the associated DO will operate as a normally open contact.
When set to the B position, the associated DO will operate as a normally closed contact.
Jumper W9 affects LED operation as follows:
W9 installed = LED operation enabled.
W9 removed = LED operation disabled.
LED On-Off Option
If power consumption is critical, the LED status indicators (DS1-DS8) can be disabled by unplugging jumper W9 whose location is shown in Figure 3GA-1. It is recommended that the jumper plug be stored in W9's Pin-1 or Pin-2 position.
CI-3310/30/35 (12/02) SSDCRDO Module / 3GA-1
Figure 3GA-1 - Solid State DC Relay Discrete Output Boards
3GA-2 / SSDCRDO Module CI-3310/30/35 (12/02)
TERMINAL DESIGNATIONS
The DO signal connections for terminal block TB1 are shown in Figure 3GA-2.
Solid State relay contact type outputs have polarity restrictions. It is required that the polarity conventions shown in Figure 3GA-2 be applied to all DOs.
Figure 3GA-2 - Terminal Block TB1 Signal Designations
CI-3310/30/35 (12/02)
Figure 3GA-3 - Solid State DC Relay Type DO
SSDCRDO Board / 3GA-3
THE EXTERNAL CIRCUIT
(see Figure 3GA-3)
The module's outputs are rated at 3 Ampere (38 Vdc max.).
The external circuit may be a controlled load or an alarm device. In all cases, the external voltage source and load current must not exceed the specified ratings of the relay-contacts given above.
NOTE
For driving AC devices, an externally mounted interposing relay can be used.
SPECIFICATIONS
Operating Temperature:
RFI:
DO Output:
Surge Suppression:
Off State Leakage Current:
Part Numbers:
-20 E C to +70 E C (-4 ° F to +158 ° F)
10V/Meter 20MHz - 500MHz
3A 38 Vdc (Max)
89 Vdc
10 F A (Max)
392567-01-6 (For 3310/30)
392567-02-4 (For 3331/35)
3GA-4 / SSDCRDO Module CI-3310/30/35 (12/02)
Section 3GB
HIGH DENSITY DISCRETE OUTPUT MODULE
Series 392586-XX-X
GENERAL
High Density Discrete Output Modules (HDDO Modules) provide 8 or 16 open drain discrete outputs. The HDDO Module (Board) can plug into any of the 12 I/O connectors on the System Interconnect Board (SIB).
Each DO channel (DO1 through DO16) contains an LED (DS1 through DS16) to indicate the signal status. The LEDs are arranged in two rows of eight LEDs each. The upper row of
LEDs (furthest from the terminal blocks), contain DS1, DS3, DS5, DS7, DS9, DS11, DS13, and DS 15. The lower row of LEDs (closest to the terminal blocks), contain DS2, DS4, DS6,
DS8, DS10, DS12, DS14, and DS16. A LED will light when its corresponding output turns
ON. For DC or very low input frequencies, the ON-OFF excursions of the LED can be followed by the eye; for high frequencies, the LED will appear to be continuously lit.
TYPICAL APPLICATIONS
DO Modules can be used to operate external alarm devices, actuate external on-off control loops, or drive a pulse duration (PD) signal communication loop. These applications are achieved by implementing the appropriate ACCOL II software modules.
When used in a PD application, the DO Module can output a 5 or 15-second pulse signal to a PD receiver. Note that an open drain type DO Module can, in some cases, be used for short-distance, indoor PD loops. However, a relay contact type module is required for longdistance, outdoor loops.
LED ON-OFF OPTION
If power consumption is critical, the LED status indicators (DS1-DS16) can be disabled by unplugging jumper W9 whose location is shown both in Figure 3GB-1. It is recommended that the jumper plug be stored in W9's Pin-1 or Pin-2 position (should it be desired to restore LED operation for testing).
TERMINAL DESIGNATIONS
Depending on the model number of the HDDO Board, field wires may be terminated to either two (2) sets of removable 12 point terminal blocks (TB1 & TB2) or a 30-pin mass termination connector (J1). The DO signal connections for the removable 12 point terminal blocks TB1 and TB2 are shown in Table 3GB-1. The hot side of the external circuit must be terminated to the appropriate terminal block number, i.e., DO1(+) to TB2-2. The neutral side of the external circuit can be terminated to any terminal point which is connected to
PCOM, e.g., DO1(-) to TB2-1. TB1 and TB2 accommodate up to 14 gauge wire.
DO signal connections for the 30-pin mass termination connector J1 are shown in Table
3GB-2. A remote termination rack can be connected to J1.
CI-3310/30/35 (11/2005) HDDO Module / 3GB-1
Figure 3GB-1 - High Density Discrete Output Board
3GB-2 / HDDO Module CI-3310/30/35 (11/2005)
TABLE 3GB-1 TB1 & TB2 PIN ASSIGNMENTS
PIN 1 2 3 4 5 6 7 8 9 10 11 12
TB1
DO#
* 2 4 * 6 8 * 10 12 * 14 16
TB2
DO#
* 1 3 * 5 7 * 9 11 * 13 15
* = PCOM
TABLE 3GB-2 - 30-PIN MASS TERMINATION CONNECTOR J1
PIN ASSIGNMENTS
J1 Pin # MNEMONIC J1 Pin # MNEMONIC J1 Pin # MNEMONIC
1 DO16 11 DO11 21 DO6
2 PCOM 12 PCOM 22 PCOM
3 DO15 13 DO10 23 DO5
4 PCOM 14 PCOM 24 PCOM
5 DO14 15 DO9 25 DO4
6 PCOM 16 PCOM 26 PCOM
7 DO13 17 DO8 27 DO3
8 PCOM 18 PCOM 28 PCOM
9 DO12 19 DO7 29 DO2
10 PCOM 20 PCOM 30 DO1
OPEN DRAIN OUTPUT REQUIREMENTS
The open drain output must be connected through the load to an external "DC Supply," as shown in Figure 3GB-2. The load current for each DO should not exceed 100 mA and the supply voltage should not exceed 35 Vdc. Observe dc polarity when making connections.
NOTE
When using inductive loads such as relay coils, the user is required to place a diode across the load as shown in Figure 3GB-2.
CI-3310/30/35 (11/2005) HDDO Module / 3GB-3
Figure 3GB-2 - HDDO Open Drain Output
SPECIFICATIONS
Number
Drain
100 mA @ 35 Vdc
Source
Surge
Termination Options:
-
(Meets ANSI/IEEE C37.90-1978)
Common Mode - @ 30 V RMS
(for Open Collector)
Local - TB1, TB2
Remote - J1
Operating Temperature:
Storage Temperature:
RFI
HDDO Board Versions:
-20°C to +70°C (-4°F to +158°F)
-40°C to +85°C (-40°F to +185°F)
Local Termination (392586-01-0) 1
Remote Termination (392586-02-9) 2
1 = For 3310/30/31/35
2 = For 3330/31/35
3GB-4 / HDDO Module CI-3310/30/35 (11/2005)
Section 3H
HIGH SPEED COUNTER MODULE
(Series 392008-XX-X & 392028-XX-X)
Note: The High Speed Counter discussed herein, i.e., series 392008 and 392028 are no longer available.
GENERAL
High Speed Counter Modules (HSC Modules) contain four presettable 16-bit counters.
Either a current or dry contact signal source may be used to clock the counters. These sources may be self powered (isolated) or powered by the Distributed Process Controller
(DPC) via the HSC Module (non-isolated).
Modules are offered with input ranges of 5V, 12 V or 24 V as noted in Table 3H-A. A minimum voltage equivalent to 90% of the input range is necessary for the HSC channel to change from an OFF to ON state. The voltage level necessary to change from ON to OFF is
10% (max.) of the input range.
Input frequency response for each channel is 10 KHz maximum. Surge suppression is 30 V rms for 24 V input modules, 10 V rms for 12 V modules, and 5 V rms for 5 V modules.
LEDs are provided for each channel to indicate the signal status. A LED will light when its corresponding input receives an ON pulse. For very slow rates, the ON-OFF excursions of the LED can be followed by the eye; for fast rates the LED will appear to be continuously lit.
Jumper Locations
Figure 3H-1 shows the location of jumpers W1 through W10 which are used to configure the module. Settings should be checked prior to startup to insure proper selection of options.
LED On-Off Option
If power consumption is critical, the user can disable the LED status indicators (DS1-DS4) by unplugging jumper W9, whose location is shown in Figure 3H-1. It is recommended that the jumper plug be stored in W9's Pin-1 or Pin-2 position (should it be desired to restore
LED operation).
TABLE 3H-A - HSC MODULE TYPES
Input
Range
#
HSCs
Surge
Suppression
Part Number
(Local Term.)
33XX
Use
Part Number*
(Remote Term.)
33XX
Use
24 V dc
24 V dc
12 V dc
12 V dc
5 V dc
5 V dc
4
4
4
4
4
4
30 V rms
30 V rms
10 V rms
10 V rms
5 V rms
5 V rms
392008-04-1
392028-04-2
392008-02-5
392028-02-6
392008-05-0
392028-05-0
10/30
31/35
10/30
31/35
10/30
31/35
392028-14-0
392028-14-0
392028-12-3
392028-12-3
392028-15-8
392028-15-8
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
30
31/35
30
31/35
30
31/35
CI-3310/30/35 (11/05) HSC Module / 3H-1
TERMINAL DESIGNATIONS
Depending on the model number of the High Speed Counter Module, field wires may be terminated to either two (2) sets of 8 point terminal blocks (TB1-A & TB1-B) or a 30-pin mass termination connector (J1). The terminal designations shown in Figure 3H-2 identify the four counter inputs HSC-1 to HSC-4 which are terminated to TB1. The grouping for
HSC #1 is shown at the left to establish the connection pattern for the remaining inputs.
3H-2 / HSC Module
Figure 3H-1 - High Speed Counter Module
CI-3310/30/35 (11/05)
Figure 3H-2 - Terminal Block Signal Designations
High Speed Counter signal connections for the 30-pin mass termination connector J1 are provided in Table 3H-B. A remote termination rack can be connected to J1.
TABLE 3H-2 - 30-PIN MASS TERMINATION CONNECTOR J1 PIN ASSIGNMENTS
J1 Pin # MNEMONIC J1 Pin # MNEMONIC J1 Pin # MNEMONIC
3
4
13 HSCRESET3 23 GROUND
5 HSCRESET4 15 +24V 25 HSCSET1
6 COMMON +24V 26 SHIELD
7 17 HSCSET2 27 GROUND
8 18 SHIELD 28 GROUND
SIGNAL GROUNDING OPTIONS
The presence of noise or common mode error on the line can affect the stability or accuracy of the signal. These effects can very often be minimized or eliminated by modifying the reference point used for signal grounding within the DPC. Jumper W10 provides a choice of three grounding modes as noted in Figure 3H-3-1.
When jumper W10 is connected to position A (as shown in Figure 3H-3-2), the signal shield terminals of TB1 are connected to the chassis. In position B (Figure 3H-3-3), they are connected to the analog common buss, while in position C (Figure 3H-3-4), they are connected to the power common buss. Unless the desired grounding point is known, it may
CI-3310/30/35 (11/05) HSC Module / 3H-3
be necessary for the user to experiment with all three positions to determine which yields the best results.
Figure 3H-3 - Shield Grounding Jumper
HSC INPUT CONFIGURATIONS
Each HSC channel may be independently configured for a single-ended or differential input via jumper arrangements. The input terminals of the four channels correspond to the jumper clusters as follows:
Debounce Mode
Signal Terminals Jumper Jumper
HSC-1
HSC-2
HSC-3
HSC-4
A1-1 A1-2 B1-1 B1-S
A2-1 A2-2 B2-1 B2-S
A3-1 A3-2 B3-1 B3-S
A4-1 A4-2 B4-1 B4-S
W1
W3
W5
W7
W2
W4
W6
W8
The configuration and wiring arrangements are discussed in the sub-topics that follow.
Although HSC-1 is referenced in the examples, the remaining inputs follow the same rules.
Configurations for Self-Powered Devices (Isolated)
Self-powered devices can be used as inputs for 5, 12 and 24 V type HSC Modules. However, it is essential that signal voltage corresponds to the input range of the module. An improper
3H-4 / HSC Module CI-3310/30/35 (11/05)
match can result in no counting or erratic counting action. The two types of configurations are described as follows:
SET Signal as Input
For this application the HSC channel presents an isolated input to a self-powered device as shown in Figure 3H-4. To achieve this configuration, the mode jumper (W2) is plugged in as shown at the upper part of the illustration and the signal source is wired across the SET and COM terminals. The "Debounce" jumper (W1) is left open so that counter reset action is provided internally by the HSC.
SET/RESET Signals as Inputs
A self-powered device wired to the SET, RESET and COM terminals of the HSC is shown in Figure 3H-5. The "Mode" jumper (W2), when set as shown, provides input isolation via the two opto-isolator circuits. Plugging in the "Debounce" jumper (W1) enables the "Debounce" logic at the flip-flop.
In this configuration, the RESET and SET pulses are processed separately and applied to a nand-gate, flip-flop circuit that develops an equivalent output pulse for counting.
The relationship between the three pulses is expressed by the timing graph at the left of
Figure 3H-5.
Configurations for HSC-Powered Devices (Non-Isolated)
External devices having open collector or relay contact outputs can be powered via the
HSC. Essentially, these configurations require 24 V power from the DPC to drive the external device. Since a DPC can be a 24 V or 12 V type, this places certain restrictions on the use of these configurations. For example, a HSC Module with a 12 V input can only be used in the HSC-powered mode when the DPC is a 12 V type. A HSC Module with a 24 V input can only be used in the HSC-powered mode when the DPC is a 24 V type. HSCs with
5 V inputs are excluded from this type of operation. Please check out your equipment before attempting any actual configuration or wiring.
Open Collector providing SET Input
An external device with an open collector output can function as the input to the HSC.
In Figure 3H-6, the mode jumper (W2) is configured to provide +24 V dc excitation for the device's open collector output. For this application the collector of the output transistor is wired to the SET terminal, while its emitter is returned to the COM terminal. The "Debounce" jumper (W1) is left open so that counter reset action is provided internally by the HSC. This input is not isolated since the HSC's 24 V supply powers the open collector.
SPDT Dry Contact Relay providing SET/RESET Inputs
A SPDT dry contact relay can be wired to the SET, RESET and COM terminals as shown in Figure 3H-7. The "Mode" jumper (W2) is plugged in to use the HSC's 24 V dc power source to power the relay contacts, while the "Debounce" jumper (W1) is plugged in to enable the "Debounce" flip-flop circuit.
CI-3310/30/35 (11/05) HSC Module / 3H-5
This configuration functions in the same manner as the input configuration of Figure
3H-5 except that the input is not isolated.
Figure 3H-4 - Self-Powered Signal Source using SET Input
3H-6 / HSC Module CI-3310/30/35 (11/05)
Figure 3H-5 - Self-Powered Signal Source using SET/RESET Inputs
CI-3310/30/35 (11/05) HSC Module / 3H-7
Figure 3H-6 - HSC-Powered Open Collector using SET Input
3H-8 / HSC Module CI-3310/30/35 (11/05)
Figure 3H-7 - HSC-Powered SPDT Dry Contacts using SET/RESET Inputs
CI-3310/30/35 (11/05) HSC Module / 3H-9
SPECIFICATIONS
High Speed Counter Specifications
Number of Inputs:
Input Range:
4
Isolated Mode
5VDC ± 10% @ 5mA
Input Frequency:
Debounce Circuitry:
Surge Suppression:
Environmental Specifications
Operating Temperature:
Storage Temperature:
Relative Humidity:
RFI Susceptibility:
Vibration: or
Internally Sourced Voltage
For Dry Contact or Open Collector operation
10 KHz Max. with 50% Duty
Field selectable to eliminate spurious counts caused by contact bounce. Requires Form “C” Contact
(SPDT) as external circuit.
Common Mode
(Meets ANSI/IEEE C37.90-1978)
@ 5V RMS for 5V Input Type
@ 10V RMS for 12V Input Types
@ 30V RMS for 24V Input Type
-20ºC to +70ºC (-4 ° F to +158 ° F)
-40ºC to +85ºC (-40 ° F to +185 ° F)
0-95% Non-condensing
10V/Meter 10MHz - 500MHz
1g for 15-150 Hz
.5g for 150-2000 Hz
3H-10 / HSC Module CI-3310/30/35 (11/05)
Section 3HA
HIGH SPEED COUNTER MODULE
(Series 400018-XX-X)
GENERAL
High Speed Counter Modules (HSC Modules) contain four or eight presettable 16-bit counters. Either a current or dry contact signal source may be used to clock the counters.
These sources may be self powered (isolated) or powered by the Distributed Process
Controller (DPC) via the HSC Module (non-isolated).
HSC Module design supports input ranges of 5V, 12 V or 24 V (see Table 3HA-A for current availability). A minimum voltage equivalent to 90% of the input range is necessary for the
HSC channel to change from an OFF to ON state. The voltage level necessary to change from ON to OFF is 10% (max.) of the input range.
Input frequency response for each channel is 10 kHz maximum. Surge suppression is 30 V rms for 24 V input modules, 10 V rms for 12 V modules, and 5 V rms for 5 V modules.
LEDs are provided for each channel to indicate the signal status. A LED will light when its corresponding input receives an ON pulse. For very slow rates, the ON-OFF excursions of the LED can be followed by the eye; for fast rates the LED will appear to be continuously lit.
Jumper Locations
Figures 3HA-1 and 3HA-2 show the location of jumpers W1 through W18 which are used to configure the module. Settings should be checked prior to startup to ensure proper selection of options.
LED On-Off Option
If power consumption is critical, the user can disable the LED status indicators (DS1-DS8) by unplugging jumper W17 (or by storing it in position 2 to 3). LEDs are assigned as follows: CR1 LEDs A, B. C & D = HSC1 through HSC4 respectively, CR2 LEDs A, B, C & D
= HSC5 through HSC8 respectively.
TABLE 3HA-A - HSC MODULE TYPES
Input
Range
#
HSCs
Surge
Suppression
Part Number
(Local Term.)
33XX
Use
Part Number*
(Remote Term.)
33XX
Use
24 Vdc
12 Vdc
05 Vdc
24 Vdc
12 Vdc
05 Vdc
8
8
8
4
4
4
30 V rms
10 V rms
05 V rms
30 V rms
10 V rms
05 V rms
400018-01-2
400018-03-9
400018-05-5
400018-02-0
400018-04-7
400018-06-3
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
10/30/31/35
N/A
N/A
N/A
400018-12-8
400018-13-6
400018-14-4
* = Remote, Mass Termination, Non-Isolated, Without Termination Module
N/A
N/A
N/A
30/31/35
30/31/35
30/31/35
CI-3310/30/35 (01/06) HSC Module / 3HA-1
TERMINAL DESIGNATIONS
Depending on the model number of the High Speed Counter Module, field wires may be terminated to either two (2) sets of 12-point terminal blocks (TB1 & TB2) or a 30-pin mass termination connector (J1). The terminal designations shown in Figure 3HA-3 identify the four or eight counter inputs HSC-1 to HSC-4/8 which are terminated to TB1 and TB2. The groupings for HSC #1 and HSC #5 are shown at the left to establish the connection pattern for the remaining inputs.
Figure 3HA-1 - High Speed Counter Module (8 Inputs)
3HA-2 / HSC Module CI-3310/30/35 (01/06)
High Speed Counter signal connections for the 30-pin mass termination connector J1 are provided in Table 3HA-B. A remote termination rack can be connected to J1. Note: Only
Four HSC Input - High Speed Counter Modules are available with the 30-pin mass termination connector.
Figure 3HA-2 - High Speed Counter Module (4 Inputs)
(see Figure 3HA-1 for Partial View of Older Unit)
CI-3310/30/35 (01/06) HSC Module / 3HA-3
Note: Terminal Block assignments for the first four HSCs are different from those of the last four HSCs, i.e., groupings for HSC #2 through HSC #4 are similar to HSC #1 and those for HSC #6 through HSC #8 are similar to HSC #5.
Figure 3HA-3 - Terminal Block Signal Designations
TABLE 3HA-B - 30-PIN MASS TERMINATION CONNECTOR J1 PIN
ASSIGNMENTS
J1 Pin # MNEMONIC J1 Pin # MNEMONIC J1 Pin # MNEMONIC
5 HSCRESET4 15 +24V 25 HSCSET1
6 COMMON4 16 +24V 26 SHIELD
SIGNAL GROUNDING OPTIONS
The presence of noise or common mode error on the line can affect the stability or accuracy of the signal. These effects can very often be minimized or eliminated by modifying the reference point used for signal grounding within the DPC. Jumper W18 provides a choice of three grounding modes as noted in Figure 3HA-4-1.
3HA-4 / HSC Module CI-3310/30/35 (01/06)
When jumper W18 is connected pin-1 to pin-4 (as shown in Figure 3HA-4-2), the signal shield terminals of TB1 are connected to the chassis. When connected with pin-1 tied to pin-
3 (Figure 3HA-4-3), they are connected to the analog common buss, and when connected with pin-1 tied to pin-2 (Figure 3HA-4-4), the shield is connected to the power common buss. Unless the desired grounding point is known, it may be necessary for the user to experiment with all three positions to determine which yields the best results.
Figure 3HA-4 - Shield Grounding Jumper
HSC INPUT CONFIGURATIONS
Each HSC channel may be independently configured for a single-ended or differential input via jumper arrangements. Jumper assignments associated with the high speed counter inputs are provided in Table 3HA-C.
TABLE 3HA-C - Mode and Debounce Jumper Assignment
HSC
Input #
Mode
Jumper #
Debounce
Jumper #
HSC
Input #
Mode
Jumper #
Debounce
Jumper #
1 W1 W9 5 W5 W14
2 W2 W10 6 W6 W13
3 W3 W11 7 W7 W16
4 W4 W12 8 W8 W15
CI-3310/30/35 (01/06) HSC Module / 3HA-5
The configuration and wiring arrangements are discussed in the sub-topics that follow.
Although HSC-1 is referenced in the examples, the remaining inputs follow the same rules.
Configurations for Self-Powered Devices (Isolated)
Self-powered devices can be used as inputs for 5, 12 and 24 V type HSC Modules. However, it is essential that the signal voltage correspond to the input range of the module. An improper match can result in no counting or erratic counting action. The two types of configurations are described as follows:
SET Signal as Input
For this application the HSC channel presents an isolated input to a self-powered device as shown in Figure 3HA-5. To achieve this configuration, the mode jumper (W1) is plugged in as shown at the upper part of the illustration and the signal source is wired across the SET and COM terminals. The "Debounce" jumper (W9) is set with pin-2 tied to pin-3 so that counter reset action is provided internally by the HSC.
SET/RESET Signals as Inputs
A self-powered device wired to the SET, RESET and COM terminals of the HSC is shown in Figure 3HA-6. The "Mode" jumper (W1), when set as shown, provides input isolation via the two opto-isolator circuits. Setting the "Debounce" jumper (W9) with pin-1 tied to pin-2 enables the "Debounce" logic at the flip-flop.
In this configuration, the RESET and SET pulses are processed separately and applied to a nand-gate, flip-flop circuit that develops an equivalent output pulse for counting.
The relationship between the three pulses is expressed by the timing graph at the left of
Figure 3H-5.
Configurations for HSC-Powered Devices (Non-Isolated)
External devices having open collector or relay contact outputs can be powered via the
HSC. Essentially, these configurations require 24 V power from the DPC to drive the external device. Since a DPC can be a 24 V or 12 V type, this places certain restrictions on the use of these configurations. For example, a HSC Module with a 12 V input can only be used in the HSC-powered mode when the DPC is a 12 V type. A HSC Module with a 24 V input can only be used in the HSC-powered mode when the DPC is a 24 V type. HSCs with
5 V inputs are excluded from this type of operation. Please check out your equipment before attempting any actual configuration or wiring.
Open Collector providing SET Input
An external device with an open collector output can function as the input to the HSC.
In Figure 3HA-7, the mode jumper (W1) is configured to provide +24 V dc excitation for the device's open collector output. For this application the collector of the output transistor is wired to the SET terminal, while its emitter is returned to the COM terminal. The "Debounce" jumper (W9) is set with pin-2 tied to pin-3 so that counter reset action is provided internally by the HSC. This input is not isolated since the HSC's
24 V supply powers the open collector.
3HA-6 / HSC Module CI-3310/30/35 (01/06)
SPDT Dry Contact Relay providing SET/RESET Inputs
A SPDT dry contact relay can be wired to the SET, RESET and COM terminals as shown in Figure 3HA-8. The "Mode" jumper (W1) is set to use the HSC's 24 Vdc power source to power the relay contacts, while the "Debounce" jumper (W9) set with pin-2 tied to pin-3 so that counter reset action is provided internally by the HSC.
This configuration functions in the same manner as the input configuration of Figure
3HA-6 except that the input is not isolated.
CI-3310/30/35 (01/06)
Figure 3HA-5 - Self-Powered Signal Source using SET Input
HSC Module / 3HA-7
Figure 3HA-6 - Self-Powered Signal Source using SET/RESET Inputs
3HA-8 / HSC Module CI-3310/30/35 (01/06)
Figure 3HA-7 - HSC-Powered Open Collector using SET Input
CI-3310/30/35 (01/06) HSC Module / 3HA-9
Figure 3HA-8 - HSC-Powered SPDT Dry Contacts using SET/RESET Inputs
3HA-10 / HSC Module CI-3310/30/35 (01/06)
SPECIFICATIONS
High Speed Counter Specifications
Number of Inputs:
Input Range:
4 or 8
Isolated Mode
5VDC ± 10% @ 5mA or
Internally Sourced Voltage
For Dry Contact or Open Collector operation
Input Frequency:
Debounce Circuitry:
Surge Suppression:
10 kHz Max. with 50% Duty by contact bounce. Requires Form “C” Contact
(SPDT) as external circuit.
Field selectable to eliminate spurious counts caused
Common Mode
(Meets ANSI/IEEE C37.90-1978)
@ 5V RMS for 5V Input Type
@ 10V RMS for 12V Input Types
@ 30V RMS for 24V Input Type
Environmental Specifications
Operating Temperature: -20ºC to +70ºC (-4 ° F to +158 ° F)
Storage Temperature: -40ºC to +85ºC (-40 ° F to +185 ° F)
Relative Humidity:
RFI Susceptibility:
Vibration:
0-95% Non-condensing
10V/Meter 10MHz - 500MHz
1g for 15-150 Hz
.5g for 150-2000 Hz
CI-3310/30/35 (01/06) HSC Module / 3HA-11
BLANK PAGE
Section 3I
LOW LEVEL ANALOG INPUT MODULE
(Four LLAI Type)
Series 389927-XX-X
GENERAL
The Low Level Analog Input Module (LLAI Module) is a dual-board assembly consisting of an LLAI CPU Board and a LLAI Isolation Board. The CPU Board is coupled to the Isolation
Board to make the module a single assembly. The complete assembly plugs into an available slot of the SI Board. Any SI Board slot can be used for LLAI Modules excluding slots 1 and 7 due to a space limitation.
The module types are as follows:
Description Part Number
LLAI Module * 389927-01-5
LLAI Module w/ Common Mode 389927-02-3 (for 3310/30)
LLAI Module w/ Common Mode** 389927-12-0 (for 3331/35)
* = Discontinued type
** = Right Angle Term. Connector
The LLAI Module accepts four, low-level analog input signals which may be the RTD, 10 millivolt, or thermocouple (J, K, T, R, S & B) types. The selection of the signal type and range is performed in software via the AIC program. Information on this subject is covered in the ACCOL II INTERACTIVE COMPILER manual, D4042.
WIRING TERMINALS
The LLAI Module contains a dual-type terminal block (A and B) that provides termination for four Low-Level AI channels. Each AI channel is assigned four connection terminals for different user configurations. The terminal designations for the first LLAI channel are shown in Figure 3I-2. The three remaining AI channels (LLAI #2-4) follow the same wiring pattern.
When making connections to the field wiring terminals, the magnitude of signals must be taken into consideration. Low-level signals (less than 100 mV) should not be intermixed randomly with higher-level signals (greater than 100 mV) because the latter will influence the readings and accuracy of the former. Therefore, all low-level and high-level signals should be wired to separate LLAI Modules.
CI-3310/30/35 (01/99) LLAI Module / 3I- 1
3I-2 / LLAI Module
Figure 3I-1 - LLAI Modules
CI-3310/30/35 (01/99)
Figure 3I-2 - Low Level Analog Input Terminals
FOUR-WIRE RTD INPUT
A four-wire RTD sensor is connected across the wiring terminals of LLAI #1 as shown in
Figure 3I-3. The RTD sensor requires a current source to provide the temperature-resistance changes. The internal 1 mA current source used for this application is activated when jumper W1 is unplugged (jumpers W2-W4 correspond to inputs #2-4). The sensor output signal, which is wired across terminals A1 and B1, is applied to the low level input circuitry of the module.
Figure 3I-3 - Four-Wire RTD Input Connections
CI-3310/30/35 (01/99) LLAI Module / 3I- 3
THREE-WIRE RTD INPUT
Figure 3I-4 shows a three-wire RTD sensor connected to the input terminals. This arrangement is identical to Figure 3I-3 except that terminals B1 and B2 are jumpered together to accommodate the return lead of the sensor. Jumper W1 must also be unplugged for this application.
NOTE
The resistance of the return line (red wire of Figure 3I-4) connected between the RTD sensor and terminal B2 will cause an offset error in the readings equivalent to the following:
[(R w
* l mA) / 0.4 mV per o C] or
Error in o C = 2.5 * R w where: R w
=Resistance of return wire in ohms.
3I-4 / LLAI Module
Figure 3I-4 - RTD Input (3-wire Type)
CI-3310/30/35 (01/99)
THERMOCOUPLE OR MILLIVOLT INPUT
A thermocouple or millivolt device produces its own voltage source and, therefore, does not require internal current excitation. For this arrangement, Jumper W1 (jumpers W2-W4 correspond to inputs #2-4) is plugged into its socket and the device is connected across terminals A1 and B1 as shown in Figure 3I-5. Signal polarity must be observed in order to obtain a proper output.
Figure 3I-5 - TC or MV Input
SPECIFICATIONS
Low Level Analog Input Specifications
Number of Inputs:
Input Types: (see Table #I-1)
4 - Differential Inputs
Thermocouple
B
R
S
J
E
K
T
RTD DN 43760
MV
Range
100
C to 1820
C
-50 C to 1720 C
-50 C to 1760 C
-210
C to 1200
C
-270
C to 1000
C
-270
C to 1370
C
-270 C to 400 C
-220 C to 850 C
+10mV
CI-3310/30/35 (01/99) LLAI Module / 3I- 5
TABLE 3I-1 - INPUT ACCURACY & RESOLUTION
Input Type
Input Type
RTD
Accuracy
B - Thermocouple 100 C to 200 C
200 C to 390 C
390 C to 840 C
840 C to 1800 C
R - Thermocouple -50
C to +50
C
+50
C to 1720
C
S - Thermocouple -50
C to +50
C
+50
C to 1760
C
J - Thermocouple -210
C to 191
C
190
C to 1200
C
E - Thermocouple -270 C to -260 C
-260 C to -225 C
-225 C to -200 C
-200 C to 1000 C
K - Thermocouple -270 C to -261 C
-260 C to -246 C
-245 C to -180 C
-179 C to -145 C
-145 C to 1372 C
T - Thermocouple -270 C to -261 C
-260 C to -251 C
-180 C to -136 C
-135 C to -400 C
Accuracy
-220 C to 850 C
Input Type
10mV -
Accuracy
-
Resolution
2.00
C
1.00
C
0.50
C
0.20
C
0.40
C
0.17
C
0.37
C
0.18
C
0.08
C
0.11
C
1.00
C
0.25
C
0.08
C
0.09
C
2.00
C
0.56
C
0.25
C
0.08
C
0.14
C
1.50
C
0.38
C
0.08
C
0.06
C
Resolution
0.09
C
Resolution
2 C
1 C
.750
C
.500
C
4 C
2 C
.750
C
.500
C
25 C
.500
C
25 C
.025%
25 C
8 C
4 C
2 C
1 C
2
C
1
C
2
C
1
C
.750
C
.500
C
3 C
1 C
.750
C
.500
C
5 C
0 C to +70 C
16 C
8 C
4 C
2 C
4
C
2
C
4
C
2
C
1.5
C
1
C
6 C
2 C
.5
C
1 C
10 C
4 C
2 C
1.5
C
1 C
8 C
4 C
1.5
C
1 C
-20 C to +70 C
1 C
0 C to +70 C
0.05%
Input Resistance: 10 Megaohms
Signal Conditioning:
Isolation - Common Mode:
Surge Protection:
20 msec Time Constant
CMRR 100 dB Channel to Channel
6V Peak with out Isolation Amplifier
600V Peak w/Isolation Amps. - Channel to Channel
IEEE 472-1978, C37.90-1978
Environmental Specifications
Operating Temperature:
Storage Temperature:
Relative Humidity:
RFI Susceptibility:
Vibration:
-20
(
C to +70
(
C (-4
F to +158
F)
-40
(
C to +85
(
C (-40
F to +185
F)
0-95% Non-condensing
10V/Meter 10MHz - 500MHz
1g for 10-150 Hz
.5g for 150-2000 Hz
3I-6 / LLAI Module CI-3310/30/35 (01/99)
Section 3J
HIGH SPEED ANALOG INPUT MODULE & SYSTEM
GENERAL
The High Speed Analog Input Module (HSAI Module) is a specialized data acquisition module that accepts four analog inputs as process variables and two discrete inputs to provide synchronized sampling periods.
The High Speed Analog Input System (HSAIS) consists of a DPC mounted HSAI Module and an externally mounted HSA Interface Panel (HSAIP). The purpose of the HSAIS is to provide termination, conversion, interfacing and monitoring of external analog signals (produced from a shaft encoder or magnetic pickup). In essence the HSAIP provides conditioning and distribution of Top Dead Center (TDC) and Degree Per Pulse signals.
HSAI Module Pressure Application
The module allows the DPC to be used as an on-line analyzer for gas pipeline compressor or engine pumping stations where the four analog input signals (AI-1 to AI-4) represent variables such as suction pressure, discharge pressure, head-end pressure, and crank end pressure. Similarly, the two discrete input signals, DI-D and DI-T, represent the rotational degree (1-360 o = 1 revolution) and top dead center mark of the engine flywheel.
The two DI signals are typically obtained from shaft encoders and are used to synchronize input sampling. The DI-D input receives the sample sync pulse needed to indicate the position of the flywheel (one pulse per degree), while the DI-T input receives the "Top Dead
Center" pulse needed to initiate the module's timing cycle.
The analog inputs are sampled at the pulse rate of the DI-D signal. An averaging option controlled by ACCOL allows more than 360 samples to be used during the input cycle. Even though an integral sample greater than 360 cycles will be taken, only 360 data values will be stored. The first data value will be the average of input sample 1, sample 361, sample 721, etc. The second will be the average of sample 2, sample 362, sample 722, etc.
The conversion of each input sample includes freezing the present value in a sample and hold circuit, digitizing the analog value, and storing the result in RAM. If the averaging option is used, the conversion will be replaced with a running average calculation. All inputs are stored as 12-bit binary values (when these inputs are transferred into the DPC's main memory, they will be stored in a 32 bit floating point format).
HSAI Module Operating Overview
In operation, the HSAI Module sequentially samples one of the four AIs via a multiplex operation, converts the selected analog signal to digital data, and transfers that data to the
HSAI RAM over an 8-bit bus. The module's AI circuitry provides filtering and isolation for each channel, while two, four-channel multiplexers perform the selection of an analog channel and a DC reference voltage channel. An A/D converter converts the selected analog signal to digital data.
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 1
Figure 3J-1 -High Speed Analog Input Module Assemblies
3J-2 / HSAI Module & System CI-3310/30/35 (01/99)
The HSAI Module contains an on-board microprocessor to perform CPU functions, a 32 kbyte EPROM to store the pressure measurement program, and a 32 k-byte RAM to store the sampled data.
A shaft encoder connected to the engine flywheel generates the timing pulses for the DI-D and DI-T inputs. These signals are applied to separate opto-isolated discrete input circuits.
The DI-D sensor outputs a pulse to the CPU for each degree of rotation of a flywheel, while the DI-T sensor outputs a pulse each time the flywheel is positioned at top dead center of the ignition cycle.
The HSAI module is comprised of two assemblies. The main assembly is the Acquisition
Board, while the subassembly is the Analog Isolation Board. The combined assembly is identified as follows:
HSAI Module, complete Pressure Application Models 3310/30 Pt. No. 390827-01-0
HSAI Module, complete Pressure Application Model 3335 Pt. No. 390827-02-9*
Note: * = Assembly with Right Angle terminal Blocks
HSAI MODULE TERMINAL DESIGNATIONS
The signal connections are made to terminal block TB1 which is shown in Figure 3J-2. The upper terminals represent the + signal connections, while the lower terminals represent the corresponding - signal connections.
Figure 3J-2 - Terminal Block Signal Designations
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 3
The analog input signals are labeled AI1, AI2, AI3 and AI4. The shields of the analog input signals may be connected to either AI shield terminal since they are internally wired to the same point in the module. Analog signal shields, however, should not be returned to the DI shield terminals.
The discrete input signals are labeled DIT (top dead center) and DID (degrees rotation). The shields of the discrete input signals can be returned to either DI shield terminal since they are internally wired to the same point. Discrete signal shields should not be returned to the
AI shield terminals.
HSAI MODULE SIGNAL GROUNDING OPTIONS
The HSAI Module is provided with separate analog and discrete grounding options. A description of each follows:
Figure 3J-3 - AI Shield Grounding Jumper
3J-4 / HSAI Module & System CI-3310/30/35 (01/99)
AI Grounding
The presence of noise or common mode error on the line can affect the stability or accuracy of the signal. These effects can very often be minimized or eliminated by modifying the reference points used for signal grounding within the DPC. Jumper W5, whose location is shown in Figure 3J-1, provides a choice of three grounding modes. These modes are identified in panel 1 of Figure 3J-3.
When W5 is connected to position A as shown in panel 2 of Figure 3J-3, the signal shield terminals of TB1 are connected to the chassis. In position B (panel 3), they are connected to the analog common bus, while in position C (panel 4), they are connected to the power common bus. Unless the desired grounding point is specifically known, it may be necessary to experiment with all three positions to determine which yields the best results.
CI-3310/30/35 (01/99)
Figure 3J-4 - DI Shield Grounding Jumper
HSAI Module & System / 3J- 5
DI Grounding
The location of the DI grounding jumper W3 is shown in Figure 3J-1. This jumper offers two
DI grounding options. In panel 1 of Figure 3J-4, the jumper is in position A which connects the DI shield terminal to power common. In panel 2, the jumper is in position B which now connects the DI shield terminal to the chassis. Choose the position that provides minimum noise for the application.
HSAI MODULE ANALOG INPUT WIRING
Each of the analog inputs on these modules may be independently configured to accept a range of 1-5 V dc or 4-20 mA. Selection of the desired input range for AIs 1-4 is accomplished via corresponding jumper clusters W1 through W4. The configuration and wiring applications are described as follows.
Figure 3J-5 - Input Wiring for 1-5 V Type Module
1-5 V dc Isolated Input
When used for this application, the AI Module accepts a 1-5 V dc signal source as shown in
Figure 3J-5. The jumper clusters are arranged as shown to configure the module for this input.
4-20 mA Transmitter Using +24 V DPC Power Source
An analog input can be configured to accept a 4-20 mA signal from a transmitter or transducer operating in a current loop. The +24 V power required to operate this loop is obtained
3J-6 / HSAI Module & System CI-3310/30/35 (01/99)
from the DPC's 24 V power supply. Figure 3J-6 shows the arrangements of the jumper clusters for this application.
If this arrangement is used to power a number of current loops, it is important to consider the combined maximum current drain of all the AIs. If the total current exceeds the maximum output of the +24 V supply, improper readings and operation will result. Use a separate DC supply whenever a large number of loops are planned.
NOTE This wiring configuration cannot be used with DPC's that operate from +12 V dc power sources. For these models, an external +24 V power source will be required
(see Figure 3J-7).
Figure 3J-6 - 4-20 mA Transmitter Loop Powered by DPC +24 V Supply
4-20 mA Transmitter using Auxiliary +24 V Power Supply
In situations where +24 V power from the DPC is insufficient to drive the desired number of transmitter loops, an auxiliary power supply must be provided as shown in Figure 3J-7. For this type of operation, the jumper clusters are connected as shown to utilize the external loop power source.
The transmitter shown in the illustration is connected in series with the 250
Ω
loop resistor to develop a 1-5 V signal drop for the module input. Power to operate this loop is obtained
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 7
from the auxiliary 24 V power source. The supply used in this application should be capable of powering all the 4-20 mA signal loops wired to it.
This arrangement must always be used for DPC's that operate from +12 V dc sources since transmitters require 24 V power.
Figure 3J-7 - 4-20 mA Transmitter Loop Powered by Auxiliary +24 V Supply
HSAI MODULE DISCRETE INPUT WIRING
Figure 3J-8 shows the wiring for the discrete inputs of the HSAI Module. Although this illustration shows the terminal grouping for the DEG signal, it also applies to the TDC signal.
For this application the differential pulse signal (+5V/-5V) is obtained from a shaft encoder or similar type output device. The pulse signal is applied to an opto-isolated circuit that provides a high degree of input isolation.
Both DIs must also be shielded to minimize interference to other inputs. The DI shield jumper positions are discussed on page 3J-6.
3J-8 / HSAI Module & System CI-3310/30/35 (01/99)
Figure 3J-8 - DI using (5V/-5V) Pulse Signal
HSAI SYSTEM OVERVIEW
(see Figures 3J-9 through 3J-13)
The HSAI Panel measures 17.65" by 5.2" and mounts to a rack mountable metal plate which measures 19" by 5.219". HSAI Systems provide an interface for RS-422 (Top Dead Center,
Pulse Per Degree Quadrature & Pulse Per Degree) from a Shaft Encoder or an interface for magnetic pickups (TDC and Pulse Per Degree). The input signal are connected to Terminal
Block TB2 of the HSAI Panel. +24VDC Power, Power Ground (24V RET) and Chassis Ground
(CHASSIS) connections are made to HSAI Panel Terminal Block TB1. The RS-422 receivers are terminated with 100 ohm resistors and are protected from transients. The magnetic pickup inputs are AC-coupled to the input circuitry via .1
F capacitors. The input circuitry is biased to 2.5V. A comparator circuit detects both positive and negative changes of state.
The bi-signal generated by the magnetic pickup must be greater than 1.5V peak-to-peak for the comparator to set or reset the one shot pulse from the TDC and Degree inputs. The magnetic pickup signal must generate a positive pulse to trigger the one shot pulse. A negative pulse from the magnetic pickup will reset the one shot circuitry. The maximum durations for a TDC or Degree pulse are 300 sec and 100 sec, respectively.
HSAI Panels provide 24 differential output pairs (2 pair per HSAI Module). Each pair provides a differential voltage range (connected to HSAI Module TDC or DEG input) of 5V and a differential current range (connected to HSAI Module TDC or DEG input) of 5mA.
The first 12 differential output pairs are provided via Terminal Block TB3 while the Second
12 differential outputs are provided via terminal Block TB4. Differential Amplifiers are used to generate the TDC and Degree signals to the HSAI Module(s).
HSAI PANEL TERMINAL DESIGNATIONS & MAJOR COMPONENTS
HSAI Panels have four Terminal Blocks which are identified in Figures 3J-9 and 3J-13 and in Tables 3J-1 through 3J-3). The HSAI Panel also has five (5) jumpers, two (2) LEDs, one
(1) test point, one (1) adjustable resistor and one (1) Fuse. Test Point 1 (TP1) monitors the on-board 7.5V Power Supply. The 7.5V supply is set by adjustable resistor (R32). F1 is a 1/4
Amp Slow Blow Fuse.
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 9
Figure 3J-9 - HSAI Panel Major Component Location Diagram
3J-10 / HSAI Module & System CI-3310/30/35 (01/99)
HSAI Panel Jumpers & LEDs
The jumpers on the High Speed Analog Interface Panel function as follows:
Jumper W1: W1 selects TDC and Degree frequency control.
Installed = Input frequency is not divided.
Not Installed = Input frequency is halved, i.e., input freq. is divided by 2.
Note: When W1 is not installed, the engine speed displayed at the RATE terminal of the ACCOL HSANIN module is 1/2 the actual engine speed. For 4-cycle engines this jumper should not be installed.
Jumper W2: W2 selects the input source for the Degree signal (see Figure 3J-10).
Figure 3J-10 JumperW2 Pin Assignment
Pin 3 connected to Pin 4 selects a magnetic pickup input as the source.
Pin 2 connected to Pin 4 selects "A" (RS-422) input from an encoder.
Pin 4 connected to Pin 6 selects "B" (RS-422) input from an encoder.
Jumper W3: W3 selects the input source for the TDC signal (see Figure 3J-11).
Figure 3J-11 Jumper W3 Pin Assignment
Pin 1 connected to Pin 2 selects the magnetic pickup as the source.
Pin 2 connected to Pin 3 selects the encoder (RS-422) as the source.
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 11
Jumper W4: W4 selects the shield wire terminations (Factory Installed) (see Fig. 3J-12).
Figure 3J-12 - Jumper W4 Pin Assignment
Jumper W5: W5 connects Chassis to PCOM when installed.
LED DS1:
LED DS2:
DS1 indicates TDC status when lit.
DS2 indicates Degree status when lit.
HSAI Panel Terminal Blocks
(see Figure 3J-13)
The function of the four HSAI Panel Term. Blocks are provided in Tables 3J-1 through 3J-3.
Figure 3J-13 provides the HSAI System Interconnections.
TABLE 3J-1 - HSAI PANEL TERMINAL BLOCK TB1 PIN DESIGNATIONS
TB1 PIN# MNEMONIC
1 No Connect
2
3
4
CHASSIS
PCOM
+24V
DESCRIPTION
CHASSIS
POWER RETURN
INPUT POWER
TABLE 3J-2 - HSAI PANEL TERMINAL BLOCK TB3 & TB4 PIN DESIGNATIONS
TB3/4 PIN#
24, 20, 16,
12, 8 & 4
23, 19, 15,
11, 7 & 3
22, 18, 14,
10, 6 & 2
21, 17, 13,
9, 5 & 1
DESIGNATIONS
TX
(T1-T6)
TX
(T1-T6)
DX
(D1-D6)
DX
(D1-D6)
MNEMONIC
TDC A HSA INTF
DESCRIPTION
TDC positive output to HSAIS
TDC B HSA INTF TDC negative output to HSAIS
DEG A HSA INTF Degree positive output to HSAIS
DEG B HSA INTF Degree negative output to HSAIS
3J-12 / HSAI Module & System CI-3310/30/35 (01/99)
CI-3310/30/35 (01/99)
Figure 3J-13 - HSAI System Interconnections
HSAI Module & System / 3J- 13
TABLE 3J-3 - HSAI PANEL TERMINAL BLOCK TB2 PIN DESIGNATIONS
TB2 PIN# MNEMONIC
1 MT
8
9
6
7
10
4
5
2
3
PCOM
MD
PCOM
SHIELD
+V
PCOM
/I
I
/A
11
12
13
A
/B
B
DESCRIPTION
Top Dead Center magnetic pickup signal
Top Dead Center magnetic pickup return
Degree magnetic pickup signal
Degree magnetic pickup return
Shield connection for magnetic pickup or encoder
5V field power for encoder
5V return for encoder
Encoder TDC RS-422 negative signal
Encoder TDC RS-422 positive signal
Encoder Degree RS-422 negative signal
Encoder Degree RS-422 positive signal
Encoder Degree (Dual Quadrature) RS-422 negative signal
Encoder Degree (Dual Quadrature) RS-422 positive signal
SPECIFICATIONS
Power Requirements
HSAI Module requires:
HSAIP requires:
+15VDC @ 9mA
-15VDC @ 7mA
+5VDC @ 115mA
-5VDC @ 4mA
+24VDC @ 43mA
+24VDC @ 4.16mA per HSAI Module
+24VDC @ Encoder Icc x 7.5/24 x 1.33
HSAI Module Inputs
Number of Analog Inputs:
Number of Digital Inputs:
HSAI Module Input Types
Analog Inputs:
Digital Inputs:
HSAI Module Accuracy
Analog Inputs:
4 Differential Inputs
2 Discrete inputs
Configurable for:
1-5V Voltage Mode
4-20mA Current Mode
5V 10%, Input Filter 20 sec
0.1% of Span at 25
(
C (77
(
F)
0.2% of Span at -20 ( to +70 ( C (-4 ( to +158 ( F)
3J-14 / HSAI Module & System CI-3310/30/35 (01/99)
HSAI Module Input Impedance
Analog Input: 2M 6 (1-5V Input)
250
6
(4-20mA Input)
680
6
Discrete Input:
HSAI Module Signal Conditioning
Analog Inputs:
Discrete Inputs:
HSAIM Common Mode Rejection Ratio
Single Pole (3 sec time constant)
20 sec to 0.1% of Input Signal
20 sec
40dB
Meets IEEE 472-1978, C37.90-1978
180V
7V
DC to 60Hz:
HSAIM Common Mode Voltage
Analog Input:
Discrete Input:
HSAIM Surge Suppression
Analog Input:
Discrete Input:
HSAI Panel Inputs
Number of Digital Inputs:
HSAI Panel Input Types
RS-422 Inputs:
Magnetic Pickup:
HSAI Panel Input Impedance
RS-422 Inputs:
Magnetic Pickup:
HSAI Panel Signal Conditioning
Magnetic Pickup:
130VAC
5VAC
2 Discrete inputs
Top Dead Center & Degree
Top Dead Center & Degree
100 6
AC coupled on signal/return tied to PCOM
TDC signal maximum on time 300 sec
Degree signal maximum on time 100 sec
CI-3310/30/35 (01/99) HSAI Module & System / 3J- 15
2 Cycle/4 Cycle Operation: Input pulse train for TDC and Degree divided by 2 for 4 Cycle operation
HSAI Panel Common Mode Voltage
RS-422 Input:
Magnetic Pickup Signal:
5V
15V
Surge Suppression
RS-422 Input:
Magnetic Pickup Signal:
HSAI Panel Outputs
Differential Voltage Range:
Meets IEEE 472-1978, C37.90-1978
6V
17V
24 Differential Pairs
(Connected to HSAI TDC or DEG Input) 5V
(Connected to HSAI TDC or DEG Input)
5mA
Environmental Specifications
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Operating: -20 ( C to +70 ( C (-4 ( F to +158 ( F)
Storage: -40
(
C to +85
(
C (-40
(
F to +185
(
F)
0-95% Non-condensing
1g for 10-150Hz
.5g for 150-2000Hz
10V/meter from 10MHz to 500MHz
3J-16 / HSAI Module & System CI-3310/30/35 (01/99)
Section 3L
REMOTE I/O UNIT - 3331
PRODUCT DESCRIPTION
The Series 3331 Remote Input/Output Unit (RIO Unit) is an extension device that can expand the I/O capacity of a host device such as a Series 3330 or 3335 Distributed Process Controller
(DPC), or provide I/Os for a Series 3332 Redundancy System. A single RIO Unit accommodates a maximum of ten I/O modules as noted in Figure 3L-2. Although ten RIO Units can communicate with the host, these systems have a practical limit of 40 I/O modules, including those modules contained in the host.
A key advantage of using RIOs in place of additional DPCs is that all of the I/Os of the DPC host and RIO Units can be constructed in a single ACCOL load. The alternative method of using multiple DPCs to replicate I/O expansion results in the creation of a separate load for each DPC
(this application uses ACCOL master and slave software modules to establish network communications). Consequently, the RIO approach greatly simplifies the task of configuring an expanded I/O system.
Although RIO Units are physically similar to Series 3335 DPCs, there is a significant software change. A specialized PROM set makes the 3331 function as a data acquisition unit that communicates with its host through an RS-485 port using synchronous communications. This application requires ACCOL 5.3 or later software versions to implement RIO expansion in the host. Other than the specialized PROM set, the RIO Unit uses the same set of PC boards and
I/O modules described in section 1 of this manual.
Figure 3L-1 RIO Unit with Optional Cover
Figure 3L-2 Front View Showing PC Board and Module Layout specialized PROM set, the RIO
Unit uses the same set of PC boards and I/O modules described in Section 1 of this manual.
A description of the features that are specific to the 3331 are as follows: o Product Line Compatibility
Series 3331 RIO Units can be slaved to Series 3330, 3335, or 3332 host devices. All plug-in modules used with the 3331 (excluding the RIO-CPU Module) are compatible with 3335 types. The plug-in modules used with the 3330 are not interchangeable with 3331 types.
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-1
o RIO Communication Ports
RIO Units provide two communication ports labeled B and A. Port 'B' is used for RIO communications and port 'A' for diagnostic tests run on an external personal computer (PC).
Rates of 187.5 kilobaud (kBd) or 1 megabaud (MBd) can be selected for port B communications.
o Communication Loss Output Control Modes
Two failure modes can be applied to the outputs (AOs and DOs) of RIO Units if communications fail: 1) hold last output values; and 2) set outputs to minimum range values.
These modes are selected by switches located on the CPU Module of the RIO.
o Power Fail Output Control Modes
This feature determines the manner in which the outputs (AOs and DOs) will be set when power returns after a power down or power failure. The outputs may be configured to
"reestablish" their last values, or to "reset" to their default values. Timing periods from 5 seconds to 5 minutes can also be combined with the "reestablish" and "reset" modes to cover various startup situations.
o Enclosures
RIO Units are housed in rack-mount enclosures designed to meet NEMA-1 specifications.
An optional front cover may be specified to enhance the appearance of the equipment (Figure
3L-1). Unit enclosures provide slots for a maximum of ten I/O modules (Figure 3L-2).
TABLE 3L-A MODEL NUMBER BREAKDOWN
The model number is stamped on a plate data affixed to the unit. The RIO's general features can be identified by comparing its model number to the breakdown that follows:
3331-10A - 1 2 0 - 0 - *
Model Number
# A B C D
Table Reference
# = BASE MODEL NUMBER
A = PACKAGING
1 = 10 I/O slots
B = FRONT COVER
1 = Without
2 = With
C = NOT AVAILABLE
D = CERTIFICATION
0 = None
1 = FM Approved **
* Attachment numbers are appended to the model number to represent additional features and options not covered here. See attachment tables in Section 1 for details.
** See HAZARDOUS AREA CLASSIFICATION in Section 1 for details.
Note: This table is only provided for identifying product features and not for sales ordering purposes.
3L-2 / Remote I/O 3331 Unit CI-3335 (07/97)
Figure 3L-2 Front View Showing PC Board and Module Layout
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-3
TYPICAL APPLICATIONS
Several RIO Units can be slaved to RS-485 ports of a Distributed Process Controller as shown in Figure 3L-3. For this application, the selected ports of the DPC are configured for "Remote
I/O Rack" (RIOR) communications. The RIOR function, which is assigned via the ACCOL
Interactive Compiler, allows the DPC port to communicate with port B of each RIO Unit. The selected DPC ports must support synchronous communications; the availability of these ports is determined by the communication engine type (see Section 3C).
The application of Figure 3L-3 utilizes two DPC ports. However, the entire communication overhead could just as easily be distributed over three ports or a single port. The advantage of using multiple ports is that it improves the execution speed of a system having a large number of RIOs. Regardless of how communications are distributed, the maximum limit of the system is ten RIO Units and 40 plug-in I/O modules (this count also includes those I/O modules contained in the DPC). These communications can be used for distances up to 1000 feet at 187.5
kBd, or 200 feet at 1 MBd, as measured from the DPC to the most distant unit.
Figure 3L-3 RIO Units Wired to Two DPC Ports
An application employing a redundancy communication system is shown in Figure 3L-4. This system is composed of two Redundant Distributed Process Controllers (RDPC) and a
Redundancy Switchover Panel (RSP). One of the RDPCs functions as the on-line unit and the other as the "live" backup unit. Should the on-line unit go into a "watchdog" condition, the
Redundancy Switchover Panel will respond and instantly switch over to the backup unit. The transfer is sufficiently fast so that the RIO Units do not detect any interruption of communications. In Figure 3L-4, the three RIO Units are wired to a single RSP port. However,
RIO communications could be distributed over two ports (or more) as described in the previous application.
3L-4 / Remote I/O 3331 Unit CI-3335 (07/97)
Figure 3L-4 Remote I/O Units Wired to Single Port of Redundancy System
INSTALLATION
RIO Unit Enclosure
The Remote I/O Unit is intended for rack or panel installations. The mounting dimensions and procedures are the same as that described for the 3335 Distributed Process Controller in Section
2 - Installation. The installation and removal procedure for the optional cover is also contained in Section 2.
Communication Ports
Communication ports B and A use nine-pin connectors. The connector that mates with port B is wired for an RS-485 interface, while that for port A (if used) is wired for an RS-423 interface.
See "Appendix CP - Communication Ports" for details.
Port B communicates with the host device which may be a DPC or Redundant System. A maximum of ten RIO drops per port can be wired to a host but the total number of plug-in I/O modules in the system must not exceed 40, including those present in the host. All RIO Units defined in the ACCOL load may be assigned to one or more host ports (see Figures 3L-3 and 3L-
4). Those ports selected for this function must all be capable of synchronous communications.
Port A is intended for use with a PC that executes the diagnostic software program (see
Diagnostic manual for details). TOOLKIT software can be used to check communication statistics on ports A and B.
Board Configuration & Field Wiring
The SI Board of the RIO (Figure 3L-2) contains field wiring terminals for +24 V power, auto/manual transfer function (watchdog detection), and a grounding option that is selected by jumpers. The SI Board is described in Section 3A -DC Power System.
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-5
The I/O modules used in the RIO will also require configuration and wiring. See Sections 3C to 3J for details.
The CPU Module used with the 3331 is not interchangeable with 3335 type described in Section
3B. The configuration of the 3331 type is described under the next topic, CONFIGURING RIO-
TYPE CPU MODULE.
CONFIGURING RIO-TYPE CPU MODULE (PT.NO. 395212-01-5)
The RIO-Type CPU Module is a dual-board assembly consisting of a Processor Board and a
Memory Board. It is physically identical to the CPU Module described in Section 3B but only differs in the type of PROM set. The switches and jumpers are configured in accordance with
Tables 3L-B and 3L-C.
Functions of Switch SW1
The general functions of switches SW1-1 to -8 are given in the Table 3L-B. More details on these functions are as follows: o Power Fail Output Control (PFOC)
The setting of switches SW1-1 to -3 determine the manner in which the RIO Unit will recover from a power interruption or failure. Essentially, these switches determine how the
AOs and DOs will be set upon a powerup. For example, these switches can be set to
Reestablish the last AO and DO values prior to the failure, or to Reset them to the equipment default values whereby AOs = 0% and DOs = OFF. They can also be set to any desired power interruption time limit ranging from 5 seconds to 5 minutes. The table below lists the possible combinations.
SW1-1 SW1-2 SW1-3 OUTPUT RECOVERY MODE
OFF
OFF
ON
OFF
ON
OFF
ON
ON
OFF
ON
OFF
OFF
ON
ON
OFF
ON
OFF
ON
ON
ON
OFF
OFF
OFF
ON
Reset (No delay)
Reestablish < 5 sec. > Reset
Reestablish < 15 sec. > Reset
Reestablish < 30 sec. > Reset
Reestablish < 1 min. > Reset
Reestablish < 2 min. > Reset
Reestablish < 5 min. > Reset
Reestablish Last State (No Delay)
The use of the above table is demonstrated by the following examples:
Examples:
A. If all three switches are set to OFF, the outputs will be Reset to the output default values upon a powerup. All AOs will be reset to 0% and all DOs to OFF.
B. If all three switches are set to ON, the last output values will be Reestablished upon a powerup.
3L-6 / Remote I/O 3331 Unit CI-3335 (07/97)
SWITCH
NUMBER
SW1-1
-2
-3
-4
-5
-6
-7
-8
SW2-1
-2
-3
-4
-5
-6
-7
-8
TABLE 3L-B SETTINGS FOR SWITCHES SW1 & SW2
SWITCH
SELECTION
ON/OFF
ON/OFF
ON/OFF
ON/OFF
-
-
FUNCTION
PFOC1 - Pwr. Fail Output Control #1
PFOC2 - Pwr. Fail Output Control #2
PFOC3 - Pwr. Fail Output Control #3
Not Used
12 MHz System Clock
ACCOL load base (RAM is standard)
-
ON
OFF
-
ON
OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
-
-
-
-
Port B Baud Rate (Synchronous):
187 KBd
1 MBd **
CLOC - Comm. Loss Output Control:
AOs & DOs held at last value
AOs held at 0% and DOs at OFF
RIO Address:
1 (LSB) Note: Maximum number
2 of avaliable addres-
4 ses is 10.
8 (MSB): Note: Even though not
used, switches 5 to
8 must be set ON.
DIP SWITCH CONVENTIONS FOR TABLE 3L-B
SET
TO
AR *
AR *
AR *
-
OFF
ON
AR
AR
AR
AR
AR
AR
ON
ON
ON
ON
Switch Open = OFF = 1
Switch Close = ON = 0
AR = As Required. Refer to text for details.
* See "Comm. Loss Output Control" text for selection.
** It is recommended that SW1-7 be set in the OFF (1 MBd) position.
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-7
C. If SW1-1 is ON, SW1-2 is OFF, and SW1-3 is OFF, the last output values will be
Reestablished upon a powerup providing that the power was off for a period less than five minutes. If the power was off for a period greater than five minutes, the outputs will be Reset to their default values. The elapsed time of the power failure is determined by the on-board real-time clock chip.
o Clock Speed & ACCOL Load Base
Switch SW1-4 of the package is not used and may be left ON or OFF.
Switch SW1-5 sets the clock speed. Since the clock speed is fixed at 12 mHz for these boards, it must always be OFF. If it is turned ON, a failure indication will result during the diagnostic startup test cycle.
Switch SW1-6 selects RAM base operation. The RIO firmware requires RAM to execute.
This switch must always be ON. Setting it to OFF will disable the RAM and cause the diagnostic LEDs to display a fault pattern. See Section 5 Service.
o Port B Baud Rate
Port B provides synchronous communications with the connected host. When switch SW1-7 is set OFF, this port communicates at 1 MBd; when it is ON, the rate is 187 kBd. It is recommended that SW1-7 be set in the OFF (1 MBd) position.
o Communications Loss Output Control
If communications between the host device and the RIO Unit fail, switch SW1-8 determines what the values of the outputs (AOs and DOs) will be. If this switch is set ON, the outputs will be frozen at their last value prior to the failure and PDOs will run to completion. If this switch is set OFF, the outputs will be reset to their default values (AOs = 0%; DOs = OFF).
When communications are restored, the host will restore the outputs to their controlled values.
RIO Address, Switch SW2
This eight-switch package sets the address of the RIO Unit. A maximum of ten RIO address can be assigned. Each switch, when in the OFF position, has the following bit values:
Switch
SW2-1
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
SW2-8
"OFF"
Bit Value
1 (LSB)
2
4
8 (MSB)
*
*
*
*
Switches SW2-5 TO -8 are not used for RIO Units. Only addresses of 1 to 10 are available for RIOs.
Note that SW2-5 to -8 must be set ON even though they are not used.
3L-8 / Remote I/O 3331 Unit CI-3335 (07/97)
TABLE 3L-C JUMPER SETTINGS
JUMPER
NUMBER
AVAILABLE
SELECTIONS
W1 1-2
FUNCTION
PROCESSOR BOARD
80C186 processor - set at factory
W1
W2
W3 - W9
W10
1-2
2-3
OUT
1-2
2-3
MEMORY BOARD
RAM Battery Circuit is ON
RAM Battery Circuit is OFF
Set at factory
Memory Selection - set at factory
12 clock - set at factory
Jumpers
Table 3L-C identifies the functions of jumpers on the Processor and Memory Boards. All jumpers are set at the factory and only W1 on the Memory Board is used in the field. This jumper is placed in the 2-3 position (off) for shipment or storage. It must be set to the 1-2 position (on) when before placing the board in service.
GENERAL STARTUP NOTES
When starting a Host/RIO system for the first time, the power switches of the host and all RIO
Units must be turned on. These switches are located on the System Monitor Board of each 3335 and 3331, and on the SI Board of each 3330. Also, the associated supply sources for any externally-powered I/Os are also turned on at this time.
At the initial powerup, all remote outputs will be set to default values (AOs = 0% and DOs =
OFF). Once the host (DPC or Redundancy System) has completed its self-test diagnostics, it will be ready to accept the download.
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-9
The personal computer that will be used for this application connects to a "cold download" port of the host. The configuration of this port is described in Section 3B under the topic, "Cold
Download Baud Rate."
The RIO utility requires an application load using ACCOL 5.3 or better. Previous version do not include the RIO.
Refer to Section 4 for preliminary checks and operating procedures.
Figure 3L-5 Memory/Peripheral Board Assembly
3L-10 / Remote I/O 3331 Unit CI-3335 (07/97)
Figure 3L-6 Processor Board Assembly
PART NUMBER ASSIGNMENT
CPU Module and associated printed circuit board (PCB) part numbers are provided in Table 3L-
D (see Figures 3L-5& 3L-6).
CI-3335 (07/97) Remote I/O 3331 Unit / 3L-11
TABLE 3L-D CPU MODULE & BOARDS PART NUMBER IDENTIFICATION
CPU MODULE
PART NUMBER
395217-01-6
CPU PCB
PART NUMBER
395212-01-4
MEM./PERIPH. PCB
PART NUMBER
395218-01-2
CONFIG.
NOTES
12MHz 64K RAM
3L-12 / Remote I/O 3331 Unit CI-3335 (07/97)
Section 3M
REMOTE TERMINATION MODULES
DESCRIPTION
The Remote Termination (RT) Modules are external termination devices for corresponding types of AI, AO, DI and DO host modules that reside in DPC 3335 and RIO 3331 units.
These modules mount on a DIN rail and connect to the host module via a cable as shown in
Figure 3M-1. A separate cable is required for each termination extension.
Feedthrough-type RT modules provide basic I/O connections from the host module to the terminal blocks. Other types will include load resistors, relay contacts, power terminals, and fuses. A complete list of RT module types and their required host module are listed in
Table 3M-A.
Host Module Requirements
The host modules residing in the DPC/RIO units must be the Mass Termination (MT) type.
These modules are similar to the I/O modules found in 3330/3335 controllers except that they provide a thirty-pin connector in place of a terminal block. The thirty-pin connector mates via cable with the RT Module. I/O modules with on-board terminal blocks cannot be used as a host MT Module.
Warning
RT Modules are not approved for operation in hazardous areas.
Do not use these modules with equipment intended for operation in such areas.
MECHANICAL INSTALLATION
This procedure covers the installation of the DIN rail and the RT modules. Proceed as follows:
1. Make sure that all ac and dc power sources are turned off prior to installation to prevent electrical shock or equipment damage.
2. Install the DIN rail within six feet of the host device (DPC or RIO).
3. Mount each RT Module onto the DIN rail. To do this, fit the widest guide of the module into the rail first. Then momentarily squeeze the end of the longer guide to relieve strain and snap the module on to the rail.
4. Remove the front cover of the DPC or RIO unit (if so equipped) to access the host modules. Connect each RT module to its corresponding host using the cable with the
30-pin "D" connectors at each end. Note that the cover of the DPC or RIO unit cannot be re-installed for this mode of operation. Store the cover separately.
CI-3335 RT Modules / 3M-1
5. Perform the field wiring connections for the module as described under the appropriate topics that follow.
TABLE 3M-A LISTING OF REMOTE TERMINATION MODULES
Type
Standard AI
Standard AI
Powered AI
Powered AI
AO
AO
Standard DIO
Standard DIO
Standard DIO
Standard DIO
Standard DIO
Fused DIO
Fused DIO
Fused DIO
Fused DIO
Fused DIO
Powered DIO
Powered DIO
Powered DIO
Powered DIO
Powered DIO
Standard DIO
Fused DIO
Powered DIO
DO Relay SPDT
DO Relay DPDT
DO SPDT **
DO DPDT **
Part Number
390994-01-4
390994-01-4
390994-02-2
390994-02-2
390995-01-0
390995-01-0
390997-03-0
390997-03-0
390997-03-0
390997-03-0
390997-03-0
390997-01-3
390997-01-3
390997-01-3
390997-01-3
390997-01-3
390997-02-1
390997-02-1
390997-02-1
390997-02-1
390997-02-1
390997-03-0
390997-01-3
390997-02-1
390998-01-0
390998-02-8
390998-02-8
390998-04-4
I/Os
4 AIs
4 AIs
4 AIs
4 AIs
2 AOs
2 AOs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DIs
8 DOs
8 DOs
8 DOs
8 DOs
8 DOs
8 DOs
8 DOs
Range
0-10 Vdc
1-5 Vdc / 4-20 mA
0-1 mA
4-20 mA
0-10 Vdc
1-5 Vdc / 4-20 mA
5 V ac/dc, 1 ms
12 V ac/dc, 1 ms
24 V ac/dc, 1 ms
12 V ac/dc, 30 ms
24 V ac/dc, 30 ms
5 V ac/dc, 1 ms
12 V ac/dc, 1 ms
24 V ac/dc, 1 ms
12 V ac/dc, 30 ms
24 V ac/dc, 30 ms
5 V ac/dc, 1 ms
12 V ac/dc, 1 ms
24 V ac/dc, 1 ms
12 V ac/dc, 30 ms
24 V ac/dc, 30 ms
24 V ac/dc, 30 ms
Open Collectors
Open Collectors
Relay Contacts
Relay Contacts
Relay Contacts
Relay Contacts
Used With
MT MODULE
392029-12-0
392086-12-3
392029-12-0
392086-12-3
392027-12-7
392025-12-4
392087-17-0
392087-18-9
392087-12-0
392087-11-1
392087-13-8
392087-17-0
392087-18-9
392087-12-0
392087-11-1
392087-13-8
392087-17-0
392087-18-9
392087-12-0
392087-11-1
392087-13-8
392076-12-8
392076-12-8
392076-12-8
392076-12-8
392076-12-8
392076-12-8
392076-12-8
3M-2 / RT Modules CI-3335
Figure 3M-1 Host Module to RT Module Connection
STANDARD ANALOG INPUT RT MODULE
The standard AI-RT Module shown in Figure 3M-2 provides termination for four analog input signals (AI1 to AI4). Each signal is assigned three terminals and a protective fuse which correspond to the labels in Table 3M-B.
Table 3M-B Standard AI-RT Module Terminal & Fuse Assignments
Signal
Name
AI1
AI2
AI3
AI4
AI +
Term.
A1
A2
A3
A4
AI -
Term.
B1
B2
B3
B4
AI Shield
Term.
CS
CS
CS
CS
AI
Fuse
F1
F2
F3
F4
These modules can be used with 0-10 V, 1-5 V, or 4-20 mA AI MT Modules (host modules).
Figure 3M-3 shows the field wiring connections for three input configurations. Panel A shows a 4-20 mA loop that obtains 24 V power via the AI-MT Module, panel B shows a 4-20
CI-3335 RT Modules / 3M-3
mA loop powered by a separate supply, and panel C shows a 0-10 V or 1-5 V signal. Each type of AI-RT Module input will require a jumper configuration for the corresponding input at the AI-MT Module (the exception is the 0-10 V module which omits jumpers). The table at the shown in Figure 3M-3 identifies the jumper setting. More information on these jumpers can be found in Section 3D - AI Module.
Figure 3M-2 Standard AI-RT Module -390994-01-4
Figure 3M-3 Voltage & Current Inputs for Std. AI-RT Module
3M-4 / RT Modules CI-3335
POWERED ANALOG INPUT RT MODULE
The Powered AI-RT Module is shown in Figure 3M-4. This module provides termination for four analog inputs using the same labels noted for the standard type.
Figure 3M-4 Powered AI-RT Module -390994-02-2
CI-3335
Figure 3M-5 Current Inputs for Powered AI-RT Module
RT Modules / 3M-5
The Powered AI-RT Module is intended for current loops that utilize a separate dc supply as shown in Figure 3M-5. Plug-in loop resistors are provided for each AI; the resistor values for this input are given in the loop configuration table shown at the upper part of this illustration.
If the host AI-MT Module is the 4-20 mA/1-5 V type, it will require a jumper configuration to obtain the 4-20 mA input as noted in the table at the upper corner of Figure 3M-5. If the host is the 0-1 mA type, no configuration is required since it does not include jumpers.
ANALOG OUTPUT RT MODULE
The AO-RT Module in Figure 3M-6 provides termination for two analog output signals.
Each signal is assigned three terminals and a protective fuse which correspond to the labeles in Tables 3M-C.
Table 3M-C AO-RT Module Terminal & Fuse Assignments
Signal
Name
AO1
AO2
AO+
Term.
A1
A2
AO -
Term.
B1
B2
AO Shield
Term.
CS
CS
AO
Fuse
F1
F2
AO-RT modules are used with 0-10 V, 1-5 V and 4-20 mA type AO-MT Modules (host modules). The wiring diagram of Figure 3M-3 uses an AO-MT Module with a 1-5 V / 4-20 mA or 0-10 V range. Switch configuration is only required for the former; the latter 0-10 V type omits switches. More information on switch configuration can be found in Section
3E - AO Module.
3M-6 / RT Modules
Figure 3M-6 AO-RT Module - 390995-01-0
CI-3335
Figure 3M-7 Voltage Output for AO-RT Module (1-5 V/0-10 V Type)
Figure 3M-8 Current Output for AO-RT Module (4-20 mA Type)
The analog load device in Figure 3M-7 is wired to the output terminals of the AO-RT
Module using shielded, two-wire conductors. The maximum load current for 1-5 V or 0-10
V outputs is 5 mA. When an AO-MT Module is specified with a 4-20 mA output, the connections are made as shown in Figure 3M-8. This configuration is obtained with the host switches set as shown.
CI-3335 RT Modules / 3M-7
The AO-MT host of Figure 3M-8 presents an open collector output to the AO-RT Module and its load. Any resistive load up to 660 ohms can be used for this application.
EXTERNALLY-POWERED DISCRETE INPUT
Standard & Fused, DIO-RT Modules
DIO-RT Modules are used with DI and DO-MT host modules. Figure 3M-9 illustrates the
"fused" version; the standard version is similar except that it omits fuses. When this module is used with DI-MT host modules, it provides termination for eight discrete inputs.
Each DI is assigned two terminals and a protective fuse which corresponds to the labels in
Table 3M-D.
Table 3M-D Standard & Fused DIO-RT Module (Used with DI & DO-MT host)
Terminal & Fuse Assignments
Signal
Name
DIO 1
DIO2 etc.
DI Term.
+/-
A1
A2
..
DI Term.
+/-
B1
B2
..
DI *
Fuses
F1
F2
..
DIO8 A8 B8 F8
* Fuses not included with all type DIO-RT Modules
Figure 3M-9 Fused Type DIO-RT Module, Pt.No. 390997-01-3
(Standard Type, Pt.No. 390997-03-0, omits F1 to F8)
3M-8 / RT Modules CI-3335
Figure 3M-10 shows the connections for a DIO-RT Module (applicable to either standard or fused types) that uses an externally-powered signal source. The signal source may be a relay contact and open collector as shown at the left of the illustration. The relay contact may be used with either ac or dc power circuits, while the open collector always requires dc power. There are no polarity restrictions since all DIs contain bi-polar, opto-isolated circuitry.
Figure 3M-10 Externally-Powered DI
(Fused-Type DIO-RT Module Shown)
CI-3335
Figure 3M-11 Powered DIO-RT Module - 390997-02-1
RT Modules / 3M-9
The DI-MT Module requires a jumper configuration for each DI. The jumper position is shown at the upper right of Figure 3M-9. More information on jumper configuration, contact rating and open collector circuits is contained in Section 3F - DI Module.
Powered DIO-RT Module
The Powered DIO-RT Module (Figure 3M-11) is similar to the standard and fused types except that it includes an additional terminal block for connections to a local supply. These terminals may be wired to an ac or dc supply as shown in Figure 3M-12. Wiring connections for the dry contact and open collector type inputs are shown at the left. The
DI-MT Module must also have its input jumper set for the application as shown at the upper right.
Figure 3M-12 Locally-Powered DI (Powered DIO-RT Module Shown)
OPEN COLLECTOR DISCRETE OUTPUT
Standard & Fused Type DIO-RT Module
DIO-RT Modules are used with DI and DO-MT host modules. Figure 3M-9 illustrates the
"fused" version; the standard version is similar except that it omits fuses. When this module is used with DO-MT host modules, it provides termination for eight DOs. Each output signal is assigned two terminals and a protective fuse which correspond to the labels in Table 3M-E.
DIO-RT Modules are used with DO-MT host modules having open collector outputs. The open collectors can be used to drive a relay coil, alarm, motor, or a control circuit that operates from a dc power source (35 V dc max.). The maximum load current is 100 mA.
3M-10 / RT Modules CI-3335
Table 3M-E Standard & Fused DIO-RT Module (Used with DO-MT host)
Terminal & Fuse Assignments
Signal
Name
DO Term.
+/-
DO Term.
+/-
DO *
Fuses
DIO 1
DIO2 etc.
A1
A2
..
B1
B2
..
F1
F2
..
DIO8 A8 B8 F8
* Fuses not included with all type DIO-RT Modules
The DO-MT Module used for this application omits jumpers and does not require configuration. More information on this module is contained in Section 3G - DO Module.
The DIO-RT Module (standard or fused) requires an externally powered load as shown in
Figure 3M-13. The load device and dc supply in this application are connected in series with the open collector output. If the load device is an inductive load (motor, transformer, relay, etc.), a diode must be connected across the load as shown to protect the output from reverse EMFs. The DO-MT Module shown in this illustration omits jumpers and does not require configuration.
Figure 3M-13 Externally-Powered DO (Fused-Type DIO-RT Module Shown)
Figure 3M-14 Locally-Powered DO (Powered DIO-RT Module Shown)
CI-3335 RT Modules / 3M-11
Powered DIO-RT Module
The Pwrd. DIO-RT Module shown in Figure 3M-11 also provides termination for eight DOs.
The wiring diagram for this module is shown in Figure 3M-14. The local supply wired to external power terminals provides power for open collector and load circuit. The DO-MT
Module in this illustrations does not require configuration.
RELAY CONTACT DISCRETE OUTPUT
SPDT Relay DO-RT Module
The SPDT Relay DO-RT Module shown in Figure 3M-15 provides eight relay DOs with
Single Pole Double Throw (SPDT) contacts. Each output signal is assigned three terminals and a protective fuse which correspond to the labels in Table 3M-F.
Table 3M-F SPDT DO-RT Module Terminal & Fuse Assignments
Signal
Name
DO Term.
N.O.
DO Term.
N.C.
DO Term.
Com.
DO1
DO2 etc.
A1
A2
..
B1
B2
..
C1
C2
..
C8 DO8 A8 B8
N.O. = Normally Open Contact
N.C. = Normally Closed Contact
* Fuses not included with all types of modules
DO *
Fuses
F1
F2
..
F8
Relay-type DO-RT Modules are used with DO-MT host modules having open collector outputs as shown in Figure 3M-16. Each open collector circuit drives a relay coil and its
SPDT relay contacts. The contacts, in turn, actuate alarms, motors, control circuits, etc...
A 24 Vdc supply wired to the Ext. Supply terminals provides power for the board relays.
When the output transistor of the host module is turned off, the relay will deenergize and the contacts will be in the position shown in Figure 3M-16 (terminals B1-C1 closed, A1-C1 open). When the output transistor is turned on, the current will energize the relay coil and the contacts will be switched (terminals A1-C1 closed, B1-C1 open). The load may be wired to either or both contacts as required.
Each relay output circuit contains diodes to protect the contacts from arcing and transients.
The diodes will provide protection for the following resistive and inductive load values:
Resistive Load: 24 Vdc @ 10 A or 120 Vac @ 10 A
Inductive Load: 24 Vdc @ 5 A or 120 Vac @ 7.5 A (L/R = 7 ms)
3M-12 / RT Modules CI-3335
Figure 3M-15 SPDT Relay Contact DO-RT Module - 390998-01-0
CI-3335
Figure 3M-16 Relay Contact w/ SPDT Contacts
RT Modules / 3M-13
DPDT Relay DO-RT Module
The Relay Module assembly shown in Figure 3M-18 provides sixteen relay DOs with
Double Pole Double Throw (DPDT) contacts. Each relay DO is assigned six terminals and a protective fuse which correspond to the labels in Table 3M-G.
Table 3M-G DPDT DO-RT Module Terminal & Fuse Assignments
Signal
Name
DO 1
DO Term.
N.O.
A1
D1
DO Term.
N.C.
B1
E1
DO Term.
Com.
C1
F1
DO *
Fuses
F1
DO2 A2
D2
..
B2
E2
..
C2
F2
..
F2 etc.
DO8 A8
D8
B8
E8
C8
F8
N.O. = Normally Open Contact
N.C. = Normally Closed Contact
* Fuses not included with all types of modules
..
F8
The DPDT, Relay-Type, DO-RT Modules operate in the same manner as previously described for the SPDT types. The wiring diagram of Figure 3M-17 identifies the connection points for the DPDT terminals. These contacts have the same load rating listed for the SPDT type.
3M-14 / RT Modules
Figure 3M-17 Relay Contact w/ DPDT Contacts
CI-3335
CI-3335
Figure 3M-18 DPDT Relay Contact DO-RT Module - 390998-02-8
RT Modules / 3M-15
BLANK PAGE
Section 3N
ISOLATED
REMOTE TERMINATION MODULES
DESCRIPTION
The Isolated Remote Termination (IRT) Modules provide external termination for corresponding types of Mass Termination (MT) Modules that reside as hosts in DPC 3335 and RIO 3331 units.
MT Modules are similar to the I/O Modules described in Section 1 except that they provide a 30pin cable connector in place of terminal blocks. MT Modules include AI, RTD, TC, AO, and DI types.
IRT modules mount on a DIN rail and connect to the host MT module via a cable as shown in
Figure 3N-1. A separate cable is required for each termination extension.
IRT Modules contain plug-in isolation units for each I/O channel. These units protect the input or output from power transients and also provide isolation from common mode voltage. In the case of AI, RTD and TC type modules, each unit is selected for the purchaser's range and application. AI-IRT Modules specified with 4-20 mA inputs will also require plug-in loop resistors for each current input.
CI-3335
Figure 3N-1 Host Module to IRT Module Connection
IRT Modules / 3N-1
TABLE 3N-A LISTING OF ISOLATED REMOTE TERMINATION MODULES
Type Part Number I/Os Range
4-20mA, 1-5 Vdc or RTD **
TC ***
Used With
MT MODULE
TYPE *
392086-12-3 Analog/RTD
Input
Thermocouple
(TC) Input
391250-01-9
391256-01-5
4 AIs
4 TC
Inputs
396086-12-3
Analog Output
Discrete Input
Discrete Input
Discrete Input
391251-01-5
391253-01-8
391253-02-6
391253-03-4
2 AOs
8 DIs
8 DIs
8 DIs
4-20 mA
24 Vdc Max.
48 Vdc Max.
120 Vac Max.
392080-12-5
392087-13-8
392087-13-8
392087-13-8
*
Discrete Input 391255-01-0 8 DIs 240 Vac Max.
392087-13-8
Requires Mass Termination Connector Cable, Pt. No. 391274-00-7
** Resistance Temperature Detector (RTD) ranges set in ACCOL.
*** Thermocouple (TC) ranges set in ACCOL.
Power and Indication
The IRT Modules contain on-board circuitry that operates from a 24 V source. This voltage is obtained from the DPC/RIO via the MT Module cable connector. Each IRT Module contains a power fuse in the 24 V dc line and a LED to indicate the power status. Fuses are also included in each signal line to protect the I/Os. DI versions include a status indicating LED for each input.
Load Requirements
DPC/RIO units that use IRT modules are subject to increased power loads. These units require a heavy-duty System Monitor Module (pt. no. 391041-01-0) to meet the increased load requirements. Note that IRT modules cannot be added to previous DPC/RIO versions without changing over to the heavy-duty System Monitor Module.
Warning
IRT Modules are not approved for operation in hazardous areas. Do not use these Modules with equipment intended for operation in such areas.
MECHANICAL INSTALLATION
This procedure covers the installation of the DIN rail and the IRT modules. Proceed as follows:
1. Make sure that all ac and dc power sources are turned off prior to installation to prevent electrical shock or equipment damage.
IRT Modules / 3N-2 CI-3335
2. Install the DIN rail within six feet of the host device (DPC or RIO).
3. When installing analog IRT Modules, note if the isolation unit subassemblies and plugin, current-input resistors (as required) are in place. These items, if obtained separately by the purchaser, must be plugged into their proper sockets.
4. Install each IRT Module on the DIN rail. To do this, fit the widest guide of the module into the rail first. Then momentarily squeeze the end of the longer guide to relieve strain and snap the module on to the rail.
5. Remove the front cover of the DPC or RIO unit (if so equipped) to access the host MT
Modules. Connect each IRT module to its corresponding host using the ribbon cable with 30-pin connectors at each end. Note that the cover of the DPC or RIO unit cannot be replaced once the cable connections are made. Store the cover near the DPC/RIO.
6. Perform the field wiring connections for the IRT Modules as described under the topics that follow.
ANALOG INPUT & RTD-TYPE IRT MODULES
The AI-IRT Module of Figure 3N-1 provides four analog inputs (AI1-AI4) that may be specified for a variety of voltage or RTD ranges. The type and range of each input is determined by plugin, analog-type, isolation units (U1-U4). These units, which perform signal isolation, conditioning and ranging, provide a 1-5 V output to the AI-MT Module.
CI-3335
Figure 3N-2 AI-IRT Module - No. 391250-01-9
IRT Modules / 3N-3
Modules intended for current inputs will require current loop resistors. These resistors (R1 to
R4) plug into the locations shown in Figure 3N-1.
AI-IRT modules contain a power fuse (F10) and four signal fuses (F1-F4). The fuses are twopin, plug-in micro types rated as shown in the illustration. A power LED (DS10) lights to indicate the presence of 24 V power.
Figure 3N-3 Voltage Signal AI
Figure 3N-4 Externally-Powered Current Signal AI
IRT Modules / 3N-4 CI-3335
Figure 3M-3 shows the wiring for a 1-5 V input, while Figure 3M-4 shows the wiring for a 4-20 mA current loop. The wiring arrangements for three-wire and two-wire RTD sensors are both contained in Figure 3M-5.
All inputs of the AI-MT Modules must be configured for 1-5 V. This is accomplished by setting the jumper block of each AI to the "B" configuration as shown above the AI-MT Module in
Figures 3N-3 to 3N-5.
Figure 3N-5 RTD Input
CI-3335
Figure 3N-6 TC-IRT Module - No. 391256-01-7
IRT Modules / 3N-5
THERMOCOUPLE (TC) TYPE IRT MODULE
The TC-IRT Module of Figure 3N-6 provides four isolated thermocouple inputs (TC1-TC4) in a number of temperature ranges. The isolation, conditioning and ranging of each input is performed by TC-type, isolation units (U1-U4). These units convert each TC measurement into
1-5 V output and applies them to the AI-MT Module.
Each input includes input temperature sensors (TS1-TS4). These sensors provide individual temperature compensation at each input junction.
The TC-IRT Module contains a two-pin, plug-in micro fuse (F10) for dc power which is rated as shown in the illustration. A power LED (DS10) lights to indicate the presence of 24 V power. It also includes terminals (TB9) that connect to an external grid ground.
Each input of the AI-MT Module must be configured for 1-5 V. The jumper block of each AI must be set to the "B" configuration as shown in Figure 3N-7.
Figure 3N-7 Thermocouple Input
ANALOG OUTPUT IRT MODULES
The AO-IRT Module of Figure 3N-8 provides two, 4-20 mA analog outputs (AO1 & AO2). These modules contain plug-in, AO-type, isolation units (U1 & U2) that perform output isolation, conditioning and ranging.
AO-IRT Modules are used with host AO-MT Modules that provide 4-20 mA outputs. This arrangement necessitates that the configuration switches present on the AO-MT Module be set as shown at the left of Figure 3N-9. A 250 ohm resistor at the input of the isolation unit functions as the current output load for the AO-MT Module.
IRT Modules / 3N-6 CI-3335
The AO-IRT Module presents a 4-20 mA current output to the external analog device. The maximum permissible resistance of the device is 600 ohms.
Figure 3N-8 AO-IRT Module - No. 391251-01-5
CI-3335
Figure 3N-9 Current Output
IRT Modules / 3N-7
These modules contain a power fuse (F10) and two signal fuses (F1 & F2). The fuses are twopin, plug-in micro types rated as shown in the illustration. A power LED indicates the presence of 24 V power when it is lit.
DISCRETE INPUT IRT MODULES
The DI-IRT Module of Figure 3N-10 provides eight discrete inputs (DI1-DI8). Eight, plug-in,
DI-type, isolation units (U1-U8) perform input conditioning and isolation. These units may be purchased as 24 V, 48 V or 120 V types.
DI-IRT Modules contain a power fuse (F10) and eight signal fuses (F1-F8). The fuses are twopin, plug-in micro types rated as shown in the illustration. A power LED provides an indication of 24 V power, while eight status LEDs indicate the status of the associated DIs (the LEDs light when the input status is high).
Figure 3N-10 Discrete Input IRT Module (24, 48 & 120 V Types)
Nos. 391253-01-8, -02-6 & -03-4
Externally-Powered DI
Figure 3N-11 shows the connections for an externally-powered DI whereby the power source is wired to the input terminals. This input may be a relay contact powered by an ac or dc supply, or an open collector powered by a dc supply. The jumpers on the DI-IRT Module must be set to the "B" position as shown above to configure the module for this application.
DI-IRT Modules require host DI-MT Modules with 24 V inputs. The host jumper for each DI must also be set to its "B" position as shown in Figure 3N-11.
IRT Modules / 3N-8 CI-3335
Figure 3N-11 Input-Powered DI
Figure 3N-12 Locally-Powered DI
Locally-Powered DI
A DI may also be powered by a locally-connected supply as shown in Figure 3N-12. For this application the IRT jumpers are set to the "A" position while the MT jumper remain in the "B" position. This configuration allows a dry contact or open collector input to receive power from a supply wired to the external power terminals.
CI-3335 IRT Modules / 3N-9
Figure 3N-13 240 V Input-Powered DI
240 Vac DI
A DI-IRT Module specified with 240 V ac inputs always uses an externally-powered signal source as shown in Figure 3N-13. This type module does not include jumpers since it is only used with 240 V inputs. However, the DI-MT must have its jumpers set to the "B" configuration shown at the right.
Figure 3N-13 Discrete Input IRT Module (240 V Type)
No. 391255-01-0
IRT Modules / 3N-10 CI-3335
Section 3P
CHECK BEFORE OPERATE SYSTEM
Note: The Check Before Operate System discussed herein is no longer available.
DESCRIPTION
The Check Before Operating (CBO) System has the ability to set and read (before writing) the output status of eight discrete outputs (DOs). The system consists of a CBO Module which plugs into an I/O slot of a DPC/RTU 33XX, and a CBO Termination Board that mounts in an external DIN rail. A cable connects the two assemblies. The description, part number, and illustration reference for the CBO assemblies are listed in Table 3P-A.
Three types of CBO Termination Boards are offered. The first type is furnished with eight relay contact outputs having fuse circuits for each relay. The second type omits fuses but provides eight relay contact outputs with surge protection for each relay. The third type provides eight open collector outputs that are wired to external, user-furnished relay circuits.
During operation, the present status of each relay contact is always reported back to the
CBO Module and, hence, to the supervisory device (DPC or RTU). This is accomplished on
Termination Boards with internal relays by using relays with DPDT contacts. One set controls the external load/power circuit, while the other reports the DO status via an internal feedback circuit. Even though a DO calls for a status change, that change will not be implemented until the present status has been verified by the software. Once verified, the DO relay will energize or de-energize in response to the status change. This operation checks the DO feedback data before and after a status change to insure the relay contacts are in the proper state.
If any DO returns a "false" feedback signal, it will cause the CBO Termination Board to switch off 24 V power to all the DO relay coils. As a result, the DO relays will de-energize and remain in that state until the failed DO is corrected. Termination boards with internal relays also include jumpers for selecting either a normally-open (NO) or normally-closed
(NC) relay contact output.
TABLE 3P-A - CBO SYSTEM COMPONENTS
Description Part Number Reference
CBO Module (plugs into I/O slot)
CBO Relay Termination Board w/DO fuses
CBO Termination Board w/Surge Protection
CBO Open Collector Termination Board
Connector Cable (Module to Termination Board)
392514-01-0
392524-01-5
392513-01-3
392529-01-7
391399-01-2
Fig. 3P-1
Fig. 3P-2
Fig. 3P-3
Fig. 3P-4
--
The CBO Modules and Termination Boards provide status LEDs for each DO. If these
LEDs are not required, they can be disabled to save power. Both the module and board provide a jumper for this purpose. An additional jumper on the CBO Module allows the current relay status to be retained or dumped during a CPU watchdog.
CI-3310/30/35 (11/05) CBO System / 3P-1
Figure 3P-1 - CBO Module
Figure 3P-2 - CBO Relay Termination Board with Fuses
3P-2 / CBO System CI-3310/30/35 (11/05)
Figure 3P-3 - CBO Relay Termination Board with Surge Protection
Figure 3P-4 - CBO Opto-Isolated Termination Board for External Relays
CI-3310/30/35 (11/05) CBO System / 3P-3
TABLE 3P-B - CBO MODULE JUMPERS
TABLE 3P-C - CBO RELAY BOARD JUMPERS
3P-4 / CBO System CI-3310/30/35 (11/05)
CONFIGURATION OF CBO MODULE
The CBO Module contains two jumpers, W1 and W2 as shown in Figure 3P-1. Jumper W1 is used to disable the DO LEDs to conserve power, and jumper W2 to set the DO status for
CPU watchdog failures. The jumper positions are given in Table 3P-B.
CONFIGURATION OF CBO RELAY BOARD
The CBO Relay Termination Boards of Figures 3P-2 and 3P-3 provides jumper W9 to disable the LED circuits to conserve power and jumpers W1 to W8 to select a normally closed (NC) or normally open (NO) relay contact. The jumper positions are given in Table
3P-C. Jumper W9 is the only one present on the Open Collector Termination Board of
Figure 3P-4 and it is set according to Table 3P-C.
BOARD WIRING
Cable Connection
The CBO Termination Board will be mounted in an external DIN rail and connected to the
CBO Module by cable. The cable connects from J1 on the Termination Board to J1 of the module. The cable part number is identified in Table 3P-A.
Connections for Relay-Type Termination Boards
The wiring terminals for relay-type termination boards appear in Figure 3P-5. Although relay contact outputs do not have any polarity restrictions, all DOs in the system should follow the same convention. The dc + and -, or ac load and neutral conventions shown in
Figure 3P-5 are recommended for field use.
Figure 3P-5 - Terminal Layout for Relay Type Boards
A load and power source may be wired to the DO terminals as shown in Figure 3P-6. The
DO relay contact load rating is 2 Ampere resistive, 0.6 Ampere inductive, and 0.4 Ampere motor (50 V max. for dc and 120 V max. @ 50/60 Hz for ac). The external load device may be
CI-3310/30/35 (11/05) CBO System / 3P-5
an electric valve, horn, lamp, bell, etc. In all cases, the external voltage source and load current must not exceed the above contact ratings.
Figure 3P-6 - Wiring of DOs (Relay-Type Boards)
Connections for Open Collector Termination Boards
Termination Boards with open collector outputs utilize a dual, sixteen-terminal block. Each
DO is assigned four terminals which are labeled as Open Collector (OC), feedback (FB), +24
V Switched (+24VS), and power common (PCOM). See Figure 3P-7.
These boards require external relays having DPDT or DPST contacts. One set of contacts actuates the load, while the other actuates the CBO feedback circuit. Figure 3P-8 shows the connections required for each circuit.
Power to operate the load is obtained from an external ac or dc supply. Power to operate the relay coil and the opto-isolated feedback input circuit is obtained from the internal +24V supply of the board. When making connections, be sure to observe the polarity of the relay coil. Reversed connections will prevent the relay from operating.
3P-6 / CBO System CI-3310/30/35 (11/05)
Wiring of +24 V Supply Terminals
The CBO Relay Termination Board requires connections to an external 24 Vdc power source as shown in Figure 3P-5 and 3P-7. Be sure that the supply voltage is within the correct limits to prevent erratic operation or relay coil burnout.
Figure 3P-7 - Terminal Layout for Open Collector Type Boards
Figure 3P-8 - Wiring of DOs (Open Collector Type Boards)
CI-3310/30/35 (11/05) CBO System / 3P-7
SERVICE
The CBO System will provide many hours of trouble-free operation. If any problems should occur, check the following: o Relay Load Operating in Reverse
Check position of relay jumper and wiring of load. o All Relays Not Operating
Check for presence of +24 Vdc at supply terminals of Relay Board. Also, the master control relay may be de-energized by a "false" feedback signal at one of the DOs.
Deter-mine which DO is at fault using regular troubleshooting techniques of via the
ACCOL DIAGNOSTIC program. See User Manual D4041 for details. o One or More DOs Stuck in Default Mode on Fuse-Type Relay Board
Look for a blown fuse on the Relay Board. See Figure 3P-2 for fuse location (F1 to F8).
Replace with a 5 Ampere, plug-in type fuse. If the fuse continues to blow, check the load circuit for shorts. o DO LEDs Fail to Light but Relays are Operating
Jumper W9 not installed in its header.
CBO SPECIFICATIONS
Number of Outputs:
Termination:
Eight CBO relay outputs
Two screw terminals per output; one #14 lead can be secured per terminal.
Relay Contact Rating:
For Resistive Loads:
For Inductive Loads:
For Motor Loads:
2.0 A, 50 Vdc or 120 Vac, 50/60 Hz
0.6 A, 50 Vdc or 120 Vac, 50/60 Hz
0.4 A, 50 Vdc or 120 Vac, 50/60 Hz
For Lamp Loads:
Open Collector Rating:
Surge Suppression:
0.2 A, 50 Vdc or 120 Vac, 50/60 Hz
For load voltages above 30 Vdc or 24 Vac, the load and neutral side of the power source should only be connected to the field wiring terminals. The relay case is connected to chassis ground.
35 Vdc (Max), 100 mA (Max)
Common mode at 130 V rms (Board No. 392513-
01-3 only)
3P-8 / CBO System CI-3310/30/35 (11/05)
DO Fusing:
Isolation:
Opto-Isolated Feedback DIs:
Power Requirements:
For CBO Module:
For CBO Relay Board:
5A Slo-blo 5 x 20 mm (Board No. 392524-01-5 only)
To 130 V rms
1500 Vac (Board No. 392529-01-7 only)
+24 Vdc @ 40 mA (from DPC)
+24 Vdc @ 200 mA (from external supply)
CI-3310/30/35 (11/05) CBO System / 3P-9
BLANK PAGE
Section 4
OPERATION
GENERAL
This section provides guidelines for starting and operating a DPC. Because of the many types of DPCs and the variety of peripheral equipment that may be included in any given installation, specific information cannot be provided to cover every situation. You must, therefore, be familiar with all the equipment involved in your system and alert to any variations in a startup procedure that could lead to trouble or danger.
PRELIMINARY CHECKS
Before applying power, the following items should be checked...
a) Be sure that all PC Boards and I/O Modules have been properly configured. Set all board jumpers and switches for the desired application. Refer to appropriate sections covering
PC boards and modules for details.
b) All DPCs should have the backup battery jumper on the CPU Module set so that the battery is in the circuit (see Section 3B CPU Module for details). If this is not done on models with RAM-based memory, all ACCOL load data will be lost during a power interruption or failure. When power returns, the DPC will perform a "cold start" boot and all of its outputs will be set to factory default levels.
Models with EPROM-based memory are unaffected by a power loss. When power returns, the DPC will perform a "cold start" boot after which all outputs will begin executing from the initial values programmed in the ACCOL load.
c) Make sure that all modules are plugged into their proper sockets and that the module ejectors are pushed in and secured.
d) Check that all I/O terminal block connectors are plugged into their proper sockets.
e) Check that the 24 Vdc supply voltage is present at the System Monitor Module wiring terminals. Refer to Section 3A for details.
f) Check for the proper size fuse in the System Monitor Module.
g) Inspect and clear the interior of the DPC of any stray tools, test clips, test prods, wire leads, etc. that could cause shorts or intermittent operating problems.
h) Check that any external process control equipment associated with the DPC is closed down or under some form of monitored control Your installation may include manual control or limiting devices that must also be checked for proper settings.
CI-3335 (07/97) Operation / 4-1
WARNING
Some processes are hazardous by nature and can become extremely dangerous during powerups, powerdowns, or power failures. If such processes are allowed to run out of control, property damage and injury to persons may result. The use of automatic backup equipment and alarm warning devices are recommended to ensure safety.
STARTING THE DPC
This startup procedure is general for most applications. Installations that utilize optional or specialized equipment may require additional steps not listed here. When such equipment is encountered, you should refer to the appropriate manufacturer's manuals before applying power to the system.
When starting a DPC for the first time, it is assumed to be set up as described under the topic,
PRELIMINARY CHECKS. This will allow you to follow the startup sequence given below.
1. Turn on the external 24 V supply source to power the DPC. Using a DMM (Digital
Multimeter), check the external supply for the correct output voltage. If the supply is adjustable, set the DC output to its proper output level.
2. Locate the DPC's power switch at the left of the System Monitor Module (see Section 3A for illustration). When this switch is OFF, neither the PF (Power Fail) or MC (Master
Clear) LED on the module will be lit. Turn the switch ON.
3. When power is applied, the PF LED on the System Monitor Module should light to indicate the presence of the +24 V, +15 V, -15 V and +5 V dc supply outputs. If PF does not light, it may indicate a blown fuse. Check F1 on the System Monitor Module and replace as required. If the fuse continues to blow, recheck wiring at signal terminals for a possible short. Further details are covered in Section 5 Service.
4. When the DPC is operating, the MC LED should be continuously lit to indicate that the supply is performing properly.
5. If an ACCOL load has not been installed in the DPC, the DPC will execute a diagnostic startup test upon powerup. This procedure is called a "cold start" and is identical to the sequence executed when the reset button on the CPU Module is pressed.
WARNING
A DPC that has not been loaded (or one that has been reset) will set all analog outputs to 0% and all discrete outputs to OFF. For some critical processes, these values could represent dangerous output levels. These installations should include auto/manual control stations or limiting devices to maintain safe standby operation.
6. The complete diagnostic test cycle can be observed on the status LEDs of the CPU
Module. In general, LEDs 1-6, as well as the Watchdog LED, will be lit throughout the test sequence. A momentary flash at the beginning of the sequence indicates the start of the RAM diagnostic.
4-2 / Operation CI-3335 (07/97)
A failure detected during testing will turn on the IDLE LED. At the same time, the lighting pattern of STATUS LEDS 1-6 will indicate the type of failure. See table 5-A in
Section 5 Service for interpreting LED failure patterns.
If the battery voltage is low, there will be a momentary flashing LED sequence, after which the diagnostic cycle will resume.
In the next part of the tests, LEDs 1-6 will go off for 1 second, on for 1 second, then go off for 1 second. The failure status of the I/O Modules, if any, will be displayed. Details are contained in Section 5 Service.
7. Full completion of the diagnostic test cycle is indicated by a ripple pattern with each
STATUS LED turned on and off in sequence beginning with LED 6 and ending with LED
1.
At this point an EPROM-based DPC will execute its ACCOL load. The DPC's
WATCHDOG LED should go on and off and its IDLE LED should be blinking.
A RAM-based DPC will now wait to be downloaded. Its WATCHDOG LED will remain on until the download is completed. See Section 5 for Communication Module failures that can be indicated by STATUS LEDs 1-6 on a RAM-based unit waiting for a download.
8. In order to download a RAM-based DPC, there must be a communications path from the external device (personal computer or central computer) to one of the RS-485/423 ports of the target DPC. Also, the external device must support "downloads" and have access to the desired ACCOL load file. A download can be initiated using the AIC, TOOLKIT, or DIAGNOSTIC software programs.
Any port on the DPC may be used for downloads. Ports A and C will default to 9600 baud for a "cold start" download. The download baud rate for ports B and D is selectable via switch settings on the CPU Engine Board (see Section 3B for switch configurations).
Both the DPC and the external device must be set to the same baud rate to achieve proper loading.
A download can be performed either locally or globally. A typical local download would be initiated from a PC or central computer directly connected to the target DPC. A typical global download would be initiated from a local area network PC or a wide area network DEC VAX computer system to a DPC network node. The required network files must be present at the originating device in order to perform a global download. For details, refer to to the ACCOL II Interactive Compiler manual.
9. When the download is complete, the DPC will begin executing the ACCOL load. The
WATCHDOG LED should go OFF and the IDLE LED should be blinking.
Once a download is complete, all DPC communication ports will take on the usage and characteristics specified by the programmer of the ACCOL load. For example, if "port
A" was used for the download but no functions were specified for "port A" in the ACCOL load, communications between the DPC and the external loading device will be lost the moment downloading is complete. Similarly, if the baud rate used for the download is different from the baud rate specified for that port in the ACCOL load, it will not be possible to communicate properly when the download concludes.
CI-3335 (07/97) Operation / 4-3
NOTE
A RAM-based DPC that has not had an ACCOL load installed will assume firmware defaults at each port. These defaults allow communications with an external device such as a personal computer. Once the DPC has been loaded, the connected port (as well as all other active ports) will assume the characteristics specified in the ACCOL load. Should communications suddenly stop after a download, it will be necessary to transfer the connector of the external device to an appropriately assigned port.
Remember, the ACCOL load determines the port's operating function!
10. Once the DPC has received the appropriate ACCOL load file, it is ready to start controlling. Set all related process valves and operating devices to their operating positions. If user-supplied manual panels are included in the installation, switch they over from manual to automatic control mode.
11. The startup procedure is now complete. The DPC should be executing the ACCOL load.
The on-line activities of a DPC can be monitored in various ways depending on the
ACCOL load configuration. For example, a PC can be connected to a Slave or Pseudo-
Slave port and the AIC or TOOLKIT software can be used to communicate with the DPC.
12. Cold Starts: If the Reset Button on the CPU Module is pressed, the DPC will perform a "cold start." In this configuration it will execute the diagnostic startup sequence and, if it is a RAM-based unit, will wait for a new download.
CAUTION
Pressing the Reset Button of DPC with RAM-based memory while it is executing a load will cause the DPC to clear out its ACCOL load and go into a "cold start" cycle.
Be sure this is what you want to do before pressing the button.
Prior to initiating a desired "Reset," make sure that any critical process functions associated with the DPC have been turned off or placed under guarded manual control.
13. Warm Downloads: A DPC executing a RAM-based ACCOL load can also be reloaded without pressing the Reset Button. A "warm download" is initiated from a PC or central computer via a menu selection of the AIC program. Once this type of download has started, the target DPC will pause momentarily and then begin accepting the new load.
The diagnostic startup cycle, in this situation, is not executed.
NOTE
The baud rate for a "warm download" is determined by the baud rate defined in the load currently being executing in the DPC.
14. Warm Start: A running DPC, either EPROM or RAM-base, will resume execution of the active load after a power fail providing that RAM has been preserved via the battery backup. This is called a "warm start." The active environment is saved when the power fails, and is resumed when the power is restored. The diagnostic startup cycle is not executed.
4-4 / Operation CI-3335 (07/97)
SHUTDOWN PROCEDURE
The procedure for shutting down a DPC will vary with the user's application. The following steps provide a general check list.
1. If critical processes are involved, close down all related process control elements, valves, and switches as required. If the installation includes auto-manual control panels, switch them over to manual control and set the processes to a safe standby level. Then close each process down as required.
2. Turn the power switch on the System Monitor Module to OFF.
3. Turn off the external +24 Vdc power source if required.
4. Turn off all associated powered signal sources (transmitters, alarms, etc.).
WARNING
High voltages may still be present at the field wiring terminals even though the
DPC is turned off. This voltage can emanate from sources that are used to power external devices (Example: 120 V Discrete Input). Make sure that all external power sources are turned off or disconnected before working in these areas.
5. When a DPC is shut down, the contents of the RAM will be retained because of the RAM battery backup system. This battery provides RAM retention for a period of approximately 4000 hours (167 days). If the DPC is not powered up within that time frame, the battery will become completely discharged and the RAM data will be lost.
If it is planned to shut the equipment down for an extended period of time, the backup battery should be disconnected to prevent unnecessary current drain. Conversely, the battery must be reconnected when the equipment is restored to service. A battery disconnect is accomplished by setting a jumper on the CPU Module (refer to Section 3B for details).
Before disconnecting the battery, it is recommended that you make sure a backup copy of the ACCOL load is available (not necessary for EPROM-based DPC models). A RAMbased DPC that has been turned off and left dormant under these conditions will require a reload upon startup. An EPROM-based DPC will automatically restart its ACCOL load upon completion of the startup diagnostics.
6. The shutdown procedure is now complete.
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BLANK PAGE
S e c t i o n 5
S E R V I C E
SERVICE NOTES
DPCs may be serviced on site. However, if the unit is on line, we recommend that any processes controlled by the DPC be closed down or placed under manual control. This precaution will prevent any critical processes from accidentally being driven out of control during tests.
Warning
Harmful electrical potentials, such as 120 V DIs, may still be present at the field wiring terminals even though the DPC’s power source is turned off. Do not attempt to unplug termination connectors or perform any wiring operations until all the associated supply sources are turned off and/or disconnected.
Test Equipment
The service procedures contained in this section will require the following type of test equipment:
DMM (Digital Multimeter): 5-1/2 digit resolution
Oscilloscope: 10 mV to 10 V per division sensitivity; 100 to 200 MHz vertical frequency response; 1 mSec to 1 Sec/division time base.
I/O Card Extender:
S/M Card Extender:
This device extends I/O modules out of the card cage so that test points and adjustments can be accessed when the DPC is powered.
This is a special card extender that accommodates the
System Monitor Module.
DC POWER SYSTEM
The DC Power System consists of the System Monitor Module, Power Supply Module and
System Interconnect Board. For the tests that follow, only the System Monitor and Power
Supply Modules are utilized.
System Monitor Module
The DC outputs are accessed at test points TP1 through TP4 on the System Monitor Module.
Figure 5-1 identifies the location of these points. Proceed as follows:
1. Turn the power switch on the System Monitor Module to OFF.
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5-2 / Service
Figure 5-1 - System Monitor Module
(01/01) CI-3335
Figure 5-2 - Power Supply Module
2. Remove the screw holding the System Monitor Module in its compartment.
3. Remove the System Monitor Module and plug the S/M card extender in between. Once the module and extender are secure, turn the power switch ON.
4. Locate test points TP1 through TP6 on the module (see Figure 5-1). Using the DMM, perform the readings in Table 5-A.
Table 5-A Readings on System Monitor Module
+ DMM to
TP6
TP4
TP5
- DMM to
*
*
*
DC Reading
22 TO 28 V for 24 V Supply
+15.0 V, ± 0.6 V
-15.0 V, ± 0.6 V
TP2
TP3
*
*
+5.0 V, ± 0.25 V
-5.0 V, ± 0.6 V
* Ground connection is made to anode of diode CR1 (labeled
GND).
5. The readings across TP6 and ground should be 24 V nominal (22-28 V range). If this reading is below the specified range, DPC performance will be degraded or inoperative.
If the reading is above the specified range, overheating and blown fuses may result.
6. If the +5 V reading at TP2 is out of tolerance, remove the two screws that hold the Power
Supply Module in place and partially slide it out to access the voltage adjustment pot (see
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adjustment pot (see Figure 5-2). Using a screwdriver, turn the adjustment pot to obtain a correct reading. Re-install the module when complete.
Table 5-B Readings on Power Supply Module
+ DMM to
- DMM to
DC Reading
TP1 * +4.700 V, ±0.002 V
* Ground connection is made to anode of diode CR1 (labeled
GND).
7. If any of the supply output readings are out of specifications, repairs or replacement of the Power Supply Module will be required.
Calibration of Supply Reference Voltage (4.7 Vdc)
A 4.7 Vdc potential is used as a reference voltage for the DPC supply section. This voltage is checked as indicated in Table 5-B.
A reference voltage adjustment pot (R17) is used to compensate for minor calibration errors.
This adjustment, located on the System Monitor Module, is coated with sealer and is not likely to go out of calibration. It should not be tampered with unless absolutely necessary. Use the
S/M card extender to access this adjustment.
Troubleshooting Hints
Power Switch
The System Monitor Module contains a power switch (SW1 in Figure 5-1) that turns off the +24 V supply source as well the internal power distribution (+15, -15 and +5 V dc and
-5 Vdc). Although all internal power may be turned off, you should note that voltages from-externally powered devices such as transmitters, transducers, on-off control elements, alarms, etc. may still be present at the wiring terminals. When working in these areas, you should exercise caution and be certain that all external power has been turned off or disconnected to prevent accidental electrical shock or equipment damage.
Power Fuse
Fuse protection is provided on the System Monitor Module. If this fuse (F1 in Figure 5-1) should blow, the +15 and +5 V power sources will close down. When changing fuses, observe the same precautions as described for the Power Switch. The 4 ampere power fuse is a fast-acting 3AB type.
Power Fail & Master Clear LEDs (DS1 & DS2)
With the power switch of the System Monitor Module turned ON, the Power Fail (PF)
LED should be lit. If this LED is out, it may indicate that fuse F1 is blown. If the fuse is not blown, check the DC power input voltage as previously described. If this voltage is normal, the Power Supply Module or the System Interconnect Bd. may be at fault.
5-4 / Service (01/01) CI-3335
During normal operation, the MC LED (DS2) will be continuously lit. This indicates that all power supply voltages are present and functioning within specifications. If it is off, supply repairs may be required.
CI-3335 (01/01)
Figure 5-3 - 186-Based CPU Boards
Service / 5-5
CPU ENGINE BOARD CHECKS
The CPU Engine Boards are illustrated in Figures 5-3 through 5-6 and Figure 5-10. In these tests, the RAM battery and the failure sequence of the status LEDs are checked.
5-6 / Service
Figure 5-4 - 186-Based CPU Module - Memory & Peripheral Board
(01/01) CI-3335
Figure 5-5 - 32-Bit CPU Engine Ass'y. Figure 5-6 - 32-Bit CPU Engine Ass'y.
Memory & Peripheral Board CPU Board (without EMB Board)
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Figure 5-7 - 32-Bit CPU Engine Assembly (End View)
5-8 / Service
Figure 5- 8 - End View of Ethernet CPU Engine Assembly
(01/01) CI-3335
Figure 5-9 Figure 5-10
Ethernet Ethernet
Memory & Peripheral Board CPU Board (without EMB Board)
CI-3335 (01/01) Service / 5-9
RAM Backup Battery Test
The backup battery is mounted on the CPU Module as shown in Figures 5-4 & 5-7. It is recommended that this battery be checked at 3-6 month intervals to ascertain its condition.
A weak or dead battery will not provide the required RAM backup capability during a power failure or power-down. The checkout procedure is as follows:
1. Unplug jumper W1 (on the Memory & Peripheral Board).
2. Connect the plus (+) side of a DMM to W1, pin 1 (186-Based CPU) or W1, pin 2
(386EX-Based CPU) and the minus (-) side of the DMM to power ground as shown in
Figure 5-11.
3. The battery voltage should be greater than +3.0 V dc. A voltage less than this value may indicate that the battery is at or near the end of its useful life.
4. Remove DMM connections and re-insert jumper W1. Jumper W1 should be plugged into its operating position across pins 1 and 2.
Note
A battery check is also included in the startup diagnostic tests.
For a low battery voltage condition, LED 5 (see Figures 5-3, 5-5
& 5-7) will be ON and LEDs 1 and 2 will blink for a brief period.
A defective battery will not halt diagnostic tests.
The on-line or background diagnostic tests will also check the battery once very 24 hours at 8:00 AM. During this test, a low battery condition will cause the system alarm signal, DIAG.001, to be turned ON.
Figure 5-11 - Battery Test
Watchdog & Idle LEDs
Referring to Figures 5-3, 5-5, 5-7 & 5-8, LED DS8 is the WATCHDOG LED. This LED turns
ON at powerup or when the DPC has been "reset." It turns OFF when the DPC starts executing an ACCOL load and should remain off as long as the system is executing normally.
Should this LED turn ON during normal operation, it indicates a failure condition has been detected and the system has been reset. The IDLE LED will also be ON to indicate that the
CPU has halted.
5-10 / Service (01/01) CI-3335
LED DS7 is the IDLE LED and it provides an indication of the activity level of the system.
When this LED turns ON, it indicates that the CPU has "halted" or is in an "idle" state. When the LED is off, it indicates that the CPU is busy.
Status LEDs
LEDs DS1-DS6 provide status information on the DPC during startup and regular operation.
When a failure or error is detected, these LEDs will light in a pattern that, when interpreted, indicates the general area of the problem.
The failure patterns of the status LEDs are given in Table 5-C (for 186-Based CPUs) and Table
5-D (for 386EX-Based CPUs). When using Tables 5C and 5D, note that they are organized into five categories: CPU/Internal Peripherals, External Peripherals, I/O Modules, Download
Communication Initialization, and Configuration. Tests in all categories (except Download
Comm. Initialization) can be initiated by pressing the Reset Button for a "cold start." Tests in the Download Comm. Initialization category are automatically initiated when a DPC with
RAM-based memory is preparing for a download (either a cold or warm download).
A failure in the first two categories will be indicated when both the WATCHDOG and IDLE
LEDs are ON and the pattern in LEDs 1-6 is static. The LED patterns for battery status and other warnings and the patterns for I/O Modules are for informational purposes only and they do not cause the test to halt.
The diagnostic test sequence runs as follows:
1. Initially the DPC is powered up (turned on) or the Reset Button of an operating DPC is pressed to begin the cold start diagnostic test program.
2. The CPU Registers, identified in Table 5-C or Table 5-D, are the first items to be tested. If a failure is detected, the test will halt and the IDLE LED will turn ON. The
STATUS LEDs will simultaneously display the failure pattern shown for this condition in the table: 0-0-0-0-0-1, where 0 is OFF and 1 is ON.
Note 1: LEDs DS1 & DS2 will alternately blink to indicate a problem. This is only a warning the unit doesn’t stop.
Note 2: Requires AC.10 or later firmware.
Note 3: Requires AG.00 or later firmware.
Note 4: If there is an I/O Module in the indicated slot and the module has passed the self test (if applicable), the corresponding LED will be ON. If the I/O Module didn’t respond (slot is unoccupied or the module has failed it’s self test), the
LED will be OFF. For Communication Engine Failures, any combinations of LEDs DS1-DS4 may be ON to correspond with the number of failed ports.
3. Assuming there was no failure in step 2, the Make-RAM test is executed next (tests are not in the same sequence shown in the table). This test checks a portion of the RAM to be used as a working stack during subsequent tests. The Programmable Interrupt
Controller is tested to verify that interruptions required for RAM testing are available.
The full RAM test is then executed. If there are any failures, the IDLE LED will turn
ON and the STATUS LEDs will display one of the patterns given in Table 5-C or 5-D.
CI-3335 (01/01) Service / 5-11
Table 5-C 186-Based CPU Engine Board Diagnostic LED Failure Indications
TEST
CPU/INTERNAL PERIPHERALS FAILURES:
CPU Registers
Internal Timer
Internal PIC
DMA
DS6 DS5 DS4 DS3 DS2 DS1
0 0 0 0 0 1
0 0 0 0 1 0
0 0 0 0 1 1
0 0 0 1 0 0
EXTERNAL PERIPHERALS FAILURES:
System RAM
System Low Battery Warning
1
256K RAM Bd. Low Btry Warning
1 & 2
Redundancy Registers
Redundancy RAM
System or ACCOL PROM
Custom PROM Warning
1 & 2
Make RAM (System RAM upper 512)
Real Time Clock (RTC)
RTC Internal Battery Warning
1 & 3
I/O MODULE STATUS:
Slot Nos. - >
First Display
4
Slot Nos. - >
Second Display
4
DOWNLOAD COMM. INITIALIZATION
FAILURES: (RAM based units only)
Ports A - D Failed
Port A Failed
Port B Failed
Port C Failed
Port D Failed
Example: Ports A & B Failed
CONFIGURATION ERRORS:
Load Version Fail
2
Insufficient RAM Available for Load 2
CPU Clk Switch - wrong position
2
0 1 0 0 0 1
0 1 0 0 X X
0 1 0 1 X X
0 1 0 1 0 0
0 1 0 1 0 1
0 1 1 0 0 0
0 1 1 0 X X
0 1 1 0 0 1
0 1 1 0 1 1
0 1 1 1 X X
#1 #2 #3 #4 #5 #6
T T T T T T
#7 #8 #9 #10 #11 #12
T T T T T T
1 0 1 1 1 1
1 0 1 X X X
1 0 X 1 X X
1 0 X X 1 X
1 0 X X X 1
1 0 1 1 0 0
1 1 0 0 0 1
1 1 0 0 1 0
1 1 1 0 0 0
LED KEY: 0 = OFF
1 = ON
X = Blinking
T = Test. May be ON or OFF (see Note 4 below).
5-12 / Service (01/01) CI-3335
4. The remaining diagnostic tests are then executed in the following order:
RAM Backup Battery
RTC (Real Time Clock) Battery
RTC - includes External PIC test.
PROM
Internal Timer
DMA (Direct Memory Access H/W)
Any failures are displayed as described in the previous steps with the exception of the battery tests and the Custom PROM test. If the RAM battery is weak or defective, a different pattern will be displayed: 0-1-0-0-X-X. In this pattern, LED DS5 will be ON,
LEDs DS6, DS 4 and DS3 will be OFF, and LEDs DS1 and DS2 will blink for a short period of time. Note that a defective battery will not halt this test. The diagnostics will proceed to the next test.
5. In the next test, the I/O Module slots are interrogated and tested as required.
At the conclusion of the I/O tests, LEDs DS1-DS6 will turn OFF for 1 second, then turn
ON for 1 second, and then OFF again for 1 second. The status of the I/O Module interrogation is then displayed on LEDs DS1-DS6.
The status for slots 1 through 6 is displayed as follows: LED DS6 indicates the status for slot #1, LED DS5 for slot #2 ... and LED DS1 for slot #6. A LED will turn ON for each slot having a module installed, providing that the module’s self test was successful. The LEDs for all unoccupied or failed slots will be OFF.
After displaying the status for slots #1-6, all six LEDs will go OFF for 1 second. The status for slots #7-10 will then be displayed using LED DS6 to indicate the status for slot #7, LED DS5 for slot #8 ... and LED DS3 for slot #10. (Note: The maximum slot
# for a 3335 is ’9’; for a 3331 it is ’10.’ LEDs 1 and 2 will always be OFF).
If no I/O Modules are installed, LEDs DS1-DS6 will remain OFF for several seconds between the completion of the diagnostic test cycle and the final "ripple" pattern described in step 6.
6. For 186-based CPU
The conclusion of the above test cycle is indicated by a "ripple" pattern on the STATUS
LEDs that sequences from LED DS6 through LED DS1. All six LEDs will then be turned OFF. At this time, an EPROM-based DPC will begin executing its ACCOL load, while a RAM-based DPC will check and initialize its ports to prepare for a download.
If Communication Engine Board #1 is not present, all four communication ports are marked as failed and it will not be possible to download. LEDs DS4 to DS1 will identify the port status as shown in Table 5-C; active or vacant ports will be indicated by an OFF LED, while a defective port will be indicated by an ON LED. If there is one or more defective ports, LED DS6 will be ON and LED DS5 will be OFF for this test.
The IDLE LED will also be OFF for this test since the CPU will remain busy monitoring all of the ports for a download sequence.
CI-3335 (01/01) Service / 5-13
Table 5-D 386EX Based CPU Board Diagnostic LED Failure Indications
TEST
CPU/INTERNAL PERIPHERALS FAILURES:
CPU Registers
Internal Timer (IT) 2
Internal PIC
DMA
Internal Timer 0 & 1/Incorrect
CPU Speed
NPX present with Software Library link* or NPX not present with Hardware link.
Error Programming ACCOL FLASH
EXTERNAL PERIPHERALS FAILURES:
System RAM
System Low Battery Warning*
Redundancy Registers
Redundancy RAM
System/ACCOL PROM
Custom PROM Warning*
Make RAM (System RAM upper 512)
Real Time Clock (RTC)
RTC Internal Battery Warning*
I/O MODULE STATUS: (see Note 2 below)
DS6 DS5 DS4 DS3 DS2 DS1
0 0 0 0 0 1
0 0 0 0 1 0
0 0 0 0 1 1
0 0 0 1 0 0
0 0 0 1 0 1
0 0 0 1 1 0
0 0 0 1 1 1
0 1 0 0 0 1
0 1 0 0 X X
0 1 0 1 0 0
0 1 0 1 0 1
0 1 1 0 0 0
0 1 1 0 X X
0 1 1 0 0 1
0 1 1 0 1 1
0 1 1 1 X X
DOWNLOAD COMM. INITIALIZATION
FAILURES: (RAM based units only)
Port A/B Failed
Port C/D Failed
Port BIP1/BIP2 Failed
Port G/H Failed
Port I/J Failed
Example: Ports A & B Failed
1 0 0 0 0 1
1 0 0 0 1 0
1 0 0 1 0 0
1 0 1 0 0 0
1 1 0 0 0 0
1 0 0 0 0 1
CONFIGURATION ERRORS:
Load Version Fail
Memory Configuration Error
ACCOL load too large for PROM.
ACCOL load too large for RAM.
Using full memory protected mode firmware without Expan-
sion Memory Board.
1 1 0 0 0 1
1 1 0 0 1 0
Note 1: * = This is only a warning the unit doesn’t stop.
Note 2: For I/O Module Status See Table 5-C.
Note 3: Italicized portions of Table 5-D pertain to Protected Mode CPUs.
For 386EX-based CPU
The conclusion of the above test cycle is indicated by a "ripple" pattern on the STATUS
LEDs that sequences from LED DS6 through LED DS1. All six LEDs will then be
5-14 / Service (01/01) CI-3335
turned OFF. At this time, an EPROM-based DPC will begin executing its ACCOL load, while a RAM-based DPC will check and initialize its ports to prepare for a download.
LEDs DS5 to DS1 will identify the port status as shown in Table 5-D; active or vacant ports will be indicated by an OFF LED, while a defective port will be indicated by an
ON LED. If there is one or more defective ports, LED DS6 will be ON for this test.
The IDLE LED will also be OFF for this test since the CPU will remain busy monitoring all of the ports for a download sequence.
7. For 186-based CPU
Configuration errors are indicated prior to the completion of the download if LEDs 5 and 6 are ON. LED 1 ON indicates a load version failure. If LED 2 is ON, there is insufficient RAM. If LED 4 is ON, the CPU Clock Switch is in the wrong position.
For 386EX-based CPU
Configuration errors are indicated prior to the completion of the download if LEDs DS5 and DS6 are ON. LED DS1 in an ON state indicates a load version failure. If LED
DS2 is ON, one of the following memory configuration errors is the probable cause:
- ACCOL load too large for PROM
- ACCOL load too large for RAM (Protected Mode only)
- Attempt to run Protected Mode firmware without Memory Expansion Module (Non-
Ethernet CPU only).
8. At the completion of the download, the LEDs DS1-DS6 and the WD LED will turn
OFF. The IDLE LED will start blinking to indicate the activity of the ACCOL load.
Note:
In the case of redundant units, LEDS DS1 through DS6 ON (on the back-up
CPU Engine Bd.) indicates that the back-up unit is waiting for a side-load (in normal operating system). If DS1 and DS2 of the System Interconnect Board are OFF, (a power problem is indicated) the CPU Engine Boards will be held in a reset state and DS1 through DS6 (of the CPU Engine Boards) will be ON.
Ethernet CPU Engine Ass’y. Ethernet Port Loopback Test
The diagnostic test program of the AIC provides a quick means of checking the transmitting and receiving functions of the Ethernet ports. Refer to User Manual D4041, Diagnostics (May,
1998 or newer), for details. Note: Diagnostic Firmware Rev. (6.2 or higher) is required for the
Ethernet CPU Engine assembly.
COMMUNICATION ENGINE BOARD TESTS
The Enhanced Communication Board (ECB) provides two or four communication ports. Port assignment is based upon the slot in which the ECB resides (see Figure 5-12). Note: Socket #1
only supports 2PECBs or an Interrupt Bypass Board. An Interrupt Bypass Board is installed
when the 3335 is equipped with an Ethernet CPU. These ports are labeled as follows:
2PECB - Contains Ports A & B (in CE Socket #1) - Contains Ports C & D ( in CE Socket #2).
4PECB - Contains Ports C, D, I, & J (Board resides in Communication Socket #2).
CI-3335 (01/01) Service / 5-15
Figure 5-12 - 2 & 4 Port Enhanced Communication Board Port Designations
The ports can be configured for either RS-485 or RS-232 type communications. The former is required for BSAP network communications, while the later is required for devices such as a
PC or printer. However; these ports can be configured for other applications, e.g., port A can be configured to interface with a PC while ports B, C, D, etc. can be configured for use with options such as Modem Boards. It should be noted that neither the Two Port or Four Port version of the Enhanced Communication Board (2PECB & 4PECB) will support use with a
Hand Held Terminal. It should also be noted that only a 2PECB or an Interrupt Bypass Board
(391938-01-0) can reside in Socket #1. The Interrupt Bypass Board must be used when an
Ethernet CPU is installed.
A DPC having a single Communication Engine Board must always use Socket #1 unless the unit is equipped with an Ethernet CPU. When equipped with an Ethernet CPU, an Interrupt
Bypass Board must be installed in Socket #1. An ECB that has been plugged into Socket #2 will not operate unless either a 2PECB or an Interrupt Bypass Board has been installed in
Socket #1.
CE Board Loopback Test
Loopback tests provide a quick means of checking the transmitting and receiving functions of the Comm. Module by feeding its output back to its input. This configuration is used for testing the module via the diagnostic test program of the AIC. See the Diagnostics manual for details.
Loopback is achieved by appropriately setting switches 3, 4, 7, & 8 of SW1 (for port A/C), SW2
(for port I), SW3 (for port B/D), and SW4 (for port J) (see Chapter 3C). The remaining switches of SW1 through SW4 may be left in their assigned positions.
5-16 / Service (01/01) CI-3335
TXD and RXD LEDs
Each port is associated with a bi-color LED that indicates the status of the communication channel (see Figure 5-12). When a LED lights up RED, that channel is transmitting data; when it lights up GREEN, it is receiving data.
If a TXD LED does not light during transmission, the defect could be in the Enhanced Comm.
Board. Check the positions of switches SW1 through SW4 (for 4PECB) or SW1 & SW2 (for
2PECB) to make sure they are set properly. If possible, try another board known to be good.
If an RXD LED fails to light when data is being transmitted to the unit, check the settings of the switches. If the positions are correct, check the signal across the RXD and GND lines with an oscilloscope. If the signal is distorted or missing, trouble is indicated at the transmitting end of the other device. If the signal appears normal, try another board known to be good.
DI AND DO MODULES
The DI and DO Modules are provided with a LED for each channel to indicate whether the signal is in an ON or OFF state. The LEDs for both types of modules function in a similar manner.
If a DI Module has a LED that does not respond to a change in signal status, it could indicate a circuit defect in the module. If all LEDS are OFF and they fail to respond to any change of status, it is possible that resistor pack R4 (in the case of the 4/8 Input DI Module) or W17 (in the case of the HDDI Module) was removed to disable the LEDs (to conserve power). Re-insert the resistor pack (see Section 3F - DI Module) or jumper W17 (see Section 3FA - HDDI
Module) as required.
If a DO Module has a LED that does not track changes in signal status, it could also indicate a circuit defect in the module or a problem in a preceding stage such as the CPU Engine
Board. If all DO LEDs stay OFF and do not respond to a change of signal status, Jumper W1 may have been removed. Replace W1 and check operation as required (see Section 3G - DO
Module for details).
HIGH SPEED COUNTER MODULE
HSC Modules are provided with four LEDs (DS1-DS4) to indicate the signal status. A LED will light when its channel receives a corresponding ON pulse. For very slow pulse rates, the
ON-OFF pulse excursions can be followed by the eye; for fast rates, the LED will appear continuously lit. An HSC channel suspected of trouble can be checked by connecting an oscilloscope across the input terminals. If proper amplitude and pulse shapes are observed, a circuit defect may be present in the target HSC channel of the HSC Module. If possible, check by module substitution.
If all HSC LEDs stay OFF and do not respond to a change of signal status, Jumper W9 may have been removed. Replace W9 and recheck operation as required (see Section 3H - HSC
Module for details).
CI-3335 (01/01) Service / 5-17
DIAGNOSTICS
Detailed off-line diagnostics allow the user to perform a more extensive evaluation of the DPC by isolating faults to specific areas such as the CPU, RAM, Serial Communications, or I/O
Modules. They also provide support for calibrating the I/O Modules.
These tests are initiated through the DIAGNOSTIC Program which is run on a personal computer (Global Diagnostics are not supported, i.e., should not be done). This program is furnished on a disk contained in the WORKBENCH software package for both Real and
Protected Modes or in the AIC software package for Real Mode. For a description of these test procedures, refer to User Manual D4041 - Diagnostics.
Note: Diagnostic Software (Rev. 6.0 or higher) is required for Protected Mode DPCs.
Diagnostic Software (Rev. 5.10 or higher, i.e., 5.XX) is required for Real Mode DPCs.
Diagnostic Software (Rev. 6.2 or higher) is required for units equipped with an Ethernet
CPU Engine Assembly.
GENERAL NOTES
Certain questions or situations frequently arise when servicing the 3335. Some items of interest are provided as follows:
Extent of Field Repairs
Field repairs to DPC 3335 units that are used in Class I, Division 2 hazardous areas are strictly limited to the replacement of complete PC boards and assemblies. Any repairs made to the com-ponent level will violate the hazardous area classification of the unit. Defective PC boards or assemblies should be returned to Bristol Babcock for authorized service or replacement.
Disconnecting RAM Battery
If the backup battery of a RAM-based DPC is not connected when the DPC’s power is turned off, the CPU Engine’s RAM memory will lose its ACCOL load. Consequently, all of the user’s process configuration will also be lost. This will necessitate a reload of the DPC.
If the RAM battery of an EPROM-based DPC is disconnected when power is off, the DPC will still execute its ACCOL load but all the current data will be lost. Upon power-up, the
EPROM-based DPC will act as though it had just been booted and it will revert back to the initial values specified in its ACCOL load.
Maintaining Backup Files
For RAM-based DPCs, it is essential to maintain a backup disk of each ACCOL load file to guard against an accidental loss of process configuration data. Without a backup record, it will be necessary to reconfigure the entire ACCOL load which can be a very time consuming procedure. Always play it safe and keep backup copies of your ACCOL loads.
5-18 / Service (01/01) CI-3335
32-Bit CPU Assembly Battery
The lithium Battery is mounted on the rear of the Memory & Peripheral Board. In order to remove/replace the Lithium Battery, the 32 Bit CPU Assembly must be removed from the 3335 and then the boards must be disconnected from each other. These boards are secured to each other via four (4) mounting post and screws.
CI-3335 (01/01) Service / 5-19
BLANK PAGE
Section 6
SPECIFICATIONS
6.1 PHYSICAL SPECIFICATIONS
Enclosure: The DPC card cage provides twelve vertical module slots. Two vertical slots are dedicated for CPU and
Comm. Modules, while the remaining ten are used for
I/O modules (models furnished with two Communication Modules are reduced to 9 I/O slots. The three horizontal slots contain a Power Supply Module,
System Monitor Module, and an optional Modem.
Utility: Enclosure constructed of metal. Intended for rack or panel mounted installations.
Optional Cover:
Dimensions:
An optional cover attaches to the front of the rack.
5.134 in. height, 19 in. width, 10.6 in. depth
6.2 PERFORMANCE SPECIFICATIONS
6.2.1 Power Supply Module (DC-DC Converter)
Supply Input:
DC Outputs:
Regulation:
Noise and Ripple:
Response:
Enclosed Type (390725-02-1): 24Vdc (22-28 Vdc)
Open Frame Type (396840-01-9): 9-30 Vdc
8A Inrush, duration 10 ms
Enclosed Type:
+5Vdc @ 3A max., ±5%
+15Vdc @ 0.5A max., ±4%
-15Vdc @ 0.5A max., ±4%
Open Frame Type:
+5Vdc @ 2A max., ±5%
+15Vdc @ 0.3A max., ±4%
-15Vdc @ 0.3A max., ±4%
±0.5% Max. for any combination of line variation (see
Supply Input specification above) and load variation
(min.to max. load).
Primary output <100mV p-p or 1% of output voltage, whichever is less. Auxiliary power <50mV p-p. microseconds change on main output (+5 Vdc). <50 microseconds for auxiliary output.
CI-3335 Specifications / 6-1
Protection:
6.2.2 System Monitor Module
DC Line Fuse:
DC Input:
Watchdog Relay:
Input is fused and reverse polarity protected. Primary output power is limited. Short circuit protection is continuous without damage. Current is limited to 50% of rated load current. Recovery is automatic when load is reduced.
4A, (Type 3AB), Fast-Acting
+24Vdc
8A Inrush, duration 10 ms
Provides relay contacts for external watchdog circuit.
Relay is de-energized during watchdog. Contacts rated
2A @ 28Vdc or 0.3A @ 115Vdc.
Auto/Man Transfer Signal: Provides warning to a backup device that a system watchdog is about to occur. The A/M transfer signal precedes watchdog by 2 ms. A/M transfer is configurable as 0-5 V, 0-24 V, or open collector output, with an active high or low status.
6.2.3 CPU Engine Module
Processor:
Memory:
80C186, 16-bit mircoprocessor used for 12 MHz and 20
MHz type CPU Engines
80386EX, Real Mode (16-bit, 24MHz) CPU Engines
80386EX, Prot. Mode (32-bit, 24MHZ) CPU Engines
80186 CPU Engine:
64K/128K, RAM or EPROM-based memory systems are offered.
80386EX (Real Mode):
512K-bytes of Asymmetrically Blocked FLASH ABF)
Mem. And 510K-bytes of Static RAM.
80386EX (Protected Mode):
ABF Memory: 512K-bytes (CPU), 2M-bytes (EMB).
Static RAM: 512K-bytes (CPU), up to 4M-bytes
(EMB).
80386EX (Ethernet CPU):
SBF Memory: 2M-bytes (CPU), 2M-bytes (EMB).
Static RAM: 1 or 2 M-bytes (CPU), up to 4M-bytes
(EMB).
RAM Lithium battery pack (3.6V) with 4000 hours cumulative backup. Battery is cut in when the +5Vdc supply source fall below +4.5 Vdc.
DPC Software: ACCOL II control language provides selection of preprogrammed modules to build multi-task load for DPC.
6-2 / Specifications CI-3335
Software Performed program that is run on PC or central computer.
6.2.4 Enhanced Communication Engine (ECB) Board
Communication Ports: Two ports on 2-Port ECB Board.
Four ports on 4-Port ECB Board.
Note: One 2-Port ECB and one 4-Port ECB can be installed. Only a 2-Port ECB can be installed in Comm.
Slot #1. Units equipped with an Ethernet CPU Engine can’t. have an ECB installed in Comm. Slot #1.
Interface: Asynchronous RS-423 and RS-485 ports up to 9600 baud. Synchronous ports up to 1 Megabaud.
Protocol: Bristol Standard Asynchronous Protocol (BSAP) compatible with International Standard, ISO 1745, 2111 &
2629. Interface compatible for use with phone-line modems (Private Line or Switched Network types).
6.2.5
Analog Input Modules
No. of Inputs:
Input Range:
Input Impedance:
Input Filtering:
4 or 8 AIs
1-5 Vdc / 4-20 mA type (range selected by jumper).
0-10 Vdc type (fixed range).
1-5 & 0-10 V inputs: 150 K w/o common mode (2 M w/
250V common mode).
4-20 mA input: 250 ohms.
Single pole (50-millisecond time constant). 300 millisecond to .1% of input value. Common mode rejection ratio dc-60 Hz is 110 db.
Surge Suppression: Modules with Std. Common Mode:
For 1-5V/4-20 mA Type:
Common mode is +5V, -10V.
Surge suppression - Input & common mode to 30V rms.
For 0-10 V Type:
Common mode +2 V, -12 V.
Surge suppression - Input & common mode to 10V rms.
Modules w/ Optional 250 V Common Mode:
For 1-5V/4-20 mA Type:
Common mode isolation to 180Vdc.
Surge suppression - Input & common mode to 130V rms.
CI-3335 Specifications / 6-3
Accuracy:
6.2.6 Analog Output Modules
No. of Outputs:
Output Ranges:
Source Current:
Compliance:
Surge Suppression:
Setting Time:
Accuracy:
6.2.7 Discrete Input Modules
Types of Modules:
At 25° C (77° F):
0.1% of span for all input ranges.
-20 to 70° C (-4 to 158° F):
0.2% of span for all input ranges.
-40 to 70° C (-40 to 158° F)
0.3% of span for all input ranges.
2 or 4AOs
1-5 Vdc / 4-20 mA type (range is switch selectable).
0-10 Vdc type (Single, fixed range).
1-5 V & 0-10 V outputs @ 5 mA maximum.
4-20 mA output into 0-650 ohms.
Meets ANSI/IEEE C37.90-1978.
0-10 V.......................................... 65 microseconds to 0.1%
1-5 V & 4-20 mA.........................100 milliseconds to 0.1%
At 25° C (77° F):
0.1% of span for all output ranges.
-20 to 70° C (-4 to 158° F):
0.2% of span for all output ranges.
-40 to 70° C (-40 to 158° F)
0.3% of span for all input ranges.
Module Type
(Input)
24V ac/dc, 10% @ 5mA
24V ac/dc, 10% @ 5mA
5V ac/dc, 10% @ 5mA
12V ac/dc, 10% @ 5mA
24V ac/dc, 10% @ 5mA
24V ac/dc, 10% @ 5mA
No.
DIs
Input
Filter
8/16 1ms
8/16 30ms
8 1ms
8 30ms
8
8
1ms
30ms
120V ac/dc, 10% @ 5mA
* Meets IEE 472-1974.
** Meets ANSI/IEEE C37.90-1978.
Surge
Protection *
30Vrms*
30Vrms*
10V rms**
30V rms**
30V rms**
30V rms**
6-4 / Specifications CI-3335
Input Filter: 30 millisecond Type: Accepts inputs from DC to 300 pulses/minute and AC. Usable with PDM and dry contact input signals.
Isolation:
Min. Closure Time:
1 millisecond Type: Accepts inputs from DC to 400 pulses/second. Usable with counter.
Opto-isolated to 10, 30 or 130 V rms
30 milliseconds, ± 3 ms.
1 millisecond, ± 0.1 ms.
Signal Conditioning: 30 millisecond delay for DC and 50/60 Hz, AC inputs. 1 millisecond delay for PDM inputs & low speed counters.
LED Indicators:
6.2.8
Discrete Output Modules
Types of Modules:
Light up when DI is in ON state. LEDs may be disabled to conserve power.
Module Type
(Output)
Open Drain
Open Collector
Relay Contact
No.
DOs
8/16
8
4
Relay
Coil
None
None
24 Vdc @ 10.0 mA
Surge
Protection *
3V rms
3V rms
130V rms
No. of Outputs:
Relay Contact 4 12 Vdc @ 26.7 mA
* Meets ANSI/IEEE C37.90-1978.
130V rms
8 or 16 DOs for open drain output types.
8 DOs for open collector output types.
4 DOs for relay output types
Types:
Output Rating: w/ 12 V dc relay coil w/ 24 V dc relay coil
Open Collector/Drain Type:
100 mA @ 35 Vdc. User required to place diode across load for surge protection.
Relay Output Type (Dry Contact):
2.0 A resistive 50 Vdc or 120 Vac, 50/60 Hz.
0.6 A inductive 50 Vdc or 120 Vac, 50/60 Hz.
0.4 A motor
0.2 A lamp
50 Vdc or 120 Vac, 50/60 Hz.
50 Vdc or 120 Vac, 50/60 Hz.
For load voltages above 30 Vdc and 24 Vac, the load and neutral side of the power source should only be connected to the field wiring terminals. The relay case must be connected to chassis ground.
CI-3335 Specifications / 6-5
Isolation:
Surge Suppression:
LED Indicators:
Open Collector/Open Drain: Non-isolated.
Relay Contact: Isolation to 130 V rms.
Open Collector/Open Drain Output:
Common mode @ 30 V rms.
Relay Contact Output:
Common mode @ 130 V rms
(Meets ANSI/IEEE C37.90-1978)
Types of Modules:
Light up when DO is in ON state. LEDs may be disabled to conserve power.
6.2.9
High Speed Counter Modules
Module Type
(Input)
5V dc. ± 10% @ 5 mA
12V dc. ± 10% @ 5 mA
No.
HSCs
4
4
Input
Filter
1ms
1ms
Surge
Protection *
5V rms
10V rms
24V dc. ± 10% @ 5 mA 4 1ms 30V rms
Frequency
* Meets ANSI/IEEE C37.90-1978.
10KHz maximum with square wave input using isolated input configuration. For dry contact operation, continuous contact closure must be greater than 125 microseconds.
Dry Contact Input: 24 Volt Type: Dry contacts may be powered by external
24V supply or strapped internally to 24V module supply.
12 Volt Type: Dry contacts must be powered by external
12V supply or strapped internally to 12V module supply.
5 Type: Dry contacts must be powered by external
5V supply.
Debouncing Circuit:
Signal Conditioning:
Field selectable.
Allows dry contact or differential input signal to clock the counter.
6.2.10 Low Level Analog Input Modules
No. of Inputs:
Input Types:
Four differential inputs
Thermocouple: Accepts B, R, S, J, E, K, and T types
RTD: Accepts 3 or 4-wire sensing devices.
Sensor Type, Platinum bulb, 100 W
(DIN43760).
6-6 / Specifications CI-3335
Accuracy:
RTD
Linearization provided for RTD and
Voltage Input: ± 10 mV
Range Resolution At 25° C -20° ° C to 70° C
-220 to 850° C .09° C ±.5° C ±1.0° C
Voltage Range Resolution At 25° C 0° ° C to 70° C
10mV - - ±.025%
10 6 ohms @ DC Input
Signal Conditioning:
Module w/ Common Mode:
Surge Suppression:
Current Ref. Source:
20 msec time constant
Isolation - CMRR 100 dB channel to channel.
±6V peak without isolation amplifiers.
600V peak (isolation amplifiers, channel to channel).
Meets C37.90-1978 (R1983).
Precision 1 mA source available for RTD field devices.
Also provides stable voltage reference for gain measurement variations over temperature when using isolation amplifiers.
Thermocouple
Type
B
R
S
J
E
Range
100 to 200 ° °C
200 to 390 ° °C
390 to 840 ° °C
840 to 1800 ° °C
-50 to +50 ° °C
50 to 1720 ° °C
-50 to +50 ° °C
50 to 1760 ° °C
-210 to +191 ° °C
190 to 1200 ° °C
-270 to -260 ° °C
-260 to -225 ° °C
-225 to -200 ° °C
-200 to 1000 ° °C
Resolution
2.0 ° °C
1.0 ° °C
0.5 ° °C
0.2 ° °C
0.4 ° °C
0.17 ° °C
0.37 ° °C
0.18 ° °C
0.08 ° °C
0.11 ° °C
1.0
° °C
0.25 ° °C
0.26 ° °C
0.09 ° °C
At 25° C
±8 ° °C
±4 ° °C
±2 ° °C
±1 ° °C
±2 ° °C
±1 ° °C
±2 ° °C
±1 ° °C
±.75 ° °C
±.5 ° °C
±3 ° °C
±1 ° °C
±.75 ° °C
±.5 ° °C
Thru Range of
0 to 70° C
±16 ° °C
±8 ° °C
±4 ° °C
±2 ° °C
±4 ° °C
±2 ° °C
±4 ° °C
±2 ° °C
±1.5 ° °C
±1 ° °C
±6 ° °C
±2 ° °C
±1.5 ° °C
±1 ° °C
K
T
-270 to -261 ° °C
-260 to -246 ° °C
-245 to -180 ° °C
-179 to -145 ° °C
-145 to 1372 ° °C
-270 to -261 ° °C
-260 to -251 ° °C
-180 to -136 ° °C
-135 to 400 ° °C
2.0 ° °C
0.56 ° °C
0.25 ° °C
0.08 ° °C
0.14
° °C
1.5 ° °C
0.38 ° °C
0.08 ° °C
0.06 ° °C
±5 ° °C
±2 ° °C
±1 ° °C
±.75 ° °C
±.5 ° °C
±4 ° °C
±2 ° °C
±.75 ° °C
±.5 ° °C
±10 ° °C
±4 ° °C
±2 ° °C
±1.5 ° °C
±1 ° °C
±8 ° °C
±4 ° °C
±1.5 ° °C
±1 ° °C
CI-3335 Specifications / 6-7
Input Filtering: Single-pole, low-pass filter.
RC time constant is 20 ms.
Input impedance is 10 6 ohms at DC.
6.2.11 High Speed Analog Input Module
Type of Inputs:
AI Range:
AI Accuracy:
AI Impedance:
AI Signal Conditioning:
DI Level:
DI Frequency Range:
DI Impedance:
Common Mode
Rejection Ratio:
4 AIs (Analog Inputs)
2 DIs (Discrete Inputs)
1-5 Vdc or
4-20 mA dc internally sourced current loop
0.1% of span @ 25° C
0.2% of span from -20 to +70° C
2M ohms for 1-5 V input
250 ohms for 4-20 mA input
Single Pole (3 x 10 -6 sec. time constant)
5 Vdc, ±10%
10K Hz maximum
680 ohms
DC to 60 Hz, 40 dB
6.2.12 Solid State DC Relay Discrete Output Board
No. of Outputs: 8 DOs
Temperature: -20° ° C (4° ° to 158° ° F)
RFI:
DC Output:
Suppression:
Off state Leakage Current:
10V/Meter (20MHz - 500MHz)
3A, 38Vdc (Max)
89Vdc
10 m A (MaX)
6.2.13 Optional Display & Keyboard Assembly
Display:
Display Viewing Area:
Liquid crystal (LCD), alphanumeric.
4 Lines x 20 Characters.
5 x 7 character dot matrix.
3 in. width x 1 in. height
6-8 / Specifications CI-3335
Keyboard:
Assembly Dimensions:
Temperature:
Membrane type with tactile feedback.
25 keys in a 5 x 5 matrix of 2.6 x 2.6 in. size.
Irregular shaped assembly.
Maximum width: 4.0 in.
Maximum length: 9.7 in.
-20 to 70° C (-4 to 158° F)
6.3
ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Vibration:
RFI Susceptibility:
Electromagnetic
Interference:
Safety Approvals:
Operating: -40 to 70° C (-40 to 158° F) *
Storage: -40 to 70° C (-40 to 158° F)
5% to 95% (non-condensing)
10-150 Hz @ 9.8 m/s 2 constant acceleration
150-2000 @ 0.5 g
10 volts/meter from 10 MHz to 500 MHz
Meets SAMA standard PMC 33.1 - l978.
FM & CSA approval pending; Class I, Division 2,
Groups A-D non-incendive.
ANSI standard C39.5
Enclosures:
Cooling:
Rack or panel mounting.
Optional
None required when operated within specified temperature limits.
* From -20 to -40° C (-4 to -40° F), the accuracy of the AI and AO Cards decreases to
±0.3%. The Display & Keyboard and LLAI Module temperature range is -20 to 70
°C (-4 to 158° F). The operating temperature range of units equipped with a floating point processor (386EX CPUs) is 0 to 70° C (32 to 158° F). The operating temperature range of units equipped with an Ethernet CPU is 0 to 70° C (32 to 158
°F). SAI Module temperature range is -20 to 70° C (-4 to 158° F).
6.4 POWER REQUIREMENTS
Supply
TYPICAL POWER REQUIREMENTS @ 24VDC
PC
Board
386 CPU Board*
Power
(Watt)
4.92
Current
(Amp)
.205
CI-3335 Specifications / 6-9
TYPICAL POWER REQUIREMENTS @ 24VDC (Continued)
PC
Board
12 MHz 186 CPU Board*
20 MHz 186 CPU Board*
System Interconnect Board*
2 Port Comm. Board
4 Port Comm. Board
Display/Keypad (Ext)
4AI Board
8AI Board
2AO Board
4AO Board
8DI Board w/LED
8DI Board w/o LED
16DI Board w/LED
16DI Board w/o LED
8DO Board (open Collector) w/LED
8DO Board (open Collector) w/o LED
8DO Solid State Relay Board w/LED
16DO Board (open drain) w/LED
16DO Board (open drain) w/o LED
HSC Board w/LED
HSC Board w/o LED
Low Level Board
HSAI Board
DO Relay Board w/LED
DO Relay Board w/o LED
Check Before Operate Board
BBTI Board
BBTI Termination Board
HWSTI Board
Private Line Modem
Switched Network Modem
Fiber Optic Modem
RDI Board
TIB Board
.190
.052
.030
.090
.048
.060
.040
.004
.030
.002
.018
.010
.003
.009
.005
.058
.058
.004
.002
Current
(Amp)
.063
.095
.125
.045
.070
.008
.018
.016
.028
.045
.006
.002
.010
.003
.006
4.50
1.25
0.72
2.20
1.15
1.45
0.95
0.10
0.73
0.04
0.45
0.24
0.07
0.22
0.12
1.40
1.40
0.10
0.04
Power
(Watt)
1.50
2.30
3.00
1.10
1.70
0.20
0.44
0.40
0.68
1.10
0.15
0.04
0.24
0.07
0.15
MIB 0.50
Note:
The figures provided for Typical Power Requirements @
24VDC do not include loop power. To account for the additional power draw of external devices, such as transmitters, add the following for each point:
6-10 / Specifications CI-3335
POWER REQUIREMENTS @ 24VDC per INPUT POINT
DI Board
HSC Board
DO Relay Board
AI Board
AO Board
PC
Board
HWSTI Board
HDAI Board
HDAO Board
HDDI Board
BBTI Board
Power
(Watt)
0.12
0.12
0.25
0.50
0.50
0.30
0.50
0.50
0.12
0.50
Current
(Amp)
.005
.005
.010
.020
.020
.012
.020
.020
.005
.020
CI-3335 Specifications / 6-11
BLANK PAGE
Appendix CA
Issue: 05/01
For Instruction Manual CI-3335
392058-01-4 392043-01-7
U10
1
J4
U15
43 P1
U1
U3
U4
392058-01-4
W12
1
U6
1
U2
U5
U7 U8
Y1
U16
U11
U12
U9
U13
U14
U17
W2
W6 W7
ON
1 2 3 4 5 6 7 8 9 10 11
W9 W8
12 1 2 3 4 5 6 7 8 9 10 11
W19 W11 W18 W10
12
1 1 1
ON
DS1
1 1 1
43 P1
U16
Y1
U13
1
1
W7
U17
U15
U14
U12
1
U11
U9 U10
U7 U8
U5 U6
W8 W9 W11
U3
W10
W1 W2
U4
U1 U2
1 1
ON ON
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
DS1
Bristol Babcock
Appendix CA
COMMUNICATION ENGINE BOARDS
Series 392043-01-7 & 392058-01-4
TABLE OF CONTENTS
SECTION TITLE PAGE #
GENERAL ..........................................................................................................................1
1.1
Section 2 -CONFIGURATION & SERVICE
2.1 CONFIGURATION NOTES..............................................................................................4
2.2
2.2.1
2.2.2
2.3
2.3.1
2.3.2
2.4
2.5
2.6
2.7
2.8
SETTING DIP SWITCHES...............................................................................................4
Communication Ports A/C - Switch SW1..........................................................................4
Communication Ports B/D - Switch SW2 .........................................................................4
SETTING JUMPERS FOR BOARD 392058-01-4............................................................6
RS-485 and RS-423 Port Connections ..............................................................................8
RASCL Option....................................................................................................................9
SETTING JUMPERS FOR BOARD 392043-01-7..........................................................10
LED INDICATORS..........................................................................................................10
LOOPBACK TESTING....................................................................................................10
MODEM DOCUMENTATION........................................................................................10
COMPATIBILITY WITH 3335 CPUs .............................................................................11
CI-3335 Appendix CA Page 0-1 CE Boards Contents
Section 1
INTRODUCTION
1.1 GENERAL
This appendix covers the Communication Engine (CE) Boards that are listed in Table CA-A.
This table identifies each board by part number and references the corresponding assembly drawing and the associated tables that will be used for switch and jumper configuration.
Note the CE Boards discussed herein are no longer available from BBI.
All CE Board versions provide two communication ports which are 9-pin, D-type, female connectors. These ports are labeled A/C and B/D. When the DPC contains two CE Boards, a maximum of four ports are available. The two communication sockets determine the physical port assignments. A board is plugged into CE socket #1 will have these ports defined as A and B, while a board plugged into CE socket #2 will have these ports defined as
C and D.
The two ports can be configured for an RS-485 or RS-423 interface. The former is required for BSAP network communications, while the latter is required for devices such as a PC or printer. However, these ports can also be configured for other applications. For example, port A/C can be configured for use with the optional Hand Held Terminal, while port B/D can be configured for use with options such as the Modem Board, Fiber Optic Interface
Board, and RASCL Board as specified in Table CA-A. The selected option board plugs directly into the upper accessory slot of the 3335 backplane.
Two types of CE Boards are discussed herein. CE Board 392043-01-7 is a version that provides selectable rates of 187.5 kBd and 1 MBd. CE Board 392058-01-4 includes all the features of the previous type with the added capability to operate in the synchronous mode at 1 MBd.
TABLE CA-A - BOARD VERSIONS
Part
Number
392043-01-7
392058-01-4
Bd. Assy.
Figure
CA-2
CA-1
SW1
Table
SW2
Table
CA-B CA-C
CA-B CA-C
Jumpers
Table
CA-D
CA-E
Use
With
Modem
Yes
Yes
Use
With
FOI
Yes
Yes
Use
With
RASCL
Yes
Yes
CI-3335 Appendix CA Page - 1 CE Boards
Figure CA-1 - CE Board Assembly - Pt. No. 392058-01-4
CI-3335 Appendix CA Page - 2 CE Boards
Figure 3CA-2A - CE Board Assembly - Pt. No. 392043-01-7
CI-3335 Appendix CA Page - 3 CE Boards
Section 2
CONFIGURATION & SERVICE
2.1 CONFIGURATION NOTES
The CE Board contains switches and jumpers that must be checked before placing the DPC into operation. The location of these items are shown in Figures CA-1 and CA-2. It will be necessary to power-down the DPC and remove the board to access these components. The procedure for removing and installing the board are described in Section 2 - Installation.
2.2 SETTING DIP SWITCHES
The procedure for setting DIP switches is identical for both versions of the CE Board discussed herein. Switch SW1 sets communication parameters for port A/C, while SW2 sets them for port B/D. Refer to Figures CA-1 or CA-2 as required.
2.2.1 Communication Ports A/C - Switch SW1
Table CA-B provides the SW1 settings (communication modes) for port A/C. The first three columns of this table identify the SWITCH NUMBER, SWITCH SELECTION and
FUNCTION of each sub-switch of SW1. The last three columns give the settings for an RS-
485, RS-423 or HHT interface. Procedures for using the HHT are described in User Manual
D4059.
Setting the switches of SW1 does not complete the configuration of Port A/C. All jumpers listed in Table CA-D or CA-E must also be set to complete the procedure.
2.2.2 Communication Ports B/D - Switch SW2
Table CA-C provides the SW2 settings (communication modes) for port B/D. This table is used in the same manner as previously described for port A/C. The last three columns give the required switch positions for an RS-485, RS-423 or MODEM/FOI interface. The
MODEM/FOI interface is only used when the DPC is specified with an optional Modem
Board (Private Line or Switched Network type) or Fiber Optic Interface Board (with respect to the CE Boards discussed herein, the FOI option is only available for use with CE Board
392058-01-4). Note that these boards also contain switches and jumpers that require configuration. See Section 2.8 for details on Private Line and Switched Network Modems; for details on the Fiber Optic Interface, refer to Appendix FB.
Setting the switches of SW2 does not complete the configuration of Port B/D. All jumpers listed in Table CA-D or CA-E must also be set to complete the procedure.
CI-3335 Appendix CA Page - 4 CE Boards
SWITCH
NUMBER
SW1-1
SW1-2
SW1-3 to
SW1-6
SW1-7
TABLE CA-B - SW1 SETTINGS FOR PORT A/C
SWITCH
SELECTION
ON
OFF
ON
OFF
ON
OFF
FUNCTION
Hand Held Terminal enabled
Hand Held Terminal disabled
RS-423 driver enabled
RS-485 driver enabled
RS-423 receiver enabled
RS-485 receiver enabled
PORT A/C
RS-485 RS-423 HHT*
OFF OFF ON
OFF
OFF
ON
ON
OFF
OFF
ON ON ON
SW1-8
SW1-9
SW1-10
SW1-11
SW1-12
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
RTS+ to CTS+ loopback enabled
RTS+ to CTS+ loopback disabled
RTS- to CTS- loopback enabled
RTS- to CTS- loopback disabled
TXD+ to RXD+ loopback enabled
TXD+ to RXD+ loopback disabled
TXD- to RXD- loopback enabled
TXD- to RXD- loopback disabled
DTR+ to DCD+ loopback enabled
DTR+ to DCD+ loopback disabled
DTR- to DCD- loopback enabled
DTR- to DCD- loopback disabled
ON
OFF
OFF
OFF
OFF
ON ON
OFF OFF
OFF OFF
OFF OFF
OFF OFF
CI-3335 Appendix CA Page - 5 CE Boards
TABLE CA-C - SW2 SETTINGS FOR PORT B/D
SWITCH
NUMBER
SWITCH
SELECTION
FUNCTION
PORT B/D
MODEM
RS-485 RS-423 /FOI*
ON ON OFF SW2-1
SW2-2
ON
OFF
ON
OFF
ON
OFF
RS-4XX Interface - BSAP
Communication option
RS-423 driver enabled
RS-485 driver enabled
RS-423 receiver enabled
RS-485 receiver enabled
OFF ON OFF
SW2-3 to
SW2-6
SW2-7
SW2-8
SW2-9
SW2-10
ON
OFF
ON
OFF
ON
OFF
ON
OFF
RTS+ to CTS+ loopback enabled
RTS+ to CTS+ loopback disabled
RTS- to CTS- loopback enabled
RTS- to CTS- loopback disabled
TXD+ to RXD+ loopback enabled
TXD+ to RXD+ loopback disabled
TXD- to RXD- loopback enabled
TXD- to RXD- loopback disabled
OFF
ON
ON
OFF
OFF
ON
ON
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
SW2-11 ON
OFF
DTR+ to DCD+ loopback enabled
DTR+ to DCD+ loopback disabled
OFF OFF OFF
SW2-12 ON
OFF
DTR- to DCD- loopback enabled
DTR- to DCD- loopback disabled
OFF OFF OFF
* The configuration of modems will be found in Appendix MP, MS or MS/P (In manuals that predate 1/95) or in CI-9600/CI-9600A (PSTN), CI-1200 (PL/PSTN) or CI-1200-PL.
The configuration of the Fiber Optic Interface Board will be found in Appendix FB.
2.3 SETTING JUMPERS FOR BOARD 392058-01-4
This CE Board contains nineteen jumpers to set various communication parameters. The location of these jumpers is shown in Figure CA-1.
CI-3335 Appendix CA Page - 6 CE Boards
The jumpers are set according to Table CA-D. The first three columns of this table list the
SWITCH NUMBER, AVAILABLE SELECTIONS and FUNCTION of each jumper. The last four columns provide the required settings for RS-485, RS-423, RASCL and HHT configurations. The jumper conventions are illustrated at the bottom of this two-part table.
Some jumper selections in the last four columns are labeled AR. These selections denote "As
Required" and are set by the user for his communication application.
Setting the jumpers alone may not provide a desired configuration. Make sure that all switches listed in Tables CA-B and CA-C have also been properly set.
TABLE CA-D - JUMPER SETTINGS FOR BOARD NUMBER 392058-01-4
(Part 1 of 2)
W8
W9
W10
W11
W12
W13
Jumper
Number
W1
Available
Selections
NONE
W2
W3
W4
W5
NONE
-
1-2
2-3
-
1-2
2-3
-
1-2
2-3
W6*
W7**
- -
IN
OUT
- -
IN
OUT
NONE
NONE
NONE
NONE
NONE
IN
OUT
Function
For factory use only
For factory use only
Port A/C:
6 MHz RTXC Clock (187.5 kBd)
16 MHz RTXC Clock (1 MBd)
Port B/D:
6 MHz RTXC Clock (187.5 kBd)
16 MHz RTXC Clock (1 MBd)
PCLK:
Select 6 MHz (187.5 kBd)
Select 16 MHz (1 MBd)
Port A/C:
Select RS-423
Select RS-485
Port B/D:
Select RS-423
Select RS-485
For factory use only
For factory use only
For factory use only
For factory use only
For factory use only
RASCL present
RASCL not present.
RS-
485
OUT
OUT
AR
AR
AR
OUT
OUT
1-2
1-2
1-2
1-2
1-2
OUT
RS-
423
OUT
OUT
AR
AR
AR
IN
IN
1-2
1-2
1-2
1-2
1-2
OUT
AR
AR
IN
IN
1-2
1-2
1-2
1-2
1-2
IN
RA-
SCL
OUT
OUT
AR
1-2
1-2
1-2
1-2
1-2
OUT
HHT
OUT
OUT
AR
AR
AR
IN
IN
CI-3335 Appendix CA Page - 7 CE Boards
TABLE CA-D - JUMPER SETTINGS FOR BOARD NUMBER 392058-01-4
(Part 1 of 2) (Continued)
Jumper
Number
Available
Selections
W14
W15
W16
W17
W18
W19
1-2
2-3
1-2
2-3
1-2
2-3
1-2
2-3
1-2
2-3
1-2
2-3
Function
RASCL TX clock to SCC
RASCL not present
Select other comm. types
Select 1 MBd non-RASCL comm.
Select other comm. types
Select 1 MBd non-RASCL comm.
RASCL RX clock to SCC
RASCL not present
RASCL Link 1 error to ECB
RASCL Link 2 error to ECB
RASCL not presebt
RS-
485
2-3
AR
AR
2-3
2-3
2-3
RS-
423
2-3
1-2
1-2
2-3
2-3
2-3
RA-
SCL
1-2
1-2
1-2
1-2
1-2
1-2
HHT
2-3
1-2
1-2
2-3
2-3
2-3
AR = As Required; see text
* Jumper W6 for port A/C may be left IN or OUT when HHT is used.
** Jumper W7 for port B/D may be left IN or OUT when an internal modem is
included.
2.3.1 RS-485 and RS-423 Port Connections
Ports configured for an RS-423 interface are RS-232 compatible and may be used with a PC or printer. The RS-485 interface is required for BSAP network communications. Details on wiring communication ports are covered in Appendix CP.
CI-3335 Appendix CA Page - 8 CE Boards
2.3.2 RASCL Option
The optional RASCL Board uses port B/D as the communications host and provides a redundant 1MBd channel (LINK 1 and LINK 2) that can be used for a coaxial data highway.
The RASCL Board will also requires configuration. Details on configuring and wiring this board are covered in Appendix RM.
TABLE CA-E -JUMPER SETTINGS FOR BOARD NUMBER 392043-01-7
Jumper
Number
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
Available
Selections
NONE
NONE
NONE
NONE
NONE
-
1-2
2-3
-
1-2
2-3
IN/OUT
IN/OUT
IN/OUT
IN/OUT
Function
For factory use only
For factory use only
For factory use only
For factory use only
For factory use only
Port A/C:
187.5 kBd Sync. Comm.
1 MBd Sync. Comm.
Port B/D:
187.5 kBd Sync. Comm.
1 MBd Sync. Comm.
Port A/C
Port A/C
Port B/D
Port B/D
-
-
AR
-
-
RS-
485
-
AR
OUT
OUT
OUT
OUT
-
-
AR
RS-
423
-
-
-
AR
IN
IN
IN
IN
AR
IN
IN
IN
IN
MO-
DEM
-
-
-
-
-
AR
HHT
-
-
-
-
-
AR
AR
IN
IN
IN
IN
AR = As Required; see text
CI-3335 Appendix CA Page - 9 CE Boards
2.4 SETTING JUMPERS FOR BOARD 392043-01-7
This board contains eleven jumpers that are set according to Table CA-E. The first three columns of this table list the JUMPER NUMBER, AVAILABLE SELECTIONS and FUNC-
TION of each jumper. The last four columns provide the required settings for RS-485, RS-
423, MODEM, and HHT configurations. The jumper conventions are illustrated at the bottom of this table.
Some jumper selections in the last four columns are labeled AR. These selections denote "As
Required" and are set by the user for his communication application.
Setting the jumpers alone may not provide a desired configuration. Make sure that all switches listed in Tables CA-B and CA-C have also been set. Ports configured for an RS-423 interface may be used as a PC or printer interface, while ports configured for an RS-485 interface are used for BSAP network communications. Details on wiring communication ports are covered in Appendix CP.
2.5 LED INDICATORS
The CE Board provides a TXD and RXD indicator for each communication channel. The
LED will be red when the channel is sending data, and green when the channel is receiving data. The left-most LED (closest to the PC board) is dedicated to Port A/C, while the rightmost LED is dedicated to port C/D.
2.6 LOOPBACK TESTING
The loopback configuration feeds the output of the CE Board back to the input. This configuration is used for testing the board via the diagnostic test program described in the User
Manual D4041 - Diagnostics.
2.7 MODEM DOCUMENTATION
Various versions of CI-3335 contain unique information on modems. CI-3335 dated 6/90 contains appendices PLM (D4065-D) and SNM (D4066-E). The 2/94 issue of CI-3335 contains appendices MP (CI-MP b) and MS (CI-MS b). Versions of CI-3335 dated 7/97 to
8/98 contain modem manuals CI-1200 (PL/PSTN), CI-1200-PL and CI-9600 (PSTN). As of
5/99, issues of CI-3335 no longer contain modem manuals or modem appendices (with the exception of the Fiber Optic Interface Board - Appendix FB. The information below is provided to help you identify the modem documentation applicable to your DPC 3335.
P/N Series 396038-XX-X -1200 bps Private Line Modem - Use CI-1200-PL
P/N Series 392569-XX-X -1200 bps Private Line or Switched Network Modem - Use CI-1200
P/N Series 396039-XX-X -9600 bps Switched Network Modem - Use CI-9600
P/N Series 396958-XX-X -9600 bps Switched Network Modem - Use CI-9600A
P/N Series 390114-01-4 - 300 or 1200 bps Switched Network Modem - Use Appendix MP
(CI-MP b) from 2/94 issue of CI-3500 (D4066-E Obsoleted)
P/N Series 389618-01-2 - 300 or 1200 bps Private Line Modem - Use Appendix MS (CI-MS b) from 2/94 issue of CI-3500 (D4065-D Obsoleted)
CI-3335 Appendix CA Page - 10 CE Boards
2.8 COMPATIBILITY WITH 3335 CPUs
CE Boards discussed herein are compatible with various versions of DPC 3335 CPUs. Table
CA-F provides CPU compatibility information for the Communication Engine Boards discussed in this appendix, as well as user documentation references for compatible CPU assemblies.
Table CA-F - COMM. BOARD COMPATIBILITY WITH 3335 CPUs
Comm. Bd.
392043-01-7
Original
Comm. Eng.
Async.
Comm.
On Ports
A, B, C & D
Sync.Comm.
On Ports
B & D
Only
392058-01-4
First
(ECB)
Enhanced
Comm. Bd.
Async. &
Sunc.Comm.
On Ports
A, B, C & D
NOTES
CPU Ass’y.
390841-XX-X
Compatible
Section 3B
9/90 Issue
CI-3335
CPU Ass’y.
391369-XX-X
Not
Compatible
CPU Ass’y.
395217-01-6
Compatible
For use on
RIO 3331
Section 3L
Section 3B
7/97 &
Newer
Issues of
CI-3335
CPU Ass’y.
395358-XX-X
Not
Compatible
Compatible
Section 3B
9/90 Issue
CI-3335
Compatible
Section 3B
7/97 &
Newer
Issues of
CI-3335
Info. First
Appeared
In 2/94
Issue of
CI-3335
Compatible
For use on
RIO 3331
Section 3L
Section 3B
7/97 &
Newer
Issues of
CI-3335
CPU
392036-XX-X
Mem./Perf.
392037-XX-X
12MHz
3331/3335
20MHz CPU
392522-XX-X
12MHz CPU
395212-XX-X
20MHz Mem.
392507-XX-X
12MHz Mem.
395218-XX-X
3335
CPU
395212-01-4
Mem./Perf.
395218-01-2
12MHz
3331
Use Info.
In Section
3B to Configure this Ass’y.
Compatible
But Not
Recommended
For
Synchronous
Comm.
Section 3BA
7/97 &
Newer
Issues of
CI-3335 or
PIP-
32RM3335
CPU
395559-01-3
Mem./Perf.
392558-XX-X
3335
386
Real Mode
CPU Ass’y.
396029-XX-X
Not
Compatible
Compatible
But Not
Recommended
For
Synchronous
Comm.
Section 3BB
7/97 &
Newer
Issues of
CI-3335 or
PIP-
32PM3335
CPU
395559-01-3
Mem./Perf.
392558-01-7
3335
386
Protected
Mode
CPU Ass’y.
392762-01-3
Not
Compatible
Compatible
But Not
Recommended
For
Synchronous
Comm.
Section 3BC
7/97 &
Newer
Issues of
CI-3335 or
PIP-
PMEN3335
CPU
392907-XX-X
Mem./Perf.
392910-XX-X
3335
386
Ethernet
CPU
CI-3335 Appendix CA Page - 11 CE Boards
BLANK PAGE
Appendix CP
COMMUNICATION PORTS
FOR SERIES 3335 CONTROLLERS
- Contents -
TYPES OF CONNECTORS ............................................................. CP-1
WIRING OF CONNECTORS .......................................................... CP-1
RS-485 Interface (Ports A, B, C, D, I, J, BIP1 & BIP2)............... CP-1
RS-232 Interface (Ports A, B, C, D, I, & J)..................................CP-3
RS-562 Interface (Ports BIP1 & BIP2) ......................................... CP-4
NETWORK INTERFACE BOX ...................................................... CP-5
Master-to-Slave Distances ............................................................ CP-6
Installing the NIBs ....................................................................... CP-6
Limits of Surge Protection ............................................................ CP-7
TYPES OF CONNECTORS
Series 3335 Distributed Process Controllers 9-pin connector for ports A, B, C, D, I, J, BIP1 &
BIP2). The mating connectors are furnished with two-piece shrouds that can be assembled to a connector even after the pin wiring has been soldered in place. The manufacturer's name and part numbers are provided as follows:
Male Connector........................................................AMP 747904-2
Split Shroud .............................................................AMP 206478-1
WIRING OF CONNECTORS
Series 3335 DPCs provide ports A and B (186-Based CPUs) or ports BIP1 and BIP2 (386-
EX-Based CPUs) as standard, and ports C, D I & J as options. Ports A, B, C, D, I & J can be wired for a RS-232 or a RS-485 communication interface. The 32-Bit CPU Board contains two ports (BIP1 and BIP2) which can be configured for either a RS-485 or RS-562 communication interface.
RS-485 Interface (Ports A, B, C, D, I, J, BIP1 & BIP2)
Series 3335 DPCs used for network communications require a port configured for RS-485.
This interface, which is an enhanced RS-422 interface, is fully compatible with 3310 and
3330 controllers. However, older models use 15-pin connectors, while the 3330/3335 use 9pin connectors. When wiring up a system of mixed models, be sure to properly identify all connectors. Refer to the appropriate controller manuals for details.
The connections for the 9-pin, RS-485 interface are shown in Figure 1, while the corresponding pin labels are given in Table A. Since this interface is intended for network com-
CI-3335 (03/03) Communication Ports / CP-1
munications, Table B provides the appropriate connections between each network drop. The three columns of Table B provide the pin number and the identifiers for the master, first slave, and the nth slave. The nth slave represents the connections for all remaining slaves that are linked to the master. Essentially, the master and the first slave transmit and receive data on opposite lines, while all slaves (from the first to the "nth") are paralleled
(daisy chained) across the same lines.
To ensure that the "Receive Data" lines are in a proper state during inactive transmission periods, certain bias voltage levels must be maintained at the master and most distant slave units. This is accomplished by using a termination device described under the topic, NET-
WORK INTERFACE BOX.
Figure 1 - RS-485 Connector
TABLE A - RS-485 PIN IDENTIFIERS
5
6
7
1
2
3
4
8
9
Pin No.
Pin Code
TXD+
TXD-
RXD+
RXD-
RTS+
CTS+
CTS -
RTS -
GND
Signal Name
Transmit Data +
Transmit Data -
Receive Data +
Receive Data -
Request To Send +
Clear To Send +
Clear To Send -
Request To Send -
Ground
TABLE B - RS-485 NETWORK CONNECTIONS (see Note 1)
From
Master
To 1st
Slave
1 TXD+
2 TXD-
3 RXD+
4 RXD-
3 RXD+ 1 TXD+
4 RXD 2 TXD-
To nth
Slave
3 RXD+
4 RXD-
1 TXD+
2 TXD-
Note 1:
Pins 5 to 9 of each connector are unused.
CP-2 / Communication Ports CI-3335 (03/03)
RS-232 Interface (Ports A, B, C, D, I & J)
An RS-232 port can be used to provide a communication interface to devices such as printers, VDTs, PCs, etc. For this application the device must be located within 25 feet of the distributed controller (this interface scheme is not intended for network communications). Pin connections for RS-232 are shown in Figure 2 and are defined in Table C.
Figure 2 - RS-232 Connector
TABLE C - RS-232 PIN IDENTIFIERS
Pin
No.
1
2
3
Pin
Code
Signal Name
DTR Data Term. Ready (Out)
TXD Tx Data (Out)
-
Pin
No.
6
7
8
Pin
Code
CTS
DCD
DTR * or
DSR *
Signal Name
Clear to Send (In)
Data Carrier Detect (In)
Data Term. Ready
Data Set Ready
* (Out)
* (In)
4
5
RXD
RTS
Receive Data (In)
Request to Send (Out)
9
-
GND
-
Ground
-
* 3335 Ports A, B, C, D, I & J (Enhanced Comm. Bds.) - ECB’s 392589-01-0 & 392589-02-
8
A, B, C, D, I & J are RS-232 ports and have both pins 1 and 8 assigned as DTR (Out).
When configuring the RS-232 cable between the PC\Panel Mount Modem and the
ECB Comm. Port in question, leave pin 8 (or pin 6 at the modem port) OPEN, unconnected.
* 3335 Ports A, B, C & D (Comm. Engine Boards) - CEB’s 392043-01-7 & 392058-01-4
A, B, C & D are RS-423 ports (RS-232 compatible) and have pin 8 assigned as DSR
(In).
Figure 3 - RS-232 Interface for PC 9-Pin RS-232 or Compatible Port
CI-3335 (03/03) Communication Ports / CP-3
An RS-232 port can be programmed to communicate with a PC (Personal Computer). This is accomplished via the ACCOL load which defines ports for various applications. For PC communications, the selected port is set to function as a slave or pseudo slave. Details on this procedure are described in the ACCOL II Interactive Compiler users manual.
Figure 3 shows the cable wiring required for a 9-Pin RS-232 Port. For other RS-232 Ports, consult the manufacturer's hardware manual.
RS-562 Interface (Ports BIP1 & BIP2)
A port configured for an RS-562 interface is compatible with devices having an RS-232 communication interface. These include devices such as printers, VDTs, PCs, etc. For this application the device must be located within 25 feet of the distributed controller (this interface scheme is not intended for network communications). Pin connections for RS-562 are shown in Figure 4 and are defined in Table D.
Figure 4 - RS-562 Connector
Notice that the pin connections shown in Figure 4 are obtained when configuration switches
SW3 (for BIP1) or SW4 (for BIP2) of the 386EX CPU are set as described in Sections
3BA/3BB/3BC of this manual. If either SW3-7/SW3-8 or SW4-7/SW4-8 is set to OFF, operation can also be achieved by wiring a jumper across pins 5 and 6 of the connector (RTS and CTS jumpered). This configuration allows these connectors to be used in applications that require the external jumper.
TABLE D - RS-562 & RS-232 PIN IDENTIFIERS
Pin
No.
1
2
3
4
5
Pin
Code
Signal Name
DTR Data Term. Ready (Out)
TXD Transmit Data (Out)
-
RXD Receive Data (In)
RTS Request to Send (Out)
Pin
No.
6
7
8
9
-
Pin
Code
Signal Name
CTS Clear to Send (In)
DCD Data Carrier Detect (In)
DTR Data Term. Ready (Out)
GND Ground
-
An RS-562 port can be programmed to communicate with a PC (Personal Computer). This is accomplished via the ACCOL load which defines ports for various applications. For PC communications, the selected port is set to function as a slave or pseudo slave. Details on this procedure are described in the ACCOL II Interactive Compiler users manual.
The typical PC 9-Pin RS-232 Port interface schemes are shown in Figure 5. For other RS-
562/232 Ports, consult the manufacturer's hardware manual.
CP-4 / Communication Ports CI-3335 (03/03)
Figure 5 - RS-562 Interface for PC RS-232/562 or Compatible Port
NETWORK INTERFACE BOX
The Network Interface Box (NIB) is a compact assembly that mounts externally to a distributed controller. It contains a dc/dc converter assembly that converts the +24 V power source to separate +15 V and -15 V regulated outputs. These outputs are used to bias the communication line through a resistive circuit.
The NIB can also be furnished on a mounting plate capable of holding four units. The plate has a 5-1/4 x 19 inch surface that is suitable for mounting in a standard 19-inch width rack.
Figure 6 - Network Interface Box with Cover Removed
A NIB is required for all RS-485 communication networks in order to maintain the correct line status during periods of inactive transmissions. While a NIB is recommended for each node, only the master and the most distant slave require bias termination. If they are not biased, communication errors can result and the system may go into a "watchdog" condition.
CI-3335 (03/03) Communication Ports / CP-5
This can lead to excessive delays as the system is checked for non-existent faults. Installing
NIBs from the start will avert this problem.
Electrical surges or spikes on the communication line are another source of trouble that can damage the input circuitry of one or more nodes. All NIBs include surge suppression circuitry designed to protect the communication ports of a node.
The NIB contains two jumpers that are used to Enable or Disable the bias termination discussed above. Since bias termination is only used with the master and most distant slave units, it should be turned off for all units in between.
Master-to-Slave Distances
The maximum distance of an RS-485 network line should not exceed 1000 feet. Shown graphically in Figure 7, this distance extends from the master unit to the last or most distant slave. Although this illustration shows three slaves, this distance is applicable to any number of slaves (each master port can support a maximum of 32 slaves).
The distance from a network line drop to a slave should be kept as small as possible. The
NIBs, that are required in the wiring scheme of Figure 7, should be located as close as possible to the node they are serving.
Installing the NIBs
Once a communication network plan has been established, use the following steps as a wiring and setup guide:
1. Start at the location of the MASTER node.
2.
Mount the NIB as close as possible to the DPC.
3.
Remove the NIB's cover. Two captive screws secure the cover.
4. With the power for the DPC turned off, wire the 24 V dc supply source to the +24V and -24V terminals of TB1 as shown in Figure 7. Connect a reliable earth ground to the grounding terminal.
5. Wire up the SDL, RDL, SDT and RDT terminals of the NIB as shown in Figure 9.
This arrangement effectively connects the NIB in the TXD (transmit) and RXD
(receive) lines of the DPC. Keep these connections as short as possible.
6. Referring to the left of Figure 7, insert jumpers W2 and W3 of the NIB into their "B" positions. This configuration implements bias termination required at this location.
7. Replace and secure the cover of the NIB. The NIB installation at this site is now complete.
8. Move to the location of the farthest slave on the line. Repeat steps 2 through 7 but this time apply the same wiring techniques and jumper configurations to the LAST
SLAVE shown in Figure 7.
CP-6 / Communication Ports CI-3335 (03/03)
9.
Wire up all MIDDLE SLAVES as shown in Figure 7 but do not make any power connections to the +24V and -24V terminals. However, be certain that the grounding terminal of each slave node is connected to a reliable earth ground.
10. For all MIDDLE SLAVES, plug in jumpers W2 and W3 as shown at the left. This configuration disables bias termination while retaining the surge protection feature required for all nodes.
11. Apply 24 Vdc power to all nodes and check the network for proper operation.
Figure 7 - Application Using NIB
Limits of Surge Protection
For RS-485 networks the NIB provides full protection from surges in accordance with ANSI-
IEEE STANDARD C37.90-1978 (published earlier as IEEE STANDARD 472-1974).
However, the limits of this protection are not automatically extended to other types of communication equipment requiring different drivers. These exceptions are noted in the following warning:
Warning
The NIB does not provide surge protection for RS-423 drivers (Type 26LS29) wired in parallel to RS-485 or RS-422 IC drivers of other equipment. For these situations,
CI-3335 (03/03) Communication Ports / CP-7
the RS-423 driver should be disengaged by using strapping options where provided, or by removing the Type 26LS29 plug-in IC from its socket at the appropriate communication port. A damaged RS-423 driver that is paralleled across an RS-485 driver will inhibit network communications.
CP-8 / Communication Ports CI-3335 (03/03)
Appendix DJA
Issue: 03/99
4 X 20 DISPLAY/KEYBOARD ASSEMBLY
(with 5 X 5 Membrane Keyboard)
For Instruction Manual CI-3335
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S C R O L L
BRISTOL
BABCOCK
F1 F2 F3 F4 INIT
7 8
4
1
ON
5
2
0
OFF
9
6
ALM
I/E
ALM
ACK
3
DEL ENT
Bristol Babcock
Appendix DJA
4 X 20 DISPLAY/KEYBOARD ASS’Y.
TABLE OF CONTENTS
SECTION TITLE
1.1
2.1
2.2
2.3
PAGE #
Section 1 - INTRODUCTION
DESCRIPTION ..........................................................................................................................1
Section 2 - INSTALLATION, OPERATION & SERVICE
INSTALLATION........................................................................................................................3
OPERATION..............................................................................................................................4
SCREEN ADJUSTMENT ..........................................................................................................4
CI-3335 Appendix DJA Page 0-1 Table Of Contents
Section 1
INTRODUCTION
1.1 DESCRIPTION
The Display-Keyboard (D-K) Assembly provides a convenient local operator interface. With this option, the operator can observe and alter certain DPC parameters defined in the
ACCOL load.
The display consists of a 4-line, 20 character readout on a 5 x 7 dot matrix LCD screen as shown in Figure DJA-1. A screen adjustment (contrast) controls the intensity of the readout.
The keyboard section utilizes 25 keys arranged in a 5 x 5 matrix as shown in the illustration.
When pressed, the keys respond with a soft touch click.
CI-3335
Figure DJA-1 - Front of Remote Unit
Display Keyboard / DJA- 1
This assembly is comprised of a remote unit and a resident component which are interconnected via a ribbon cable. The remote unit contains the Display and Keyboard assemblies and a buffer board. The buffer board provides the driver and receiver circuitry for communications with the resident board. The resident board, which fits into the DPC, contains the processing and system interface circuitry.
The remote unit is of metal construction and is open at the back. It mounts against a flat surface such as a wall or relay rack. The back of the unit contains a flexible gasket and several mounting studs to ensure a tight seal against the mounting surface.
DJA-2 / Display Keyboard CI-3335
Section 2
INSTALLATION, OPERATION & SERVICE
2.1 INSTALLATION
The Remote Unit connects to the DPC via a 10-foot, 50-conductor ribbon cable. One end of the cable plugs into connector X1 on the Remote 4 X 20 Display/Keyboard Interface Board
(which in turn is mounted to the SIB Board), while the other end plugs into the back of the
Remote Unit (See Figures DJA-2 & DJA-3).
Note that the Remote Unit is open at the back and uses the mounting surface as a back plate. It is designed to mount against a surface such as a cabinet wall having a cutout to accommodate the ribbon cable. The mounting holes and cable cutout dimensions are also given in Figure DJA-3.
When attaching the Remote Unit to the mounting surface, all eight nuts and washers
(supplied) must be installed on the threaded studs. All nuts must be tightened sufficiently so that there is a good seal between the rear gasket and the mounting surface. The threaded plug and o-ring that provide access to the screen adjustment must also be installed and secured.
CI-3335
Figure DJA-3 - Display-Keyboard Mounting Arrangement
Display Keyboard / DJA- 3
2.2 OPERATION
When power is first applied to the DPC, a menu or random text may appear on the LCD screen. Press the F4 key to clear the display and bring up the initial menu. This menu will give two choices on the bottom line: SIGN-ON and SCROLL. Also, if user-defined text has been programmed into the load, it will appear on lines above the function selections
(maximum of three lines). If no user-text has been defined in the load, only the bottom line will appear. Figure DJA-1 shows a menu having both types of text in the display.
If the user has an authorized password, he may press the SIGN-ON key (F1). Doing so will present a PASSCODE display that allows access to many read/write parameters and options.
If the user does not have a password, pressing the SCROLL key will initiate a list of menus that display the "read only" parameters. When the last menu in the list has been scrolled, pressing the SCROLL key again returns the display sequence to the top of the list.
Further details covering the keyboard functions and the menu displays are contained in the
Display-Keyboard User Manual (D4085) furnished with the software package.
2.3 SCREEN ADJUSTMENT
The screen adjustment is concealed behind a threaded plug (Figure DJA-1). Remove this plug with a socket wrench or similar tool. Use a screwdriver to turn the pot; clockwise rotation of the pot will increase the contrast. When adjustments are complete, replace the plug and o-ring. The plug must be properly secured to comply with NEMA 4 requirements.
DJA-4 / Display Keyboard CI-3335
Appendix DJB
Issue: 03/99
4 X 20 DISPLAY/KEYBOARD ASSEMBLY
(with Remote Only Membrane Keyboard)
For Instruction Manual CI-3335
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F1 F2 F3 F4
7 8
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1
ON
-
2
0
OFF
9
6
3
INIT
ALM
I/E
ALM
ACK
DEL
A/M
OPER
I/E
ENTER
Bristol Babcock
Appendix DJB
4 X 20 DISPLAY/KEYBOARD ASS’Y.
(with Remote Only Membrane Keyboard)
Series 721614-01-9
TABLE OF CONTENTS
SECTION TITLE
1.1
2.1
2.2
2.3
2.4
PAGE #
Section 1 - INTRODUCTION
DESCRIPTION..............................................................................................................1
Section 2 - INSTALLATION, OPERATION & SERVICE
INSTALLATION ...........................................................................................................2
OPERATION .................................................................................................................6
SCREEN ADJUSTMENT..............................................................................................6
LCD DISPLAY/KEYBOARD TESTS ............................................................................6
CI-3335 Appendix DJB Page 0-1 Table Of Contents
Section 1
INTRODUCTION
1.1 DESCRIPTION
The 4 X 20 Display/Keyboard Assembly (with Remote Only membrane keyboard) provides a convenient operator interface to the DPC 3335. This 4 X 20 Display/Keyboard option can be situated up to 10 feet from the DPC and the unit can be panel or cover/door mounted.
The display consists of a 4-line, 20 character readout on a 5 x 7 dot matrix LCD screen as shown in Figure DJB-1. A screen adjustment (contrast) controls the intensity of the readout.
The keyboard section is a membrane key matrix that utilizes 25 keys as shown in Figure
DJB-1. Keys must be firmly pressed to respond.
Figure DJB-1 - Remote 4 X 20 Display/Keyboard Assembly
CI-3335 Appendix DJB Page 1 D/K (Remote Only Membrane Keyboard)
Section 2
INSTALLATION, OPERATION & SERVICE
2.1 INSTALLATION
The 4 X 20 Display/Keyboard Assembly option (with Remote Only membrane keyboard) can be situated up to 10 feet from the DPC 3335. The 50-conductor cable assembly that interfaces the DPC to the 4 X 20 Display/Keyboard Assembly connects to connector X1 on the Remote 4 X 20 Display/Keyboard Interface Board which is part of a resident two board module (Extended Display/Keyboard Interface Assembly) in the DPC 3335 and to connector
P4 on the Remote 4 X 20 Display/Keyboard Assembly’s Backplane Board (see Figures DJB-2,
DJB-3 & DJB-4). In addition to communication signals this cable provides the power (from the DPC 3330) required by the 4 X 20 Display/Keyboard Assembly.
Figure DJB-2 - Remote 4 X 20 Display/Keyboard Assembly Installation Diagram
CI-3335 Appendix DJB Page 2 D/K (Remote Only Membrane Keyboard)
The Panel or Cover onto which the Remote 4 X 20 Display/Keyboard Assembly is to be mounted will require six .166” diameter mounting holes, a cutout area of 1.4” x 3.4” for the
Display and a cutout area of .25” x 1.875” for the Keyboard’s flat cable and the flat Ground
Lead (see Figure DJB-2). After machining the area where the unit is to be mounted, follow steps 1 through 9 below to install the Remote 4 X 20 Display/Keyboard Assembly.
1. Disconnect power from the DPC 3335 (Shut down or place under manual control any critical processes prior to disconnecting power).
2. Unplug the Remote 4 X 20 Display/Keyboard Assembly’s Keyboard Cable from its connector P1 on the Backplane Board (the larger Printed Circuit Board). Remove the six screws and washers that secure the assembled boards to the Mounting Spacers and place the assembled boards on an ESD safe area
Figure DJB-3 - Remote 4 X 20 Display/Keyboard Ass’y. Interfaced to DPC 3335
3. Remove the six Mounting Spacers from the rear of the unit’s Face/Mounting Plate.
4. Carefully remove the paper from the self-adhesive mounting tape.
CI-3335 Appendix DJB Page 3 D/K (Remote Only Membrane Keyboard)
5. Carefully align the Face/Mounting Plate with the machined mounting area (on the panel or enclosure in question) and feed the flat Keyboard Cable and the flat Ground
Lead through the area that was cutout to accommodate them.
6. With Mounting Studs aligned with their machined mounting holes, firmly press the
Face/Mounting Plate onto the panel or enclosure in question.
7. Install the flat Ground Lead over its designated Mounting Stud. Install the six
Washers and the six Mounting Spacers onto the Mounting Studs that protrude through the inside of the panel or enclosure in question. Note: The flat Ground Lead is to be attached to the associated equipment’s Chassis Ground in the event that the mounting panel or enclosure cover/door is non-metallic.
8. With the units Display aligned with its cutout area, place the assembled boards onto the six Mounting Spacers and replace the six washers and screws.
9. Plug the Keyboard Cable Connector into Connector P1 of the Remote 4 X 20
Display/Keyboard Assembly’s Backplane Board (the larger Printed Circuit Board).
Plug one end of the 50 conductor DPC Display/Keyboard Interface Cable into
Connector P4 on the Backplane Board. Plug the other end of this cable into the
Connector X1 on the Extended Display/Keyboard Interface Assembly’s Remote 4 X 20
Display/Keyboard Interface Board (which is installed in the DPC 3335). Apply Power and test the Remote 4 X 20 Display/Keyboard Assembly.
Figure DKB-4 - Extended Display/Keyboard Interface Assembly
CI-3335 Appendix DJB Page 4 D/K (Remote Only Membrane Keyboard)
Note:
The Extended Display/Keyboard Interface Assembly is a two board set that is installed on the System Interconnect
Board in the rear of the DPC 3335. This assembly is secured to four standoffs (on the SIB Board) by three mounting screws and one captive locking screw (see
Figures DJB-4 and DJB-5).
Figure DJB-5 - SIB Board with Extended Display/Keyboard Interface Assembly
CI-3335 Appendix DJB Page 5 D/K (Remote Only Membrane Keyboard)
2.2 OPERATION
When power is first applied to the DPC 3330, a menu or random text may appear on the remote 4 X 20 Display/Keyboard Assembly’s LCD screen. Press the F4 key to clear the display and bring up the initial menu. This menu will give two choices on the bottom line:
SIGN-ON and SCROLL. If user-defined text has been programmed into the load, it will appear on lines above the function selections (maximum of three lines). If no user-text has been defined in the load, only the bottom line will appear. Figure DKB-1 shows a menu having both types of text in the display.
The user is presented with two choices on the initial menu: SIGN-ON and SCROLL. If the user has an authorized password, he may press the SIGN-ON key (F1). Doing so will present a PASSCODE display that allows access to many read/write parameters and options. If the user does not have a password, pressing the SCROLL key will initiate a list of menus that display the “read only” parameters. When the last menu in the list has been scrolled, pressing the SCROLL key again returns the display sequence to the top of the list.
Further details covering the keyboard functions and the menu displays are contained in the
Display-Keyboard User Manual (D4085) furnished with the software package.
2.3 SCREEN ADJUSTMENT
The LCD Display Screen Adjusting Pot. is situated near connector P4 on the Remote 4 X 20
Display/Keyboard Assembly’s Backplane Board (see Figure DKB-2). Use a screwdriver to turn the Pot. Clockwise rotation of the Pot. Will increase the contrast.
2.4 LCD DISPLAY/KEYBOARD TESTS
LCD Display testing can be perform in conjunction with Chapter 15 of the Diagnostics
Manual (D4041). Four off-line diagnostic tests can be performed for the Remote 4 X 20
Display/Keyboard Assembly.
CI-3335 Appendix DJB Page 6 D/K (Remote Only Membrane Keyboard)
Appendix FB
FIBER OPTIC INTERFACE BOARD
PT. NO. 392047-01-9
- Contents -
FiberOpticFeatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-2
Board Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-3
CONFIGURATION AND WIRING OF LINK-SELECT DI . . . . . . . . . . . . . . . . . . . . . . . . . . FB-6
Master-Slave-Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-8
Point-to-Point Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FB-9
DESCRIPTION
The Fiber Optic Interface Board (FOI Board) provides communications using coherent infra-red light transmission over fiber optic cable. The board provides single-channel communications at asynchronous rates from 300 Bd to 38.4 kBd; the rates are selectable via the ACCOL
Interactive Compiler (AIC) software.
The FOI Board is a subassembly that plugs into the Communication Engine Board (CE Board).
It communicates with the fiber optic network through two links (LINK 1 & LINK 2), each of which contains two ports labeled TX and RX (transmit and receive). In a network application, one link communicates with the preceding node, and the other with the succeeding node. In a less common application, two DPCs with FOI Boards can function as a point-to-point redundant link.
The TX and RX ports of each link are intended for use for use with dual-line cable. The cable provides bi-directional communication paths for the FOI's transmitter and receiver (full-duplex line; half-duplex transmission).
The FOI Board employs a miniature fiber optic transmitter module with a planar 850 nm GaA/Ax emitter capable of efficiently launching optical power into 100/200 um cable. The module also contains a spherical lens that collimates the light to aid in launch efficiency.
CI-3335 FOI Board / FB-1
To Comm. Engine Board
Comm Expansion Bus
Connector
Configuration
Switches
SW1 & SW2
Uninterruptable
24V Supply
2-Pin
Terminal
Block
TB2
+24V
Auxiliary
Power
Input
System
+5V
FIBER OPTIC
CONTROL
LOGIC
Link 1
Fiber
Optic
Xmitter
Link 1
Fiber
Optic
Receiver
Link 2
Fiber
Optic
Xmitter
Link 2
Fiber
Optic
Receiver
LS *
2-Pin
Terminal
Block
TB1
Link
Select
Discrete
Input
*
LINK SELECT DI
ACCOL - CONTROLLED DI
FOR REDUNDANT LINK
APPLICATION.
Status Indicators
S1 DS
Figure 1 Block Diagram of Board o o
The fiber optic receiver module incorporates a monolithic photo IC that contains a photodetector and a dc amplifier. Consistent optical coupling into the receiver is assured by an integral-lensed system.
Fiber Optic Features
o o o
Infra-red transmissions are impervious to radio and electromagnetic noise interference.
In many situations where communication links are required, the distance-vs.-speed characteristics are above that of standard wire specifications.
Fiber optic systems offer excellent data security since they do not radiate signals that can be picked up by unauthorized monitoring equipment.
For areas subject to lightning strikes, the use of a fiber optic link eliminates the possible destruction of the electrical interfaces of two units located in separate buildings.
Fiber optic lines eliminate the possibility of ground loops and common mode voltage potentials even when ground potentials of two FOI units are at different levels.
FB-2 / FOI Board CI-3335
Board Overview
The block diagram of Figure 1 illustrates the essential board components. The Fiber Optic
Control Logic circuit at the center performs the processing and control functions of the board.
The single-channel signals are sent and received through the LINK 1 and LINK 2 blocks at the right. Each link consists of a transmitter and receiver circuit that communicates via the TX and
RX ports of each link. In a network configuration, one link communicates with the preceding node, and the other link with the succeeding node.
The board employs six LEDs to indicate signal status and two configuration switches to select the operating mode. It also includes a two-pin connector for an auxiliary 24 V uninterruptable supply source that provides power to operate the optic transmission system in the event that the regular supply source fails; this allows the board to maintain signal continuity to other nodes even though it is not functioning.
A two-pin connector is also provided for switching links in a redundant point-to-point link application. Since the FOI Board does not possess the ability to monitor and evaluate the link statuses, these functions must be programmed into the ACCOL load (version 5.1 or greater).
ACCOL contains a software module called Port Status that retains port statistics; if either "no data" or "bad data" is detected for the on-line link, ACCOL can be programmed to change the status of a DO wired to the link-select DI. The status of this DO determines which link will be on line.
ADDING FOI BOARD TO EXISTING UNIT
An FOI Board can be added to any version of the CE Board. Before installing the FOI Board, check the configuration switches and jumpers as described in this appendix. Then, power down the DPC to prevent any circuit damage and remove the Comm. Engine Module to configure it for the FOI application (see Section 3C for details). Once configured, install both boards in the
DPC and re-apply power (see Section 2 for board removal and installation procedures).
SWITCH SETUP
Before performing any configuration, it will be necessary to power down the DPC and remove the CE Board in order to access the FOI Board. General details on board removal and installation are covered in Section 2 - Installation.
The board contains two eight-switch packages (SW1 and SW2 in Figure 2) that provide the functions noted in Tables A through D. Table A lists the positions of SW1 that are used to assign an FOI Board as a point-to-point redundant link, or as master or slave node in a network.
Table B lists the SW1 positions that set the links for single or redundant applications, and those that disable the indicating LEDs for power conservation. Table C provides the optical gain settings necessary to compensate for cable losses over varying distances using switch SW2.
Table D lists the SW2 selections for Normal mode; the procedures for Loopback mode are described in User Manual D4041 - Diagnostics.
CI-3335 FOI Board / FB-3
FB-4 / FOI Board
Figure 2 Fiber Optic Interface Board Assembly
CI-3335
The ON/OFF conventions for the DIP switches used in Tables A through D are as follows:
DIP SWITCH
CONVENTIONS
OFF
ON
On = Close
Off = Open
CI-3335
TABLE A. MASTER/SLAVE ASSIGNMENTS (SW1-1 TO -3)
FOR MASTER NODE
Redundant Link on Port B
Redundant Link on Port D
Master/Slave Network on Port B
Master/Slave Network on Port D
FOR SLAVE NODE
Redundant Link on Port B
Redundant Link on Port D
Master/Slave Network on Port B
Master/Slave Network on Port D
SW1-1
ON
OFF
ON
OFF
SW1-1
ON
OFF
ON
OFF
SW1-2
ON
ON
OFF
OFF
SW1-2
ON
ON
OFF
OFF
SW1-3
ON
ON
ON
ON
SW1-3
OFF
OFF
OFF
OFF
TABLE B. LINK RECEIVER/LED CONTROL (SW1-4 to -8)
SWITCH
NO.
SW1-4
SW1-5
SW1-6
SW1-7
SW1-8
FUNCTION
Factory use only
Factory use only
LEDs enabled
LEDs disabled to conserve power
Not used
Not used
SWITCH
POSITION
OFF
OFF
ON
OFF
-
-
FOI Board / FB-5
TABLE C. LINK GAIN SELECTIONS (SW2-1 to -4)
FOR LINK 1
For cable distance 2500-5000 ft.
For cable disrance 500-2500 ft.
For cable distance 1-500 ft.
FOR LINK 2
For cable distance 2500-5000 ft.
For cable disrance 500-2500 ft.
For cable distance 1-500 ft.
SW2-1
ON
ON
OFF
SW2-3
ON
ON
OFF
SW2-2
ON
OFF
OFF
SW2-4
ON
OFF
OFF
TABLE D. NORMAL/LOOPBACK MODE (SW2-5 to -8)
SWITCH
NO.
SW2-5
SW2-6
SW2-7
SW2-8
NORMAL/LOOPBACK
FUNCTIONS
/RTSB to /CTSB Loopback disable
/DTRB to /DCDB Loopback disable
/RTSD to /CTSD Loopback disable
/DTRD to /DCDD Loopback disable
NORMAL
MODE
ON
OFF
ON
OFF
Note: ON = Enabled, OFF = Disabled
CONFIGURATION AND WIRING OF LINK-SELECT DI
As previously explained, the Link-Select Discrete Input (LSDI) feature is only required for a redundant, point-to-point link. The source of the LSDI signal is a DO Module (hardware) that is driven by a Port Status Module residing in ACCOL software.
Jumper W1 of the FOI Board configures the LSDI for the external signal. This jumper is always plugged into position A as shown in Figures 3 and 4 to utilize the DPC's internally "+ Supply" which is 5 V dc.
Figure 3 shows the LSDI actuated by the open collector output of a DO Module (hardware), while Figure 4 shows it actuated by a relay contact output. Where both types of DOs are available in the same DPC, it is recommended that the open collector type be chosen so that relay contacts are available for heavier load-switching applications.
FB-6 / FOI Board CI-3335
JUMPER CLUSTER
W1
"A" CONFIGURATION
DO MODULE
P
OPEN COLLECTOR TYPE
A1
B1
+
_
+ SUPPLY
P
P
FIBER OPTIC INTERFACE
BOARD
Figure 3 Internally-Powered DI
JUMPER CLUSTER
W1
"A" CONFIGURATION
+ SUPPLY
DO MODULE
RELAY CONTACT TYPE
A1
B1
+
_
P
P
FIBER OPTIC INTERFACE
BOARD
Figure 4 Externally-Powered DI
CI-3335 FOI Board / FB-7
Jumper W2 is used for configuration of the Link Select Discrete Input (LSDI) feature as follows:
W2 - 1 to 2 = DTRB to Link Select DI
W2 - 2 to 3 = DTRD to Link select DI
W2 - Open = External DI is the Link Select
LED INDICATORS
The FOI Board contains six LEDs whose locations are shown on the board assembly of Figure
2. Three of these LEDs apply to LINK 1 and the other three to LINK 2. The LED functions are as follows: o TX (Transmit Data)
This LED lights to indicate that a link is transmitting data over the line.
o o
RX (Receive Data)
RX lights to indicate that the link is receiving data. It will typically blink on and off when there is data activity.
ST (Link Status)
In a redundant link application, this LED lights to indicate that a link has been selected to be the primary or on-line link. Conversely, the opposite ST LED will be off to indicate it is the secondary or backup link.
GENERAL APPLICATIONS
Master-Slave Networks
A master/slave FOI Board network consists of a master and a number of slaves as shown in
Figure 5. Each FOI Board shown in this illustration is installed in a DPC-3335.
In Figure 5, the master is positioned at the top of the network with its slaves connected in daisychain fashion down to the most distant unit. This application shows the slave lines connected to the LINK 1 terminals of the DPC master.
LINK 1 and LINK 2 of each board contains two fiber optic ports labeled TX and RX. Each link transmits through the TX and receives through RX. These connectors are intended for use for use with dual-line cable that provide the bi-directional communications required for fiber optic systems.
The maximum communication distance between each node is 5000 feet. Because of line losses, the gain of each FOI Board must be optimized for best performance. This procedure is accomplished by setting switches SW2-1 and SW2-2 as noted in Table C.
Figure 5 also shows an optional arrangement whereby a backup power supply is wired to the auxiliary input terminals of each slave FOI Board. This supply maintains 24 V dc on the optical communication system in the event that the node experiences a power failure. Without this
FB-8 / FOI Board CI-3335
backup, a power failure at any one node would halt communications for the remainder of the line. The only node not requiring backup is the last or end node since its failure will have no impact on communications between the preceding slaves and the master.
DPC MASTER
DO
Aux.
Pwr.
Input
FOI
BOARD
LINK 1
TX RX
DI
LINK 2
TX RX
Max. Length 5000 Ft.
Subsequent Nodess
Power
TX RX TX RX
LINK 1
+
_
Aux.
Pwr.
Input
LINK 2
FOI
BOARD
DI
DPC SLAVE
Backup
Power
Supply
TX RX TX
LINK 1 LINK 2
+
_
Aux.
Pwr.
Input
FOI
BOARD
DI
DPC SLAVE
RX
DO
Figure 5 Basic Master/Slave Fiber Optic Network
The DPC master need not necessarily be placed at one end of the line as shown in Figure 5. As an alternate method, the master may also be positioned anywhere along the line with slaves loops extending in both directions. Figure 6 shows such an example where the LINK 1 and
LINK 2 terminals of the master connect to separate slave runs. The activation of both pairs of
LINK terminals is obtained by setting switches SW1-4 and -5 as noted in Table B. When the switches of the master are configured for this application, both LINK 1 and LINK 2 will carry the same data. Except for the location of the master node, the master/slave relationship is the same as presented in Figure 5.
Point-to-Point Link
Redundancy can be obtained for a point-to-point link by using the wiring arrangement of Figure
7. When switches SW1-4 and -5 are configured for redundancy as noted in Table B, both LINK
1 and LINK 2 will carry the same data. The determination for selecting the on-line link is made by a link-select discrete status signal wired to the LS connector on the FOI Board. This signal, which is obtained from DO terminals of a DO Module, is set by the Port Status Module in
CI-3335 FOI Board / FB-9
ACCOL software. The DO-DI connection is represented symbolically in Figure 6, while the actual physical connections are detailed under the topic, CONFIGURATION AND WIRING OF
LINK-SELECT DI. The optional backup power supply is not required for this application since a failure of either node would halt communications with or without power backup.
DPC MASTER
DO
Aux.
Pwr.
Input
FOI
BOARD
LINK 1
TX RX
DI
LINK 2
TX RX
Max. Length 5000 Ft.
Backup
Power
Supply
TX RX TX RX
LINK 1
+
_
Aux.
Pwr.
Input
LINK 2
FOI
BOARD
DI
DPC SLAVE
DO
End Node
Backup
Power
Supply
TX RX TX RX
LINK 1 LINK 2
+
_
Aux.
Pwr.
Input
FOI
BOARD
DI
DPC SLAVE
DO
Max. Length 5000 Ft.
Subsequent Nodess
Backup
Power
Supply
TX RX TX RX
LINK 1
+
_
Aux.
Pwr.
Input
FOI
LINK 2
BOARD
DI
DPC SLAVE
DO
Backup
Power
Supply
TX RX TX RX
LINK 1 LINK 2
+
_
Aux.
Pwr.
Input
FOI
BOARD
DI
DPC SLAVE
DO
Figure 6 Master/Slave Network with Centrally-Positioned Master
FB-10 / FOI Board CI-3335
DPC MASTER
DO
Aux.
Pwr.
IInput
FOI
BOARD
LINK 1
TX RX
DI
LINK 2
TX RX
+
_
TX RX
LINK 1
Aux.
Pwr.
IInput
FOI
TX RX
LINK 2
BOARD
DI
+
_
DPC SLAVE
D O
Figure 7. Point-to-Point Redundant Link
If desired, the setup of Figure 7 could also be wired for a non-redundant point-to-point link. In this instance, the connections for LINK 2 would be eliminated, leaving only connections to LINK
1. This application will require the switch configuration noted in Table B.
FIBER OPTIC CONNECTORS AND CABLE
The fiber optic connector system recommended for this application is the Ensign-Bickford Crimp and Cleave system. This system, which uses a buffer and cladding, is relatively easy to use and provides quick, reliable termination. The cladding, which remains on after the buffer is removed for termination, provides end-to-end fiber strength and resistance to fatigue. A metal crimp insert is applied directly to the protective hard cladding, providing permanent fiber retention, thereby eliminating the need for epoxy or adhesives. The crimped fiber is precisely cleaved, eliminating all polishing steps. This method of connection requires only a few hand tools and no consumable materials.
CI-3335 FOI Board / FB-11
The recommended cable is Ensign-Bickford Type HCP, Hard Clad Silica. This cable has a core diameter of 200 um and provides low attenuation over the spectral range of 400-1400 nm, with a very low loss at the 850 nm transmission range of the FOI Board. This cable provides excellent performance for short to medium haul applications.
HCP offers features such as higher power levels and crimp and cleave terminations. The fiber design incorporates a high, core-to-clad ratio and a pure silica core with a chemically bonded hard polymer optical cladding. A Tefzel buffer protects the fiber from chemicals and abrasion, but it can be easily removed for quick, simple termination.
Ensign-Bickford offers the TK-6 Fiber Optic Termination Kit. This kit contains assembly instructions and the necessary tools required to perform connections.
FB-12 / FOI Board CI-3335
Appendix HD
Issue: 01/03
For Instruction Manuals CI-3310/30/35
5
J1
1
9 6
1
W2
1
W6
TB1
W4 W3W5
1
1 1
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T1
TB2
Bristol Babcock
Appendix HD
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER
)
(HART
DEVICE INTERFACE
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
3.1
3.2
3.3
3.4
3.5
3.6
2.1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
2.2.3
2.2.3.1
2.2.3.2
SECTION
TABLE OF CONTENTS
TITLE PAGE #
GENERAL INTRODUCTION.................................................................................................... 1
FEATURES................................................................................................................................ 1
THEORY.................................................................................................................................... 1
HDI DESCRIPTION.................................................................................................................. 2
HDI Board Connectors ...................................................................................................... ........ 2
HDI Board Status LEDs............................................................................................................ 3
HDI Board Circuitry....................................................................................................... ........... 4
Section 2 - CONFIGURATION & CONNECTIONS
RESTRICTIONS & ASSUMPTIONS......................................................................................... 7
HART Slave Devices .................................................................................................................. 7
3508 Smart Transmitters .......................................................................................................... 7
CONFIGURAING A SINGLE HDI BOARD .............................................................................. 8
RS-485 Interface - To a Single HDI Board ................................................................................ 8
RS-232 Interface - To a Single HDI Board .............................................................................. 10
Configuring Multiple HDI Assemblies into a Single 33XX Master ......................................... 11
Multiple HDI Boards Configured for RS-485 Operation ......................................................... 11
Multiple HDI Boards Configured for RS-232 Operation ......................................................... 13
HART COMMUNICATION PROTOCOL PARAMETERS
FOR PHYSICAL LINK ............................................................................................................ 15
HART DEVICE IMPEDANCE SPECIFICATION ................................................................... 15
HART DEVICE POWER SUPPLY REQUIREMENTS............................................................ 15
PHASE SHIFT SPECIFICATION ........................................................................................... 15
PERFORMANCE SPECIFICATION ....................................................................................... 15
ENVIRONMENTAL SPECIFICATION ................................................................................... 16
SUPPLEMENTS
REFERENCE DOCUMENTS
(Note: These documents are not provided in this manual)
BBI HART MASTER PROTOCOL MANUAL.................................................................... D4068
BBI ACCOL II REFERENCE MANUAL ........................................................................... D4044
HART
§
FSK PHYSICAL LAYER SPECIFICATION -
HART
§
Communication Foundation Document Number .................................... HCF_SPEC-54
CI-3310/30/35 Page 0-1 HART Contents
Section 1
INTRODUCTION
1.1 GENERAL INTRODUCTION
Note: HART is a registered trademark of the HART Communication
Foundation of Austin, Texas, USA. Any time the term ‘HART’ is used hereafter in this document, the term implies the registered trademark.
Highway Addressable Remote Transducer (HART) Device Interfaces (HDI) allows HART slave devices or BBI 3508 transmitters to communicate with a BBI Series 33XX DPC/RTU, i.e., 3305s, 3310s, 3330s, and 3335s. The HDI supports RS-232 and RS-485 interfaces. The interface to the field devices is composed of a jumper selectable 249 ohm resistor in parallel with an AC coupled transformer. An HART/TIB ACCOL Custom Module and the configuration of a host (33XX) communications port as a custom port in ‘HART mode’ are required to support the protocol (Data Link Layer) for HART devices. The ACCOL Master
Module is used to support RS-232 configured HDIs for communication with BBI 3508 transmitters. Each HDI can interface with up to 15 HART slave devices.
1.2 FEATURES
Selectable RS-232 or RS-485 Interface to DPC/RTU
Transformer Coupled Comm. Interface to HART devices
Operates from external 9 to 30 VDC power source
Usable with both HART slave devices and BBI 3508 transmitters. RS-232/RS-485 mode of communications is valid for HART slave devices. RS-232 mode is valid for BBI 3508s.
Conforms to HART
·
FSK Physical Layer Specification.
1.3 THEORY
The BBI HART Device Interface (HDI) provides for master/slave communications, with the master originating each transaction, and slaves only generating replies when prompted by the master. HART allows for 2 ‘masters’ on a single link. The “Primary Master” is the normal control-system master, and when required, a hand-held communicator can be used as the “Secondary Master,” for maintenance purposes. Primary and secondary masters must be configured to use separate addresses.
The BBI HDI board provides an RS-485/232 interface to a BBI 33XX DPC/RTU Communications Port and a two-wire (voltage sourced or current sourced) connection to a ‘HART device’ or to a BBI 3508. Twisted-pair copper cable is used as the medium.
The HART Device Interface operates from 9 to 30 VDC bulk supply. The assembly supports
RS-232 or RS-485 interfaces to the host BBI 33XX DPC/RTU. The signals are TXD, RXD,
CTS, RTS and CD for RS-232 operations and +TXD, -TXD, +RXD and -RXD for RS-485 operation. Interface to the field device is composed of a jumper selectable 249 ohm resistor in parallel with an AC coupled transformer. FSK signal amplitude during transmission is between 400 to 600 mV with the average value of the FSK signal at 0 V. The HDI board
CI-3310/30/35 Appendix HD Page - 1 HART Device Interface
receiver input requires a signal that must be in the range of 120 mV to 1.5 V (Peak-to-Peak).
FSK signals from the field devices below 80 mV (Peak-to-Peak) will be ignored by the interface board.
1.4 HDI DESCRIPTION
The HART Adapter Interface Board is assembled in a DIN Rail Mounting Assembly. This assembly measures 5.56” long by 4.37” in high by 1.06” deep. In addition to 8 selectable jumpers and 4 status LEDs, the HDI Board contains three connectors (see Figures 1 & 10).
1.4.1 HDI Board Connectors
J1 - a 9-Pin D-Type Connector for the RS-232 Interface (see Table 1)
TB1- a 6-Point Term. Block for the RS-485 Interface and the Input Power (see Table 2)
TB2- a 2-Point Terminal Block for Slave Device Field Connections (see Table 3)
Figure 1 - HART Device Interface Assembly
CI-3310/30/35 Appendix HD Page - 2 HART Device Interface
Table 1 - RS-232 Interface Connector J1 Signal Identification
PIN # RS-232 SIGNAL SIGNAL DESCRIPTION
1 DCD Data Carrier Detect
2
3
5
6
7
/TXD
/RXD
GND
CTS
RTS
Transmit Data NOT
Receive Data NOT
Ground
Clear to Send
Request to Send
DCE I/O
Output
Input
-
Output
Output
Input
Table 2 - Power & RS-485 Interface Connector TB1 Signal Identification
PIN #
1
2
3
4
5
6
NAME DESCRIPTION
VIN +9 - +28 VDC Input Power (+)
GND
- RXD
+RXD
- TXD
+TXD
Power Ground (-)
- TX Data from 33XX
+TX Data from 33XX
- RX Data to 33XX
+RX Data to 33XX
Table 3 - Slave Device Field Connector TB2 Signal Identification
PIN #
1
2
FIELD CONNECT
Field Loop (no polarity)
Field Loop (no polarity)
Table 4 - HDI Board Jumper Identification and Assignment
JUMPER #
W1
W2
W3
DESCRIPTION
RS-232 Mode
3508 Mode (10 mS ON Delay)
*RS-485 Rcvr. 120 ohm Terminator
POS. 1-2
Disabled
Disabled
Enabled
POS. 2-3
N/A**
Enabled
Disabled
W4
W5
W6
W7
*RS-485 Rcvr. Positive Bias
*RS-485 Rcvr. Negative Bias
*RS-485 Xmtr. 120 ohm Terminator
Status LED Enable
Enabled
Enabled
Enabled
Enabled
Disabled
Disabled
Disabled
Disabled
W8 249 Ohm Loop Resistor
* = Install on RS-485 End Node
Connected Open
** = W1 is a 2 position Jumper, Installed = RS-232 Disabled/RS-485 Enabled,
Removed = RS-232 Enabled/RS-485 Disabled
1.4.2 HDI Board Status LEDs
There are four status LEDs on the HDI Board. LEDs CR14 through CR17 reflect the status of the active states of Transmit Data NOT (/TXD), Receive Data NOT (/RXD), Data Carrier
Detect NOT (/DCD) and Request to Send NOT (/RTS). A logic “0” state of TXD or RXD will
CI-3310/30/35 Appendix HD Page - 3 HART Device Interface
light CR14 or CR15 respectively. The four LEDs can be disabled by placing jumper W7 in position 2-3.
CR14 = /TXD (Transmit Data NOT)
CR15 = /RXD (Receive Data NOT)
CR16 = /DCD (Data Carrier Detect NOT)
CR17 = /RTS (Request to Send NOT)
1.4.3 HDI Board Circuitry
The HDI board has a built-in 5V DC Switching Power Supply that is fused and operates from a bulk 9V to 30V DC A blocking diode protects the power supply circuitry from reversed input power conditions.
Except for the Power Supply, the major components of the HART Device Interface board are shown in the block diagram (Figure 2).
There are independent RS-232 and RS-485 transceivers which are jumper selectable. An 120 ohm biasing resistor is jumper selectable for the RS-485 transmit lines. An 120 ohm terminator and biasing resistors are jumper selectable for the RS-485 receive lines.
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Figure 2 - Block Diagram of BBI HDI Board
CI-3310/30/35 Appendix HD Page - 4 HART Device Interface
When the HDI is configured to communicate with slave devices which support the HART protocol, and the communication mode between the HDI and the 33XX device is RS-232. CTS
NOT is asserted 100 microseconds after RTS NOT becomes valid. In the RS-485 mode, RTS
NOT is generated by a 1 to 0 transition of TXD. For BBI 3508 applications in RS-232 mode, a 10 millisecond RTS NOT to CTS NOT delay is selected to emulate the existing TIB design.
The added combination of RTS232 NOT and RTS485 NOT enables the 20C12 FSK modem’s transmit circuitry, enables the CMOS switch to the transformer and disconnects the receive signal to the FSK modem’s receiver.
The 20C12 FSK modem operates at Bell 202 standards with a 460.8 KHz clock. The modulated CMOS digital signal from the 20C12 is scaled to a constant
0.6V level via a transformer drive circuit which provides a constant output signal with varying loads. The transformer drive circuit is isolated from the output transformer with a CMOS switch. This switch is only closed during transmission cycles. The received FSK signal is routed through a doubler and bandpass filter to the FSK modem. A CMOS switch disconnects the filtered signal from the input of the FSK receiver during transmit cycles.
The field side of the transformer is AC coupled with a 2.2
P
F capacitor to the field devices and to a jumper selectable 249 ohm load resistor.
RS-232 and RS-485 signals are transorb protected from surge transients and electo-static discharge (ESD).
CI-3310/30/35 Appendix HD Page - 5 HART Device Interface
CI-3310/30/35 Appendix HD Page - 6 HART Device Interface
Section 2
CONFIGURATION & CONNECTIONS
2.1 RESTRICTIONS & ASSUMPTIONS
For multidrop configurations, the field devices are placed in a “digital mode” of operation with the loop current for the device set at 4mA or less. The input impedance of the master in receive mode is 249 ohms. The maximum number of field devices which can be placed in parallel with a 24V supply is determined by the following equation: Max. # of Field devices =
{(24V - V(Field device) - [4mA x 249 x #(Field Devices)] - [4mA x #(Field devices) x Wire
Resistance] - 2Vloop} >0V. This calculation implies that the maximum number of transmitters, which require a minimum of 12V to operate in a loop, is 10 when the wire resistance is not included. The power supply voltage must exceed 24V if more than 10 transmitters are to be connected in parallel. Note: The maximum number of transmitters that can be connected in parallel is not to exceed 15.
Field devices with a maximum ID number of 15 cannot be mixed with field devices with a maximum ID number of 2
24
.
2.1.1 HART Slave Devices
The Carrier On Delay and Carrier Off Delay as specified in the HART Foundation Data Link
Layer specification, states that the delay from an idle line to/from an acceptable signal level is 5 bit times maximum. For HDIs configured for RS-232 communications mode, the carrier
On delay will be met, but, the off delay may exceed the 5 bit time requirement (but the delay will be less than 12 bit times). HART slave devices are required to send a minimum of 5 preambles. The 20C12 FSK Modem located on the HDI board will output receive data within 9 to 15 milliseconds after the transmit cycle is completed. At 1200 baud, one character time is 11 x 0.833 milliseconds or 10 milliseconds. The slave device will start to transmit the preamble one character time after the end of the last character sent from the master device. The total delay from the end of the last character sent from the master to valid receive data is 25 milliseconds. Since there is a 1 character delay from the HART module, the receive communications driver will synchronize on the third preamble at the latest. The receive communications driver for the HART ACCOL module requires one preamble before the start of data.
For the RS-485 mode, the off delay will be between 12 to 18 milliseconds. This is equivalent to 2 characters. The 20C12 FSK Modem takes 9 to 15 milliseconds to assert Carrier Detect
(CD) and valid data. The total delay is 33 milliseconds. The slave device will delay 1 character time, which is 9 milliseconds. The difference is 33 - 9.2 = 23.8 milliseconds. This is about 2.6 characters. Two valid preambles will be seen by the receive communications driver for the HART ACCOL module, which is sufficient before the start of data.
2.1.2 3508 Smart Transmitters
In the RS-232 communications mode, the HDI can operate properly with 3508 transmitters.
The 10 millisecond RTS/CTS delay must be selected.
CI-3310/30/35 Appendix HD Page - 7 HART Device Interface
With existing 33XX firmware, the HDI will not communicate with 3508 TELETRANS when configured in the RS-485 communications mode. A programmable length preamble is required.
2.2 CONFIGURING A SINGLE HDI BOARD
2.2.1 RS-485 Interface - To a Single HDI Board (see Figures 3, 4 & 5)
Note: The maximum length of an RS-485 cable should not exceed 4000 feet.
Follow steps 1 through 4 below to configure a single HDI assembly for RS-485/HART interface operation.
1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
2. Connect the HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage sourced transmitter).
3. Configure the 33XX Port in question for RS-485 operation (see the HART Master Protocol
Manual, Document # D4068) and connect the port in question to TB1 of the HDI board
(see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485 designations). Note: With existing 33XX firmware, the HDI board will not communicate with a 3508 TELETRANS when configured for RS-485 operation.
Figure 3 - 33XX RS-485 D-Type Port Assignment
4. Set the HDI board Jumpers as follows:
Jumper W1 - RS-232 Mode - in position 1-2 (Disabled).
Jumper W2 - In position 1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 receive lines.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled.
Jumper W6 In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 transmit lines.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable them.
CI-3310/30/35 Appendix HD Page - 8 HART Device Interface
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the
Power Supply loop (for 4-20 mA Current Loop Transmitters). In position
2-3 for a voltage output slave device.
Figure 4 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)
Connected to 33XX via HDI Board in RS-485 Mode
Figure 5 - Hart Slave (Transmitter)(with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-485 Mode
CI-3310/30/35 Appendix HD Page - 9 HART Device Interface
2.2.2 RS-232 Interface - To a Single HDI Board (see Figures 6, 7 & 8)
Follow steps 1 through 4 below to configure a single HDI assembly for RS-232 interface operation.
Note: The maximum length of an RS-232 cable should not exceed 25 feet.
1. Install the HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
2. Connect the HDI board to the HART slaves as shown in Figure 7 (for 4-20mA current sourced transmitters) or to a single HART voltage output slave device as shown in
Figure 8.
3. Configure the 33XX Port in question for RS-232 operation (see the HART Master
Protocol Manual, Document # D4068 is HART operation is required or the ACCOL II
Reference Manual, Document # D4044 when interfacing to a 3508 transmitter) and connect the port in question to J1 of the HDI board (see Table 1 for HDI - J1 designations) (see Figure 6 for 33XX RS-232 cable designations.
Figure 6 - 33XX RS-232 Cable
Figure 7 - Hart Slaves (Transmitters)(with 4-20 mA Current Source)
Connected to 33XX via HDI Board in RS-232 Mode
CI-3310/30/35 Appendix HD Page - 10 HART Device Interface
4. Set the HDI board Jumpers as follows:
Jumper W1 - RS-232 Mode - stored in position 1 or 2 (Enabled).
Jumper W2 - In position 2-3 (Enabled) for 3508 Mode - 10 millisecond delay. In position 1-2 (Disabled) - for all except 3508 Mode.
Jumper W3 - In position 2-3 = Disabled.
Jumper W4 - In position 2-3 = Disabled.
Jumper W5 - In position 2-3 = Disabled.
Jumper W6 - In position 2-3 = Disabled.
Jumper W7 - In position 1-2 to Enable the Status LEDs, or position 2-3 to disable them.
Jumper W8 - In position 1-2 (Connected) - places a 249 ohm loop resistor into the
Power Supply loop (for 4-20 mA Current Loop Transmitters). In position
2-3 for a HART voltage output slave device.
Figure 8 - Hart Slaves (Transmitters) (with +12 to +45 VDC Voltage Source)
Connected to 33XX via HDI Board in RS-232 Mode
2.2.3 Configuring Multiple HDI Assemblies into a Single 33XX Master
2.2.3.1 Multiple HDI Boards Configured for RS-485 Operation
When configured for RS-485 operation, more than one HDI board may be used in conjunction with a single 33XX Port to support multiple groups (1 to 15 slave devices interfaced to a single HDI board) of HART slave devices. When so configured, the 33XX port as well as the HDI boards must be configured for RS-485 communications. Figure 9 shows an example of such a network (configured for RS-485 operation). Depending on the type of transmitter, the HDI board will be configured for Current Source or Voltage Source as described earlier.
This configuration requires the use of a BBI Network Interface Box at the 33XX.
Note: The maximum length of an RS-485 cable should not exceed 4000 feet.
Follow steps 1 through 5 below to configure multiple HDI assemblies for RS-485/HART inter-face operation.
1. Install each HDI Assembly in a suitable location (DIN Rail mounted). Connect the power supply (+9V to +30V DC) to TB1 as follows: Pin 1 = + Voltage, Pin 2 = Ground.
CI-3310/30/35 Appendix HD Page - 11 HART Device Interface
2. Connect each HDI board to the HART slaves as shown in Figure 4 (for 4-20mA current sourced transmitters) or to a single HART slave device as shown in Figure 5 (for a +12 to
+45 VDC voltage output transmitter).
3. Install a BBI NIB assembly at the 33XX in question. Refer to the appropriate 33XX product manual for information on installing the NIB assembly.
4. Configure the 33XX Port in question for RS-485 operation (see the HART Master
Protocol Manual, Document # D4068) and connect the port in question to TB1 of the HDI board (see Table 2 for HDI - TB1 designations) (see Figure 3 for 33XX D-Type RS-485 desig-nations).
Figure 9 - Multiple HDI Assemblies Connected to Multiple Groups of HART Slaves
5. Set the HDI board Jumpers as follows:
Jumper W1 - Installed = RS-485 Mode Enabled.
Jumper W2 - In position 1-2.
Jumper W3 - In position 1-2 (Enabled) places a 120 ohm termination resistor across the RS-485 receive lines. Jumper W3 should be placed in position 1-2 for the most distant HDI board (End Node) and placed in position 2-3
(Disabled) for all other nodes.
Jumper W4 - RS-485 Receiver Positive Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W4 should be placed in position 1-2 for the most distant HDI board (End Node) and placed in position 2-3 (Disabled) for all other nodes.
Jumper W5 - RS-485 Receiver Negative Bias - position 1-2 = Enabled, position 2-3 =
Disabled. Jumper W5 should be placed in position 1-2 for the most distant HDI board (End Node) and placed in position 2-3 (Disabled) for all other nodes.
CI-3310/30/35 Appendix HD Page - 12 HART Device Interface
Jumper W6 In position 1-2 (Enabled) places a 120 ohm termination resistor across the
RS-485 transmit lines. Jumper W6 should be placed in position 1-2 for the most distant HDI board (End Node) otherwise in position 2-3
(Disabled).
Jumper W7 In position 1-2 to Enable the Status LEDs, or in position 2-3 to disable them.
Jumper W8 In position 1-2 (Connected) - places a 249 ohm loop resistor into the Power
Supply loop (for 4-20 mA Current Loop Transmitters). In position 2-3 for a HART voltage output slave device.
2.2.3.2 Multiple HDI Boards Configured for RS-232 Operation
When configured for RS-232 operation, no more than one HDI board may be used in conjunction with a single 33XX Port. Each 33XX Port can support a group of up to fifteen
(15) HART or five (5) 3508 slave devices. If a single 33XX device must communicate with multiple groups, the HDI board associated with each group must be wired to a discrete 33XX
Port, i.e., a Port dedicated to the HDI board (and group) in question. Depending on the type of transmitters, each HDI board will be configured for Current Source or Voltage Source as described earlier.
5 .7 0 “
Figure 10 - HART Device Interface Assembly Dimensions
CI-3310/30/35 Appendix HD Page - 13
1 .0 6 “
HART Device Interface
CI-3310/30/35 Appendix HD Page - 14 HART Device Interface
Section 3
SPECIFICATIONS
3.1 HART COMM. PROTOCOL PARAMETERS FOR PHYSICAL LINK
DESCRIPTION
Master Transmitted Signal
Slave Transmitted Signal
Minimum Slave Signal, Converted by a 230 ohm load
Maximum Slave Signal, Converted by a 1100 ohm load
Receiver Sensitivity (must receive correctly)
Receiver Sensitivity (must ignore)
VALUE
Min 400 mV p-p
Max 600 mV p-p
Min 0.8 mA p-p
Max 1.2 mA p-p
184 mV p-p
1320 mV p-p
120 mV to 2.0 V p-p
80 mV p-p
3.2 HART DEVICE IMPEDANCE SPECIFICATION
DEVICE
Primary Master (Including
Load Resistor)
Secondary Master
Slave Device
Miscellaneous Devices (Total)
DESIGNATION
Shunt Impedance (Rx)
Max. Source Impedance (Tx)
Min. Shunt Impedance (Rx)
Max. Source Impedance (Tx)
Min. Shunt Resistance
Maximum Shunt Capacitance
Min. Shunt Impedance
Max. Series Impedance
VALUE
230 - 1100 ohms
700 ohms
5 Kohms
100 ohms
100 Kohms
5000 pF
10 Kohms
100 ohms
3.3 HART DEVICE POWER SUPPLY REQUIREMENTS
DESCRIPTION
Maximum Ripple (47 to 125 Hz)
VALUE
0.2V p-p
Maximum Noise (500 Hz to 10 KHz) 1.2mV rms
Maximum Series Impedance (500 Hz to 10 KHz) 10 ohms
3.4 PHASE SHIFT SPECIFICATION
The maximum phase shift for the master or slave at 1200 and 2200 Hz input frequencies is
45 degrees [3dB (0.707) attenuation]. Each device in the loop and the loop wire must be considered for capacitance and resistance.
3.5 PERFORMANCE SPECIFICATION
HDI Communications Interface:
HART Device Interface:
RS-232/485 Interface - switch selectable
Current Input Device
CI-3310/30/35 Appendix HD Page - 15 HART Device Interface
3.5 PERFORMANCE SPECIFICATION (Continued)
FSK Modem:
Power Consumption:
Bell 202 Compatibility (1200 Hz/2200 Hz Modulation)
RS-232 @ 9V - 35.57mA
@ 28V - 17.9mA
RS-485 @ 9V - 42.66mA when receiving
@ 28V - 20.09mA when receiving
3.6 ENVIRONMENTAL SPECIFICATIONS
Temperature:
Relative Humidity:
Operating - (-40 to 70) C (-40 to 158) F
Storage - (-40 to 85) C (-40 to 185) F
15 - 95% non-condensing
Vibration:
RFI Susceptibility:
1G for 10 - 150 Hz
0.5G for 150 - 2000 Hz
10V/Meter - 20MHz to 500MHz
CI-3310/30/35 Appendix HD Page - 16 HART Device Interface
HART ® Device Interface
Special Instructions for Class I, Division 2 Hazardous Locations
1. The BBI Highway Addressable Remote Transceiver (HART) Device Interface (HDI) is listed by Underwriters Laboratories (UL) as nonincendive and is suitable for use in
Class I, Division 2, Groups A, B, C and D hazardous locations or nonhazardous locations only. Read this document carefully before installing a nonincendive BBI
HART Device Interface. In the event of a conflict between the HART Device Interface
User Manual (Appendix HD - HART Device Interface) and this document, always follow the instructions in this document.
2. All power and I/O wiring must be performed in accordance with Class I, Division 2 wiring methods as defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations within the United States, or as specified in Section 18-152 of the
Canadian Electrical Code for installation in Canada.
3. WARNING: EXPLOSION HAZARD - Substitution of components may impair suitability for use in Class I, Division 2 environments.
4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location, turn off power before servicing/replacing the unit and before installing or removing I/O wiring.
5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the power has been switched off or the area is known to be nonhazardous.
06/09/98 Appendix A - Appendix HD - HART Device Interface Page 1 of 1
BLANK PAGE
Appendix IA
MULTIPURPOSE INTERFACE BOARD
SERIES 392059-01-0
- Contents -
DESCRIPTIONIA-1
COMM. MODULE SETUP.................................................................................IA-1
MI BOARD SETUP ............................................................................................IA-4
Switch Settings.......................................................................IA-4
Jumper Settings .....................................................................IA-5
CONFIGURATION AND WIRING OF LINK-SELECT DI (JUMPER W1) .....IA-5
LED INDICATORS.............................................................................................IA-7
DESCRIPTION
The Multipurpose Interface Board (MI Board) provides two RS-485 links which can be configured to operate in two communication modes. In the first mode it functions as a dual
Network Interface Board (NIB) providing connections for two RS-485 ports (B and D). In this mode the NIB provides separate surge protection circuits for each port; it also provides bias termination which must be implemented for only the master and the last slave node.
Biasing consists of applying +15 V and -15 V voltage levels through resistive pads to the transmit and receive lines in order to maintain the correct line status during periods between transmissions.
In the second mode, the MI Board functions as a redundant physical link whereby both RS-
485 links carry the same data from port B or D. One link is on line, while the other link is the backup. The assignment of redundant links are programmed by the user in ACCOL software. Should ACCOL detect failed or distorted data during operation, it will change the status of a DO signal wired to the select terminals of the MI Board. This change of status will cause a switchover from the on-line to the backup link to maintain communications.
The MI Board plugs into the upper left modem slot of the 3335 and establishes an interface with the Comm. Board via the backplane. The board provides switches and jumpers for configuration, and six LEDs to indicate the transmit, receive, and link status of each port.
COMM. MODULE SETUP
To achieve communications, port B/D of the Comm. Module must be configured for the
MODEM mode. This allows the Comm. Module to communicate with the MI Board via the backplane instead of using the Comm. Boards ports. The procedure for configuring the
Comm. Module is contained in Section 3C.
CI-3335 MI Board / IA-1
Figure IA-1 - MI Board Assembly
Figure IA-2 shows the pictorial arrangement when the NIB mode is used. For this mode the MI Board communicates with two Comm. Modules to produce two independent RS-485 ports. In a typical application, one port could be used to communicate with a network, while the other could communicate with lower-level slaves.
IA-2 / MI Board CI-3335
Figure IA-2 - NIB Mode - Two Independent Ports
CI-3335
Figure IA-3 - Redundancy Mode - Single Channel , Dual Links
MI Board / IA-3
Figure IA-3 shows the arrangement when the redundant link mode is selected. For this mode the data from port B/D of the Comm. Module are communicated to both links of the
MI Board. The redundancy application requires two communication lines and an MI Board
(configured for redundancy) at each node. If ACCOL detects bad data on one link, it will switch over to the other link. Each node can switch independently of the other. Typically the lines connected to each link take different routes to minimize the risk of both being damaged simultaneously.
MI BOARD SETUP
Before performing any configuration, it will be necessary to power down the DPC and remove the MI Board. General details on board removal and installation are covered in
Section 2 - Installation.
Switch Settings
The board contains two eight-switch packages (SW1 and SW2 in Figure 1A-1) whose functions are described in Tables A through C. In Table A, switches SW1-1 and -2 are identified as mode selectors for ports B and D; these switches select either NIBs or redundant physical links for the ports as noted in Table B. Switches SW1-3 to SW1-6 are used to enable or disable the loopback mode. This mode places the MI Board in a configuration for testing. The related software test procedures required for loopback mode are described in User Manual D4041 - Diagnostics.
TABLE A - SWITCH SW1 SETTINGS
SWITCH
NO.
SW1-1
SW1-2
SW1-3
SWITCH
FUNCTION *
Mode Select, Port B
Mode Select, Port D
/RTSB to /CTSB Loopback
REQD’
SETTING
**
**
ON
SW1-4
SW1-5
SW1-6
SW1-7
/DTRB to /DCDB Loopbak
/RTSB to /CTSD Loopback
/DTRD to /DCDD Loopback
Not Used
OFF
ON
OFF
OFF
SW1-8 Not Used OFF
* For all switches: Disable = OFF; Enable = ON
** See Table B for details.
TABLE B - RS-485 PORT ASSIGNMENTS, SW1-1 & -2
SWITCH FUNCTION
Redundancy Link on Port B
Redundancy Link on Port D
Dual NIBs on Ports B and D
Future application
SW1-1 SW1-2
ON ON
OFF ON
ON OFF
OFF OFF
In Table C, switches SW2-1 & -2 set the Master-Slave termination functions for Link 1, while SW2-5 & -6 do so for Link 2. When the board is set for the NIB mode, these switches, when set ON, define the link as a Master or Last Slave; when set OFF, they define the link as a middle node (the need for terminating the end nodes of a network was explained on page IA-1). The remainder of the switches in Table C are used to select the communication parameters for both links.
IA-4 / MI Board CI-3335
Jumper Settings
The MI Board contains five jumpers as noted in Table D. Only one jumper, W1, is used for customer configuration. The remaining jumpers, W2 through W5, are not used and must always be in the required positions.
TABLE C - SWITCH SW2 SETTINGS
SWITCH
NO.
SW2-1
SW2-2
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
SWITCH
FUNCTION *
Link 1 Receiver Termination
ON = Master or Last Slave
OFF = Middle Slave
Link 1 Receiver Termination
Same as SW2-1
Link 1 Transmit (+) to
Receiver (+) Loopback
Link 1 Transmit (-) to
Receiver (-) Loopback
Link 2 Receiver Termination
Same as SW2-1
Link 2 Receiver Termination
Same as SW2-1
Link 2 Transmit (+) to
Receiver (+) Loopback
REQD’
SETTING
AR **
AR **
OFF
OFF
AR **
AR **
OFF
SW2-8
Link 2 Transmit (-) to
Receiver (-) Loopback
OFF
* For SW2-3 to -4: Disable = OFF; Enable = ON
** As required
TABLE D - JUMPER SETTINGS
JUMPER
#
FUNCTION
W1
W2
W3
W4
Discrete Input Power Source
A = Internally powered (24V)
B = Externally powered (24V)
RS-485 Mode (Factory-soldered
jumper. (Do Not Remove.)
Not Used (No jumper furnished.)
Not Used (No jumper furnished.)
Future use (Store jumper by plug-
W5
ging only one pin into socket.)
** As required. See Link-Select text for details.
REQD’
SETTING
AR*
IN
OUT
OUT
OUT
CONFIGURATION AND WIRING OF LINK-SELECT DI (JUMPER W1)
The Link-Select input is only used when the MI Module is configured for a redundant physical link. This configuration requires that a DI status signal be wired to the LSEL + and - terminals to perform link switching. The status signal is obtained from a DO Module
(hardware) that is driven by a Port Status Module residing in ACCOL software (version 5.1
or greater). It is the responsibility of the user to include the switching parameters in the
ACCOL load.
CI-3335 MI Board / IA-5
Figure IB-4 - Open Collector DI, Internally-Powered
Figure IB-5 - Relay Contact DI, Internally-Powered
Jumper W1 on the MI Board configures the LSEL input for the external DI. This jumper is plugged into position A to utilize the DPC's +24 V supply. Figure IA-4 shows the connections for an open collector DI, while Figure IA-5 shows a relay contact DI. Where both types of DOs are available in the same DPC, it is recommended that the open collector type be chosen so that relay contacts are available for heavier load-switching applications.
IA-6 / MI Board CI-3335
LED INDICATORS
The MI Board contains six LEDs whose locations are shown on the board assembly of
Figure 1. Three of these LEDs apply to LINK 1 and the other three to LINK 2. The LED functions are as follows: o TX (Transmit Data)
This LED lights to indicate that a link is transmitting data over the line.
o RX (Receive Data)
RX lights to indicate that the link is receiving data. It will typically blink on and off when there is data activity.
o ST (Link Status)
In a redundant link application, this LED lights to indicate that a link has been selected to be the primary or on-line link. Conversely, the opposite ST LED will be off to indicate it is the secondary or backup link. In the NIB mode, the status of these
LEDs do not apply.
CI-3335 MI Board / IA-7
BLANK PAGE
Appendix RM
RASCL BOARD
PT. NO. 392075-01-6
- Contents -
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-3
Configuration Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-3
ADDING RASCL BOARD TO EXISTING UNIT . . . . . . . . . . . . . . . . . . . . . . RM-3
JUMPER CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-4
RASCL Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-4
LIB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-5
DATA HIGHWAY APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-6
Redundant Highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-6
SingleHighway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-8
RASCL-to-LIB Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-8
Comm. Board-to-RASCL Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-8
EFFECTS OF POOR GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RM-9
GENERAL
The Redundant Automatic Switchover Communication Link (RASCL) Board, pt. no. 392075-01-
6, provides a redundant 1 MBd data highway communication channel. Shown in Figure 1, the
RASCL Board plugs into the backplane of a DPC-3335 or an RIO-3331 and communicates
Manchester-coded data via port B/D of the Comm. Module.
The RASCL Board provides two links identified as LINK 1 and LINK 2, for the redundant communication channel. These links provide 15-pin, female "D" connectors that communicate the same data. If redundant communications is not required, the RASCL Board can be configured to operate on a single link.
The RASCL Board requires a Line Interface Box (LIB) to interface with a coaxial data highway link. The LIB, pt. no. 392073-01-3, is an external device that mounts in a DIN rail assembly and provides impedance matching, isolation, and surge protection for the equipment. One LIB is required for each active link.
CI-3335 RASCL Board / RM-1
Figure 1 Layout of RASCL Board - Part No. 392075-01-6
RM-2 / RASCL Board CI-3335
J3
(9-PIN "D" CONNECTOR)
3 2 1
NODE:
J3
LINK: T1
IN
CR1
J1 R3
R1
W1
C1 R4
R2
J2
OUT
TB1
W1
COAX OUTT
Figure 2 Layout of LIB Board
Mode of Operation
The detector circuitry on the RASCL Board monitors LINK 1 and LINK 2 for activity. If data are not detected on the primary link, the detector will switch communications over to the secondary link. Each RASCL connected to a data highway can switch independently of others to select the best communication link.
All communication periods are timed by the RASCL so that messages are automatically terminated if they exceed a programmed time limit. This limit prevents a failed RASCL Board from tying up the line for long periods.
Configuration Requirements
Certain jumpers on the RASCL Board will require configuration before the board is placed into service. It will be necessary to power down the 3335/3331 and remove the RASCL Board and
Comm. Module from the unit; general details on board removal and installation are covered in
Section 2 - Installation.. The LIB may be checked while it is in the DIN rail.
RASCL and LIB configuration are covered under the topic, JUMPER CONFIGURATIONS. The configuration of the Comm. Module is covered in Section 3C.
ADDING RASCL BOARD TO EXISTING UNIT
Before adding a RASCL Board to an existing unit, make sure it is properly configured for the application (see topic below, JUMPER CONFIGURATIONS). Then power down the DPC or RIO and insert the RASCL into the upper slot designated for the optional RASCL or MODEM board
(see Section 1 for front view of DPC).
CI-3335 RASCL Board / RM-3
While the power is still OFF, remove the Comm. Module and configure it for the RASCL application (see Section 3C). Once configured, re-install the Comm. Module but don't apply power.
Make the necessary communication connections to the RASCL and LIB as described under
DATA HIGHWAY APPLICATIONS. Apply power and check communications.
JUMPER CONFIGURATIONS
RASCL Board
The RASCL Board contains five jumpers to set the communication parameters. The location of these jumpers is shown in Figure 1.
The jumpers are set according to Table A. This table describes the functions of each jumper and illustrates the conventions at the bottom. All jumpers must be set as specified in the REQUIRED
SETTING column which is subdivided into REDUNDANT HIGHWAY and SINGLE HIGHWAY selections. Details on these applications are described under DATA HIGHWAY APPLICATIONS.
TABLE A. RASCL JUMPERS
JUMPER
NO.
W1
W2
W3
W4
W5
JUMPER
SELECTIONS
NONE
NONE
1-2
2-3
NONE
NONE
FUNCTION
Reserved
Reserved
Dual Link
Single Link
Reserved
Reserved
REQUIRED SETTING
REDUNDANT
HIGHWAY
2-3
SINGLE
HIGHWAY
2-3
OUT
1-2
OUT
2-3
2-3
OUT
2-3
OUT
RM-4 / RASCL Board CI-3335
TABLE B. LIB JUMPER
JUMPER
NO.
W1
JUMPER
SELECTIONS
IN
OUT
FUNCTION
75 Ohm termination enabled
Termination disabled
REQUIRED SETTING
UNITS AT
EACH END
IN
MIDDLE
UNITS
OUT
LIB Assembly
The Line Interface Box contains one jumper which is identified as W1 in Figure 2. This jumper configures the LIB to either add or remove line termination. Line termination, which places a
75-ohm load across the coaxial line, is only applied to the end units. Termination must not be applied to the middle units. Refer to Table B for the jumper settings.
LED INDICATORS
The RASCL Board contains eight LEDs whose locations are shown on the board assembly of
Figure 1. Three of these LEDs apply to communications for LINK 1, three for LINK 2, and two for board status. The LED functions are as follows: o LINK ERR (Link Error)
When this LED is lit, it indicates that a communication error has been detected for this link.
o PRIM LINK (Primary Link)
This LED lights to indicate that a link has been selected as the primary or on-line link.
Conversely, the opposite PRIM LINK LED will be off to indicate it is the backup link.
o RXD (Receive Data)
RXD lights when data is being received for the indicated link. These LEDs will typically blink on and off during data activity.
o TD (Transmit Data)
This LED lights when RASCL is transmitting data over the line.
CI-3335 RASCL Board / RM-5
o CD (Carrier Detect)
This LED lights to indicate that a carrier has been detected on the line.
DATA HIGHWAY APPLICATIONS
Redundant Highway
Figure 3 illustrates a redundant highway application using one Gateway 3000 interface and two distributed process controllers labeled DPC #1 and DPC #2. The GW-3000 is the originating node, DPC #2 is the middle node, and DPC #3 is the end or terminating node. Although not shown in the illustration, the GW-3000 could also be connected at or near the middle of the highway with DPC nodes extending in both directions.
Each unit in the network requires one RASCL Board and two externally-mounted LIBs. The
RASCL Boards connect to the LIBs via a cable having a maximum length of six feet. Each cable has a 15-pin connector at the RASCL end, and a 9-pin connector at the LIB end. If these cables are constructed by the user, the wiring must consist of two twisted and shielded pairs as shown in Figure 4. Also, the leads of each twisted pair must not be crossed during wiring as erratic communication problems will result.
When connecting highway cables of a redundant link, it is imperative that the LINK 1 and LINK
2 cables at each node be connected to the same link throughout the network. Any crossovers will complicate troubleshooting procedures intended to localize a communication fault.
A limit is imposed on the maximum cable distance and the maximum number of nodes. Tables
C and D provide loss figures for various types of cables. Table C applies to a maximum of 25 nodes, and Table D to a maximum of 8 nodes.
TABLE C. LINE CHARACTERISTICS FOR MAXIMUM OF 25 NODES
Cable Type Max. Distance
RG59 coax
RG6 coax
RG11 coax
Alumifoam
2400 ft.
3400 ft.
6700 ft
16500 ft
Line Loss
0.7 dB/100 ft.
0.5 dB/100 ft.
0.25 dB/100 ft
0.1 dB/100 ft.
TABLE D. LINE CHARACTERISTICS FOR MAXIMUM OF 50 NODES
Cable Type Max. Distance
RG59 coax
RG6 coax
RG11 coax
Alumifoam
1300 ft.
1900 ft.
3700 ft
9300 ft
Line Loss
0.7 dB/100 ft.
0.5 dB/100 ft.
0.25 dB/100 ft
0.1 dB/100 ft.
RM-6 / RASCL Board CI-3335
CI-3335
Figure 3. Redundant Highway Network
RASCL Board / RM-7
Each LIB is provided with a jumper circuit to configure it as an end or middle node. When a unit is configured as an end node, the LIB applies a 75 ohm load impedance to the line.
Conversely, when a unit is configured as a middle node, the load is removed. In Figure 3, the
GW-3000 and the last DPC node are configured as the end units. Line termination is selected by jumper cited in Table B.
Single Highway
The single coaxial data highway can be used when redundancy is not a requirement. This application is similar to Figure 3 except that all wiring is confined to LINK 1 and the connections for LINK 2 are eliminated. All RASCL Boards in this network will also require configuration for single-link operation (jumper W1 in Table A).
RASCL-to-LIB Cable
RASCL communication systems furnished by Bristol Babcock will include the necessary RASCLto-LIB cable. If the purchaser constructs his own cables, the pin-out connections will be found in Figure 4. Notice that the signal leads must be individual twisted pairs that are encased in a braided shield. It is essential that both lead pairs do not cross. If they become crossed, noise and cross-signal interference problems will result that are difficult to troubleshoot. Figure 4 identifies the correct signal pairs.
Comm. Board-to-RASCL Cable
The RASCL Board is furnished with a short cable to provide communications between the
Comm. Module and the RASCL Board. This cable, part number 391241-00-1, consists of a ninepin male D-type connector at one end, and two bare leads at the other as shown in Figure 5.
The nine-pin connector plugs into port BH/D of the Comm. Module, while the red and black leads at the other end are connected to Terminal Block TB1 on the RASCL Board. TB1 is labeled to correspond with the wire colors.
NOTE 2
9 1
A
B
NOTE 1
5
9
NOTE 1
A
B
1
6
LIB 9-PIN 15
8
RASCL 15-PIN
FOR ASSEMBLED CABLE,
ORDER PT. NO. 391239-00-7
NOTES: 1. A AND B ARE TWISTED PAIR
MAKE SURE LEAD PAIRS ARE
NOT CROSSED.
2. BOTH TWISTED PAIR MUST BE
ENCLOSED IN A BRAIDED SHIELD.
THE SHIELD MUST ONLY CONNECT
TO RASCL, PIN 15.
Figure 4. RASCL-to-LIB Cable Wiring
RM-8 / RASCL Board CI-3335
3
2
1
5
4
9
8
7
6
RED
BLACK
}
TO TB1
ON
RASCLE BOARD
Figure 5 - Comm. Board to RASCL Cable
EFFECTS OF POOR GROUNDING
The performance of high-speed communication equipment such as the RASCL can be adversely affected by poor electrical grounds. As communication rates increase, poor grounding can result in signal errors and erratic readings. It is therefore essential that proper grounding techniques be followed throughout the system. To ensure a reliable and error-free communication link, it is strongly recommended that the reader review the material contained in Supplement S1400 -
Guidelines for System Grounding.
CI-3335 RASCL Board / RM-9
BLANK PAGE
Appendix SA
RADIO DELAY BOARD
PT. NO. 392504-01-4
- Contents -
JUMPER CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2
Leading Edge Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-2
Trailing Edge Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-4
Carrier Time Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-4
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-5
RD Board to Transceiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-5
Carrier Keyed Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-6
DESCRIPTION
The Radio Delay Board (RD Board) functions as an interface between a Series 33XX Distributed
Process Controller and an external radio frequency (rf) transceiver or modem. The board includes an open collector output that can be used to key the carrier "on" or "off."
In a 3330, the RD Board plugs into the Communication Engine Board (CE Board). In a 3310 and
3335, the RD Board is assembled to a mating board that plugs into the Modem Board slot.
The RD Board contains a 9-pin female D connector (J1) that provides an RS-232 interface to an external modem or transceiver. A terminal block (TB4) provides an open collector output that can be used to key a radio carrier.
The following timing options can be used for communications: o Leading Edge Delay (RTS-to-CTS Delay). This feature delays the start of data transmissions after a "Request To Send" (RTS) signal has been initiated. It allows the rf carrier to reach full power before initiating a "Clear To Send" (CTS) signal. The leading edge delay also allows sufficient time for the remote rf receiver to recover from a squelched condition, thereby preventing a loss of the initial data.
CI-3330/35 (12/97) Radio Delay Board / SA-1
Figure 1. RD Board No. 392504-01-4
o Tailing Edge Delay. This delay keeps the transmitter "on" for a short period at the conclusion of a transmission even though RTS has just been set "off." This action ensures that the radio carrier remains on the air so that the last data are not corrupted by premature squelching or carrier "turn off" transients at the receiver. o Carrier Time Out. This feature prevents a transceiver from tying up network communications should it fail with the rf carrier set "on." This is especially true in an application where a master station polls a field of remotes that operate on the same frequency; a remote that fails with the "carrier on" will halt network polling. By using this feature, the carrier of the failed remote will be forced of the air after the "time out" has lapsed. In this application RTS must be inactive in order to reset the carrier time out.
JUMPER CONFIGURATION
Board jumpers provide configuration of leading and trailing edge delays and carrier time out.
Leading Edge Delay
The leading edge delay is the time from the start of a Request To Send (RTS) signal to the start of a Clear To Send (CTS) signal. The delay times are determined by plugging in a combination of two jumper headers, W1 and W2. Header W1 provides four time periods from 1.25 ms to 1
SA-2 / Radio Delay Board CI-3330/35 (12/97)
sec, while header W2 provides seven multiplier positions from X1 to X8. Table A is a matrix that shows the time periods for all combinations of W1 and W2. For example, if W1 is placed in the "C" position and W2 in the "A" position, the delay will be 100 milliseconds.
TABLE A. LEADING EDGE DELAY SELECTIONS
Jumper
W2
Position
D
E
F
G
A
B
C
W2
Set To:
Mutiplier
X1
X2
X3
X4
X5
X6
X8
Jumper W1 Set To:
A B C D
(ms) (ms) (ms) (s)
1.25 10 100 1
2.50 20 200 2
3.75 30 300 3
5.00 40 400 4
6.25 50 500 5
7.50 60 600 6
10.0 80 800 8
Jumper W1 Jumper W2
A B C D A B C D E F G
Example: Above jumpers set for 100ms delay.
TABLE B TRAILING EDGE DELAY SELECTIONS
Jumper
W4
Position
A
B
C
D
E
F
G
W4
Set To:
Mutiplier
X1
X2
X3
X4
X5
X6
X8
Jumper W3 Set To:
A B C D
(ms) (ms) (ms) (s)
1.25 10 100 1
2.50 20 200 2
3.75 30 300 3
5.00 40 400 4
6.25 50 500 5
7.50 60 600 6
10.0 80 800 8
Jumper W3 Jumper W4
CI-3330
B C A B C D E F G
Example: Above jumpers set for 6 second delay.
Radio Delay Board / SA-3
Trailing Edge Delay
The trailing edge delay occurs from the time RTS is made inactive by the initiating station (with
CTS still enabled) until the time that the RD Board removes RTS from the radio. This delay will not apply if the initiating station inhibits RTS before it receives CTS. Since there is no data to be protected, RTS will be removed instantly from the radio.
The delay times are determined by plugging in a combination of two jumper headers, W3 and
W4 as noted in Table B. Header W1 provides four time periods from 1.25 ms to 1 sec, while header W2 provides seven multiplier positions from X1 to X8. This table is used in the same manner as previously described for Table A.
TABLE C CARRIER TIME OUT SELECTIONS
W5
Set To:
E
F
G
A
B
C
D
Time Out
Period
4 Sec.
8 Sec.
16 Sec.
1 Min.
4 Min.
17 Min.
Infinite
Jumper W5
A B C D E F G
Example: Above Jumpers set for 1 Minute.
Carrier Time Out
The carrier time out period starts when an RTS is received by the RD Board. If RTS is not inhibited within the selected time out period, the rf carrier or the modem will be turned off. The timer is reset only when RTS is inhibited by the initiating station.
The time out period is determined by jumper header W5. This jumper provides seven selectable periods from 4 seconds to infinity as shown in Table C. The infinite selection prevents a time out when the delay is not needed.
SA-4 / Radio Delay Board CI-3330/35 (12/97)
WIRING CONNECTIONS
RD Board to Modem
The basic wiring concept is shown in Figure 2. The combined RD Board and CE Board assembly plugs into the communication slot #2 of the DPC and requires an RS-232 cable connection to the transceiver or external modem. Pin connections for the cable are shown in Figure 3.
The RD Board is wired to the rf transceiver as instructed in the manufacturer's instruction manual.
DPC 3330
CE BOARD
#2
J1
RD
BOARD
RS-232
MODEM
*
RS-232
RF
TRANSCEIVER
Antenna
Carrier Keyed
Output **
* Only required for transceivers without internal modem circuitry.
* N ot qu d ffo l ttrra nssc
Figure 2. Block Diagram of Application
5
9
4
8
3
7
2
6
1
D-Type Connector
Pin #
5
6
7
8
1
2
3
4
9
9-Pin D-Type Connector
Pin Assignments
Label
DCD
RXD
TXD
DTR
GND
Not Used
RTS
Not Used
Not Used
Description
Data Carrier Detected
Received Data
Transmitted
Data Terminal Ready
Power Ground
Request to Send
Figure 3. Pin Connections for RS-232 Connector J1
CI-3330 Radio Delay Board / SA-5
Carrier Keyed Output
A carrier keyed output is present across terminal block TB4. These terminals provide an open collector output (50 mA max.) that may be applied to rf transmitters requiring a separately keyed input. Essentially the open collector conducts when the DPC sends an RTS to the RD
Board. This action switches on the transmitter and places the carrier on the air. The carrier stays on the air as long as RTS is on.
DISPLAY LEDS
Two LEDs, labeled RTS and DCD are at the front of the board (Figure 1). The RTS LED lights when the board receives a "Request To Send." The DCD (Data Carrier Detected) LED lights when the board receives data from the transceiver; this also denotes the presence of a radio carrier.
SA-6 / Radio Delay Board CI-3330/35 (12/97)
Appendix SB
TRANSMITTER INTERFACE BOARD
FOR BRISTOL BABCOCK 3508 TRANSMITTERS
PT. NO. 392518-01-5
-Contents-
DESCRIPTION............................................................................................. SB-1
WIRING CONNECTIONS............................................................................ SB-1
Transmitter Powered By Internal 24V................................................ SB-1
Transmitter Powered By External 24V............................................... SB-2
LED INDICATORS....................................................................................... SB-2
DESCRIPTION
The Transmitter Interface Board (TI Board) allows up to five Bristol Babcock, Series 3508
Transmitters to communicate with a Series 3335 Distributed Process Controller (DPC). The
DPC polls each transmitter FOR NETWORK communicates.
The TI Board, shown in Figure 1, plugs into the modem utility connector of the CE Board and is assembled to the CE Board using screws and spacers. The TI Board does not contain any switches or jumpers that require configuration. Three LEDS on the board (TXD, CTS and RXD) indicate the communication status.
All Transmitters wired to the TI Board must be operated in the minimum current mode (3.8
mA). This mode is selected via the SMARTKIT program as described in the 3508 transmitter manual.
WIRING CONNECTIONS
The TI Board is equipped with seven dual-terminal blocks for field wiring connections.
Terminal block TB1 and TB7 are provided for the transmitter power source, while TB2 through TB6 are provided for the signal/power inputs of the transmitters #1 to #5.
Transmitter Powered by Internal 24V DPC Supply
To operate the 3508 Transmitters from the internal 24V supply of the DPC, make the connections as shown in Figure SB-2. For this configuration, the +24VINT and +24VEXT terminals are jumpered, as are the +24VRETINT and +24VRETEXT terminal jumpers. The
250 ohm loop resistor is already present on the TI Board and an external one is not required.
CI-3335 Transmitter Interface Bd. / SB-1
Figure SB-1 - TI Board Layout
Transmitter Powered by External 24V Supply
To use an external supply to power the 3508 Transmitters, wire it as shown in Figure SB-3.
In this situation the external 24V supply is wired across the +24VEXT and +24RETEXT terminals; no jumpers are required. The 250 ohm loop resistor is built into the TO Board circuitry and an external one is not required.
LED INDICATORS
The board contains three LEDs having the following functions: Transmit Data (TXD),
Receive Data (RXD), and Clear to Send (CTS). When the board is sending data, TXD and
CTS are ON and RXD is OFF. Conversely, when the board is receiving data, TXD and CTS are OFF and RXD is ON.
SB-2 / Transmitter Interface Bd.
CI-3335
Figure SB-2 - 3508 Transmitters Powered by
Internally Sourced 24V Supply
CI-3335
Figure SB-3 - Transmitters Powered by
Externally Sourced 24V Supply
Transmitter Interface Bd. / SB-3
BLANK PAGE
Product Information Package
PIP-ISORS485
Mar., 2007 Series 33XX, 3508-XX-X, 3530-XX-X & 3808-XX-X
Isolated RS-485 Interface Board
For The Following Bristol Instruction Manuals:
CI-3305, CI-3310, CI-3330, CI-3335
CI-3508-XXX, CI-3530-XXX & CI-3808 www.EmersonProcess.com/Bristol
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, failsafe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional in-formation is required, the purchaser is advised to contact Bristol .
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol and save Bristol harmless from any liability or damage which Bristol may incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 at the back of this manual for proper care and handling of ESD-sensitive components.
Bristol 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
WARRANTY
A. Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing.
B. Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited to the terms of the warranties given by the manufacturer of such goods.
D. All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without Bristol's consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by Bristol, or (iv) worn, injured or damaged from abnormal or abusive use in service time.
E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
F. No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.
REMEDIES
A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
B. Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation, from use of the information herein or from the purchase or use by Buyer, its em-ployees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com) and sending it via E-Mail to [email protected]
. A Bristol Repair Dept. representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Inc.
Repair
1100 Buckingham Street
Watertown, CT 06795
A Bristol Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.
Bristol
Repair Authorization Form
(off-line completion)
(Providing this information will permit Bristol to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH
Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
•
Evaluate / Test / Verify Discrepancy
•
Repair / Replace / etc. in accordance with this form
•
Return to Customer
Line No.____________
Please be aware of the Non warranty standard charge:
•
There is a $100 minimum evaluation charge, which is applied to the repair if applicable (
√
in “returned”
B,C, or D of part III below)
Part I Please complete the following information for single unit or multiple unit returns
Address No.
Bill to :
Purchase Order:
Phone:
(office use only) Address No.
Ship to:
Fax:
(office use only)
Contact Name: ____________________________________
E-Mail:
Model No./Part No. Description
Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1.
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3. What is the Firmware revision? _____________________ What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A.
If product is within the warranty time period but is excluded due to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B.
If product were found to exceed the warranty period, would you like the product:
C.
If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?
D.
If Bristol is unable to verify the discrepancy, would you like the product: returned replaced *see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: ______________________________ phone_____________________
If we are unable to contact this person the backup person is: _________________________ phone_____________________
Special Requests: ____________________________________________________________________________________
____________________________________________________________________________________________________
Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
A Few Words About Bristol Inc.
For over 100 years, Bristol ® has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Inc. instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about Control Wave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865 or e-mail: [email protected]
For technical questions regarding ACCOL products, OpenBSI Utilities , UOI and all other software except for Control Wave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/
For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464 .
You can e-mail the Communication Technology Group at: [email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
Questions of a non-technical nature (product orders, literature requests, price and delivery information, etc.) should be directed to the nearest sales office (listed on the rear cover of this manual) or to your Bristol-authorized sales representative.
Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office covers your particular area.
Visit our Site on the World Wide Web
For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com
Training Courses
Bristol’s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown, Connecticut headquarters, and at selected Bristol regional offices, throughout the year. Contact our Training Department at (860) 945-2343 for course information, enrollment, pricing, and scheduling.
PIP-ISORS485
ISOLATED RS-485 INTERFACE BOARD
PT. NO. 392909-XX-X
TABLE OF CONTENTS
TITLE PAGE #
Function .................................................................................................................................... 1
Features .................................................................................................................................... 1
Two-Wire End Node Jumpers W1, W3 & W4 .......................................................................... 3
Four-Wire End Node Jumpers W2, W5 & W6 ......................................................................... 3
Connectors ................................................................................................................................ 4
Switches .................................................................................................................................... 5
Indicators .................................................................................................................................. 5
RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 5
RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node .......................... 6
Isolated RS-485 Port Interface to LAN .................................................................................... 6
Field Terminations for RS-485................................................................................................. 6
ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specifications ...................................................................................................... 9
Environmental Specifications .................................................................................................. 9
Part Numbers ........................................................................................................................... 9
SUPPLEMENTS
PIP-ISORS485 Page 0-1 Table Of Contents
ISOLATED RS-485 INTERFACE BOARD
DESCRIPTION
Function
An Isolated RS-485 Interface Board allows any Bristol Network 3000 product to communicate over an isolated master/salve network. Each node on the network that incurporates an Isolated RS-485 Interface Board is optically isolated from the rest of the network, thereby eliminating ground loop and potential difference effects that may degrade network communication performance. The result is a reliable communication medium for in-plant or building to building LANs. The Isolated RS-485 Board effectively replaces the
Network Interface Box (NIB).
Features
• On-Board Power Supply
A power supply, operating from a bulk +9 to +35 VDC source, powers the RS-485 circuitry, generating a regulated 5VDC. A 30V transient Voltage Suppresser provides over-voltage protection on the input terminals. A separate IC provides the -5VDC required by the RS-232 transceiver. Bulk DC power is interfaced to the board on
Connector TB1. The + DC Bulk is connected to TB1 Pin 1 and the VDC Return or
Ground is supplied to TB1 Pin 2. TB1 Pin 3 is not used.
• Optical Isolation
Optically Isolated 2-Wire or 4-Wire RS-485 circuits with 300VDC isolation eliminates ground loops and potential difference effects.
• 100 Ω Isolated RS-485 Termination For 2\4-Wire Boards & Receiver Biasing
Installation of Jumper W1 is required at each Isolated RS-485 Board associated with an end node of a Two-wire or Four-wire RS-485 network. In the case of a Four-wire RS-
485 network, the Isolated RS-485 Board’s Jumper W2 must also be installed at each end node. Units installed at the master node of a 2-wire RS-485 network must also have Jumper W3 (Receiver Bias to Isolated Ground) & Jumper W4 (Receiver Bias to
Isolated VCC) installed, while units installed at the master node of a 4-wire RS-485 network must also have Jumper W5 (Receiver Bias to Isolated Ground) & Jumper W6
(Receiver Bias to Isolated VCC) installed (See Section - End Node Jumpers W1 through
W6).
• RS-232 or RS-485 Node Interfaces
Networks nodes may connect to the Isolated RS-485 Interface Board via an RS-232 or
RS-485 interface. For installations where each node will include its own Isolated RS-
485 Interface Board and asynchronous operation is required (38.4 KBaud max) an RS-
232 interface may be used. In situations where several nodes will be mounted in close proximity, as in an equipment cabinet containing two or more DPCs, a single Isolated
RS-485 Interface Board may be employed by multidropping to each slave using the RS-
485 Interface Connector TB3. For LANs that will operate synchronously (187.5 KBaud to 1 MBaud), all nodes are required to have an RS-485 interface. As with the isolated
LAN itself, up to 32 nodes can be included in a multidrop arrangement. The maximum distance between communicating nodes on a 2-wire 187.5 KBaud LAN is approximately
PIP-ISORS485 Page 1 Isolated RS-485 Interface Board
1000 feet (300 meters). The maximum distance between communicating nodes on a 4wire 1 MBaud LAN is approximately 200 feet (60 meters).
• Surge Protection
Surge suppression on input ports and on the isolated output port meets IEC-801 to isolated ground.
• Isolated RS-485 Common-Mode Voltage Range
The Isolated RS-485 Port features -7V to +12V common-Mode Input Voltage range with respect to Isolated ground. The port also includes current limiting and thermal shutdown circuitry for driver overload protection.
• Switch Selectable Termination, Operating Mode, and 2/4-Wire Configuration
8 position DIP switches S1 and S2 are used to configure the Isolated RS-485 Board’s various operating parameters associated with port usage and LAN configuration.
• Mounting
The Isolated RS-485 Interface Board measures 4.302” (10.917cm) in width x 4.230”
(10.744cm) in height and may be mounted externally or to the top of an RTU 3305 via a
DIN Rail and DIN Rail Mounting Base. When mounted in a DIN Rail Mounting Base the unit measures 4.375” (12.112cm) in width x 4.375” (12.112cm) in height.
• PC LAN Functionality
The RS-232 Interface port allows PCs (which only have an RS-232 port) to be networked over an Isolated RS-485 LAN at asynchronous communication rates.
Figure 1 - Isolated RS-485 Board Component Identification Diagram
PIP-ISORS485 Page 2 Isolated RS-485 Interface Board
COMPONENT IDENTIFICATION
The Isolated RS-485 Interface Board has four wiring connectors; J1, TB1, TB2 and TB3, two configuration switches; S1 and S2, six 2-pin end node configuration jumpers; W1 through W6. Jumpers W1, W3 and W4 are used in on 2-wire networks and Jumpers W1,
W2, W5 & W6 are used on 4-wire networks. The board is protected by an on-board fuse F1 that is rated at .25A.
Figure 2 - Isolated RS-485 Board in a DIN Rail Mounting Base
Two-Wire End Node Jumpers W1, W3 & W4
Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes except the end nodes. Jumper W1 provides a 100-Ohm termination across TXD/RXD- and
TXD/RXD+ at the most distant (end) nodes. Two-wire RS-485 LANs also require the use of jumper W3 to provide Tx\Rx bias to isolated ground and jumper W4 to provide Tx\Rx bias to isolated VCC. Jumpers W3 and W4 are only required at the Master Node (see Table 1 and Figure 3).
Four-Wire End Node Jumpers W2, W5 & W6
Jumpers should be placed in an open position, i.e., installed on pin 1 or pin 2 for all nodes except the end nodes. Jumper W2 provides a 100-Ohm termination across RXD- and RXD+ at the most distant (end) nodes. On these networks, W5 provides receiver bias to isolated
PIP-ISORS485 Page 3 Isolated RS-485 Interface Board
ground and W6 provides receiver bias to Isolated VCC. Four-wire networks use W2, W5 and
W6 at the master node and W2 at the other end node, unless the network is to operate at other than 1Mbaud (synchronous), in which case jumpers W5 & W6 must also be installed at both end nodes (see Table 1 and Figure 4).
Table 1 - End Node Jumper Assignment
Network
Type
RS-485 - 2-Wire
RS-485 - 4-Wire - 1Mbaud
Master Node
Jumpers Installed
W1, W3, W4
W2, W5, W6
RS-485 - 4-Wire - Not 1Mbaud W2, W5, W6
Last Node (Slave
Jumpers Installed
W1
W2
W2, W5, W6
Connectors
When Connector J1 (9-Pin D-Type) of the Isolated RS-485 Interface Board is connected to a
DPC/RTU, transmitter or computer communications D-Type Connector, an RS-232 interface is established. Connector TB3 of the Isolated RS-485 Interface Board is a 6-Pin
Terminal Block that accommodates interface to an RS-485 port. RS-485 Input Connector
TB3 can be multidropped with up to 32 other RS-485 ports. Connector TB2 provides an interface to a 2-wire or 4-wire isolated RS-485 network. Input power is provided on
Terminal Block TB1. Tables 2 through 5, which follow, provide a description of each connector’s functionality:
Table 2 - Power Connector TB1 Wiring List
Pin #
1
Signal Name
+VDC Input
Description
+9V to +35V DC Bulk
2 VDC Return Bulk Return/Ground
N/A
Table 3 - Isolated RS-485 Port Interface Connector TB2 Wiring List
Pin # Signal Name
(2-Wire)
TXD+ (4-Wire)
2 TXD/RXD-(2-Wire)
TXD- (4-Wire)
3
4
RXD+ (4-Wire)
RXD- (4-Wire)
5
6
Isolated GND
Chassis GND
TXD/RXD+ Signal on 2-wire circuits
TXD+ Signal on 4-wire circuits
TXD/RXD- Signal on 2-wire circuits
TXD- Signal on 4-wire circuits
RXD+ Signal on 4-wire circuits
RXD- Signal on 4-wire circuits
Isolated Ground
Chassis Ground
Description
Table 4 - RS-232 Input Port Interface Connector J1 Wiring List
Pin #
2
4
5
TXD
RXD
RTS
Signal Name Description
RS-232 Transmit Data
RS-232 Receive Data
RS-232 Request To Send
9 GND
Note: Connector Pins 1, 3, 6, 7 & 8 are not used on Connector J1
PIP-ISORS485 Page 4 Isolated RS-485 Interface Board
Table 5 - TB3 RS-485 Input Port Interface Connector TB3 Wiring List
Pin #
1
2
3
4
Signal Name
TXD+
TXD-
RXD+
RXD-
Description
RS-485 Input Interface Signal Transmit Data Plus (+)
RS-485 Input Interface Signal Transmit Data Minus (-)
RS-485 Input Interface Signal Receive Data Plus (+)
RS-485 Input Interface Signal Receive Data Minus (-)
5
6
RTS+
RTS-
RS-485 Input Interface Signal Request To Send Plus (+)
RS-485 Input Interface Signal Request To Send Minus (-)
Switches
Two eight position DIP Switches are provided for board and network configuration. The functionality of these switches are provided in Tables 6 and 7 below:
Table 6 - Switch S1 Configuration Settings
Position Setting Function
1
1
3 & 4
3 & 4
5 & 6
5 & 6
7 & 8
7 & 8
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Select RS-232 Input Port
Select RS-485 Input Port
Enable RS-485 Terminator for TXD+/-
Disable RS-485 Terminator for TXD+/-
Enable RS-485 Terminator for RTS+/-
Disable RS-485 Terminator for RTS+/-
Enable RS-485 Terminator for RXD+/-
Disable RS-485 Terminator for RXD+/-
Table 7- Switch S2 Configuration Settings
Position
1, 3 & 5
1, 3 & 5
Setting
ON
OFF
Function
Select RS-232 Input Port
Select RS-485 Input Port
2, 4 & 6
2, 4 & 6
ON
OFF
Select RS-485 Input Port
Select RS-232 Input Port
Indicators
There are Two LEDs on the Isolated RS-485 Interface Board. LED DS1 will be illuminated when data is being transmitted and LED DS2 will be illuminated when data is being received.
WIRING
RS-232 Interface Between Isolated RS-485 Intf. Board and the Host Node
When it is desired to establish an RS-232 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU, transmitter or computer a 24-gauge conductor cable, such as
PIP-ISORS485 Page 5 Isolated RS-485 Interface Board
Belden 9535 should be used. It should be noted that the Isolated RS-485 Interface Board provides 15KV surge protection per IEC-801 on all signals associated with this interface.
RS-485 Interface Between Isolated RS-485 Intf. Board and the Host Node
When it is desired to establish an RS-485 Interface between the Isolated RS-485 Interface
Board and the Host DPC/RTU or transmitter a low capacitance 24-gauge 3-twisted pair communications grade cable, such as Belden 9843 should be used. It should be noted that the Isolated RS-485 Interface Board provides 15KV surge protection per IEC-801 on all signals associated with this interface.
Isolated RS-485 Port Interface to LAN
Two-wire or four-wire RS-485 networks are supported. For two-wire applications, a low capacitance 24-gauge communications grade 2-twisted pair cable, such as Belden 9842, should be used. The cable shield should be connected to the Chassis Ground terminal, i.e.,
TB2 Pin 6 (at one end only). For four-wire applications a similar 3-twisted pair cable, such as Belden 9843, should be used. Again, the cable shield should be connected to the Chassis
Ground terminal (at one end only). It should be noted that the Isolated RS-485 Interface
Board provides 15KV surge protection on all signals associated with this interface.
Figure 3 - 2-Wire RS-485 LAN using Isolated RS-485 Interface Boards
Note: Jumpers W5 & W6 aren’t required at the most distant Slave Node unless the LAN is operating at other than 1Mbaud; however, they aren’t detrimental if they are installed.
Figure 4 - 4-Wire RS-485 LAN using Isolated RS-485 Interface Boards
Field Terminations for RS-485
The maximum number of nodes that can be connected to a RS-485 network is 32 including the master. For maximum protection against unwanted interference, noise and spurious
PIP-ISORS485 Page 6 Isolated RS-485 Interface Board
emission, the shield of each LAN segment should be terminated to the Chassis Ground at one end only. This practice will eliminate the formation of ground loops, thereby minimizing ground induced noise currents in the LAN. A Chassis Ground connection is provided on each Isolated RS-485 Interface Board at TB2 - Pin 6. In addition, the chassis of each Isolated RS-485 Interface Board should be connected to the nearest earth ground via a short length of 12-gauge stranded copper wire in order to take advantage of the built-in surge protection capability. The Isolated Ground terminal (TB2-5) of all nodes on the twowire RS-485 LAN must be connected via a third wire (within the second twisted pair).
For four-wire LANs 3-twisted pairs of wires are required. Shielding is not required (but is recommended). The maximum network length for the available asynchronous speeds (up to
38.4 KBaud) is 4000 feet (point to point) 1000 feet (for multiple nodes). For LANs utilizing synchronous speeds up to 187.5 KBaud (for two-wire LANs) or up to 1 MBaud (for four-wire
LANs) the maximum network length is 1000 feet (300 meters) or 200 feet (60 meters) respectively. The Isolated Ground terminal (TB2-5) of all nodes on the four-wire RS-485
LAN must be connected via a fifth wire (within the third twisted pair).
Figure 5 - Typical 2-Wire Asynchronous RS-485 LAN
Figure 6 - Typical 2-Wire Synchronous 187.5KBaud RS-485 LAN
Figure 7 - Typical 4-Wire Synchronous 1MBaud RS-485 LAN
PIP-ISORS485 Page 7 Isolated RS-485 Interface Board
PIP-ISORS485
Figure 8 - Isolated RS-485 LAN - Typical Installation
Page 8 Isolated RS-485 Interface Board
ISOLATED RS-485 INTERFACE BOARD SPECIFICATIONS
Performance Specifications
Baud Rate (Max.): 38.4K Asynchronous (2-wire or 4-wire)
187.5K
Multidrop (Max.):
Network Termination:
32 Nodes
100 Ohm Resistors for TX and RX Circuits on End Nodes
Topology:
Isolation:
Common Mode Range:
Master/Slave: (TXD+ to RXD+) & (TXD- to RXD-)
Optically Isolated Data Signals
-7 Volts to +12 Volts (DC) (With respect to Isolated Ground)
Surge Protection:
Isolated Ground
Meets IEC-801 (To Isolated Ground)
Surge Path:
Terminal Provided for Local Connection to Cable Shield
(one end of shield only)
Terminal Provided for Local Connection from Isolated Chassis
Ground to Earth Ground through a 280V Sealed Surge
Absorber
Input Voltage:
Input Power:
+9 to +35 VDC
(4-Wire) 65 mA @ 24 VDC (1.56 watt)
(2-Wire) 40 mA @ 24 VDC (1 watt)
Environmental Specifications
Operating Temperature: -40 ° to +70 ° (C) [-40 ° to +158 ° (F)]
Storage Temperature: -40 ° to +85 ° (C) [-40 ° to +185 ° (F)]
Humidity:
RFI Susceptibility:
5% to 95% (Non-condensing)
Per SAMA Standard PMC 33.1-1978, Using Field of 10V/Meter
(From 20 MHz to 500 MHz)
Vibration: 10-150 Hz, 1g
150-2000 Hz, 0.5g
Part Numbers
Two-wire Isolated RS-485 Interface Board: With DIN Base:
DIN
Four-wire Isolated RS-485 Interface Board: With DIN Base:
Without
392909-01-4
Base:
392909-03-0
PIP-ISORS485 Page 9 Isolated RS-485 Interface Board
Isolated RS-485 Interface Board
Special Instructions for Class I, Division 2 Hazardous Locations
1. The Bristol, Inc. Isolated RS-485 Interface Board is listed by Underwriters Laboratories
(UL) as nonincendive and is suitable for use in Class I, Division 2, Groups A, B, C and D hazardous locations and non-hazardous locations only. Read this document carefully before installing a nonincendive Bristol Isolated RS-485 Interface Board. In the event of a conflict between the Isolated RS-485 Interface Board User Manual (PIP-ISORS485) and this document, always follow the instructions in this document.
2. All power and I/O wiring must be performed in accordance with Class I, Division 2 wiring methods as defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations within the United States, or as specified in Section 18-152 of the
Canadian Electrical Code for installation in Canada.
3. WARNING: EXPLOSION HAZARD - Substitution of components may impair suitability for use in Class I, Division 2 environments.
4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location, turnoff power before servicing/replacing the unit and before installing or removing I/O wiring.
5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the power has been switched off or the area is known to be nonhazardous.
03/14/2007 Appendix A, Document PIP-ISORS485 Page 1 of 1
Product Information Package
Isolated RS-485 Interface Board - 33XX, 3508, 3530 & 3808
PIP-ISORS485
Mar., 2007
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882 www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955 www.EmersonProcess.com/Bristol
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol, Inc. assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software delivered herewith. The Customer shall inspect and test such software and other materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for a particular purpose, concerning the software and other materials delivered herewith.
TeleFlow
™
is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol, Inc.
Product Information Package
PIP-CW_35 Upgrade Kit
Mar., 2007
CW_35 & CW-31 Hardware
Control
Wave
_35 & Control
Wave
_31
HARDWARE INSTALLATION GUIDE
For upgrade of the following 33XX Series Products:
3335 DPC & 3331 RIO
www.EmersonProcess.com/Bristol
IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!
Be sure that these instructions are carefully read and understood before any operation is attempted. Improper use of this device in some applications may result in damage or injury. The user is urged to keep this book filed in a convenient location for future reference.
These instructions may not cover all details or variations in equipment or cover every possible situation to be met in connection with installation, operation or maintenance. Should problems arise that are not covered sufficiently in the text, the purchaser is advised to contact Bristol for further information.
EQUIPMENT APPLICATION WARNING
The customer should note that a failure of this instrument or system, for whatever reason, may leave an operating process without protection. Depending upon the application, this could result in possible damage to property or injury to persons.
It is suggested that the purchaser review the need for additional backup equipment or provide alternate means of protection such as alarm devices, output limiting, failsafe valves, relief valves, emergency shutoffs, emergency switches, etc. If additional in-formation is required, the purchaser is advised to contact Bristol .
RETURNED EQUIPMENT WARNING
When returning any equipment to Bristol for repairs or evaluation, please note the following: The party sending such materials is responsible to ensure that the materials returned to Bristol are clean to safe levels, as such levels are defined and/or determined by applicable federal, state and/or local law regulations or codes. Such party agrees to indemnify Bristol and save Bristol harmless from any liability or damage which Bristol may incur or suffer due to such party's failure to so act.
ELECTRICAL GROUNDING
Metal enclosures and exposed metal parts of electrical instruments must be grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).
The grounding requirement is also applicable to mechanical or pneumatic instruments that include electrically-operated devices such as lights, switches, relays, alarms, or chart drives.
EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE
This product contains sensitive electronic components that can be damaged by exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude and duration of the ESD, this can result in erratic operation or complete failure of the equipment. Read supplemental document S14006 at the back of this manual for proper care and handling of ESD-sensitive components.
Bristol 1100 Buckingham Street, Watertown, CT 06795
Telephone (860) 945-2200
WARRANTY
A. Bristol warrants that goods described herein and manufactured by Bristol are free from defects in material and workmanship for one year from the date of shipment unless otherwise agreed to by Bristol in writing.
B. Bristol warrants that goods repaired by it pursuant to the warranty are free from defects in material and workmanship for a period to the end of the original warranty or ninety (90) days from the date of delivery of repaired goods, whichever is longer.
C. Warranties on goods sold by, but not manufactured by Bristol, are expressly limited to the terms of the warranties given by the manufacturer of such goods.
D. All warranties are terminated in the event that the goods or systems or any part thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or modified without Bristol's consent, (iii) not installed, maintained and operated in strict compliance with instructions furnished by Bristol, or (iv) worn, injured or damaged from abnormal or abusive use in service time.
E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
F. No agent of Bristol is authorized to assume any liability for it or to make any written or oral warranties beyond those set forth herein.
REMEDIES
A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or replacement without cost to Buyer of any goods or parts found by Seller to be defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days of discovery of the alleged defect and within the warranty period stated above, and if the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Watertown office designates a different location, transportation prepaid, within thirty (30) days of the sending of such notification and which upon examination by Bristol proves to be defective in material and workmanship. Bristol is not responsible for any costs of removal, dismantling or reinstallation of allegedly defective or defective goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can arrange to have a Bristol service person come to the site. The Service person's transportation time and expenses will be for the account of the Buyer. However, labor for warranty work during normal working hours is not chargeable.
B. Under no circumstances will Bristol be liable for incidental or consequential damages resulting from breach of any agreement relating to items included in this quotation, from use of the information herein or from the purchase or use by Buyer, its em-ployees or other parties of goods sold under said agreement.
How to return material for Repair or Exchange
Before a product can be returned to Bristol for repair, upgrade, exchange, or to verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA (Return
Authorization) number and thus ensure an optimal lead time. Completing the form is very important since the information permits the Bristol Repair Dept. to effectively and efficiently process the repair order.
You can easily obtain a RA number by:
A. FAX
Completing the form (GBU 13.01) and faxing it to (860) 945-3875. A Bristol Repair
Dept. representative will return call (or other requested method) with a RA number.
B. E-MAIL
Accessing the form (GBU 13.01) via the Bristol Web site (www.bristolbabcock.com) and sending it via E-Mail to [email protected]
. A Bristol Repair Dept. representative will return E-Mail (or other requested method) with a RA number.
C. Mail
Mail the form (GBU 13.01) to
Bristol Inc.
Repair
1100 Buckingham Street
Watertown, CT 06795
A Bristol Repair Dept. representative will return call (or other requested method) with a RA number.
D. Phone
Calling the Bristol Repair Department at (860) 945-2442. A Bristol Repair Department representative will record a RA number on the form and complete Part I, then send the form to the Customer via fax (or other requested method) for Customer completion of Parts II & III.
A copy of the completed Repair Authorization Form with issued RA number should be included with the product being returned. This will allow us to quickly track, repair, and return your product to you.
Bristol
Repair Authorization Form
(off-line completion)
(Providing this information will permit Bristol to effectively and efficiently process your return. Completion is required to receive optimal lead time. Lack of information may result in increased lead times.)
Date___________________ RA #___________________SH
Standard Repair Practice is as follows: Variations to this is practice may be requested in the “Special Requests” section.
•
Evaluate / Test / Verify Discrepancy
•
Repair / Replace / etc. in accordance with this form
•
Return to Customer
Line No.____________
Please be aware of the Non warranty standard charge:
•
There is a $100 minimum evaluation charge, which is applied to the repair if applicable (
√
in “returned”
B,C, or D of part III below)
Part I Please complete the following information for single unit or multiple unit returns
Address No.
Bill to :
Purchase Order:
Phone:
(office use only) Address No.
Ship to:
Fax:
(office use only)
Contact Name: ____________________________________
E-Mail:
Model No./Part No. Description
Range/Calibration S/N
Reason for return : Failure Upgrade Verify Operation Other
1.
Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)
(Attach a separate sheet if necessary)
2. Comm. interface used: Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other: ______________
3. What is the Firmware revision? _____________________ What is the Software & version?
Part III If checking “replaced” for any question below, check an alternate option if replacement is not available
A.
If product is within the warranty time period but is excluded due to Bristol’s warranty clause, would you like the product: repaired returned replaced scrapped?
B.
If product were found to exceed the warranty period, would you like the product:
C.
If product is deemed not repairable would you like your product: repaired returned replaced scrapped? returned replaced scrapped?
D.
If Bristol is unable to verify the discrepancy, would you like the product: returned replaced *see below?
* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that has the most knowledge of the problem is: ______________________________ phone_____________________
If we are unable to contact this person the backup person is: _________________________ phone_____________________
Special Requests: ____________________________________________________________________________________
____________________________________________________________________________________________________
Ship prepaid to: Bristol Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: 860-945-2442 Fax: 860-945-2220 Form GBU 13.01 Rev. C 04/27/06
Bristol
Training
GET THE MOST FROM YOUR BRISTOL
BABCOCK INSTRUMENT OR SYSTEM
• Avoid Delays and problems in getting your system on-line
• Minimize installation, start-up and maintenance costs.
• Make the most effective use of our hardware and software.
• Know your system.
As you know, a well-trained staff is essential to your operation. Bristol Inc. offers a full schedule of classes conducted by full-time, professional instructors. Classes are offered throughout the year at three locations: Houston, Orlando and our Watertown, CT headquarters. By participating in our training, your personnel can learn how to install, calibrate, configure, program and maintain any and all Bristol products and realize the full potential of your system.
For information or to enroll in any class, contact our training department in Watertown at
(860) 945-2343. For Houston classes, you can also contact our Houston office, at (713) 685-
6200.
A Few Words About Bristol Inc.
For over 100 years, Bristol ® has been providing innovative solutions for the measurement and control industry. Our product lines range from simple analog chart recorders, to sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas measurement, water purification, and wastewater treatment industries.
On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water company, there are Bristol Inc. instruments, controllers, and systems running year-in and year-out to provide accurate and timely data to our customers.
Getting Additional Information
In addition to the information contained in this manual, you may receive additional assistance in using this product from the following sources:
Help Files / Release Notes
Many Bristol software products incorporate help screens. In addition, the software typically includes a ‘read me’ release notes file detailing new features in the product, as well as other information which was available too late for inclusion in the manual.
Contacting Bristol Inc. Directly
Bristol's world headquarters is located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.
Our main phone numbers are:
(860) 945-2200
(860) 945-2213 (FAX)
Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time, excluding holidays and scheduled factory shutdowns. During other hours, callers may leave messages using Bristol's voice mail system.
Telephone Support - Technical Questions
During regular business hours, Bristol's Application Support Group can provide telephone support for your technical questions.
For technical questions about TeleFlow products call (860) 945-8604.
For technical questions about Control Wave call (860) 945-2394 or (860) 945-2286.
For technical questions regarding Bristol’s OpenEnterprise product, call (860) 945-3865 or e-mail: [email protected]
For technical questions regarding ACCOL products, OpenBSI Utilities , UOI and all other software except for Control Wave and OpenEnterprise products, call (860) 945-2286.
For technical questions about Network 3000 hardware, call (860) 945-2502.
You can e-mail the Application Support Group at: [email protected]
The Application Support Group maintains an area on our web site for software updates and technical information. Go to: www.bristolbabcock.com/services/techsupport/
For assistance in interfacing Bristol hardware to radios, contact Bristol’s Communication
Technology Group in Orlando, FL at (407) 629-9463 or (407) 629-9464 .
You can e-mail the Communication Technology Group at: [email protected]
Telephone Support - Non-Technical Questions, Product Orders, etc.
Questions of a non-technical nature (product orders, literature requests, price and delivery information, etc.) should be directed to the nearest sales office (listed on the rear cover of this manual) or to your Bristol-authorized sales representative.
Please call the main Bristol Inc. number (860-945-2200) if you are unsure which office covers your particular area.
Visit our Site on the World Wide Web
For general information about Bristol Inc. and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com
Training Courses
Bristol’s Training Department offers a wide variety of courses in Bristol hardware and software at our Watertown, Connecticut headquarters, and at selected Bristol regional offices, throughout the year. Contact our Training Department at (860) 945-2343 for course information, enrollment, pricing, and scheduling.
PIP-CW_35 Upgrade Kit
Control Wave _35 & Control Wave _31
Hardware Installation Guide
TABLE OF CONTENTS
SECTION TITLE
SECTION 1 – Control Wave _35/31 INTRODUCTION
PAGE #
................................... 1
SECTION 2 – Control Wave PROGRAMMING ENVIRONMENT ......................... 1
SECTION 3 – PHYSICAL DESCRIPTION ............................................ 3
3.1 CPU
3.1.1 CW_35/31 CPU Board Serial Comm. Port Connectors.................................................... 8
3.1.2 CW_35/31 CPU Board Memory......................................................................................... 8
3.1.3 CW_35/31 CPU Board Configuration Jumpers................................................................ 9
3.1.4 CW_35/31 CPU Board Configuration Switches ............................................................. 10
3.1.5 CW_35/31 CPU Module LEDs......................................................................................... 11
3.1.6 CW_35/31 Expansion Board Ethernet Ports.................................................................. 13
3.1.6.1 Ethernet CPU Engine 10Base-T Connectors J1 & J2 ................................................... 13
3.2 CW_35 Communication Board (CB) Overview .............................................................. 15
3.2.1 Setting CB Board DIP Switches ..................................................................................... 18
3.2.2 Setting CB Board Configuration Jumpers ..................................................................... 18
3.2.3 CB Board LED Indicators ............................................................................................... 20
3.2.4 CB Board Communication Port Information ................................................................. 20
SECTION 4 – ControlWave_35/31 CONFIGURATION ............................... 21
4.1
Step 1 - Hardware Configuration ................................................................................... 21
4.2 Step 2 - Software Installation on the PC Workstation.................................................. 25
4.3 Step 3 - Establish Communications using either LocalView or NetView, and Run the Flash Configuration Utility....................................................................... 25
4.4 Step 4. - Create an Application-specific Control Strategy in
ControlWave Designer..................................................................................................... 26
4.5 Step 5 - Create Application Specific Web Pages OPTIONAL) ...................................... 27
4.6 Step 6 - Create an Open BSI Network Containing the CW_35/31, or add the CW_35/31 to an Existing Open BSI Network .............................................. 27
4.7 Step 7 - Download the Application-specific Control Strategy
into
SECTION 5 – OPERATIONAL DETAILS ........................................... 28
5.1
5.2 CW_35/31
5.2.1 Using LocalView to Upgrade CW_35/31 Firmware ....................................................... 29
5.2.2 Using HyperTerminal to Upgrade CW_35/31 Firmware .............................................. 32
5.2.3 Remote Upgrade of CW_35/31 Firmware....................................................................... 34
5.3
SECTION 6 – GENERAL SERVICE NOTES ........................................ 35
Extent
6.2
6.3
PIP-CW_35 Upgrade Kit Contents / 0 - 1
PIP-CW_35 Upgrade Kit
Control Wave _35 & Control Wave _31
Hardware Installation Guide
TABLE OF CONTENTS
SECTION TITLE
7.1 Using
7.1.1 Communication
PAGE #
SECTION 7 – WINDIAG DIAGNOSTICS ........................................... 36
Diagnostic Port Loop-back Tests......................................................... 38
7.1.2 Serial Comm. Port External Loop-back Test Procedure ............................................... 38
Port
7.1.3.1 10Base-T (RJ-45 – Twisted Pair) Port Hardware Setup ............................................... 41
Ethernet
7.1.3.3 Loop-back Out Twisted Pair Test RUN Button ............................................................. 42
7.1.3.4 Return Hardware Address Test RUN Button................................................................ 42
7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages........................................................ 42
SECTION 8 – DISPLAY/KEYPAD ASSEMBLY OPERATION ......................... 42
8.1 Operation of the Dual-button Display/Keypad Assembly ............................................. 43
9.1
SECTION 9 – CW_35/31 SPECIFICATIONS ........................................ 46
CPU
9.1.1 CPU Module Communication Port Specifications ......................................................... 46
9.1.2 CPU Module 3.3V Power Supply Specifications ............................................................ 47
9.1.3 CPU Module Environmental Specifications................................................................... 47
9.2 CW_35 Comm. Board (CB) Specifications...................................................................... 47
9.2.1 CB Connectors ...................................................................................................... 47
9.2.2 CB Board Communication Port Specifications .............................................................. 47
9.2.3 CB Board 3.3V Power Supply Specifications ................................................................. 47
9.2.4 CB Board Environmental Specifications........................................................................ 48
APPENDICES
ControlWave_35 DISPLAY/KEYPAD (with 25 Keys) ASSEMBLY GUIDE .........Appendix DKA
REFERENCED BRISTOL CUSTOMER INSTRUCTION MANUALS
WINDIAG - Windows Diagnostics for Bristol Controllers ...................................D4041A
BSI
Getting
ACCOL
Web_BSI Manual...................................................................................................... D5087
ControlWave Reference
ControlWaveMICRO
ControlWave
Quick
Designer
0 - 2 / Contents PIP-CW_35 Upgrade Kit
ControlWave_35 & ControlWave_31
HARDWARE INSTALLATION GUIDE
SECTION 1 - Control
Wave
_35/31 INTRODUCTION
3335 DPC and 3331 RIOs can be field upgraded to become a Control Wave_ 35 DPC or
Control Wave_ 3 1 RIO (herein referred to as CW_35/31 ) by utilizing the hardware provided in an installation kit. Upgrade will require removal of the standard DPC 3335/RIO 3331
CPU Module and Comm./ECOM Boards and then adding the CW_35/31 CPU Module
(CPUM) and CW_35 Communication (CB) Boards provided in the upgrade kit.
Control Wave ® products have been designed and integrated as a highly adaptable, high performance Distributed Open Controller family with exceptional networking capability that provides a complete Process Automation Management Solution. The CPU Module and
CB Boards were designed with an emphasis on providing high performance with low power consumption and scalability.
The CPU Module utilizes Sharp’s LH7A400 System-on-Chip Advanced RISC Machine
(ARM) microprocessor with 32-bit ARM9TDMI Reduced Instruction Set Computer (RISC)
Core. In addition to the microprocessor and control logic, the CPU Board includes two communication ports that can be individually configured for RS-232 or RS-485 operation,
1MB of battery backed Static RAM (SRAM), 4MB of Synchronous Dynamic RAM (SDRAM),
512kB Boot/Downloader FLASH, 16MB simultaneous read/write FLASH, an I/O Bus
Connector, and up to two optional Ethernet ports.
In addition to Idle and Watchdog LEDs, there are six status LEDs located on the CPU LED
Board that will display run time status information. Two LEDs are also provided for each
Comm. Port.
CW_35/31 DPC/RIOs provide the following key features:
• ARM processor provides exceptional performance and low power consumption
• Up to six independently configurable asynchronous serial communication ports (RS-
232/RS-485) and one 3-wire serial RS-232 Utility Port
• Up to two optional Ethernet ports (10/100Base-T) (one on CW_31 )
• Optional Expansion Comm. Modules (2 Port or 4 Port)
• Wide temperature range: (-40 to +70 ° C) (-40 to 158 ° F)
• Utilizes existing DPC 3330/ RIO 3331 Chassis, Power Supply and I/O Boards
• RS-232/RS-485 Comm. Ports provided with LED status Indicators
• Battery backup for the real-time clock and the system’s SRAM is provided by a 3.0V,
300mA-hr lithium coin cell battery located on the CPU Board Ass’y.
• Class I, Div. 2 Hazardous Location approval
SECTION 2 - Control
Wave
PROGRAMMING ENVIRONMENT
The Control Wave programming environment uses industry-standard tools and protocols to provide a flexible, adaptable approach for various process control applications in the water treatment, wastewater treatment, and industrial automation business.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 1
The Control Wave programming environment consists of a set of integrated software tools which allow a user to create, test, implement, and download complex control strategies for use with Bristol’s CW_351 Distributed Process Controller or CW_31 Remote I/O Unit.
The tools that make up the programming environment are:
• Control Wave Designer load building package offers several different methods for generating and debugging control strategy programs including function blocks, ladder logic, structured languages, etc. The resulting process control load programs are fully compatible with IEC 61131-3 standards. Various communication methods are offered, including TCP/IP, serial links, as well as communication to Bristol’s Open BSI software and networks.
• The I/O Configuration Wizard , accessible via a menu item in Control Wave Designer, allows you to define process I/O modules in the CW_35 and configure the individual mapping of I/O points for digital and analog inputs and outputs.
• The ACCOL3 Firmware Library , which is imported into Control Wave Designer, includes a series of Bristol specific function blocks. These pre-programmed function blocks accomplish various tasks common to most user applications including alarming, historical data storage, as well as process control algorithms such as PID control.
• The OPC Server ( O bject Linking and Embedding (OLE) for P rocess C ontrol) allows real-time data access to any OPC [Object Linking and Embedding (OLE) for Process
Control] compliant third-party software packages.
• A series of Configuration Controls are available for setting up various aspects of the system such as historical data storage, system security, and soft switches. Additional
Data Access Controls are also available for retrieval of real-time data values and communication statistics. The configuration controls and the data access controls utilize
ActiveX technology and are called through a set of fixed Web pages, compatible with
Microsoft® Internet Explorer. Alternatively, developers can place the controls in thirdparty ActiveX compatible containers such as Visual BASIC or Microsoft® Excel.
• User-defined Web Pages - If desired, user-defined web pages can be stored within a
PC to provide a customized human-machine interface (HMI).
• Flash Configuration Utility – Parameters such as the BSAP local address, IP address, etc. are set using the Flash Configuration Utility, accessible via Open BSI
LocalView or NetView.
Note: DPC 3335s or RIO 3331s that are upgraded with “CW_35/31 Hardware,” must have their ACCOL application load converted to an IEC 61131 ControlWave
Program Load. This is accomplished via the ACCOL Translator (see User Guide
D5086).
Pg. 2 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 1 - ControlWave - Control Strategy Software Diagram
SECTION 3 - PHYSICAL DESCRIPTION
CW_35 Upgrade kits are comprised of the following major components:
• CW_35 CPU Module (CPUM) Overview (Section 3.1)
CW_35 CPU Board
CW_35 LED Board
CW_35 Expansion Board (with 2 Ethernet Ports and a Display/Keypad Jack)
• CW_35 Communication Board (CB) Overview (Section 3.2)
2-Port CB or 4-Port CB
CW_31 Upgrade kits are comprised of the following major components:
• CW_35/31 CPU Module (CPUM) Overview (Section 3.1)
CW_35/31 CPU Board
CW_35/31 LED Board
CW_35/31 Expansion Board (with 1 Ethernet Port)
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 3
Figure 2A – CW_35 Front View
Showing PC Boards, Module Layout & LED Assignments
Pg. 4 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 2B – CW_31 Front View
Showing PC Boards, Module Layout & LED Assignments
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 5
3.1 CW_35/31 CPU Module Overview
CW_35/31 CPU Modules (CPUM) provide CW_35/31 CPU, I/O monitor/control, memory and communication functions. CW_35/31 CPU Modules operate over an extended temperature range with long-term product reliability. Each CPUM consists of a CPU Board
(CPUB), a CPU LED Board and an Expansion Board (EB).
CW_35/31 CPUMs are based on a 32-bit ARM9TDMI RISC Core Processor. The CPU Board is specified to operate on CW_35/31 (+12Vdc or +24Vdc systems) and with a system clock speed of 150 MHz. In addition to the microprocessor and control logic, the CPU Board includes two independently Jumper configurable communication ports (RS-232/RS-485)
(COM5 & COM6), up to two optional 10/100Base-T Ethernet ports (two for CW_35 & one for CW_31 ), CPU Memory consists of 1MB of battery backed Static RAM (SRAM), 512kB
Boot/Downloader FLASH and 16MB simultaneous read/write FLASH.
CPU Boards are provided backup power via a coin cell socket that accepts a 3.0V, 300mA-hr lithium battery. This 3.0V battery provides backup power for the real-time clock and the system’s Static RAM (SRAM). Backup power is enabled when Configuration Jumper W3
(just below the battery) is installed in position 1 to 2.
If the 3.3Vdc that powers the unit goes out of specification, a supervisory circuit on the CPU
Board switches the battery voltage to the CPU’s SRAM and RTC. For maximum shelf life, the battery may be isolated from the circuit by removing the Backup Enable Jumper W3 from position 1 to 2 and then installing it in position 2 to 3. If the Real-time clock looses its battery backup a ControlWave Designer system variable bit (_QUEST_DATE) is set. This bit can be used to post a message or alarm to the PC (see the ControlWave Designer
Programmer’s Handbook - D5125, System Variables Section).
The system SRAM is specified to have a standby current of 20 : A for each part (1MB),
(40 : A maximum) (plus 2uA for the RTC). A worst-case current draw of 42 : A allows a battery life of approximately 7142 hours.
Basic CPU Module components and features are summarized as follows:
• LH7A400 System-on-Chip 32-bit ARM9TDMI RISC Core microprocessor
• Supports process control loads that are fully compatible with IEC 61131-3 standards
• 512KB FLASH Boot/Downloader, 29LV040B, 90 nS, 8-bit access
• 1MB SRAM, 3.3V, 256 x 16, 70 nsec., with Battery Back-up
• 4 MB SDRAM via two 1M x 16, 100MHz SDRAMs configured as a 1M x 32-bit array.
• 16MB simultaneous read/write FLASH, 90 nsec.
• 2 user configurable serial Comm. ports (RS-232/RS-485) (COM5 & COM6) (compatible with existing 3335/3331 communication cables)
• I/O Bus Interface, control for up to 12 I/O Boards
• MAC address in serial EEPROM
• Spread Spectrum clock for lower EMI
• Serial Real Time Clock with battery backup
• 8-Position general-purpose switch bank plus a 4-Position recovery switch bank
• Coin cell socket accepts a 3.0V, 300mA-hr lithium battery
Pg. 6 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Note: Expansion Bd. Connectors J2 & J3 aren’t available on CW_31s
Figure 3 – CW_35/31 CPU Module Component Identification Diagram
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 7
• LEDs: CPUB has 4 Serial Comm. Port LEDs (two for each port) plus Power Good,
Utility Port TX and Utility Port RX LEDs; CPU LED Board has Six Status LEDs plus
Watchdog and Idle LEDs and the EB has TX and RX LEDs built into the Ethernet
Ports
• 3-wire (RS-232) Utility Port: Provides compatibility with existing FLASH load cable used with the 3335 CPU.
3.1.1 CW_35/31 CPU Board Serial Comm. Port Connectors
The CPU Board supports up to two serial communication ports (COM5 and COM6). These ports are supported by Female D-Type connectors (see Table 10 for Comm. Port D-type connector pin assignments). Connector J1 (BIP1) supports Comm. Port 5 while connector J2
(BIP2) supports Comm. Port 6. When configured for RS-485 operation Comm. Port 5 and
Comm. Port 6 receivers are enabled by DTR the RS-485 driver is enabled by RTS. An eight position DIP-Switch (SW3) is assigned to Comm. Port 5 and another (SW4) is assigned to
Comm. Port 6. These switches provide user configuration of RS-485 port receiver biasing and termination as well as 2-wire or 4-wire operation (see Section 1.3.5). Configuration
Jumpers on the CPU Board RS-232/485 configuration and control of BIP1/BIP2 communication ports (see Section 3.1.4).
The following information is provided to support use of CPU Board Serial Comm. Ports:
• When configured for RS-232 operation, CPU Board Comm. Ports support RTS, DTR,
CTS, DCD and DSR modem control signals.
• RS-232 transceivers are enabled by the port’s DTR signal, i.e., when DTR goes high the port becomes active.
• Each RS-232 transceiver has one active receiver while in the power-down mode
(disabled). DCD is connected to the active receiver.
• When configured for RS-485 operation, the CB Comm. Port receiver is enabled by DTR while the driver is enabled by RTS.
• For RS-485 operation, an eight-position DIP switch (one per port) enables receiver biasing and termination as well as two-wire and 4-wire selection.
3.1.2 CW_35/31 CPU Board Memory
Boot/downloader FLASH
Boot/download code is contained in a single 512Kbytes FLASH IC. 4-Position DIP-Switch
SW1’s position 3 allows start-up menu options to be displayed or boot-up from system
FLASH. If SW1-3 is ON when a reset occurs, the boot-up code will cause a recovery menu to be sent out the Utility Port to a terminal program running on an external host computer.
Note: Recovery Mode will also be initiated if CPU Board Switch SW1 positions 1 and 2 are both set ON or OFF when a reset occurs.
FLASH Memory
The base version of the CPU Board has 16Mbytes of 3.3V, simultaneous read/write (DL)
FLASH memory. System Firmware and the Boot Project are stored here.
System Memory (SRAM)
The CPU Board has 1Mbyte of static RAM, implemented with two 256K x 16, 70 nanosecond asynchronous SRAMs. All random access memory retained data is stored in
SRAM. During power loss periods, SRAM is placed into data retention mode (powered by a backup 3.0V lithium battery). SRAM’s operates at 3.3V and are packaged in a 44-pin uTSOP. Critical system information that must be retained during power outages or when
Pg. 8 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
the system has been disabled for maintenance is stored here. Data includes: Last states of all I/O, historical data, retain variables and pending alarm messages not yet reported.
Synchronous Dynamic RAM (SDRAM)
The CW_35/31 CPU Board contains 4 Mbytes of Synchronous Dynamic RAM (SDRAM) implemented with two 1M x 16, 100MHz Synchronous DRAMs. The running application is stored here. This allows the system to run faster than it will from the FLASH memory.
SDRAM is not battery-backed.
3.1.3 CW_35/31 CPU Board Configuration Jumpers
CW_35/31 CPU Boards are provided with 18 Configuration Jumpers that function as follows:
• W3 - Enable/Disable Battery Back-up Selection
1 to 2 = Enable Battery Back-up
2 to 3 = Disable Battery Back-up
• W5 - Power Good LED (CR1 on CPU Bd.) Enable/Disable Selection
1 to 2 = Enable Power Good LED
2 to 3 = Disable Power Good LED
• W6 - Status LEDs (on LED Bd.) Enable/Disable Selection
1 to 2 = Enable Six Status LEDs
2 to 3 = Disable Six Status LEDs
• W9 - Serial Comm. Port Status LEDs (on CPU Bd.) Enable/Disable Selection
1 to 2 = Enable Serial Comm. Port Status LEDs
2 to 3 = Disable Serial Comm. Port Status LEDs
• W10 -- BIP1 (Comm. Port 5) Configuration Selection Note: W11, W12, W13 & W16 ditto
1 to 2 = Set for RS-232 Operation
2 to 3 = Set for RS-485 Operation
• W14 - BIP1 (Comm. Port 5) Control
1 to 2 = CTS Source is from Port
2 to 3 = RTS to CTS Loopback
• W15 - BIP1 (Comm. Port 5) DSR/DTR Control
1 to 2 = DSR on Pin-8 of D-type Connector
2 to 3 = DTR on Pin-8 of D-type Connector
• W18 -- BIP2 (Comm. Port 6) Configuration Selection Note: W19, W20, W21 & W24 ditto
1 to 2 = Set for RS-232 Operation
2 to 3 = Set for RS-485 Operation
• W22 BIP2 (Comm. Port 6) Control
1 to 2 = CTS Source is from Port
2 to 3 = RTS to CTS Loopback
• W23 - BIP2 (Comm. Port 6) DSR/DTR Control
1 to 2 = DSR on Pin-8 of D-type Connector
2 to 3 = DTR on Pin-8 of D-type Connector
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 9
3.1.4 CW_35/31 CPU Board Configuration Switches
Four configuration DIP-Switches are provided on the CPU Board. Eight-bit DIP-Switch
SW2 is provided for user configuration settings while four-bit DIP-Switch SW1 provides forced recovery functions. Eight-bit DIP-Switch SW3 provides loopback, termination control, and receiver bias settings for the Comm. Port 5 when it has been configured for RS-
485 operation (via jumpers W10 through W13 and W16). Eight-bit DIP-Switch SW4 provides loopback, termination control, and receiver bias settings for Comm. Port 6 when it has been configured for RS-485 operation (via jumpers W18 through W21 and W24).
Table 1 – CW_35/31 CPU Board (General Purpose Switch SW2) Assignments
Note: Except for SW2-4, ON = Factory Default
Switch Function Setting - (ON = Factory Default)
SW2-2
SW2-3
SW2-4
Lock/Unlock
Soft Switches
Use/Ignore
Soft Switches
Core Updump
See Section 3.6
SW2-6
System Firmware
Load Control
SW2-7 N/A
ON = Write to Soft Switches and FLASH files
OFF = Soft Switches, configurations and FLASH files are locked
ON = Use Soft Switches (configured in FLASH)
OFF = Ignore Soft Switch Configuration and use factory defaults
ON = Core Updump Disabled
OFF = Core Updump Enabled via Recovery Switch (SW1)
ON = Retain values in SRAM during restarts
OFF = Force system to reinitialize SRAM
ON = Enable remote downloading of System Firmware*
OFF = Disable remote downloading of System Firmware
* = Boot PROM version 4.7 or higher and System PROM version 4.7 or higher
Table 2 – CW_35/31 CPU Board (Switch SW1) Assignments
Recovery Mode/Local Mode Control (Note: SW1-4 not used)
Switch Function
SW1-1/2 Recovery/Local Mode *
SW1-3 Force Recovery Mode
Setting
Both ON or OFF = Recovery Mode
SW1 OFF & SW2 ON = Local Mode
ON = Force Recovery Mode (via CW Console)
OFF = Recovery Mode disabled
* Note: Only the CPU Switch SW1 setting listed in this table have been tested.
Table 3 – CW_35/31 CPU Board Switch SW3/SW4 Assignments
RS-485 Loopback & Termination Control (COM5 = SW3 & COM6 = SW4)
Switch
RS-485 Function
Switch ON
Setting
SW3/4-1 TX+ to RX+ Loopback/2-Wire ON - Only for Diagnostics
SW3/4-2 TX − to RX − Loopback/2-Wire ON - Only for Diagnostics
SW3/4-3 100 Ohm RX+ Termination ON - End Nodes Only
SW3/4-4 100 Ohm RX − Termination
SW3/4-7 RX+ Bias (End Nodes/Node)
ON - End Nodes Only
ON - 4-Wire = Both End Nodes
ON - 2-Wire = One End Node Only
SW3/4-8 RX − Bias (End Nodes/Node)
ON - 4-Wire = Both End Nodes
ON - 2-Wire = One End Node Only
Pg. 10 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
3.1.5 CW_35/31 CPU Module LEDs
CW_35/31 CPU Modules are equipped with up to 15 LEDs (plus 2 LEDs in each Ethernet
Jack). Table 4 provides CPU Module LED assignments. Table 5 provides definitions for the six Status LEDS.
Table 4 – Assignment of CW_35/31 CPU Module LEDs
LED Ref.
CR1
Function
Power Good
Color Location
Green CPU Bd. - Next to SW3 (Not User Viewable)
CR3 (1) - Right COM5 (BIP1) TX Red CPU Bd. - Card Edge (Top - Next to J1)
CR3 (2) - Left COM5 (BIP1) RX Red CPU Bd. - Card Edge (Top - Next to J1)
CR4 (3) - Right COM6 (BIP2)TX Red
CR4 (4) - Left COM6 (BIP2) RX Red
CR5 Utility Port TX Red
CR6
CR1
CR2
CR3
Utility Port RX
Status 1
Status 2
Status 3
Red
Red
Red
Red
CPU Bd. - Card Edge (Bottom - Next to J2)
CPU Bd. - Card Edge (Bottom - Next to J2)
CPU Bd. - Behind CR3/4 (Not User Viewable)
CPU Bd. - Behind CR3/4 (Not User Viewable)
LED Bd. - Bottom
LED Bd.
LED Bd.
CR4
CR5
Status 4
Status 5
Red
Red
LED Bd.
LED Bd.
CR6 Status 6 Red LED Bd.
CR7 Idle Bd.
CR8 Watchdog Red LED Bd. - Top
Note: Optional Ethernet Port Jacks are equipped with two LEDs that function as follows: yellow = TX, Green = RX activit y.
Two red LEDs provide for the following status conditions when lit: WD (CR18 on the LED
Board - Indicates a Watchdog condition has been detected) & IDLE (CR7 on the LED Board
- Indicates that the CPU has free time at the end of its execution cycle). Normally, the Idle
LED should be ON most of the time. When the Idle LED is OFF, it indicates that the CPU has no free time, and may be overloaded). The green Power Good LED (CR1 on the CPU
Board) is on when power is within specification. Six status LEDs provide run time status codes.
Table 5 - System Status Codes for Status LCDs
CW_35/31 CPU Module LED Board (see Figures 4 & 5)
LED
6
CR6
LED
5
CR5
LED
4
CR4
LED
3
CR3
LED
2
CR2
LED
1
CR1
Status
In Hex
Indication
Definition
1 0 1 0 0 0 28 Stopped Point
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 11
Table 5 - System Status Codes for Status LCDs
CW_35/31 CPU Module LED Board (see Figures 4 & 5) (Continued)
LED
6
CR6
LED
5
CR5
LED
4
CR4
LED
3
CR3
LED
2
CR2
LED
1
CR1
Status
In Hex
Indication
Definition
* = Flashed at startup
Figure 4 – CW_35/31 CPU Module LED Identification
(Note: EB Connectors J2 & J3 not available for CW_31s)
Pg. 12 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 5 – CW_35/31 CPU Status LED Hexi-decimal Codes
3.1.6 CW_35/31 Expansion Board Ethernet Ports
Connection to the Ethernet can be established via one or two Ethernet Ports situated on the
CPU Module’s Expansion Board (EB). Ethernet Ports utilize 10/100Base-T RJ45 modular connectors (J1 & J2) that typically provide a twisted pair interface to an Ethernet Hub.
Ethernet Port Jacks are equipped with two LEDs that function as follows: yellow = TX,
Green = RX activity. Note: Ethernet Port 2 isn’t available on CW_31 EBs.
3.1.6.1 Ethernet CPU Engine 10/100Base-T Connectors J1 & J2
8-pin 10/100Base-T Connectors J1 and J2 typically provide connection to a twisted pair
Ethernet via an Ethernet Hub. Both ends of the Ethernet cable are equipped with modular
RJ45 connectors. A typical hub provides eight (8) 10/100Base-T RJ45 ports (with port 8 having the capability to link to another hub or to an Ethernet communication port. The cable used between a CPU Module Convergence Expansion Board’s Ethernet 10/100Base-T connector and an Ethernet Hub has a one-to-one wiring configuration as shown in Figure 7.
Table 6 provides the assignment and definitions of the 8-pin 10/100Base-T Connector P2.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 13
It is possible to connect two nodes in a point-to-point configuration without the use of a
Hub. However; the cable used must be configured such that the TX ± Data pins are connected to the RX ± Data pins (swapped) at the opposite ends of the cable (see Figure 6).
Table 6 - Ethernet 10/100Base-T Connector P2 Pin Assignments
Pin # Description Pin # Description
1TX+ Transmit Data+ 5 Not Connected
2TX- Transmit Data- 6RX- Receive Data-
3RX+ Receive Data+ 7 Not Connected
Note: TX & RX are swapped at Hub’s .
The maximum length of one segment (CPU to Hub) is 100 meters (328 feet). The use of
Category 5 shielded cable is recommended.
Figure 6 - Point-to-Point 10/100Base-T Ethernet Cable
Figure 7 - Standard 10/100Base-T Ethernet Cable (CPU Board to Hub)
Pg. 14 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 8 – 10/100Base-T Connector (P2) with Cable Configured for Loopback
3.2 CW_35 Communication Board (CB) Overview
Communication Boards (CB) provide either four or two communication ports that utilize 9pin, D-Type, female connectors. These communication ports are compatible with existing
3335 Comm. Port cables. One CB can be installed in a CW_35 . It should be noted that a CB won’t fit into the first Comm. Slot, i.e., Chassis Slot 13 (see Figure 2). CB Board communication ports are labeled as follows:
4-Port CB contains Ports 3, 4, 9, & 10 (resides in Communication Socket #2).
2-Port CB Contains Ports 3 & 4 (resides in Communication Socket #2).
Note: The communication port numbering scheme is compatible with your existing ACCOL application program.
Standard 9-Pin D-Type Connectors are used in the two port version of the CB and dual stacked D-Type Connectors are used on four port versions. When the DPC contains a 4-Port
CB, a maximum of six serial Comm. ports are available (four on the CB and two on the
CW_35 CPU Board). When a 2-Port CBs is installed in a CW_35 DPC, a maximum of four serial Comm. ports are available (two on the CB assembly and two on the CW_35 CPU
Board).
The communication ports can be configured for an RS-485 or RS-232 interface. The former is required for BSAP network communications, while the latter is required for devices such as a PC or other RS-232 device. However; these ports can also be configured for other applications. For example, port 3 can be configured to interface with a PC while ports 4, 5,
6, etc. can be configured for use with options such as modems. It should be noted that internal chassis mounted modems, RASCL "redundancy," and use of a Hand Held Terminal aren’t supported.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 15
Figure 9 - CW_35 2-Port CB Board Component Identification Diagram
Pg. 16 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 10 - CW_35 4-Port CB Board Component Identification Diagram
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 17
3.2.1 Setting CB Board DIP Switches
The procedure for setting DIP switches is identical for the two different board versions except that the 4-Port Communication Board contains four DIP switches while the 2-Port
CB contains two DIP switches. When an individual switch (toggle) is pressed to the right it is set to its ON position (see Figure 11). Switches SW1 through SW4 control port configuration and are assigned as follows:
SW1 - Controls Port 3
SW2 - Controls Port 9
SW3 - Controls Port 4
SW4 - Controls Port 10
Switch functions are provided for RS-485 operation, in Table 7.
Figure 11 - Enlarged View of SW1-SW4
Table 7 – CB Board DIP Switches SW1 - SW4 - RS-485 Configuration Selections
SW1- SW4
1
2
Function
TX+ to RX+ Loopback
TX − to RX − Loopback
5 OFF
Setting
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
ON = Loopback Enabled, 2-Wire
OFF = Loopback Disabled, 4-Wire
ON = Termination Installed
OFF = No Termination
ON = Termination Installed
OFF = No Termination
6 OFF
7
8
RS-485 Bias Termination
RS-485 Bias Termination
ON = Bias Enabled
OFF = No Bias
ON = Bias Enabled
OFF = No Bias
Setting switches SW1 through SW4 does not complete the set-up configuration. The jumpers listed in Table 7 must also be set to complete the procedure.
3.2.2 Setting CB Board Configuration Jumpers
The 4-Port CB and 2-Port CB Boards contains up to twenty-one configuration jumpers to set various communication parameters. Figures 9 and 10 provide the location of the configuration jumpers. CB configuration jumpers are set according to Table 8.
Pg. 18 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Table 8 – CB Board Configuration Jumper Settings
Jumper
W1
Description
Comm. Port Status LED Control
W2 Port 3 Configuration
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
Port 3 Configuration
Port 3 Configuration
Port 3 Configuration
Port 3 C RTS/CTS Control
Port 3 DSR/DTR Selection
Port 3 Configuration
Port 4 Configuration
Port 4 Configuration
Port 4 Configuration
Port 4 RTS/CTS Control
Port 4 DSR/DTR Selection
Port 4 Configuration
Port 4 Configuration
Port 9 RS-XX/Modem Control
Port 9 Configuration
Port 9 Configuration
Port 9 Configuration
Port 9 Configuration
Port 9 RTS/CTS Control
Port 9 DSR/DTR Selection
Port 9 Configuration
Port 10 Configuration
Port 10 Configuration
Port 10 Configuration
Port 10 Configuration
PIP-CW_35 Upgrade Kit
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
Setting
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
1 to 2
2 to 3
Hardware Upgrade Installation Guide / Pg. 19
Configuration
Enable Comm. Status LEDs
Disable Comm. Status LEDs
Port 3 = RS-232
Port 3 = RS-485
Port 3 = RS-232
Port 3 = RS-485
Port 3 = RS-232
Port 3 = RS-485
Port 3 = RS-232
Port 3 = RS-485
Port 3 CTS Source is from Port C
Port 3 RTS to CTS Loopback
Port 3 Pin 8 = DSR
Port 3 Pin 8 = DTR
Port 3 = RS-232
Port 3 = RS-485
Port 4 = RS-232
Port 4 = RS-485
Port 4 = RS-232
Port 4 = RS-485
Port 4 = RS-232
Port 4 = RS-485
Port 4 CTS Source is from Port D
Port 4 RTS to CTS Loopback
Port 4 Pin 8 = DSR
Port 4 Pin 8 = DTR
Port 4 = RS-232
Port 4 = RS-485
Port 4 = RS-232
Port 4 = RS-485
Port 9 = RS-232 or RS-485
Port 9 = Modem
Port 9 = RS-232
Port 9 = RS-485
Port 9 = RS-232
Port 9 = RS-485
Port 9 = RS-232
Port 9 = RS-485
Port 9 = RS-232
Port 9 = RS-485
Port 9 CTS Source is from Port I
Port 9 RTS to CTS Loopback
Port 9 Pin 8 = DSR
Port 9 Pin 8 = DTR
Port 9 = RS-232
Port 9 = RS-485
Port 10 = RS-232
Port 10 = RS-485
Port 10 = RS-232
Port 10 = RS-485
Port 10 = RS-232
Port 10 = RS-485
Port 10 = RS-232
Port 10 = RS-485
Table 8 - CB Board Configuration Jumper Settings (Continued)
Jumper
W28
W29
Description
Port 10 RTS/CTS Control
Port 10 DSR/DTR Selection
Setting
1 to 2
2 to 3
1 to 2
2 to 3
Configuration
Port 10 CTS Source is from Port J
Port 10 RTS to CTS Loopback
Port 10 Pin 8 = DSR
Port 10 Pin 8 = DTR
W30
Pin #
Port 10 Configuration
1 to 2
2 to 3
Port 10 = RS-232
Port 10 = RS-485
3.2.3 CB Board LED Indicators
The CB Boards provide a TX and RX indicator for each communication channel. TX will light when the channel is transmitting data and RX lights when the channel is receiving data. Depending upon the data activity, the LEDs may blink or appear continuously lit during communication activity. The LEDs will be out when there is no activity (see Figures
9 & 10).
3.2.4 CB Board Communication Port Information
CB Boards will have 2 or 4 serial communication ports that are supported by 9-pin female
D-type connectors that have pinouts the same as DPC 3335 ECOM Boards (see Figures 9 &
10 and Table 9. All CB Board Comm. Ports can be individually user configured for RS-232 or RS-485 operation.
Table 9 - CB Board RS-232/RS-485 D-Type Connector Pin Assignments
Note: Identical to CW_35 CPU Bd. Ports 5 & 6
Signal
RS-232
Description:
RS-232 Signals
Signal
RS-485
Description:
RS-485 Signals
4
5
6
7
1
2
3
DTR
TXD
RXD
RTS
CTS
DCD
Data Terminal Ready Output TXD+
Transmit Data Output TXD −
Transmit Data +
Transmit −
RXD+ Receive Data +
Receive Data Input
Request To Send Output
Clear To Send Input
Data Carrier Detect Input
RXD − Receive −
9 GND Ground GND Ground
* Jumper Configured, typically set for DTR on Pin-8
The following information is provided to support use of CB Board Serial Comm. Ports:
• When configured for RS-232 operation, CB Comm. Ports support RTS, DTR, CTS, DCD and DSR modem control signals.
• RS-232 transceivers are enabled by the port’s DTR signal, i.e., when DTR goes high the port becomes active.
• Each RS-232 transceiver has one active receiver while in the power-down mode
(disabled). DCD is connected to the active receiver.
• When configured for RS-485 operation, the CB Comm. Port receiver is enabled by DTR while the driver is enabled by RTS.
• For RS-485 operation, an eight-position DIP switch (one per port) enables receiver biasing and termination as well as two-wire and 4-wire selection.
Pg. 20 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
SECTION 4 - Control
Wave
_35/31 CONFIGURATION
There are seven (7) main steps required to configure a CW_35 DPC. This document provides an overview of these steps with an emphasis on the installation and configuration of the hardware. This section is also intended to serve as a reference for users who may have already upgraded at least one CW_35 DPC or CW_31 RIO.
4.1 Step 1 - Hardware Configuration
This involves unpacking the CW_35/31 upgrade hardware, setting switches and setting jumpers on the new CW_35/31 boards, replacing the unit’s CPU and ECOM Boards with the CW_35/31 CPU and Comm. boards, reconnecting any permanent communication cables, and connecting a communications cable to a PC workstation to facilitate downloading the application load. Note: In the case of the RIO 3331 upgrade to a
CW_31, the 3331 ECOM Board must be removed and will not be replaced.
To upgrade the DPC 3330 to a CW_35 or RIO 3331 to a CW_31 , follow Hardware
Configuration steps 1 through 5 below:
1. Remove the boards from their carton. Remove all communication cables and the CPU and ECOM Boards from the unit being upgraded. (see Figures 2, 3, 9 & 10 as required). Note make sure the Comm. Cables are identified for proper reinstallation.
2. Make sure that the Lithium Backup Battery has been enabled, i.e., Backup Battery
Jumper W3 on the CW_35/31 CPU should be installed across jumper posts 1 and 2.
Configure the CW_35/31 CPU Board’s DIP Switches and Jumpers. Section 3.1.5 provides information on Switch Settings. Jumper and Switch settings are provided in
Sections 1.3.4 and 1.3.5, respectively. Install the CPU Board into the CW_35/31 .
3. Configure the DIP Switches and Jumpers on the CB (if provided) (see Figures 9 and 10).
Sections 3.2.1 and 3.2.1 provide information on CB Board DIP Switches and Jumpers, respectively. Install the CB Board into the CW_35 (see Figure 2).
4. Connect the communication port cables removed in step 1. Connect Ethernet Port 1 and
Ethernet Port 2 (if present) to their assigned networks (see Section 3.1.71). Connect the
CW_35/31 CPU’s 3-Wire Utility Port to a Communication Port of a PC (typically PC
COMM. Port 1).
A CW_35 can be configured as a Master or Slave node on either a MODBUS network or a BSAP network; the CW_31 can be configured as a Slave. A variety of communication schemes are available. Three serial communication ports are contained on the
CW_35/31 CPU Module. 2 or 4 serial communication ports are contained on the CW_35
CB Board. These communication ports are discussed in Section 3.1.1 through 3.1.6
(CPU) and 3.2, through 3.2.4 (CB). 1 or 2 Ethernet communication ports are available on the CPUM’s Expansion Board (1 for the CW_31 and 2 for the CW_35 ). Serial RS-
232/485 communication ports are designated as follows:
CW_35/31 CPU Module:
COM5 - Port BIP1: (9-Pin Female D-Type Connector J1) RS-232 or RS-485 operation
(Configured by CPU Board Jumpers W10 through W16) (RS-485 operation utilizes CPU Switch SW3). Note: This port was named BIP1 on original
DPC 3335s. When set for factory defaults, COM5 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 21
COM6 - Port BIP2: (9-Pin Female D-Type Connector J2) RS-232 or RS-485 operation
(Configured by Jumpers W18 through W24) (RS-485 operation utilizes Switch
SW4). Note: This port was named BIP2 on original DPC 3335s. When set for factory defaults, COM6 defaults to 9600 baud, 8-bits, no parity, 1 stop bit,
BSAP/ControlWave Designer protocol operation.
Utility Port: (3-Wire Connector J1 on the LED Board) RS-232 (for FLASH Firmware and Core Updumps) (Utilizes CPU Switch SW1). The Utility Port operates at
115.2 Kbaud and utilizes the 1KXModem or Xmodem protocol.
CW_35 CB Boards:
COM3 - Port 3 on CB: (9-Pin Female D-Type Connector J1) (J1 Bottom on 4-Port CB)
RS-232 or RS-485 operation (Configured by CB Jumpers W2 through W8) (RS-
485 operation utilizes CB SW1). Note: This port was named C on original
DPC 3335s. When set for factory defaults, COM3 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
COM4 - Port 4 on CB: (9-Pin Female D-Type Connector J2) (J2 Bottom on 4-Port CB)
RS-232 or RS-485 operation (Configured by CB Jumpers W9 through W15) (RS-
485 operation utilizes CB Switch SW3). Note: This port was named D on original DPC 3335s. When set for factory defaults, COM4 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
COM9 - Port 9 on 4-Port CB: (9-Pin Female D-Type (J1 Top) RS-232 or RS-485 operation (Configured by CB Jumpers W16 through W23) (RS-485 operation utilizes CB SW2). Note: This port was named I on original DPC 3335s.
When set for factory defaults, COM9 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
COM10 -Port 10 on 4-Port CB: (9-Pin Female D-Type) (J2 Top) RS-232 or RS-485 operation (Configured by CB Jumpers W24 through W30) (RS-485 operation utilizes CB Switch SW4). Note: This port was named J on original DPC
3335s. When set for factory defaults, COM10 defaults to 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ControlWave Designer protocol operation.
4.1 Step 1 - Hardware Configuration (Continued)
Communication Ports COM3 through COM6, COM9, COM10 and the Utility Port support serial asynchronous operation as listed above. Communication ports COM3 through COM10 can be configured for local communications, i.e., connected to a PC loaded with Control Wave Designer and OpenBSI software. The Utility Port (J1 on the
CW_35/31 LED Board) is used for FLASH firmware loads or Core Updumps. The pin labels for the various RS-232/485 interface connectors are provided in Table 9 (see
Figure 12 for RS-232 wiring diagrams and CPUM Utility Port Pin assignments).
RS-232 & RS-485 Interfaces
CW_35/31 RS-232 & RS-485 communication schemes are discussed herein.
RS-232 Ports
An RS-232 interface supports Point to Point, half-duplex and full-duplex communications (20 feet maximum, using data quality cable). Half-duplex communications supported by the CW_35/31 utilize MODBUS or BSAP protocol, while fullduplex is supported by the Point to Point (PPP) protocol. CW_35/31 RS-232 ports utilize the cable shown in Figure 12A - Top to interconnect with other devices such as a PC or another Control Wave series unit (other than a CW_10/3035/31 ) when the CW_35/31 is
Pg. 22 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
communicating using the full-duplex PPP protocol. The half-duplex cable of Figure 12A
(Bottom), is utilized when the CW_35/31 is connected to a Control Wave series unit other than a CW_10/3035/31 and is running other than the PPP protocol. If communicating with a Bristol series 3305, 3310, 3330, 3335, or to a CW_10/30/35/31
DPC/RTU, one of the cables shown in Figure 12B must be used.
Figure 12 - Communication Port RS-232 Cable Wiring Diagram
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 23
CW_35/31 CPU Utility Port (on the LED Board) utilizes the cable shown in Figure 12C.
Note: The following facts regarding CW_35/31 RS-232 serial communication ports should be observed when constructing communications cables:
• DCD must be high to transmit (except when dialing a modem)
• Each RS-232 transceiver has one active receiver while in powerdown mode
(disabled); the DCD signal is connected to the active receiver.
• CTS must be high to transmit.
• When port is set for full-duplex operation - RTS is always ON.
• DTR is always high (when port is active); DTR enables RS-232 Transceivers.
• When port is set for half-duplex operation - CTS must go low after RTS goes low.
• All RS-232 Comm. ports support RTS, DTR, CTS, DCD and DSR control signals.
RS-485 Ports
CW_35/31 s can use an RS-485 communication port for local network communications to multiple nodes up to 4000 feet away. Since this interface is intended for network communications, Table 11 provides the appropriate connections for wiring the master,
1st slave, and nth slave. Essentially, the master and the first slave transmit and receive data on opposite lines; all slaves (from the first to the "nth") are paralleled (daisy chained) across the same lines. The master node should be wired to one end of the RS-
485 cable run. A 24-gauge paired conductor cable, such as Belden 9843 should be used.
Note: Only half-duplex RS-485 networks are supported.
Table 10 - RS-485 Port
Connector Pin Assignments (COM3 through COM10))
Pin
#
Signal
RS-485
1 TXD+
Description:
RS-485 Signals
Transmit Data + Output
2 TXD − − Output
3 RXD+ Receive Data + Input
4 RXD − − Input
9 Power Ground Ground
Receiver biasing and termination as well as 2-wire or 4-wire selection are enabled by eight-position DIP-Switches situated on the CW_35/31 CPU Board for COM5 and
COM6 or on CW_35 CB Boards for COM 1 through COM 4 and COM7 through COM10 as follows:
COM3: CB Board Switch SW1 (see Figures 9 & 10) (see Table 7)
COM4: CB Board Switch SW3 (see Figures 9 & 10) (see Table 7)
COM5: CPU Board Switch SW3 (see Figure 3) (see Table 3)
COM6: CPU Board Switch SW4 (see Figure 3) (see Table 3)
COM9: 4-Port CB Board Switch SW2 (see Figures 9 & 10) (see Table 7)
COM10: 4-Port CB Board Switch SW4 (see Figures 9 & 10) (see Table 7)
Table 10 provides the connector pin assignments for all CW_35/31 RS-485 communication ports. Tables 3 and 7 provide the RS-485 termination and loopback control
Switch Settings for the RS-485 Ports on the CPU and CB Boards (respectively).
To ensure that the “Receive Data” lines are in a proper state during inactive transmission periods, certain bias voltage levels must be maintained at the master and most distant slave units (end nodes). These end nodes also require the insertion of 100-
Pg. 24 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Ohm terminating resistors to properly balance the network. CPU and CB Board switches must be configured at each node to establish proper network performance. This is accomplished by configuring the appropriate CPU/CB Board Switches so that the 100-
Ohm termination resistors and biasing networks are installed at the end nodes and are removed at all other nodes on the network (see Table 3 for CPU Boards and Table 9 for
CB Boards).
Table 11 - RS-485 Network Connections
(see Table 10 for CW_35 RS-485 Port Pin # Assignments)
From
Master
To 1st
Slave
To nth
Slave
TXD+ RXD+ RXD+
TXD − RXD − RXD −
RXD+ TXD+ TXD+
RXD − TXD − TXD −
GND GND GND
Note: Pins 1, 2, 3, 4 & 9 of Series 3305, 3310, 3330, 3335 & 3340 RTU/DPC RS-485 Comm.
Ports are assigned as follows: 1 = TXD+, 2 = TXD − , 3 = RXD+, 4 = RXD − and 9 = GND.
4.1 Step 1 - Hardware Configuration (Continued)
5. Apply power to the CW_35/31 DPC/RIO. Continue with Steps 2 through 7 below
(Sections 4.2 through 4.7 and 5.1) and the CW_35/31 will be ready for on line operation.
4.2 Step 2 - Software Installation on the PC Workstation
Control Wave Designer software must be installed on the PC. This is accomplished by installing the Control Wave Designer Package from the Open BSI CD ROM.
You must install the Open BSI Network Edition . For information on minimum system requirements and more details of the installation, see the installation procedure in Chapter
2 of the Open BSI Utilities Manual (document # D5081).
IMPORTANT:
When you start ControlWave Designer, you will be reminded to register the software. Unregistered software can only be used for a maximum of 30 days. For more information on the registration process, see Chapter 2 of the Open BSI
Utilities Manual (document# D5081).
4.3 Step 3 - Establish Communications using either LocalView or NetView, and run the Flash Configuration Utility
Communications must be established with the CW_35/31 using either LocalView or
NetView.
The CW_35/31 CPU Board ships from the factory with a default Flash configuration. Most users will need to edit this configuration to set the IP address (if using Ethernet – default
IP address = 10.0.1.1 with IP Mask = 255.255.255.0), BSAP local address, user accounts, and port parameters. This can be done in one of two ways:
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 25
• Either open the supplied Flash Configuration Profile (FCP) file and modify it, directly in the Flash Configuration Utility, or in a text editor,
• or retrieve existing Flash Parameters directly from the unit, and edit them in the Flash
Configuration Utility.
Detailed information on the Flash Configuration Utility and LocalView is included in
Chapter 5 of the Open BSI Utilities Manual (document # D5081). NetView is described in
Chapter 6 of that same manual.
4.4 Step 4 - Create an Application-specific Control Strategy in Control-
Wave Designer
At this point, you can create your application-specific control strategy using Control Wave
Designer. If you are upgrading this unit from a DPC 3335 ACCOL II-based unit, you can start by using the ACCOL Translator utility to take an existing ACCOL II load, and convert it to a ControlWave Designer project. You will then need to examine the translated project, and modify it, as necessary, to re-work logic that is unsupported in ControlWave Designer.
If you don’t have a pre-existing ACCOL load to translate, you can create an all-new project in ControlWave Designer. This involves opening a new project using the ‘ Control Wave
MICRO ’ template, defining I/O boards using the I/O Configurator, and creating a program using one or more of the five supported IEC 61131 languages (FBD, ST, SFC, LD, or IL).
Some of these languages are text based, others use graphical diagrams. The choice is up to you, depending upon your particular application.
The Control Wave MICRO Quick Setup Guide (document # D5124) includes a simple LD example. Additional examples are included in the manual, Getting Started with
Control Wave Designer (document # D5085). More detailed information about
Control Wave Designer and IEC 61131 is included in the Control Wave Designer Reference
Manual (document # D5088).
The ACCOL3 Firmware Library, which is automatically accessible through the template referenced above, includes a series of function blocks which perform a variety of process control and communication functions. These can be included within your program to perform various duties including PID control, alarming, calculations, etc. Detailed information about each function block is included in the Control Wave Designer on-line help files.
On the variables declaration page(s) in Control Wave Designer, you will need to mark any variable you want to make accessible to external programs, such as Open BSI’s DataView utility, as “PDD” . Similarly, any variables which should be collected into a database, or exported using the O LE for P rocess C ontrol (OPC) Server must be marked as “OPC”.
Variables marked as OPC can be built into a text file by the Open BSI Signal Extractor.
The text file can then be used in the creation of a database for human machine interface
(HMI) software such as OpenEnterprise, or Iconics’ Genesis. These HMI software packages require that the "Datatype conversion enable" option be selected when generating the file using Signal Extractor. Information about the Open BSI Signal Extractor is included in
Chapter 12 of the Open BSI Utilities Manual (document # D5081).
Once the program has been created, it is assigned to an executable task. The entire project is then saved and compiled.
Pg. 26 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Debugging of your completed control strategy program can be performed using the built-in debugger, and the I/O Simulator. Optionally, you can also use the I/O Simulator to simulate the outputs on your I/O boards, as your project executes. Note, however, that the I/O
Simulator only supports the IPC xx resource; therefore, to use it, you will need to add a second resource (IPC xx ) to your project, and make copies of your tasks and global variable worksheets under the new resource.
NOTE:
From this point on, the order of steps may be varied, somewhat, depending upon the requirements of the user's application.
4.5 Step 5 – Create Application-specific Web Pages (OPTIONAL)
Control Wave series controllers, including the CW_35/31 , can optionally export data to user-created web pages.
A series of ActiveX controls for data collection and configuration are provided on the Open
BSI CD that can be included as part of these web pages (For information on the ActiveX controls, see the Web_BSI Manual (document# D5087).
You can use whichever HTML creation package you want to create the pages, however, all
Control Wave web pages must be viewed within Microsoft® Internet Explorer.
The web pages may reside either on the PC workstation, or they can be downloaded into
FLASH memory at the CW_35/31 . If stored at the CW_35/31 , you must use the
ControlView utility to retrieve the page (using FTP) for viewing in Internet Explorer.
4.6 Step 6 – Create an Open BSI Network Containing the CW_35/31, or add the CW_35/31 to an Existing Open BSI Network
In order for the CW_35 unit to function as part of a Bristol network, it is necessary to include it in the Bristol network.
If no Bristol network exists:
You need to run Open BSI’s NetView software on the PC workstation in order to define a Bristol network. A series of software wizards are used to define a Network Host PC, a network, and the DPC/RTUs (controllers) assigned to the network. Finally, communication lines must be specified which handle the address assigned to the
CW_35 . Chapters 3 and 4 of the Open BSI Utilities Manual (document # D5081) include
‘quick start’ examples for performing these steps. More detailed information is included in the NetView chapter (Chapter 6) of D5081.
If a Bristol network already exists:
You will need to add the CW_35 to the existing network using NetView’s RTU Wizard.
Chapter 6 of the Open BSI Utilities Manual (document # D5081) includes different subsections depending upon whether you are adding the unit to a BSAP network, or an IP network.
4.7 Step 7 – Download the Application-specific Control Strategy into the
CW_35/31 DPC/RIO
Either Control Wave Designer or the Open BSI 1131 Downloader allows you to download your completed control strategy (application load) file into the CW_35/31 DPC/RIO. Users
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 27
download the control strategy into the BOOT Project area of FLASH memory; this ensures that if the CW_35/31 is reset, or if there has been a failure of the backup battery, that the control strategy can be restarted from the beginning, i.e., from the BOOT Project in FLASH memory.
The Open BSI 1131 Downloader also allows the user to download files (such as user-created web pages) into FLASH memory in the Control Wave_ 35/31 DPC/RIO. These can then be uploaded to the PC using the ControlView utility. To download the application load, see
Section 5.1 titled Downloading the Application Load.
SECTION 5 - OPERATIONAL DETAILS
CW_35 DPCs are shipped from the factory with firmware that allows the unit to be configured in conjunction with an IEC 61131, application program. This section provides information as follows:
-
Steps required to download the application load and place the unit into ‘Run’ mode.
-
Steps required to download system firmware.
Core Updumps
5.1 Downloading the Application Load
Any CW_35/31 DPC/RIO must have a configured application load before it can be placed into operation. For units being upgraded with the hardware discussed herein, this will require connection of the CW_35/31 to a PC running Windows NT (4.0 or higher), Windows 2000 or
Windows XP Professional and equipped with Control Wave Designer software & OpenBSI software. Configuration of the application load must be performed by an individual familiar with the various programming tools. The following software user documentation is referenced:
Getting Started with Control Wave Designer Manual - D5085
Control Wave Designer Reference Manual - D5088
Open BSI Utilities Manual - D5081
Web_BSI Manual - D5087
An application load download can be initiated, i.e., from Control Wave Designer, or from the
OpenBSI 1131 Downloader for CW_35/31 DPC/RIO Nodes.
1.
Make sure that the CW_35/31 CPU Board’s Recovery Switch (SW1) is set in ‘Local Mode,’ i.e., SW1-1 set to the OFF position and SW1-2 set to the ON position.
Note:
From the factory, COM1 defaults to 115.2 Kbaud (RS-232) using the BSAP
Protocol. Don’t connect COM1 to a PC unless the PC’s RS-232 port in question has been configured for BSAP operation.
2.
Once the CW_35/31 DPC/RIO project has been defined, communications and configuration parameters have been set, perform the download according to either
‘ Control Wave Designer’ (see D5088 - chapter 11) or ‘The Open BSI 1131 Downloader’
3.
After the download has been completed leave the CPU Recovery Switch (SW1) in the
‘Local Mode’ position.
4.
(see D5081 - Chapter 7).
Pg. 28 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
5.2 Upgrading CW_35/31 Firmware
CW_35/31 CPU Boards ship from the factory with system firmware already installed. If an upgrade of the system firmware is required, use one of the procedures below to download the new or replacement firmware from the PC. Upgrade of system firmware via LocalView
FLASH Mode requires OpenBSI 5.1 (or newer). If you have an older version of OpenBSI,
FLASH upgrades are to be performed via HyperTerminal. You will need a binary (*.BIN) system firmware file that is read as follows: c_30450.bin (where c_3 is the product code and
0450 is the release number). Upgrade of an unattended DPC CW_35 or RIO CW_31 can be accomplished from a remote PC. This capability is introduced in Section 5.2.3.
5.2.1 Using LocalView to Upgrade CW_35/31 Firmware
NOTE
Your CW_35 DPC or CW_31 RIO must be set to Recovery Mode ENABLE (ON) prior to per-forming the FLASH upgrade, then set to Recovery Mode DISABLE
(OFF) after the upgrade. On CW_35/31s this is accomplished via the CPU Board’s
Recovery Switch SW1. Set SW1-3 to the ON position for Recovery Mode. After setting SW1-3 to the ON position, turn power OFF and then ON again.
A communication cable (see Figure 12C) must be connected to the Utility Port on the
CW_35/31 CPU Board and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at 115.2 Kbaud. CW_35/31 CPU Switch SW1, position, 3 must be set ON.
Start LocalView, Choose FLASH, Enter A Name, Click on [Create]
Start LocalView by clicking on: Start Æ Programs Æ OpenBSI Tools Æ LocalView . The
New View Mode dialog box will appear (see Figure 13).
Figure 13 - Local View - New View Mode Menu
"Mode"
Choose 'Flash' for the mode.
"Name"
Enter a name for the View Mode File in the "Name" field.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 29
"Location"
If you want to store the View Mode File in a directory other than that shown in the
"Location" field, enter the new location there, or use the [Browse] push button to find the directory.
When the "Mode" , "Name" , and "Location" have been specified, click on the [Create] push button to activate the Communication Setup Wizard.
Step 1 - Communication Setup
Choose the communication port you want in the What port would you like to use: field.
Click on the [Next] pushbutton to activate the next wizard.
Step 2 - Flash RTU Setup
In the Flash RTU Setup Wizard, you need not set the RTU type or local address, since these are unused in this mode. Click on the [Next] push button to activate the Flash Data Setup
Wizard.
Figure 14 - Communication Setup: Step 1 Menu
CW_30
Figure 15 - Flash RTU Setup Menu
Pg. 30 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Step 3 - Flash Data Setup
Complete the following fields in the Flash Data Setup Wizard:
"Please enter the name of the binary file to Flash"
To upgrade system firmware, you must specify the path and name of a binary (*.BIN) file on your hard disk containing the firmware.
Click on [Finish] to install the specified BIN file in FLASH memory at the DPC.
D:\OpenBSI\c_30450.bin
Figure 16 - Flash Data Setup Menu
Path and filename of BIN file
Total number of bytes in BIN file
Progress of the flash download
D:\OpenBSI\c_30450.bin
These fields do
NOT apply to
Controlwave-series units.
Number of bytes already downloaded
Message area
‘Mod’ indicates unsaved changes to LVG file.
If necessary, click here to cancel the flash download
Figure 17 - LocalView Downloading System Firmware Menu
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 31
Once the Flash download has begun, you will NOT be allowed to shut down LocalView, unless you cancel the download, or it has been completed.
The progress of the Flash download will be displayed in the window. Any mismatch in file versions, or if the type of .BIN file does not match the type of RTU/DPC, the download will be aborted.
Once the download has completed, set CPU Board Switch SW1-3 to the OFF position and then turn power OFF and then ON again.
5.2.2 Using HyperTerminal to Upgrade CW_35/31 Firmware
A communication cable (see Figure 12C) must be connected to the CW_35/31 CPUM LED
Board’s Utility Port and to any RS-232 port on the associated PC. The PC’s RS-232 port used for this purpose must be set to run at 115.2 Kbaud. CW_35/31 CPU Board Switch
SW1, position, 3 must be set to the ON position.
1.
If not already running, apply power to the associated PC.
2.
Start the HyperTerminal program on the PC. Note: HyperTerminal is a Windows 95 (or newer) application utility program. If using HyperTerminal for the first time, set the communications properties (for the PC Port being utilized) via the Properties Menu as follows: Bits per second: = 115200, Data bits: = 8, Parity: = None, Stop bits: = 1, and Flow control: = None. After setting the communications properties, click OK.
3. Set the CPU Board’s Recovery Switch (SW1) for ‘Recovery Mode,’ i.e., set CPU
Board Switch SW1-3 to the ON position.
4. Apply power to the CW_35 DPC or CW_31 RIO. The resident BIOS will initialize and test the hardware, this process is referred to as POST (Power On Self Test).
Unless there is a problem status code 10 (Status LED #5 ON) will be posted to the CPU
Board’s Status LEDs. Detection of a fault during POST will be posted on the Status
LEDs. When the Power On Self Test has completed, a system status code will be posted to the Status LEDs (see Table 5 and Figure 5).
From the HyperTerminal Recovery Mode menu (Figure 18), press the ‘F’ key to enter
FLASH download. A message will be displayed warning that the FLASH is about to be erased; press the ‘Y’ key at the prompt. The screen will display dots as the flash devices are being erased; this could take a few minutes.
5. When the FLASH is ready for download the letter C will be displayed on the screen. In the HyperTerminal command bar click on Transfer and then Send File (see Figure 19).
In the Send File Dialog Box (see Figure 20), select “1KXmodem” for the protocol, enter the filename of the appropriate .bin file in the format “C_3 xxxx .bin” (where xxxx varies from release to release). Click on the Send button to start the download (see Figure 20).
When the HyperTerminal Recovery Mode Menu of Figure 18 appears, the download has completed.
Pg. 32 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 18 - HyperTerminal Recovery Mode Menu
Figure 19 - HyperTerminal FLASH Download Menu
(Ready to Download) - (Transfer/Send File Selected)
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 33
Figure 20 - HyperTerminal Flash Download (Send File Dialog Box)
6. Close the HyperTerminal program. The communication cable connected between the
CW_35/CW_31 (DPC/RIO) and the PC can be removed if desired.
7. Set the CPU Board’s Recovery Switch (SW1) for ‘Local Mode,’ i.e., set SW1-1 OFF and
SW1-2 ON). Set SW1-3 OFF and then switch power OFF/ON.
Once the CW_35 DPC or CW_31 RIO is running its application load, status codes will be posted to the six Status LEDs on the CPU Board. These Status LED (Hex) Codes are listed in
Table 5 (see Figure 5).
Figure 21 - HyperTerminal FLASH Download (Download in Process )
5.2.3 Remote Upgrade of CW_35/31 Firmware
It is possible to download system firmware into an unattended remote CW_35 DPC or CW-
31 RIO. This function can only be accomplished if CPU Board Switch SW2-6 (associated with the unit in question) is set in the ON position (factory default). The procedure for
Pg. 34 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
performing a remote download of system firmware is discussed in Appendix J of the Open
BSI Utilities Manual (document D5081).
5.3 Core Updump
In some cases a copy of the contents of SRAM and SDRAM can be uploaded to a PC for evaluation by Bristol, Inc. engineers. This upload is referred to as a ‘Core Updump.’ A Core
Updump may be required if the CW_35 DPC or CW_31 RIO repeatedly enters a ‘Watchdog
State’ thus ill effecting system operation. A Watchdog State is entered when the system crashes, i.e., a CPU timeout occurs due to improper software operation, a firmware glitch, etc. In some cases the Watchdog State may reoccur but may not be logically reproduced.
‘Crash Blocks’ (a function of firmware provided for watchdog troubleshooting) are stored in
CPU RAM. The user can view and save the ‘Crash Blocks’ by viewing the Crash Block
Statistic Web Page (see Chapter 4 of the Open BSI Technician’s Toolkit - D5087). Crash
Block files should be forwarded to Bristol, Inc. for evaluation. If additional information is required to evaluate the condition, a Core Updump may be requested by Bristol. Once the file generated by the Core Updump has been forwarded to Bristol, it will be evaluated and the results will be provided to the user.
Follow the five steps below to perform a Core Updump.
1. Set CPU Board Switch SW2-1 OFF (Disable Watchdog Timer). If Switch SW2-4 is ON, set it to OFF (Enable Core Updump). Note: The factory default setting for SW2-4 is
OFF.
2. Wait for the error condition (typically 3F on CPU Board Status LEDs).
CW_35/31 Utility Port to a PC (see Figure 12C).
CW_35/31 Expansion Board Jumper W1.
5. Start the PC’s HyperTerminal Program (at 115.2kbaud) and generate a file using the
1KX-Modem protocol. Save the resulting Core Updump in a file to be forwarded to
Bristol, Inc. for evaluation.
When the Core Updump has been completed, install Expansion Board Jumper W1.
SECTION 6 - GENERAL SERVICE NOTES
Certain questions or situations may frequently arise when servicing the CW_35 DPC or
CW_31 RIO. Some items of interest are provided in Sections 6.1 through 6.3.
6.1 Extent of Field Repairs
Field repairs to CW_35 DPCs or CW_31 RIOs are strictly limited to the replacement of complete modules. Component replacement on a CW_35/31 Module constitutes tampering and will violate the warranty. Defective CW_35/31 components (printed circuit boards, LCD
Displays, etc.) must be returned to Bristol, Inc. for authorized service.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 35
6.2
Disconnecting RAM Battery
The CW_35/31 ’s Lithium RAM battery cannot be replaced while power is on. Once the RAM battery has been replaced, the unit will still execute its FLASH-based application load
(Boot Project) upon power-up, but all of the current process data will have been lost. Upon power-up, the unit will act as though it had just been booted and it will revert back to the initial values specified in its application load. The battery may be disabled by setting the
CPU Board’s Battery Backup Board Jumper (W3) in position 2 to 3.
6.3 Maintaining Backup Files
It is essential to maintain a backup disk of each application load file to guard against an accidental loss of process configuration data. Without a backup record, it will be necessary to reconfigure the entire application load; that can be a very time consuming procedure.
Always play it safe and keep backup copies of your operating system loads. A copy of the application load can be loaded into CW_35/31 FLASH memory and/or saved to a PC’s Hard
Drive as a ZIP file.
SECTION 7 - WINDIAG DIAGNOSTICS
Bristol’s WINDIAG Software is a diagnostic tool used for testing CW_35 DPC or CW_31
RIO electronics including, I/O circuitry, CPU memory, communications ports, etc., for proper performance. The CW_35/31 must be communicating with a PC equipped with the
WINDIAG program. CW_35/31 CPU Board configuration switch SW2-8 must be set to the
OFF (Closed) position to enable diagnostics. Communication between the CW_35/31
(with/without application loaded) and the PC can be made via a Local or Network Port with the following restrictions:
• CW_35/31 CPU Board Switch SW2-8 must be OFF to run the WINDIAG program.
Setting SW2-8 OFF will prevent the ‘Boot Project’ from running and will place the unit into diagnostic mode.
• The communication port connected to the PC (running the WINDIAG program) must match the speed of the PC. All serial communication ports (except
COM1) can be configured for 9600 baud, 8-bits, no parity, 1 stop bit, BSAP/ Control -
Wave Designer protocol operation by setting CW_35/31 CPU Switch SW2-3 OFF This can also be accomplished via user defined Soft Switches.
• Communication port COM1 is forced to 9600 baud operation when CW_35/31 CPU
Switches SW2-3 and SW2-8 have both been set OFF. COM1 can also be set to 9600 baud operation via user defined Soft Switches.
To use the WINDIAG program place any critical process (associated with the CW_35/31 unit in question) under manual control. WINDIAG cannot be run while the CW_35/31 application is running. Set CW_35/31 CPU Board Switch SW2-8 to the OFF position. Perform steps 1 through 6 below.
1. Start the OpenBSI NetView Program. A menu similar to Figure 22 will appear.
2. To start the WINDIAG program, go to the Start Program’s menu, select OpenBSI Tools, then select Utilities Programs and then select Diagnostics.
3. Once WINDIAG has been entered, the Main Diagnostics Menu of Figure 23 will appear.
Pg. 36 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
4. Select the module to be tested. Enter any prompted parameters (slot #, etc.). WINDIAG will perform the diagnostics and display pass/fail results.
5. After all diagnostic testing has been performed, exit the WINDIAG program and then exit the NetView Program if there aren’t any other CW_35/31 units to be tested.
When you close the NetView program you will be prompted as to whether or not you want to close the OpenBSI program; select Yes.
Figure 22 - NetView Startup Menu - Example with Multiple Networks
Figure 23 - WINDIAG Main Diagnostics Menu
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 37
6. Set CW_35/31 CPU Board Switch SW2-8 to the ON (Open) position and reboot the unit.
The CW_35/31 DPC/RIO should resume normal operation.
7.1 Diagnostics Using WINDIAG
CW_35/CW_31 electronics can be tested using the WINDIAG program. From WINDIAG’s
Main Diagnostics Menu (see Figure 23) the following diagnostic tests can be performed:
CPU & Peripherals Diagnostic: Checks the CPU Board [except for RAM & PROM
(FLASH)].
PROM/RAM Diagnostic:
EEPROM Diagnostic:
Communications Diagnostic:
Checks the CPU Board’s RAM and PROM (FLASH) hardware.
Checks I/O Module EEPROM on an I/O Module.
Checks all Comm. Ports - The External loop-back tests require the use of a loop-back plug.
Checks Ethernet Port 1 and 2 on the CPU Module.
Checks AOs on various AO Modules.
Checks AIs on various AI Modules.
Ethernet Diagnostic:
Analog Output Diagnostic:
Analog Input Diagnostic:
Low Level Analog Input Diag.:
Discrete I/O Diagnostic:
Checks AIs on the Low Level AI Module.
Checks DIs or DOs on various DI and DO Modules.
High Speed Counter Diagnostic: Checks HSCs on various High Speed Counter Modules.
Keyboard & Display Diagnostics Checks Keyboard/Keypad & Display hardware
Information on serial communication port loop-back testing is provided herein. For additional information on WINDIAG tests, see document D4041A.
7.1.1 Communication Diagnostic Port Loop-back Tests
WINDIAG’s Communications Diagnostic Menu (see Figure 26) provides for selection of the communication port to be tested. Depending on the type of network (RS-232 or RS-485) and the port in question, a special loop-back plug is required as follows:
Ports 3 through 10 - RS-232: use a 9-pin male D-type loop-back plug or loop-back wires
(see Fig. 24).
Ports 3 through 10 - RS-485: use a 9-pin male D-type loop-back plug or loop-back wires
(see Fig. 25) or configure CW_35/31 CPU Module Switches
(SW3 and SW4) and/or CB Switches (SW1, SW2, SW3 and
SW4) for loopback operation (see Tables 3 & 7).
This group of tests verifies the correct operation of the Communication Interface. COM1, through COM10 can be tested with this diagnostic. The CW_35/31 communication port that is connected to the PC (local or network and used for running these tests) can’t be tested until diagnostics has been established via one of the other ports, i.e., to test all CW_35/31 serial RS-232/485 communication ports (via WINDIAG), communications with the PC will have to be established twice (each time via a different port). It should be noted that the
CW_35/31 communication port that is connected to the PC (RS-232, RS-485 or Ethernet) must be good for WINDIAG to run the Communications Diagnostics
7.1.2 Serial Comm. Port External Loop-back Test Procedure
1. Connect an external loop-back plug or loop-back wires to the Communication Port to be tested (see Figures 24 and 25). For RS-485 Loopback testing, CPU Switch SW3 and/or
Pg. 38 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
SW4 or CB Switches SW1 through SW4 can be configured for loopback operation (see
Table 4 or 8).
9-Pin Male
“D” Connector
Loop-back Plug
(Looking from rear/wire side of Plug)
5 = RTS
4 = RXD
7 = DCD
2 = TXD
6 = CTS
1 = DTR
Figure 24 - RS-232 Loop-back Plug/Wires
9-Pin Male
“D” Connector
Loop-back Plug
(Looking from rear/wire side of Plug)
4 = RXD
_
3 = RXD+
2 = TXD
_
1 = TXD+
Figure 25 - RS-485 Loop-back Wires
Figure 26 - WINDIAG’s Communications Diagnostic Menu
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 39
2. Type "1," "2," "3," etc. (up to "10") for the port to test.
3. Set baud rate to test to 115200 baud or ALL ASYNC and the number of passes to 5.
4. Click on RUN button next to External loop-back. responses: a) Success - All sections of test passed b) Failure - TXD RXD Failure
- CTS RTS Failure
Execution time < 5 sec.
7.1.3 Ethernet Port Diagnostics
The Ethernet Diagnostic menu of Figure 27 is entered from the WINDIAG Main Diagnostic
Menu (Figure 23). This menu provides four poke points (three associated with Ethernet circuitry test and one that provides the Return Hardware Address [which resides in
FLASH]). These tests verify the operation and integrity of the PCNET (Ethernet) Controller and the Ethernet port hardware on the CPU Board and CB Board.
Figure 27 - Ethernet Diagnostic Menu
Pg. 40 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
7.1.3.1 10Base-T (RJ-45 - Twisted Pair) Port Hardware Setup
The 10Base-T Port typically provides an interface (4-twisted pair) to an Ethernet Hub. To configure the system for the Loop-Back Out Twisted Pair diagnostic test either remove the standard R-J45 cable from the CPU Board's R-J45 connector and replace it with an R-J45 cable configured for loop-back, or remove the R-J45 cable associated with the port in question from the hub and install the unterminated end into an RJ-45 Jack configured for loop-back. Table 12 provides the pin identification and description for the RJ-45 port. Pin-1
(TX+) must be connected to Pin-3 (RX+) and Pin-2 (TX-) must be connected to Pin-6 (RX-) for proper loop-back test configuration (see Figure 28).
If the "Loop-Back Out Twisted Pair" Test RUN button is selected while the port is attached to an Ethernet Hub, a Failures Status will be posted.
Table 12 - Ethernet 10Base-T (RJ45) Connector Pin Assignments
Pin # Pneumonic
1 TX+
2 TX-
3 RX+
4 -
5 -
6 RX-
7 & 8 -
Description
Not Connected
Figure 28 - RJ-45 Ethernet Loop-back Plug
7.1.3.2 Ethernet Port Diagnostic Test Execution
There are four unique test buttons provided on the Ethernet Diagnostic Menu. Note: Only the "RUN Loop-back out twisted pair" and "RUN Return hardware address" tests are applicable to CW_35/31 units, i.e., the "RUN Chip internal loop-back" and "RUN Loop-back out AUI port" tests aren’t applicable. The applicable tests are discussed below.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 41
7.1.3.3 Loop-back Out Twisted Pair Test RUN Button
Set the Number of Passes. Make sure that the port is properly configured with a cable or jack for loop-back testing (see Section 7.1.3.1). Click on the "RUN Loop-back out twisted pair" Test button. The test will proceed and return either 'Success' or one of the following responses under the STATUS column:
Fail - No Hardware Present
- Loop-back Send Failed
- Loop-back Receive Failed
- Loop-back Compare Failed
-
Error Information Returned
When you have finished with Ethernet Diagnostic Loop-back testing, be sure to return the hardware to its normal operating configuration, i.e., disconnect the loop-back cable or jackplug and reconnect the Ethernet cable to both the CW_35/31 Ethernet port and the
Ethernet Hub.
7.1.3.4 Return Hardware Address Test RUN Button
Set the Number of Passes. Click on the "Return hardware address" Test button. The test will proceed and if successful the hardware address will be displayed. The hardware address will appear as 00-10-41-XX-XX-XX. The prefix 00-10-41 appears for all Bristol
Ethernet Comm. ports. The remainder of the hardware address is unique for each board manufactured and is stored in EEPROM. If the error message "Error Information
Returned" is displayed instead of the hardware address, and the unit has been programmed with a proper hardware address, the CPU Module should be replaced.
7.1.3.5 Ethernet Port Diagnostic Error/Failure Messages
If either a "No Hardware Present" or "Error Information Returned" message is displayed, ensure that the loop-back test requirements have been properly established (see Section
7.1.3.1). If test requirements have been met and the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
In the case of a "Loop-back Send Failed," "Loop-back Receive Failed" or Loop-back Compare
Failed" message, check the cable in question. If the cable associated with the port test in question is known to be good, the CPU Module should be replaced with a good unit.
SECTION 8 – DISPLAY/KEYPED ASSEMBLY OPERATION
CW_35 s support Display/Keypad assemblies (local or remote) that were present prior to the conversion to the Control Wave Platform. Additionally, connector J3 on the Expansion
Board accommodates connection to one of two unique remote Display/Keypad Assemblies; one with a dual-button Keypad (see Figure 29) and one with a 25-button Keypad (see
Figure 2-30). Both Display/Keypad assemblies utilize identical 4 x 20 LCD Displays. Each
Display/Keypad assembly employs a unique microcontroller based Display/Keypad
Interface Circuitry (situated on the remote Display/Keypad assembly that drive the LCD
Display and interfaces the Keypad. Interface to the CW_351 is made via a cable equipped with two plugs. This cable connects to the RJ-45 Display Jack (J3) on the CW_35
Expansion Board and RJ-45 Jack (J1) on the remote Display or Display/Keypad assembly.
A potentiometer is provided on the Display or Display/Keypad to set the contrast of the
LCD Display.
Pg. 42 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Figure 2-29 provides mounting hardware information for the Dual-button Display/Keypad
Assembly. Operation of the Dual-button Display/Keypad Assembly is discussed in Section
2.4.5.1 of this document.
Figure 2-30 provides mounting hardware information for the 25-button Display/Keypad
Assembly. Information on configuring the ‘Display Function Block’ (required to configure the Display associated with the 25-button Display/Keypad Assembly) is provided in
ControlWave Designer’s On-Line Help.
Note: Operation of the 25-button Display/Keypad Assembly is discussed in Appendix DKA of this document.
8.1 Operation of the Dual-button Display/Keypad Assembly
The Display will have a timeout of 20 minutes. If there has been no keypad activity for this time the display will “logout,” i.e., the display will be turned off and scrolling stopped until a key press occurs. When a key press occurs after a timeout the display will return to the opening screen.
If a shorter timeout of the display is needed for power savings, another timeout may be implemented. The processor connected to the display will control the timeout. When the timeout occurs the display will be blanked, but communications between the CW_35/31
CPU and display processor will still occur. The display processor will ignore posting the messages to the screen when in the low power mode. When a key is pressed the display processor will return to displaying information to the display.
Displays are organized into screens as follows:
Opening Screen: User defined strings
List Selection Screen: List Name
List
<Blank
Line>
The List Selection screen is entered from the main opening screen by pressing the right arrow. Once here the operator can select which list is to be viewed. The operator can traverse though different list numbers by pressing the down arrow key. When the list to be scrolled is shown on the display, pressing the right arrow key will bring the operator to the
Display Element screen.
Display Element Screen: <Blank Line>
Line>
Variable
Name
Name
Variable
The Display Element screen is entered from the list selection screen by pressing the right arrow. Once here the operator can view the variables in the list. Once entered the first element of the list is displayed and then next element will be displayed after the scroll timeout occurs. The scrolling will continue displaying the next element in the list and then wrapping around to the beginning of the list. The down arrow key will toggle the display through hold and scroll mode. Pressing the right arrow key will bring the operator to the list selection screen.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 43
Figure 29 - Dual-button Display/Keypad Assembly Installation Drawing
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode .
Automatic Mode
In Automatic mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and responding to key presses. Screens are fixed and start off with an opening screen, which displays user information passed into the function block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled has been selected, the user can scroll through the list by pressing the down arrow key. List elements will be displayed automatically, scrolling at a predetermined rate (determined by iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing the right arrow key again will cause the list to start scrolling again.
Pg. 44 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
The essence of Automatic mode is that the user can supply inputs into the function that will determine which list can be displayed, but cannot change the menu or display. The user is allowed to select a list and to start/stop scrolling.
Figure 2-30 - 25-Button Display/Keypad Assembly Installation Drawing
Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the next desired screen, based on key inputs. The programmer has access to all lines of the display and can provide any string that he/she desires to display. Special formats that must be adhered to that allow the programmer to display what they want on the screen are provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode does not support reading Keypad key-presses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 45
SECTION 9 - CW_35/31 SPECIFICATIONS
9.1 CW_35/CW_31 CPU Module Specifications
Processor: Sharp’s LH7A400 32-bit System-on-Chip with 32-bit
ARM9TDMI RISC Core
Memory:
Real Time Clock:
16 Mbytes of simultaneous read/write FLASH
1 Mbyte of on-board SRAM
512 Kbytes FLASH Boot/Downloader
4 Mbytes of SDRAM
A Semtech SH3000 support IC provides a full BCD clock calendar with programmable periodic/wakeup interrupt and a programmable clock generator with adjustable spectrum spreading.
Connectors: (see Table 13)
Table 13 - CPU Board Connector Summary
Ref. # Pins
P1
Function
68-Pin EB Intf. to P2 on CPUB Male (on EB)
Notes
P1
J1
J1
J1
14-Pin LED Board (Status/Utility Port Intf. Male (on LED Bd.)
14-Pin LED Board (Status/Utility Port Intf. Female (on CPUB)
3-Pin Utility Port - RS-232
9-Pin Serial Comm. Port 5 (BIP1)
Male (on LED Bd.)
Female D-Sub (on CPUB)
P2
J2
68-Pin CPU Bd. Intf. to P1 on CEB
9-Pin Serial Comm. Port 6 (BIP2)
J2 8-Pin Ethernet Port 1
J3* 8-Pin Ethernet Port 2
Female (on CPUB)
Female D-Sub (on CPUB)
RJ-45 - 10/100BaseT (on EB)
RJ-45 - 10/100BaseT (on EB)
J3* 8-Pin Display/Keypad Interface
J3 80-pin Backplane I/O Bus Interface
RJ-45 (on CEB) see Section 8
3335 Backplane Intf. (on CPUB)
* = Not available on CW_31 Remote Input/Output (RIO) units
9.1.1 CPU Module Communication Port Specifications
CPUM Comm. Ports: LED Board
J1: 3-pin In-line – Utility Port (RS-232)
CPU Board
J1: 9-pin D-Type Female Connector - Serial Comm. Port
BIP1/COM5 is configurable for RS-232 or RS-485 operation
J2: 9-pin D-Type Female Connector - Serial Comm. Port
BIP2/COM6 is configurable for RS-232 or RS-485 operation
Expansion Board
J1: 8-pin 10/100Base-T (Female) Ethernet Port 1
J2: 8-pin 10/100Base-T (Female) Ethernet Port 1
Baud Rate: 300 to 115Kbps for RS-232 or RS-485
See Table 9 for connector pin assignments
Pg. 46 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
9.1.2 CPU Module 3.0V Power Supply Specifications
Input: +5Vdc
+3.3Vdc ± 1% Output Voltages:
Output Current:
Output Ripple P/P:
0.6A Max. @ 3.3Vdc
+3.3V Output: 10mV
9.1.3 CPU Module Environmental Specifications
-40 to +185 ° F (-40 to +85 ° C)
-40 to +185 ° F (-40 to +85 ° C)
Temperature: Operating:
Storage:
Relative Humidity: 0-95% Non-condensing (Operating & Storage)
Vibration:
RFI/Emissions:
1g acceleration over 10 to 150 Hz
.5g acceleration over 150 to 2000 Hz
In conformity with the following standards: ENV 50140
Radio-frequency electromagnetic field amplitude modulated
EMV
9.2 CW_35 Comm. Board (CB) Specifications
9.2.1 CB Board Connectors
Table 14 – CB Board Connector Summary
Ref. # Pins Function
P1 44-pin Backplane Interface.
J1
Bottom 9-pin
RS-232/485 Serial Comm. Port 3
J2
Bottom 9-pin
J1
Top
J2
Top
9-pin
9-pin
(
(
RS-232/485 Serial Comm. Port 4
RS-232/485 Serial Comm. Port 9
Not On 2-Port CCBs )
RS-232/485 Serial Comm. Port 10
Not On 2-Port CCBs )
Notes
CW_35 COM Bus Interface
Female D-Type: (Bottom Left)
Female D-Type: (Bottom Right)
Female D-Type: (Top Left)
Female D-Type: (Top Right)
9.2.2 CB Board Communication Port Specifications
CB Board Comm. Ports: see Table 14
Baud Rate: 300 to 115Kbps for RS-232 or RS-485
See Table 9 for connector pin assignments
9.2.3 CB Board 3.3V Power Supply Specifications
Input: +5Vdc
Output Voltages: +3.3Vdc ± 1%
PIP-CW_35 Upgrade Kit Hardware Upgrade Installation Guide / Pg. 47
Output Current:
Output Ripple P/P:
9.2.4 CB Board Environmental Specifications
Temperature: Operating:
Storage:
-40 to +185
-40 to +185
°
°
F (-40 to +85
F (-40 to +85
°
°
C)
C)
Relative Humidity:
Vibration:
0.6A Max. @ 3.3Vdc
+3.3V Output: 10mV
0-95% Non-condensing (Operating & Storage)
1g acceleration over 10 to 150 Hz
.5g acceleration over 150 to 2000 Hz
RFI/Emissions: In conformity with the following standards: ENV 50140
Radio-frequency electromagnetic field amplitude modulated
EMV
Pg. 48 / Hardware Upgrade Installation Guide PIP-CW_35 Upgrade Kit
Product Information Package
PIP-CW_35 Upgrade Kit
Nov., 2006
CW_35 Display/Keypad (25 Keys)
Control
Wave
_35 DISPLAY/KEYPAD
(with 25 Keys) ASSEMBLY GUIDE
Appendix DKA
www.EmersonProcess.com/Bristol
APPENDIX DKA
Control
Wave
_35 DISPLAY/KEYPAD
(with 25 Keys) Assembly Guide
TABLE OF CONTENTS
SECTION TITLE PAGE #
DKA1.1 OVERVIEW ..............................................................................................................DKA-1
FUNCTION
DKA2.1.1 DISPLAY
DKAE3.1 PREPARING THE ControlWave PROJECT...........................................................DKA-3
DKA4.1 USING THE KEYPAD .............................................................................................DKA-4
DKAE4.1.1 Scrolling.....................................................................................................................DKA-5
DKA4.1.2 Signing-On ................................................................................................................DKA-6
DKAE4.1.3 Using the Clock Functions .......................................................................................DKA-7
DKAE4.1.3.1 Changing the Time ...................................................................................................DKA-8
DKA4.1.3.2 Changing the Date....................................................................................................DKA-8
DKA4.1.4 Choosing a Variable List from the List Menu.........................................................DKA-8
DKA4.1.5 Moving Through a Variable List..............................................................................DKA-9
DKA4.1.6 Changing Variable Parameters ...............................................................................DKA-9
DKA4.1.7 Signing-Off ..............................................................................................................DKA-12
DKA5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO....................................DKA-13
NOTE: The Dual-button Display/Keypad Assembly is discussed in Section 8.1 of
PIP-CW_35 Upgrade Kit.
PIP-CW_35 Upgrade Kit Appendix DKA – Display/Keypad Contents / 0 - 1
Appendix DKA
DISPLAY/KEYPAD ASSEMBLY GUIDE
DKA1.1 OVERVIEW
Bristol Display/Keypad assemblies provide a local, user interface for the Control Wave
3335 ( CW_35 ) DPC. These assemblies allow an operator or engineer to view and modify variable values and associated status information, via an ACCOL3 Function Block.
Variables can include inputs, process variables, calculated variables, constants, set-points, tuning parameters and outputs used in a measurement or control application. Status bits include alarm state, alarm acknowledge, control, manual, and questionable data.
Setting up the Display/Keypad is a simple matter of configuring a Display Function Block in the ControlWave Designer project.
The Display/Keypad is comprised of a four line by twenty character liquid crystal display, with adjustable LCD Contrast, and a 25 button membrane key matrix. Each key has a microswitch for positive tactile feedback. This means that as you firmly depress the keys, you will feel it click as it engages. In the case of the CW_35 DPC, the Display/Keypad is located (typically panel or Enclosure Front Cover mounted) within the proximity of the
CW_35 and is installed in the field by field service personnel, user, integrator, contractor, etc.
Figure 1 - Display/Keypad Assembly – 25 Button Keypad & 4 X 20 Display
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 1
Display/Keypad Assemblies are supported by Automatic Mode and Manual Mode .
Automatic Mode
In Automatic Mode a set of screens (based on the application load) are displayed. The application programmer provides strings for the opening screen. From there the firmware is responsible for displaying the screens and responding to key presses. Screens are fixed and start off with an opening screen, which displays user information passed into the function block. Users can view a list to select which list is to be scrolled. Once the list to be scrolled has been selected, the user can scroll through the list by pressing the down arrow key. List elements will be displayed automatically, scrolling at a predetermined rate (determined by iiScrollTime). The user may pause on a variable by pressing the right arrow key. Pressing the right arrow key again will cause the list to start scrolling again.
The essence of Automatic Mode is that the user can supply inputs into the function that will determine which list can be displayed, but cannot change the menu or display. The user is allowed to select a list and to start/stop scrolling.
Manual Mode
In Manual Mode the programmer is responsible for creating each screen and displaying the next desired screen, based on key inputs. The programmer has access to all lines of the display and can provide any string that he/she desires to display. Special formats that must be adhered to that allow the programmer to display what they want on the screen are provided in the description of iaScrnSruct in the ACCOL 3 Display function block within
ControlWave Designer’s On-Line Help. It should be noted that currently, Manual Mode does not support reading Keypad keypresses. Note: Manual Mode operation requires
ControlWave Firmware 4.50 or newer.
If you're setting up the keypad, follow the configuration instructions provided in Section E3 of this appendix.
If your keypad has already been set up, Section E4 will tell you how to use the keypad and interpret the display.
DKA2.1 DISPLAY FUNCTION BLOCK DESCRIPTION
Keypad and display control/configuration are handled by the DISPLAY Function Block.
This function block allows an operator to view/change variable data or to be allowed to scroll through lists of variable data based upon their login privileges.
In order for the keypad and display to operate, the ControlWave Designer project must include a properly configured DISPLAY Function Block. Use ControlWave Designer to configure this function block and assign the parameters according to the four steps covered in Section 3.
DKA2.1.1 DISPLAY Function Block Parameters
Referring to Figure 2, various DISPLAY Function Block Parameters are available. For information on configuring the Display Function Block, please reference on-line help in
ControlWave Designer.
DKA 2 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
Figure 2 - ACCOL3 DISPLAY Function Block Parameters
DKA3.1 PREPARING THE ControlWave PROJECT
In order for the keypad and display to operate, the ControlWave Designer project must include a properly configured Display Function Block. Once the Keypad is operating, a user who has signed on with a password can scroll through the names of variable lists and choose a list to read or change. Use Up Arrow and Down Arrow keys to select the Username and use the numeric keys to enter your password. The steps that follow describe how to configure this function block.
Step 1: Creating the Identifier Display
The Identifier Display is the first display to appear when the Display Function Block is initialized and begins to execute. This display will look similar to Figure 3. Each of the first three lines of the display contains the text value of a string variable. These string variables are created utilizing iaScrnStruct parameters of the Display Function Block (See Figure 2) and your computer keyboard. Since this is the first display that the user will see, you may want the display to contain general information such as the node name of the controller or the process that the controller is monitoring.
The bottom line on the display is called the legend line. It shows which function keys are currently active and their purpose. Function keys are those keys on the Keypad that are marked ([F1] through [F4]). Function key assignments are preconfigured and cannot be changed. Using function keys is described in Section KDA4.1, Using the Keypad.
The legend line in Figure 3 shows that the user has two choices: to Log-in (using [F1]) or scroll (using [F2]).
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 3
Figure 3 - Creating the Identifier Message
Step 2: Defining a Scroll List
Once the Keypad is operating properly, you can automatically scroll through a list of variables created via DISPLAY Function Block Parameters iiList2Scroll and iiListMode.
Scrolling can be done without entering a password. The variables in the list are displayed one at a time and in the same order in which they were entered in the variable list.
Later, we'll discuss other variable lists that can be accessed with the keypad. To distinguish this list from others, let's call this variable list the Scroll List.
Enter the number of a variable list to be scrolled. This variable list becomes the Scroll List.
The Scroll List can contain different types of variables (that is, logical, analog and string).
You can create a specific scroll variable list or use any list in the ControlWave Project.
Each variable in the Scroll List will be displayed for the number of seconds defined by the iiScrollTime parameter. If you don't specify a time for this parameter, the hold time will be two seconds. If you signed-on and then started scrolling you will be signed-off in 20 minutes if no keys are pressed. If you don’t want to automatically stop scrolling after 20 minutes, sign-off (INIT key) before starting scrolling.
Step 3: Assigning Passwords
A valid RTU username/password combination must be entered to go beyond the initial displays. Passwords can be any combination of numbers up to 16 digits in length, from
0000000000000000 to 9999999999999999. If none are specified, the default values are system for User-name and 666666 for Password (read/write access).
Step 4: Status Information
Enter a variable name on the odiStatus terminal.
See On Line Help in ControlWave Designer for Status Values.
The next section describes how to use the Keypad to access variable information.
DKA4.1 USING THE KEYPAD
The Identifier Display is the starting point from which you can go to other displays. It shows an identification message and the words Login and Scroll at the bottom of the screen
(see Note 1). The identification message may contain the name of the controller, the plant equipment it is monitoring, or the variables you can expect to see when you use this display.
DKA 4 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
Note 1 : If your display shows something else, press the [F4] key until you see the words
Login and Scroll on the bottom line.
If your screen is blank, turn the brightness screw clockwise. This screw is located to the left of the Keypad (looking at the rear of the 25-Button Display/Keypad Assembly (see Figure 14). If no letters appear, the controller has not been programmed properly to operate the keypad.
The words Login and Scroll at the bottom of the screen are on the legend line. It tells you which function keys (that is, key [F1] through [F4]) are active and their purpose at that time.
Up to four legends can appear on the legend line. The legend on the far left corresponds to the function of the [F1] key. The assignment for the [F4] key is on the far right. Keys [F2] and [F3] are described to the left and right of center. When no legend appears, that function key is not active at that time. For example, in Figure 4 only [F1] and [F2] are active.
From the Identifier Display, you have two choices. Pressing [F1] will allow you to sign-on if you have a password. By pressing [F2] you can activate automatic scrolling through a list of variables.
Figure 4 - The Identifier Display
Figure 5 - Identifier Display Legends and Corresponding Keypad Alignment for 25 Button Membrane Key Matrix Keypad System
DKA.1.1 Scrolling
To begin automatic scrolling, press [F2] from the Identifier Display (Figure 4). Variable information will appear on the screen and remain there for 1 to 30 seconds (default = 2). The
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 5
variable name appears on the first line. The variable value appears on the second line and status information appears on the third line. An example is shown in Figure 6.
When all variables in the list have been displayed, they will be shown again in the same order. This is called Single Variable Mode.
Pressing Mlti [F2] activates Multiple Variable Mode. Multiple Variable Mode displays up to three (3) variables and their values on the screen simultaneously. Pressing Sngl [F2] terminates Multiple Variable Mode and returns you to Single Variable Mode.
Figure 6 - Scrolling
Press HOLD [F1] to halt scrolling. Changing variable values will continue to be displayed.
Press GO [F1] to resume scrolling.
Press EXIT [F4] to return to the Identifier Display (Figure 4).
DKA4.1.2 Signing-On
To access the List Menu, you must first sign-on with a proper password. From the
Identifier Display (Figure 4), press [F1]. The screen will look like Figure 7A or 7C. If the display looks like Figure 7C:
Someone else has already signed on. Go to the paragraph below that starts "Once you have successfully signed on,…".
If the display looks like Figure 7A:
Select the Username (default = system) by using the Up and Down Arrow Keys. If the
Username system is displayed and no other Username is available (i.e., no others have been assigned), press [ENTER].
Enter a password using the 0 to 9 keys. For security, asterisks will appear as you enter the digits. If you make a mistake, press [F1] and try again or use the delete key to delete the previously pressed key action. The default password is 666666 (used when a password is not known or no password has been assigned). After typing the password, press [ENTER].
If your password is not recognized, the asterisks will be erased after you press
[ENTER]. Check your password and try again.
DKA 6 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
Figure 7 - Logging On
Once the correct password has been entered, the display will look like Figure 7C.
When the second line shows READ/WRITE, you can read and write variable parameters.
When it shows READ ONLY you cannot change variable parameters. You are only permitted to read variable information. If your display shows READ ONLY and you want to change variable values, sign-off (press the [INIT] key) and log on with a username and password that provides Read/Write privileges.
Once you have successfully signed on, the legend line will show that you have four options.
You can view and change the time and date of the local clock, access more variable lists,
Scroll, or return to the Identifier Display. Use function keys F1 through F4 to select the next menu (F1 = Clock, F2 = Menu, F3 = Scroll list & F4 = Exit). Let's start by setting the local clock.
DKA4.1.3 Using the Clock Functions
From the Logged-On Display (Figure 7C), press [F1]. The screen will show the present date and time and will look like Figure 8. Follow the instructions below to change the time or date. When you're finished, press [F4] to exit.
Today's date is shown in the first line in the format month/day/year.
The current time is shown in the form of hours:minutes:seconds.
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 7
Figure 8 - Clock Display
DKA4.1.3.1 Changing the Time
From the display shown in Figure 8, press Time [F2]. Colons (:) will appear on the third line. Enter the new time there and press [ENTER]. Valid times range from 00:00:00 to
23:59:59. Invalid entries will be ignored. The display will be updated to show the new time.
Figure 9 - Time Set Display
If you make a mistake while entering the new time, use [DEL] to backspace and delete one character at a time.
DKA4.1.3.2 Changing the Date
From the clock display (Figure 8, press [F1]. Slash marks (/) will appear on the third line.
Enter the new date there and press [ENTER].
Figure 10 - Date Set Display
If you make a mistake while entering the new date, use [DEL] to back space and delete one character at a time. Press [F4] to return to the Logged-On Display (Figure 7C).
DKA4.1.4 Choosing a Variable List from the List Menu
The List Menu is another area where variable information can be seen. As explained earlier in this section, your first opportunity to read variable information is by choosing the
DKA 8 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
SCROLL function from the Initial Display. The variable name and value are presented from the Scroll List. This function is available to all users even without signing-on.
The List Menu will show other groups of variable which you can choose to read. This information will be more detailed than the Scroll List.
To get to the List Menu, choose MENU (press [F2]) from the Logged-On Display (Figure
7C).
Figure 11 - Using the List Menu Display
The first variable list number in the menu will appear on the second line.
Press PREV (F1) and NEXT (F2) to see the other variable lists that are available in the List
Menu. You can also use the Up and Down Arrow Keys to scroll through the various lists. To move directly to a list, enter the list number, then press [ENTER].
DKA4.1.5 Moving Through a Variable List
After READ (F1) or WRITE (F2) has been pressed, the display will show the first variable in the list. An example is shown in Figure 12. Each time NEXT (F2) is pressed; the display will show the next variable in the list. PREV (F1) will show the previous variable. You can also use the Up and Down Arrow Keys to move through a list.
Automatic wraparound occurs in either direction. When you reach the end of the list, [F1] will display the first variable again. At the top of the list, [F2] will display the last variable.
DKA4.1.6 Changing Variable Parameters
From Figure 11, you can change variable parameters by pressing F2 [Write]. Then follow the directions summarized below (see Note 2).
Note 2: If your display does not contain the legend Write in the legend line, your password will only allow you to read variables. If you want to change variable values at this time, you must first log-off and then log-on using the correct password. See your
Systems Engineer for the correct password.
Before making any changes, first check the signal inhibit status field (See Figure 12). When
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 9
the display shows ME (manual enable) you can change variable parameters. When it shows
MI (manual inhibit), you cannot alter the parameters of this variable. If the field indicates
MI, press the OPER I/E key to change it to ME.
To change an analog value:
Press CHNG (F3) to clear the third line. Use the number keys 0 through 9 to enter the new value. The minus sign and period are also permitted. Press [ENTER].
If you make a mistake, press CHNG (F3) and enter the number again or use the [DEL] key to erase a character.
Another way to enter new values is by using the arrow up and arrow down keys (located below the [F3] key and left of the [INIT] key). These keys will raise and lower the value by 1% of the displayed amount.
To change the status of a logical variable:
Press CHNG (F3), then use either the down and up arrow keys or the [0/OFF] and
[1/ON] keys to change the state of a logical variable. If the [0/OFF] and [1/ON] keys are used, you must also press [ENTER].
Figure 12 - Interpreting Variable Information
To acknowledge an alarm:
Press [ALM ACK].
To change the alarm enable/inhibit status for alarm variables:
Press [ALM I/E] key. (Note: This will only inhibit alarm reporting, and not alarm level detection.)
DKA 10 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
Notes for Figure 12
1. Variable Name (Example 1: @GV.FLOW_RATE) (Example 2: @GV.TOTAL_FLOW_RATE)
2. Value - analog value, string value, or logical value. Values which cannot fit in this field will be shown as asterisks.
Analog values are displayed in floating point format, for example, 0.0125, 99.627, and 1287.66.
When the value cannot be shown in floating point format, scientific format is used
(1.287668E+10 or 1.25E-02 for example).
3. Questionable Data Status - for analog variables, column 1 will be clear if the status is valid. It will display a question mark if the status is questionable.
4. Variable Inhibit Status
CE (Control Enable) means this variable can be updated by the ControlWave project.
CI (Control Inhibit) means the variable cannot be updated by the ControlWave project.
ME (Manual Enable) means the variable can be changed manually.
MI (Manual Inhibit) means the variable cannot be changed manually.
5. Alarm Enable (for alarm variables only)
AE - variable is alarm enabled (changes will be reported).
AI - variable is alarm inhibited (changes will not be reported).
6. Alarm State
For
HH - high-high alarm TA - true alarm
- HI
LO low
LL - low-low alarm
! - alarm is unacknowledged
Notes for Figure 12 (Continued)
7 Multiple Signal Display
In Read Mode, pressing MULT (F3) will display the variable name extension, value, and units for three variables at one time. These variables include the variable displayed when NEXT (F2) was pressed and the next two variables in the list. Press SNGL [F3] to return to viewing one variable at a time (see Figure 12A).
Figure 12A - Example of MULT Display in READ Mode
Variables are shown below as they would appear in SNGL mode.
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 11
1) String
SITE_NAME
WEST SUNBURY PUMP STATION
CE ME
2) Analog
TOTAL_FLOW_RATE
1260.578
CE MI
3) Logical
FLOW_ALARM
OFF
CE MI AE NA
DKA4.1.7 Signing-Off
Once you have logged-on, use the [INIT] key at any time to log-off. When this key has been pressed, the screen will look like Figure 13. Press Yes (F1) to sign-off. You are signed-off when the Identifier Display (Figure 3C) appears.
If you do not want to log-off, press Exit (F4) to leave the Log-Off Display.
Once you are signed-on an automatic sign-off will occur if 20 minutes has elapsed since the last key was pressed.
Figure 13 - Log-Off Display
DKA 12 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
DKA5.1 KEYPAD IDENTIFICATION & INSTALLATION INFO.
Figure 14 - 25-Button Display/Keypad Assembly Installation Drawing
PIP-CW_35 Upgrade Kit Appendix DKA - Display/Keypad / DKA 13
ALM I/E
ALM ACK
A/M
OPER I/E
DEL
Figure 15 - 25 Button Keypad
Table 1 - 25 Button Keypad Keys
KEY
F1, F2, F3,
F4
INIT
0 to 9, -, .
Δ
∇
ENTER
FUNCTION
Function keys will take on a variety of different functions depending on the situation. The function of these keys is listed on the legend line (bottom line) of the display.
The INIT key is used to terminate the keyboard session and sign-off.
These keys are used to change the value of analog variables in the
CONFIGURATION mode. The 0/OFF and 1/ON keys are used to change the state of logical variables.
Each press of this key will raise an analog variable value by 1% of the displayed value or turn a logical variable ON.
Each press of this key will lower an analog variable value by 1% of the displayed value or turn a logical variable OFF.
Use this key to enable or inhibit alarm variables.
Use this key to acknowledge alarms.
Toggle between AUTO (CE) and MANUAL (CI) with this key.
Toggle between manual inhibit (MI) and enable (ME) with this key.
Use this backspace key to erase digits that have been entered on the keypad.
This key is used to enter new data from the display into the controller, e.g., password or variable values.
DKA 14 / Appendix DKA - Display/5x5Keypad PIP-CW_35 Upgrade Kit
Control Wave_ 35 & Control Wave_ 31
Material Safety Data Sheets
A Material Safety Data Sheet is provided herein to comply with OSHA’s Hazard Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific requirements.
Material Safety Data Sheets are provided in the order listed in Table Z-1 below.
TABLE Z-1
MSDS for Control Wave_ 35 & Control Wave_ 31 Instruction Document
(PIP-CW_35 Upgrade Kit)
Manufacturer General Description Part Number
Bristol, Inc Part Number = 395620-01-5
The 3V Lithium Manganese Dioxide Battery is situated on the CW_35 or CW_31 CCPU
Board.
11/01/06 Appendix Z – PIP-CW_35 Upgrade Kit MSDS
BLANK PAGE
Gillette
Environment
Health and Safety
37 A Street
Needham, MA 02492
Tel 781.292.8151
Page 1 of 4
NAME:
CAS NO:
MATERIAL SAFETY DATA SHEET
DURACELL LITHIUM MANGANESE DIOXIDE COIN BATTERIES
Not applicable Effective Date: 8/8/03
A. — IDENTIFICATION
Formula: Mixture
Molecular Weight:
Mixture
NA
Manganese Dioxide (1313-13-9)
Propylene Carbonate (108-32-7)
Lithium (7439-93-2)
Graphite, synthetic (7440-44-0)
1,2-Dimethoxyethane (110-71-4)
Lithium Perchlorate (7791-03-9)
%
65-75
10-15
5-10
5-10
1-10
<1.5
Synonyms:
Rev: 3
Lithium Manganese Dioxide Coin Cells:
3V-DL2016; DL2025; DL2430; DL2450;
DL2032; DL1616; DL1620
B. — PHYSICAL DATA
NA
Boiling Point
°
F
NA °
C
Specific Gravity (H
2
O=1)
NA
(
Evaporation
Ether
NA
% Volatiles
NA
=1)
NA
Melting Point
°
F
NA
Vapor Density (air=1)
NA
Saturation in Air
(by volume@
NA
Solubility in Water
NA
°
F)
°
C
NA
Freezing Point
NA
°
F
Vapor Pressure @
Autoignition Temperature
°
F pH
NA
NA mm Hg
NA
°
°
C
°
C
F
Appearance/Color Coin cells. Contents dark in color.
Flash Point and
Test Method(s)
Flammable Limits in Air
(% by volume)
1,2-Dimethoxyethane (Approximately 3-7% of contents): 42.8
°
F, 6
°
C (Closed Cup)
Lower NA % Upper NA %
C. — REACTIVITY
Stability X stable unstable
Conditions to Avoid
Do not heat, crush, disassemble, short circuit or recharge.
Polymerization
Not applicable may occur
Conditions to Avoid
X will not occur
Incompatible Materials Hazardous Decomposition Products
Contents incompatible with strong oxidizing agents.
Thermal degradation may produce hazardous fumes of manganese and lithium; oxides of carbon and other toxic by-products.
* IF MULTIPLE INGREDIENTS, INCLUDE CAS NUMBERS FOR EACH NA=NOT AVAILABLE
Footnotes
Not applicable
GMEL# 2033.3
Page 2 of 4
D. — HEALTH HAZARD DATA
Occupational Exposure Limits PEL’s, TLV’s, etc.)
8-Hour TWAs: Manganese Dioxide (as Mn) - 5 mg/m 3 (Ceiling) (OSHA); 0.2 mg/m 3 (ACGIH/Gillette)
1,2-Dimethoxyethane - 0.15 ppm (Gillette)
Graphite (all kinds except fibrous) - 2 mg/m 3 (synthetic, ACGIH); 15 mg/m 3 (total, OSHA);
5 mg/m 3 (respirable, OSHA)
These levels are not anticipated under normal consumer use conditions.
Warning Signals
Not applicable
Routes/Effects of Exposure
These chemicals and metals are contained in a sealed can. For consumer use, adequate hazard warnings are included on both the package and on the battery. Potential for exposure should not exist unless the battery leaks, is exposed to high temperature, is accidentally swallowed or is mechanically, physically, or electrically abused.
1. Inhalation
2. Ingestion
3. Skin
4. Eye Contact
5. Other
Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or an abundance of leaking batteries.
An initial x-ray should be obtained promptly to determine battery location. Batteries lodged in the esophagus should be removed immediately since leakage, burns and perforation can occur as soon as 4-6 hours after ingestion. Irritation to the internal/external mouth areas may occur following exposure to a leaking battery.
a. Contact
Irritation may occur following exposure to a leaking battery.
b. Absorption
Not anticipated.
Irritation may occur following exposure to a leaking battery.
Not applicable
E. — ENVIRONMENTAL IMPACT
1. Applicable Regulations All ingredients listed in TSCA inventory.
2. DOT Hazard Class -
3. DOT Shipping Name -
Not applicable
Not applicable
While lithium batteries are regulated by IATA and ICAO, the type of lithium batteries offered for sale by DURACELL are considered non-hazardous per provision A45 of the IATA Dangerous Goods Regulations and provision A45 of the ICAO
Technical Instructions For The Safe Transport Of Dangerous Goods By Air. Per section A45 of the IATA and ICAO regulations, properly marked, labeled and packaged DURACELL consumer lithium batteries, which are of the solid cathode type, with less than 1g lithium per cell and less than 2g lithium per battery, are exempt from further regulation. When these batteries are separated to prevent short circuits and properly packaged in strong packaging (except when installed in electronic devices), they are acceptable for air transport as airfreight without any other restrictions. In addition, when installed in equipment or when no more than 24 cells or 12 batteries meeting the A45 provision are shipped, they are not subject to special packaging, marking, labeling or shipping documentation requirements. Thus, these batteries are not considered hazardous under the current regulations and are acceptable for air transport.
Environmental Effects
These batteries pass the U. S. EPA's Toxicity Characteristic Leaching Procedure and therefore, maybe disposed of with normal waste.
GMEL# 2033.3
F. — EXPOSURE CONTROL METHODS
Engineering Controls
General ventilation under normal use conditions.
Eye Protection
None under normal use conditions. Wear safety glasses when handling leaking batteries.
Skin Protection
None under normal use conditions. Use butyl gloves when handling leaking batteries.
Respiratory Protection
None under normal use conditions.
Page 3 of 4
Other
Keep batteries away from small children.
G. — WORK PRACTICES
Handling and Storage
Store at room temperature. Avoid mechanical or electrical abuse.
DO NOT
short or install incorrectly.
Batteries may explode, pyrolize or vent if disassembled, crushed, recharged or exposed to high temperatures.
Install batteries in accordance with equipment instructions. Replace all batteries in equipment at the same time. Do not carry batteries loose in pocket or bag.
Normal Clean Up
Not applicable
Waste Disposal Methods
No special precautions are required for small quantities. Large quantities of open batteries should be treated as hazardous waste. Dispose of in accordance with federal, state and local regulations. Do not incinerate, since batteries may explode at excessive temperatures.
GMEL# 2033.3
Page 4 of 4
H. — EMERGENCY PROCEDURES
Steps to be taken if material is released to the environment or spilled in the work area
Evacuate the area and allow vapors to dissipate. Increase ventilation. Avoid eye or skin contact.
DO NOT
inhale vapors. Clean-up personnel should wear appropriate protective gear. Remove spilled liquid with absorbent and contain for disposal.
Fire and Explosion Hazard
Batteries may burst and release hazardous decomposition products when exposed to a fire situation. See Sec. C.
Extinguishing Media
As for surrounding area. Dry chemical, alcohol foam, water or carbon dioxide. For incipient fires, carbon dioxide extinguishers are more effective than water.
Firefighting Procedures
Cool fire-exposed batteries and adjacent structures with water spray from a distance. Use self-contained breathing apparatus and full protective gear.
I. — FIRST AID AND MEDICAL EMERGENCY PROCEDURES
Eyes
Not anticipated. If battery is leaking and material contacts eyes, flush with copious amounts of clear, tepid water for 30 minutes. Contact physician at once.
Skin
Not anticipated. If battery is leaking, irrigate exposed skin with copious amounts of clear, tepid water for a least 15 minutes. If irritation, injury or pain persists, consult a physician.
Inhalation
Not anticipated. Respiratory (and eye) irritation may occur if fumes are released due to heat or an abundance of leaking batteries. Remove to fresh air. Contact physician if irritation persists.
Ingestion
Consult a physician. Published reports recommend removal from the esophagus be done endoscopically
(under direct visualization). Batteries beyond the esophagus need not be retrieved unless there are signs of injury to the GI tract or a large diameter battery fails to pass the pylorus. If asymptomatic, follow-up x-rays are necessary only to confirm passage of larger batteries. Confirmation by stool inspection is preferable under most circumstances. If mouth area irritation/burning has occurred, rinse the mouth and surrounding area with clear, tepid water for at least 15 minutes.
Notes to Physician
1) For information on treatment, telephone (202)-625-3333 collect.
2) Potential leakage of less than 50 milligrams of propylene carbonate (CAS #108-32-1) and dimethoxyethane (CAS #110-71-4).
3) Dimethoxyethane readily evaporates.
4) Under certain misuse conditions and by abusively opening the battery, exposed lithium can react with water or moisture in the air causing potential thermal burns or fire hazard.
Replaces # 1461
The information contained in the Material Safety Data Sheet is based on data considered to be accurate, however, no warranty is expressed or implied regarding the accuracy of the data or the results to be obtained from the use thereof.
MSDS-4 (8/95) GMEL# 2033.3
BLANK PAGE
CW_35/31 Hardware Installation Guide
Product Information Package
PIP-CW_35 Upgrade Kit
Mar., 2007
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882 www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955 www.EmersonProcess.com/Bristol
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol, Inc. assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software delivered herewith. The Customer shall inspect and test such software and other materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for a particular purpose, concerning the software and other materials delivered herewith.
The Emerson logo is a trade mark and service mark of Emerson Electric Co.
Trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2007, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol, Inc.
Appendix TM
MASS TERMINATION CONNECTORS
Some Distributed Process Controller models may be used in conjunction with a user-supplied mass termination panel. The panel, which is connected through appropriate cables, provides remote field wiring connections for each module.
This application requires an extension cable with a thirty-pin connector for each module. The connector end plugs into the module's terminal block receptacle, while the other end is wired to the user's termination panel.
The wiring pattern for each thirty-pin connector varies with the type of module. Refer to the list below for the proper wiring table.
Page
TABLE A. ANALOG INPUT MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-2
TABLE B. ANALOG OUTPUT MODULE . . . . . . . . . . . . . . . . . . . . . . . . . TM-2
TABLE C. DISCRETE INPUT MODULE (4 INPUT TYPE) . . . . . . . . . . . TM-3
TABLE D. DISCRETE INPUT MODULE (8 INPUT TYPE) . . . . . . . . . . . TM-3
TABLE E. DISCRETE OUTPUT MODULE . . . . . . . . . . . . . . . . . . . . . . . TM-4
TABLE F. HIGH SPEED COUNTER MODULE . . . . . . . . . . . . . . . . . . . . TM-4
TABLE G POLARIZATION BAR LOCATION FOR P1 AND P2 . . . . . . . TM-5
29
30
END VIEW OF CONNECTOR
1
2
BOARD
END VIEW OF
CONNECTOR
CI-3330/35 (07/97)
Figure 1. Mass Termination Connector Diagram
Mass Termination Connectors / TM-1
INPUT
AI1-
AI2-
AI3-
AI4-
SHIELD
SHIELD
TABLE A. ANALOG INPUT
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
30
28
26
24
6
4
2
12
10
8
MASS TERM.
CONNECTOR
21
19
17
15
13
29
27
25
23
5
3
1
11
9
7
INPUT
AI1+
AI2+
AI3+
AI4+
SHIELD
SHIELD
INPUT
A01-
A02-
SHIELD
TABLE B. ANALOG OUTPUT
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
12
10
8
6
4
2
30
28
26
24
MASS TERM.
CONNECTOR
29
27
25
23
21
19
17
15
13
11
9
7
5
3
1
INPUT
A01+
A02+
SHIELD
TM-2 / Mass Termination Connectors CI-3330/35 (07/97)
INPUT
DI1-
DI2-
DI3-
DI4-
TABLE C. DISCRETE INPUT, 4-INPUT TYPE
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
30
28
26
24
6
4
2
12
10
8
MASS TERM.
CONNECTOR
21
19
17
15
13
29
27
25
23
5
3
1
11
9
7
INPUT
DI1+
DI2+
DI3+
DI4+
INPUT
DI1-
DI2-
DI3-
DI4-
DI5-
DI6-
DI7-
DI8-
TABLE D. DISCRETE INPUT, 8-INPUT TYPE
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
12
10
8
6
4
2
30
28
26
24
MASS TERM.
CONNECTOR
29
27
25
23
21
19
17
15
13
11
9
7
5
3
1
INPUT
DI1+
DI2+
DI3+
DI4+
DI5+
DI6+
DI7+
DI8+
CI-3330/35 (07/97) Mass Termination Connectors / TM-3
INPUT
DO1-
DO2-
D03-
D04-
D05-
D06-
DO7-
D08-
TABLE E. DISCRETE OUTPUT, OPEN COLLECTOR TYPE
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
30
28
26
24
6
4
2
12
10
8
MASS TERM.
CONNECTOR
21
19
17
15
13
29
27
25
23
5
3
1
11
9
7
INPUT
DO1+
D02+
D03+
D04+
D05+
D06+
D07+
DO8+
INPUT
HSC1-C
SHIELD
HSC2-C
SHIELD
HSC3-C
SHIELD
HSC4-C
SHIELD
TABLE F. HIGH SPEED COUNTER TYPE
MASS TERMINATION SIGNAL DESIGNATION
MASS TERM.
CONNECTOR
22
20
18
16
14
12
10
8
6
4
2
30
28
26
24
MASS TERM.
CONNECTOR
29
27
25
23
21
19
17
15
13
11
9
7
5
3
1
INPUT
HSC1-R
HSC1-S
HSC2-R
HSC2-S
HSC3-R
HSC3-S
HSC4-R
HSC4-S
The connectors of the mass termination cable require that polarization plugs be inserted into certain pin openings on female connectors P1 and P2. These plugs key the connectors so that they only mate with specific I/O boards and termination modules.
TM-4 / Mass Termination Connectors CI-3330/35 (07/97)
In some instances the plugs will be pre-installed at the factory. If this is not the case, the plugs will be included with the cable for field installation. The connector pin/s that require plugs are identified for each type of module in Table G. The pin layout for P1 and P2 are shown in Figure
2 below.
TABLE G POLARIZATION BAR LOCATION FOR P1 AND P2
I/O
Module
Type
AI
AO
DI
DO
HSC
HWSTI
Insert Polarization Plug into:
P1 Pin No. P2 Pin No.
to I/O Bd. to Term. Bd.
28 28
27 27
7
8
3
4
3
4
1, 9, 17 & 25
8
P1 OR P2
29 30
Arrow on connector
11
7
3
1
8
4
2
Example: Place plug in 8 for HWSTI Module
Figure 2. P1 or P2 Pin Layout
CI-3330/35 (07/97) Mass Termination Connectors / TM-5
BLANK PAGE
Appendix TT
BRISTOL BABCOCK
TELETRANS INTERFACE SYSTEM
- Contents -
DESCRIPTION ........................................................................... TT-1
CABLE CONNECTIONS ........................................................... TT-3
FIELD WIRING CONNECTIONS ............................................. TT-3
TRANSMITTER SETUP & CONFIGURATION ....................... TT-3
LED INDICATORS ..................................................................... TT-5
DESCRIPTION
The Bristol Babcock TELETRANS Interface system allows up to eight Series 3508
TELETRANS Transmitters per I/O board to communicate with a Series 33XX Distributed
Process Controller (DPC). The DPC polls and stores data from each transmitter and communicates with the network. The DPC can accommodate up to four BBTI board systems for a total of 32 transmitters provided that local metering of the 4-20 mA output is not required
(fixed 3.8 mA current mode).
This system includes a single BBTI I/O Board that plugs into any available I/O slot, and a pair of Field Termination Boards that mount in an external DIN rail. The two boards are interconnected by cables. The component part numbers are as follows:
BBTI I/O Board
Field Termination Board
Cable for single FT Board
Cable for dual FT Board
392535-01-7
392536-01-3
395334-00-4
395335-00-0
Each BBTI I/O Board handles eight transmitter signal channels, while each Field
Termination Board provides wiring for four transmitters. Two Termination Boards will be required for each BBTI I/O Board unless the number of transmitter loops is less than five.
Power to operate the transmitter dc loops can be furnished by the DPC's power source or a separate power supply.
The BBTI system utilizes the 4-20 mA output of each TELETRANS Transmitter. This output represent the measured parameter for which the transmitter was named (DP or GP depending upon model). Also, superimposed on this output is an FSK serial channel that communicates all transmitter data (DP, GP, SP, RTD, etc.) to the DPC. All transmitter signal/power loops operate independently of each other.
CI-3310/30/35 (11/05) BBTI Board / TT-1
TT-2 / BBTI Board
Figure 1 - BBTI I/O Board
CI-3310/30/35 (11/05)
Figure 2 - Termination Board
CABLE CONNECTIONS
If the system is furnished for less than five 3508 transmitters, it will require one cable connection from the BBTI I/O Board to the Field Termination Board. If the system is furnished for five to eight 3508 transmitters, it will require a separate cable connection from the BBTI
I/O Board to each Field Termination Board. The connections are made via a flat, fortyconductor cable.
FIELD WIRING CONNECTIONS
Figures 3 and 4 show the transmitter & supply connections for a single Field Termination
Board having four 3508 TELETRANS Transmitters (#1 to #4). The equivalent circuitry for a single input circuit is shown at the top of the illustration. Each transmitter can have its own separate supply or all may use a common supply source to power each 4-20 mA loop.
When wiring the transmitters, make sure the total loop resistance and supply voltages conform with the transmitter specifications. Refer to the 3508 transmitter manual for details.
TRANSMITTER SETUP & CONFIGURATION
The transmitter operates when power is applied to the loop. The transmitter will assume default values programmed into it at the factory. If the transmitter is operated in a control application, note that the default values could produce dangerous output conditions cable of damaging equipment or causing human injury. For these circumstances it is recommended
CI-3310/30/35 (11/05) BBTI Board / TT-3
that the transmitter be isolated from the control system unit it has been checked and configured.
For most transmitter models, configuration is typically performed via a local PC connected to the transmitter's FSK serial comm. port. The PC must be running SMARTKIT, the transmitter's utility program, in order to configure the transmitter. Some transmitter models include an RS-232/485 port which can be used to set up the transmitter. Details on making connections and performing transmitter configuration are contained in the 3508 instruction manual.
Figure 3 - Transmitter & Supply Connections to Field Termination Board
Note: For improved RTD performance see Figure 4.
TT-4 / BBTI Board CI-3310/30/35 (11/05)
Figure 4 - Transmitter & Supply Connections to Field Termination Board
(for Improved RTD Performance)
LED INDICATORS
The BBTI I/O Board contains four LEDs having that indicate carrier activity. The LEDs blink or light when receiving or sending data.
CI-3310/30/35 (11/05) BBTI Board / TT-5
BLANK PAGE
DPC 3335
Material Safety Data Sheets
Material Safety Data Sheets are provided herein to comply with OSHA’s Hazard
Communication Standard, 29 CFR 1910.1200. This standard must be consulted for specific requirements.
Material Safety Data Sheets are provided in the order listed in Table Z-1 below.
TABLE ZZ-1 MSDS for Model DPC 3335 Instruction Manual CI-3335
Manufacturer General Description
Eagle Pitcher 3.6V Lithium Thionyl
Chloride Battery
SAFT America 3.6V Lithium Thionyl
Chloride Battery
3.6V LithiumThionyl
Chloride Battery
Bristol Babcock Part Number or Media Notes
390618-01-2 (Use - 3335)
Eagle Pitcher P/N LTC-7PMP
389986-01-1 (Use - 3331/3335)
SAFT P/N LS14250AX formerly LS3AX
389986-02-0 (Use 3331/3335)
SAFT P/N LS14250AX formerly LS3AX
390618-01-2 (Use - 3335)
(Tadiran P/N TL-5135)
389986-01-1 (Use - 3331/3335)
Tadiran P/N TL-2150-1/2AA/P)
7/28/97 Appendix ZZ - CI-3335 MSDS
BLANK PAGE
Material/Product Safety Data Sheet
(MSDS-PSDS)
LS/LST/LSX/LSH products
Revision 5 Date 06/05
Lithium /Thionyl chloride single cells and multi-cell battery packs
Simplified Advice Code
G
1. Identification of the Substance or Preparation and Company
Product
Production sites
Primary Lithium/Thionyl chloride unit cells and multi-cell battery packs
Saft Ltd.
River Drive
Tyne & Wear
(Li–SOCl
2
)
Saft
Rue Georges Leclanché
BP 1039
Saft America Inc
313 Crescent Street
Valdese
South Shields
NE33 2TR – UK
Ph. :+44 191 456 1451
Fax :+44 191 456 6383
86060 Poitiers cedex 9
FRANCE
Ph. :+33 (0)5 49 55 48 48
Fax :+33 (0)5 49 55 48 50
NC 28690 – USA
Ph. :+1 (828) 874 4111
Fax :+1 (828) 874 2431
Emergency contact +1 (703) 527 3887 (CHEMTREC US Service Center)
Within the USA +1 (800) 424 9300
2. Composition & Information on Ingredients
Each cell consists of an hermetically sealed metallic container containing a number of chemicals and materials of construction of which the following could potentially be hazardous upon release.
Ingredient
Lithium
(Li)
Thionyl chloride
(SOCl
2
)
Content CAS No.
3.5-5% 7439-93-2
40-46% 7719-09-7
CHIP Classification
F ; R14/15
C ; R34
R14/15, R21,R22, R35,
R41, R43
S2, S8, S45
C; R14, R21, R22, R35,
R37, R41,R42/43
S2, S8, S24, S26, S36,
S37, S45
Aluminum chloride anhydrous
(AlCl
3
)
1-5% 7446-70-0
Carbon (C n
) 3-4%
Amount varies depending on cell size
R14, R22, R37, R41, R43.
S2, S8, S22, S24, S26,
S36, S45
MSDS Li-SOCl
2
Rev. 5 June 2005
3. Hazards Identification
Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion. The
Lithium-Thionyl chloride batteries described in this Product Safety Data Sheet are sealed units which are not hazardous when used according to the recommendations of the manufacturer.
Under normal conditions of use, the electrode materials and liquid electrolyte they contain are not exposed to the outside, provided the battery integrity is maintained and seals remain intact. Risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery containers. Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.
4. First Aid Measures
Inhalation
Skin contact
Eye contact
Ingestion
Further treatment
Remove from exposure, rest and keep warm. In severe cases obtain medical attention.
Wash off skin thoroughly with water. Remove contaminated clothing and wash before reuse. In severe cases obtain medical attention.
Irrigate thoroughly with water for at least 15 minutes. Obtain medical attention.
Wash out mouth thoroughly with water and give plenty of water to drink.
Obtain medical attention.
All cases of eye contamination, persistent skin irritation and casualties who have swallowed this substance or been affected by breathing its vapours should be seen by a Doctor.
5. Fire Fighting Measures metal they contain is exposed.
Do not use for this purpose sand, dry powder or soda ash , graphite powder or fire blankets.
Use only metal (Class D) extinguishers on raw lithium.
Extinguishing media
Use water or CO
2
on burning Li-SOCl
2
cells or batteries and class D fire extinguishing agent only on raw lithium.
6. Accidental Release Measures
Remove personnel from area until fumes dissipate. Do not breathe vapours or touch liquid with bare hands.
If the skin has come into contact with the electrolyte, it should be washed thoroughly with water.
Sand or earth should be used to absorb any exuded material. Seal leaking battery and contaminated absorbent material in plastic bag and dispose of as Special Waste in accordance with local regulations.
MSDS Li-SOCl
2
Rev. 5 June 2005
7. Handling and Storage
Handling
Storage
Do not crush, pierce, short (+) and (-) battery terminals with conductive
(i.e. metal) goods. Do not directly heat or solder. Do not throw into fire.
Do not mix batteries of different types and brands. Do not mix new and used batteries. Keep batteries in non conductive (i.e. plastic) trays.
Store in a cool (preferably below 30°C) and ventilated area, away from moisture, sources of heat, open flames, food and drink. Keep adequate clearance between walls and batteries. Temperature above 100°C may result in battery leakage and rupture. Since short circuit can cause burn, leakage and rupture hazard, keep batteries in original packaging until use and do not jumble them.
Other
Lithium-Thionyl chloride batteries are not rechargeable and should not be tentatively charged.
Follow Manufacturers recommendations regarding maximum recommended currents and operating temperature range.
Applying pressure on deforming the battery may lead to disassembly followed by eye, skin and throat irritation.
8. Exposure Controls & Personal Protection
Occupational exposure standard
Compound
Sulfur dioxide
Hydrogen chloride
8hr TWA
1 ppm
1 ppm
15min TWA
1 ppm
5 ppm
SK
-
-
Respiratory protection
In all fire situations, use self-contained breathing apparatus.
Hand protection
In the event of leakage wear gloves.
Eye protection
Safety glasses are recommended during handling.
Other In the event of leakage, wear chemical apron.
MSDS Li-SOCl
2
Rev. 5 June 2005
9. Physical and Chemical Properties
Appearance Cylindrical shape
Odour pH
Flash point
Flammability
If leaking, gives off a pungent corrosive odour.
Not Applicable
Not applicable unless individual components exposed
Not applicable unless individual components exposed
Relative density
Solubility (water)
Solubility (other)
10. Stability and Reactivity
Not applicable unless individual components exposed
Not applicable unless individual components exposed
Not applicable unless individual components exposed
Product is stable under conditions described in Section 7.
Conditions to avoid .
Heat above 100°C or incinerate. Deform. Mutilate. Crush. Pierce. Disassemble
Recharge. Short circuit. Expose over a long period to humid conditions.
Materials to avoid Oxidising agents, alkalis, water. Avoid electrolyte contact with aluminum or zinc .
Hazardous decomposition
Products
Hydrogen (H
2
) as well as Lithium oxide (Li
2
O) and Lithium hydroxide (LiOH) dust is produced in case of reaction of lithium metal with water.
Chlorine (Cl
2
), Sulfur dioxide (SO
2
) and Disulfur dichloride (S
2
Cl
2
) are produced in case of thermal decomposition of thionyl chloride above 140°C.
Hydrochloric acid (HCl) and Sulfur dioxide (SO
2
) are produced in case of reaction of Thionyl chloride with water at room temperature.
Hydrochloric acid (HCl) fumes, Lithium oxide, (Li
2
O), Lithium hydroxide (LiOH) and Aluminum hydroxide (Al(OH)
3
) dust are produced in case of reaction of
Lithium tetrachloroaluminate (LiAlCl
4
) with water.
11. Toxicological Information
Signs & symptoms
None, unless battery ruptures. In the event of exposure to internal contents, corrosive fumes will be very irritating to skin, eyes and mucous membranes.
Overexposure can cause symptoms of non-fibrotic lung injury and membrane irritation.
Inhalation
Skin contact
Eye contact
Ingestion
Medical conditions generally aggravated by exposure
Lung irritant.
Skin irritant
Eye irritant.
Tissue damage to throat and gastro-respiratory tract if swallowed.
In the event of exposure to internal contents, eczema, skin allergies, lung injuries, asthma and other respiratory disorders may occur.
12. Ecological Information
Mammalian effects
Eco-toxicity
None known if used/disposed of correctly.
None known if used/disposed of correctly.
Bioaccumulation potential
Environmental fate
None known if used/disposed of correctly.
13. Disposal Considerations
None known if used/disposed of correctly.
Do not incinerate, or subject cells to temperatures in excess of 100 o
C. Such abuse can result in loss of seal, leakage, and/or cell explosion. Dispose of in accordance with appropriate local regulations.
MSDS Li-SOCl
2
Rev. 5 June 2005
14. Transport Information
Label for conveyance
UN number
Shipping name
Hazard classification
Packing group
IMDG Code
CAS
EmS No.
Marine pollutant
ADR Class
15. Regulatory Information
Risk phrases
For the single cell batteries and multicell battery packs which are non-restricted to transport, use lithium batteries inside label.
For the single cell batteries and multicell battery packs which are restricted to transport (assigned to the Miscellaneous Class 9), use Class 9 Miscellaneous
Dangerous Goods and UN Identification Number labels.
In all cases, refer to the product transport certificate issued by the Manufacturer.
UN3090
Lithium Batteries
Depending on their lithium metal content, some single cells and small multicell battery packs may be non- assigned to Class 9 (Refer to Transport Certificate)
II
9033
4.1-06
No
Class9
Lithium
(Li)
R14/15
R21
R22
R35
R41
R42/43
Reacts violently with water, liberating extremely flammable gases.
Harmful in contact with skin.
Harmful if swallowed.
Causes burns.
Risk of serious damage to eye.
May cause sensitization by inhalation and skin contact.
Thionyl chloride
(SOCl
2
)
Aluminum chloride anhydrous
(AlCl
3
)
R14
R22
R35
R37
R41
R42/43
R14
R22
R37
R41
R43
Reacts with water.
Harmful if swallowed.
Causes burns.
Irritating to respiratory system.
Risk of serious damage to eye.
May cause sensitization by inhalation and skin contact.
Reacts with water.
Harmful if swallowed.
Irritating to respiratory system.
Risk of serious damage to eye.
May cause sensitization by skin contact.
Safety phrases
UK regulatory references
Lithium
(Li)
Thionyl chloride
(SOCl
2
Aluminum chloride anhydrous
(AlCl
3
)
)
S2
S8
S45
S2
S8
S24
S26
S36
S37
S45
S2
S8 S22
S24 S26
S36
Keep out of reach of children
Keep away from moisture
In case of incident, seek medical attention.
Keep out of reach of children.
Keep away from moisture.
Avoid contact with skin.
In case of contact with eyes, rinse immediately with plenty of water.
Wear suitable protective clothing.
Wear suitable gloves.
In case of incident, seek medical attention.
Keep out of reach of children.
Keep away from moisture.
Do not breathe dust.
Avoid contact with skin.
In case of contact with eyes, rinse immediately with plenty of water.
Wear suitable protective clothing.
Classified under CHIP
MSDS Li-SOCl
2
Rev. 5 June 2005
16. Other information
This information has been compiled from sources considered to be dependable and is, to the best of our knowledge and belief, accurate and reliable as of the date compiled. However, no representation, warranty
(either expressed or implied ) or guarantee is made to the accuracy, reliability or completeness of the information contained herein.
This information relates to the specific materials designated and may not be valid for such material used in combination with any other materials or in any process. It is the user’s responsibility to satisfy himself as to the suitability and completeness of this information for his particular use.
Saft does not accept liability for any loss or damage that may occur, whether direct, indirect, incidental or consequential, from the use of this information. Saft does not offer warranty against patent infringement.
MSDS Li-SOCl
2
Rev. 5 June 2005
B
MSDS No.- T-36-01 (Revision. -G)
Q u a l i t y F i r s t
MATERIAL SAFETY DATA SHEET
SECTION 1- CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Manufacturer Name- Tadiran Batteries Ltd., P. O. Box 1, Kiryat Ekron, Israel 70500.
US office address- 2 Seaview Blvd. Port Washington NY 11050
Emergency Telephone No. – CHEMTREC: 1-800-424-9300
Tel. for information: 1-516-621-4980
Tel. for information 972-8-944-4503
Products Name: Primary Lithium Thionyl Chloride (Li/SOCl
2
) cells and batteries, Nonrechargeable. Cells include the models of TL, TLH, and TLL, 3.6V series.
SECTION 2- COMPOSITION, INFORMATION ON INGREDIENTS
Ingredient Name
Lithium Metal (Li)
CAS # % ACGIH (TLV) OHSA
(PEL)
7439-93-2 <5% Not Established None
CHIP
Classification
F: R14/15
C: R34
Thionyl Chloride (SOCl
Lithium Chloride (LiCl)
2
) 7719-09-7 <47
7447-41-8
%
1 ppm
(5 mg/M 3 )
<2% Not Established
R: 14/15, 34
S: (1/2), 8,43,45
5 mg/m 3 R: 14,20/22,29,
35.
S: (1/2),26,36/
37/39, 45
Carbon (C)
Aluminum Chloride (AlCl
3
1333-86-4 <6% 3.5 mg/m
) 7446-70-0 <5% 2 mg/m 3
3 3.5
(Al salt, soluble)
R:
S:
45
34
(1/2),7/8,28,
SECTION 3 - HAZARD IDENTIFICATION
The lithium Thionyl chloride batteries described in this MSDS are hermetically sealed units, which are not hazardous when used according to the recommendations of the manufacturer.
Under normal condition of use of the batteries, the electrode materials and the liquid electrolyte they contained are non-reactive provided the battery integrity is maintained. Risk of exposure exists only in case of mechanical, electrical or thermal abuse. Thus the batteries should not short circuit, recharge, puncture, incinerate, crush, immerse in water, force discharge, or expose to temperatures above the temperature range of the cell or battery. In these cases there is risk of fire or explosion
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SECTION 4- FIRST AID MEASURES
Q u a l i t y F i r s t
In case of battery rupture, explosion, or major leakage, evacuate personnel from contaminated area and provide good ventilation to clear out corrosive fumes, gases or the pungent odor. Seek immediate medical attention.
Eyes -
First rinse with plenty of water for 15 minutes (remove contact lenses if easily possible), and then seek medical attention.
Skin -
Remove contaminated clothes and rinse skin with plenty of water or shower for
15 min. Refer to medical attention.
Inhalation -
Remove to fresh air, rest, and half-upright position, use artificial respiration if needed, and refer to medical attention.
Ingestion -
rinse mouth,
DO NOT
induce vomiting, give plenty of water to drink, and refer to medical attention.
SECTION 5- FIRE FIGHTING MEASURES
FLAMMABLE LIMIT IN AIR: NA
EXTINGUISHING MEDIA:
1. Lith- X (Class D extinguishing media) is the
only
effective on fires involving a few lithium batteries. If the cells are directly involved in a fire
DO NOT USE:
WATER,
SAND, CO
2
, HALON, and DRY POWDER OR SODA ASH EXTINGUISHERS.
2. If the fire is in adjacent area and the cells that are either packed in their original containers or unpacked, the fire can be fought based on fueling material, e.g., paper and plastic products. In these cases the use of copious amounts of
cold
water is effective extinguishing media. Storage area may employ sprinkler system with cold water.
AUTO-IGNITION: NA
SPECIAL FIRE FIGHTING PROCEDURES: Wear self-contained breathing apparatus to avoid breathing of irritant fumes (NIOSH approved SCBA & full protective equipment). Wear protective clothing and equipment to prevent body contact with electrolyte solution.
Fire may be fought, but only from safe fire-fighting distance. Evacuate all persons from immediate area of fire.
UNUSUAL EXPLOSION AND FIRE EXPLOSION: Battery may explode when subject to: excessive heat (above 150ºC), recharged, over-discharged (discharge below 0V), punctured and crushed. During thermal decomposition generation of chlorine (Cl
2
), hydrogen chloride (HCl), and sulfur dioxide (SO
2
) can be formed.
SECTION 6- SPILL OR LEAKAGE PROCEDURES
PROCEDURES TO CONTAIN AND CLEAN UP LEAKS OR SPILLS: The material contained within the battery would only be released under abusive conditions.
In the event of battery rapture and leakage: contain the spill while wearing proper protective clothing and ventilate the area. Than, cover with sodium carbonate
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Q u a l i t y F i r s t
(Na
2
CO
3
) or 1:1 mixture of soda ash and slaked slime. Keep away from water, rain, and snow. Placed in approved container (after cooling if necessary) and disposed according to the local regulations.
NEUTRALIZING AGENT: Sodium carbonate (Na
2 and slaked slime.
CO
3
) or 1:1 mixture of soda ash
WASTE DISPOSAL METHOD: Product decomposed by water must be neutralized.
May be added to waste water in sufficiently diluted form.
PRECAUTIONS IN HANDLING AND STORING; Avoid short-circuiting, overcharging and heating to high temperatures. Store the batteries in dry and cool area and keep container dry and tightly closed in well-ventilated area. Store away from food and drink.
OTHER PRECAUTIONS; Never attempt to disassemble, machine, or otherwise modify batteries or injury may result.
SECTION 7- HANDLING AND STORAGE
The batteries should not be opened, destroyed or incinerate, since they may leak or rupture and release to the environment the ingredients that they normally contained in the hermetically sealed container.
HANDLING-
Do not short circuit terminals, or expose to temperatures above the temperature rating of the battery, over charge the battery, forced over-discharge
(voltage below 0.0V), throw to fire.
Do not crush or puncture the battery, or immerse in liquids.
STORAGE-
Storage preferably in cool (below 30ºC), dry and ventilated area, which is subject to little temperature change.
Do not place the battery near heating equipment, nor expose to direct sunlight for long periods. Elevated temperatures can result in shortened battery life and degrade performance.
Keep batteries in original packaging until use and do not jumble them.
Do not store batteries in high humidity environment for long periods.
OTHER-
the cells and the batteries are not rechargeable batteries and should not be charged.
Applying pressure and deforming the battery may lead to disassembly followed by eye skin and throat irritation.
Follow manufacturers recommendations regarding maximum recommended current and operating temperature range.
SECTION 8 - EXPOSURE CONTROLS & PERSONAL PROTECTION
RESPIRATORY PROTECTION: None necessary under normal use. In case of abuse and leak of liquid or fumes, use NIOSH approved Acid Gas Filter Mask or Self-
Contained Breathing Apparatus.
VENTILATION: Not necessary under normal use. In case of abuse, use adequate mechanical ventilation (local exhaust) for battery that vent gas or fumes.
PROTECTIVE GLOVES: None under normal use. In case of spill use PVC or Nitrile gloves of 15 mils (0.015 inch) or thicker.
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Q u a l i t y F i r s t
EYE PROTECTION: Use ANSI approved chemical worker safety goggles or face shield.
OTHER PROTECTIVE EQUIPMENT: Chemical resistance clothing is recommended along with eye wash station and safety shower should be available meeting ANSI design criteria.
WORK HYGIENIC PRACTICES: Use good chemical hygiene practice. Wash hands after use and before drinking, eating or smoking. Launder contaminated cloth before reuse.
SUPPLEMENTARY SAFETY AND HEALTH DATA: If the battery is broken or leaked the main hazard is the electrolyte. The electrolyte is mainly solution of Lithium chloride (LiCl), and aluminum chloride (AlCl
3
) in Thionyl chloride (SOCl
2
).
Fires may be fought but only from safe fire fighting distance, evacuate all persons from immediate area of fire.
Prevent heating of the battery, charging the battery, discharge to predetermined limit, do not crush, disassemble, incinerate or short circuit.
SECTION 9- PHYSICAL DATA
BOILING POINT (760 mm Hg)
VAPOR PRESSURE (mm Hg, 25ºC)
VAPOR DENSITY (air=1)
NA, unless individual components exposed
NA, unless individual components exposed
NA, unless individual components exposed
DENSITY (gr/cc)
VOLATILE BY VOLUME (%)
> 1 gr/cc
NA
EVAPORATION RATE (butyl acetate=1) NA, unless individual components exposed
PHYSICAL STATE Solid
SOLUBILITY IN WATER (% by weight) NA, unless individual components exposed
PH
APPEARANCE
ODOR
NA, unless individual components exposed
Geometric Solid Object
If leaking, gives off pungent corrosive odor
SECTION 10- STABILITY AND REACTIVITY
STABLE OR NOT STABLE Stable
INCOMPATIBILITY (MATERIAL TO AVOID) Strong mineral acids, water and alkali solutions.
HAZARDOUS
DECOMPOSITION
PRODUCTS
1. Reaction of lithium with water: Hydrogen (H
2 hydroxide (LiOH).
), Lithium
2. Thermal decomposition over 150ºC: Sulfur oxides, (SO
2
SO
3
), Sulfur chorides (SCl
2
, S
2
Cl
2
), Chlorine (Cl
2 oxide (Li
2
O).
,
), Lithium
3. Electrolyte with water: Hydrogen Chloride (HCl) and SO
2
DECOMPOSITION TEMPERATURE (ºF)
NA
HAZARDOUS POLYMERIZATION: May Occur____ Will Not Occur __X__
CONDITIONS TO AVOID Avoid mechanical abuse, and electrical abuse such as short-circuiting, overcharge, over-discharge,
(voltage reversal) and heating.
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SECTION 11- TOXICOLOGICAL INFORMATION
Q u a l i t y F i r s t
THRESHOLD LIMIT VALUE (TLV) AND SOURCE: NA
HEALTH HAZARD ACUTE AND CHRONIC: Inhalation, skin contact, eye contact and ingestion are not likely by exposure to sealed battery.
Inhalation, skin contact and eye contact are possible when the battery is opened.
Exposure to internal contents, the corrosive fumes will be very irritating to skin, eyes and mucous membranes. Overexposure can cause symptoms of non-fibrotic lung injury and membrane irritation.
Carcinogenicity- NTP: No
Carcinogenicity- IARC: No
Carcinogenicity- OSHA: No
Explanation of Carcinogenicity- No ingredient of a concentration of 0.1% or greater is listed as a carcinogen or suspected carcinogen.
SIGNS AND SYMPTOMS OF OVEREXPOSURE: Exposure to leaking electrolyte from ruptured or leaking battery can cause:
Inhalation
- Burns and irritation of the respiratory system, coughing, wheezing, and shortness of breath.
Eyes
- Redness, tearing, burns. The electrolyte is corrosive to all ocular tissues.
Skin
- The electrolyte is corrosive and causes skin irritation and burns.
Ingestion
- The electrolyte solution causes tissue damage to throat and gastro/ respiratory track.
MEDICAL CONDITION AGGRAVATED BY EXPOSURE: Preexisting skin, asthma and respiratory diseases are generally aggravated by exposure to liquid electrolyte vapors or liquid. For further information refer to section 4.
SECTION 12- ECOLOGICAL INFORMATION
1. When properly used and disposed the battery does not present environmental hazard.
2. The battery does not contain mercury, cadmium, or lead.
3. Do not let internal components enter marine environment. Avoid release to waterways, wastewater or ground water.
SECTION 13- DISPOSAL CONSIDERATIONS
1. Disposal must be in accordance with the applicable regulations in every country and state.
2. Disposal of the Lithium batteries should be performed by permitted, professional disposal firms knowledgeable in Federal, State or Local requirements of hazardous waste treatment and hazardous waste transportation.
3. Incineration should never be performed by battery users, but eventually by trained professional in authorized facility with proper gas and fume treatment.
4. Recycling of battery can be done in authorized facility, through licensed waste carrier.
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SECTION 14- TRANSPORTATION /SHIPPING
Q u a l i t y F i r s t
Lithium batteries UN number 3090, class 9 (miscellaneous)
Lithium batteries contained in equipment, UN number 3091, class 9 (miscellaneous).
Packing instructions for 3090- ICAO 903 for air transport
IMDG 903 for sea transport
ADR/RID 903 and 903a for road /rail transport
Packing instructions for 3091- ICAO 912/918 for air transport
IMDG 903 for sea transport
ADR/RID 903 and 903a for road /rail transport
In the USA transportation is according to Code of Federal Regulations (CFR 49
Chapter 1, paragraph 173.185)
A list of Tadiran batteries and cells that are subject to transport regulations and those that are exempted can be obtained from Tadiran Batteries Ltd.
Identification and labeling in compliance with the product drawing should include the battery title, nominal voltage, lot number and warning.
SECTION 15- REGULATORY INFORMATION
1. The transport of the lithium batteries is regulated by the United Nations, “Model
Regulations on Transport of Dangerous Goods”, 13 revised edition-2003 (special provisions 188, 230, and 310).
2. Within the US the lithium batteries and cells are subject to shipping requirements under 49 CFRCh. 1, paragraph 173.185, “lithium batteries”.
3. Shipping of lithium batteries in aircrafts are regulated by the International Civil
Aviation Organization (ICAO) and the International Air Transport Association
(IATA) 2003 requirements in Special Provisions A45, A88 and A99.
4. Shipping of lithium batteries on sea are regulated the International Maritime
Dangerous Goods (IMDG) 2002 requirements in special provisions 188, 230 and 310.
5. Shipping of lithium batteries on Road and Rail, 2002 requirements in special provisions 188, 230 and 310.
6. The internal component (thionyl chloride) is hazardous under the criteria of the
Federal OHSA Hazard Communication Standard 29 CFR 1920.1200.
SECTION 16- OTHER INFORMATION/DISCLAIMER
The information and the recommendations set forth are made in good faith and believed to be accurate at the date of preparation. The present file refers to normal use of the product in question. Tadiran Batteries makes no warranty expressed or implied.
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BLANK PAGE
DPC 3335 & RIO 3331
Customer Instruction Manual
CI-3335
Jan., 2007
Emerson Process Management
Bristol, Inc.
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2262
Fax: +1 (860) 945-2525 www.EmersonProcess.com/Bristol
Emerson Electric Canada, Ltd.
Bristol Canada
6338 Viscount Rd.
Mississauga, Ont. L4V 1H3
Canada
Phone: 905-362-0880
Fax: 905-362-0882 www.EmersonProcess.com/Bristol
Emerson Process Management
BBI, S.A. de C.V.
Homero No. 1343, 3er Piso
Col. Morales Polanco
11540 Mexico, D.F.
Mexico
Phone: (52-55)-52-81-81-12
Fax: (52-55)-52-81-81-09 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol Babcock, Ltd.
Blackpole Road
Worcester, WR3 8YB
United Kingdom
Phone: +44 1905 856950
Fax: +44 1905 856969 www.EmersonProcess.com/Bristol
Emerson Process Management
Bristol, Inc.
22 Portofino Crescent,
Grand Canals Bunbury, Western Australia 6230
Mail to: PO Box 1987 (zip 6231)
Phone: +61 (8) 9725-2355
Fax: +61 (8) 8 9725-2955 www.EmersonProcess.com/Bristol
The information in this document is subject to change without notice. Every effort has been made to supply complete and accurate information. However, Bristol, Inc. assumes no responsibility for any errors that may appear in this document.
If you have comments or questions regarding this manual, please direct them to your local Bristol sales representative, or direct them to one of the addresses listed at left.
Bristol, Inc. does not guarantee the accuracy, sufficiency or suitability of the software delivered herewith. The Customer shall inspect and test such software and other materials to his/her satisfaction before using them with important data.
There are no warranties, expressed or implied, including those of merchantability and fitness for a particular purpose, concerning the software and other materials delivered herewith.
TeleFlow
™
is a trademark of Bristol, Inc. The Emerson logo is a trade mark and service mark of Emerson Electric Co. Other trademarks or copyrighted products mentioned in this document are for information only, and belong to their respective companies, or trademark holders.
Copyright (c) 2006, Bristol, Inc., 1100 Buckingham St., Watertown, CT 06795. No part of this manual may be reproduced in any form without the express written permission of
Bristol Inc.
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