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IM300/H Series 3 Plus Hardware Referencemanual
Series 3 Plus
Hardware Reference
Publication IM300/H (6.2.4)
April 2010© 1987-2001, Compressor Controls Corporation. All rights reserved.
This manual is for the use of Compressor Controls Corporation and is not to be reproduced without written permission.
Air Miser, Guardian, Recycle Trip, Reliant, Safety On, SureLink, TTC, Total Train Control, TrainTools, TrainView, TrainWare, Vanguard, Vantage, WOIS, and the TTC and impeller logos are registered trade-marks; and COMMAND, TrainPanel, and the Series 3++ and Series 5 logos are trademarks of Compressor Controls Corporation. Other company and product names used in this manual are trademarks or registered trademarks of their respective holders.
The control methods and products discussed in this manual may be covered by one or more of the following patents, which have been granted to Compressor Controls Corporation by the United States Patent and Trademark Office:
4,949,276 5,347,467 5,508,943 5,609,465 5,622,042 5,699,267 5,743,715 5,752,378 5,879,133 5,908,462 5,951,240 5,967,742 6,116,258 6,217,288 6,317,655 6,332,336 6,494,672 6,503,048
Many of these methods have also been patented in other countries, and additional patent applications are pending.
The purpose of this manual is only to describe the configuration and use of the described products. It is not sufficiently detailed to enable outside parties to duplicate or simulate their operation.
The completeness and accuracy of this document is not guaranteed, and nothing herein should be construed as a warranty or guarantee, expressed or implied, regarding the use or applicability of the
Series 3 Plus Hardware Reference 3
Document Scope
This manual provides the information you will need to physically install and maintain Series 3 Plus Controllers:
Chapter 1 describes the controller and its major components, and discusses basic maintenance strategies and spare parts stocking.
Chapter 2 tells how to mount, replace, disassemble, reassemble, and convert controllers, and discusses general troubleshooting.
Chapter 3 describes the parameter memory and tells how to view or alter parameter values or run tests from the engineering panel.
Chapter 4 provides installation and troubleshooting instructions for the serial communication circuits.
Chapter 5 provides installation and troubleshooting instructions for the discrete input and output circuits.
Chapter 6 provides installation, calibration, and troubleshooting instructions for the Analog PCB’s analog input and output circuits.
Chapter 7 describes and tells how to install, calibrate, and troubleshoot the high-current output and speed and position inputs.
Chapter 8 describes the fault indicators and redundant controller set up.
Appendix A describes each configuration or tuning parameter discussed in the body of this manual.
Appendix B describes the controller test procedures that can be executed from the Engineering Panel of a Series 3 Plus Controller.
Additional information can be found in the following supporting documents, which are included at the back of this manual:
DS300/P lists the replaceable components of the Series 3 Plus Controller.
DS300/H specifies the physical and electrical characteristics of Series 3 Plus Compressor Controllers.
DS307/H specifies the physical and electrical characteristics of Series 3 Plus Turbine Controllers.
DS300/T specifies the physical and electrical characteristics of Series 3 Plus Compressor Controller Field Termination Assemblies.
DS307/T specifies the physical and electrical characteristics of Series 3 Plus Turbine Controller Field Termination Assemblies.
4 Contents
The document title appears in the header of each odd-numbered page, while the chapter or appendix title appears in the header of even-numbered pages. Odd-page footers list the document number and revision level [IM300/H (6.2.4)], while even-page footers provide the publication date (April 2010).
Acronyms are defined in the sections of this manual that discuss the corresponding subjects, by placing them in parentheses following the spelled-out terms they represent. As an example, a three-letter acronym (TLA) is a way to represent a three-word subject by com-bining and capitalizing the initial letters of those three words. Most are also listed under Symbols and Acronyms on page 10.
Cross-references to other documents specify a section and chapter, while cross-references between chapters of this document specify a page number. References that do not specify a location are internal to the chapter in which they appear. In computerized versions of this manual, all such references are hot-linked to their target locations and appear in green. Entries in the tables of contents, illustration and table lists, and index are also hot-linked but are not green.
Attention may be drawn to information of special importance by using this text styling or one of the following structures:
Note:
Notes contain important information that needs to be emphasized.Caution:
Cautions contain instructions that, if not followed, could lead to irre-versible damage to equipment or loss of data.Warning!
Warnings contain instructions that, if not followed, could lead to personal injury.The appearance of this electrical hazard warning symbol on CCC equipment or the word Warning appearing in this manual indicates dangerously-high voltages are present inside its enclosure. To reduce the risk of fire or electrical shock, do not open the enclo-sure or attempt to access areas where you are not instructed to do so. Refer all servicing to qualified service personnel.
The appearance of this user caution symbol on CCC equipment or the word Caution appearing in this manual indicates damage to the equipment or injury to the operator could occur if operational proce-dures are not followed. To reduce such risks, follow all proceproce-dures or steps as instructed.
Series 3 Plus Hardware Reference 5
Table of Contents
Document Scope . . . 3 Document Conventions . . . 4 Table of Contents. . . 5 List of Figures. . . 8 List of Tables . . . 9Symbols and Acronyms . . . 10
Chapter 1 Description
. . . 13Components and Configurations . . . 13
Mounting Configuration . . . 14 Component Configuration . . . 14 CPU PCB Assembly. . . 16 Serial Ports . . . 17 Discrete Inputs . . . 17 Discrete Outputs. . . 17 Auxiliary PCB Assembly. . . 18 Frequency Inputs . . . 19 High-Current Output . . . 19 Position Inputs . . . 19
Discrete Inputs and Outputs . . . 19
Analog PCB Assembly . . . 20
Analog Inputs . . . 20
Analog Outputs. . . 20
Front Panel Assembly . . . 21
Engineering Panel Assembly . . . 22
Back Panel Assemblies . . . 23
Field Termination Assemblies . . . 26
Power Supply Assembly. . . 27
Maintenance Strategies . . . 28
Spare Parts . . . 28
Return Procedure . . . 29
Support Software . . . 30
Chapter 2 Installation and Maintenance
. . . 31Controller Mounting . . . 31
Power Cable. . . 33
Input Power Filter . . . 33
Controller Replacement . . . 34
Internal Component Access . . . 35
Disassembly . . . 35
Reassembly . . . 36
Testing and Adjusting Internal Components . . . 37
6 Contents
General Troubleshooting . . . .39
Blank Front Panel . . . .39
Visible Damage . . . .39
Controller Faults . . . .39
Power Supply Voltages . . . .40
Chapter 3 Configuration and Testing
. . . .41Parameter Memory . . . .41
Alternate Parameter Sets . . . .42
Parameter Checksum . . . .42
Configuration Forms . . . .42
Data Groups and Pages . . . .42
Engineering Panel . . . .43
Key Descriptions . . . .44
Key Sequence Illustrations . . . .45
Viewing and Changing Parameter Values . . . .46
Key Sequence Examples. . . .47
Enabling Parameters . . . .47
List Parameters . . . .50
Numeric Parameters . . . .53
Parameter Memory Procedures. . . .56
Diagnostic Messages. . . .57 Bad CRC . . . .57 Com# POF . . . .57 CS= XXXX . . . .57 Error! . . . .57 No Store. . . .57 Reset . . . .57
Chapter 4 Serial Ports
. . . .59Installation . . . .59
Isolated Port Grounding. . . .59
Configuring Communications. . . .60 Surge Suppression . . . .61 Port 1 . . . .61 Port 2 . . . .61 Ports 3 and 4 . . . .62 RS-232 Converter . . . .62 Modbus TCP Converter . . . .62
Serial Port Bus . . . .63
Termination Resistors . . . .64
Troubleshooting. . . .65
Serial Port Activity Test . . . .65
Series 3 Plus Hardware Reference 7
Chapter 5 Discrete Inputs and Outputs
. . . 67Installation . . . 67
Discrete Output Jumpers . . . 69
Factory Testing Jumpers . . . 69
Basic I/O Controllers . . . 70
Compressor Controllers with FIOM . . . 71
24 Vdc Power Circuits . . . 71
Discrete Input Circuits . . . 71
Discrete Output Circuits . . . 71
Extended I/O Turbine Controllers. . . 72
24 Vdc Power Circuit . . . 72
Discrete Input Circuits . . . 72
Discrete Output Circuits . . . 72
Troubleshooting . . . 73
Discrete Input Troubleshooting . . . 73
Discrete Output Troubleshooting . . . 73
Chapter 6 Analog PCB I/O
. . . 75Installation . . . 75
Analog Input Installation . . . 76
Early-Model Analog PCB Replacement . . . 77
Compression-Terminal Back Connections . . . 78
Field Input-Output Module Connections . . . 79
Field Input Module Connections . . . 80
Analog Output Installation . . . 81
Output Isolation . . . 82
Calibration . . . 83
Analog Input Calibration . . . 83
Analog Output Calibration . . . 85
Current Outputs . . . 85
Voltage Outputs . . . 86
Troubleshooting . . . 87
Analog Input Troubleshooting . . . 87
Analog Output Troubleshooting . . . 88
Chapter 7 Extended I/O Circuits
. . . 89Description . . . 89
High-Current Analog Output. . . 90
Position Inputs . . . 90
Speed Inputs . . . 91
Installation . . . 92
Jumper Settings . . . 92
Inductive Load Jumper . . . 92
Maximum Output Jumpers . . . 93
Daughter Board Jumper . . . 93
Miscellaneous Jumpers . . . 93
8 Contents
Position Input Installation. . . .94
Output Calibration . . . .95
Output Circuit Calibration. . . .97
Loopback Circuit Calibration . . . .99
Troubleshooting. . . .101
High-Current Output Troubleshooting . . . .101
Speed Input Troubleshooting. . . .101
Position Input Troubleshooting . . . .102
Chapter 8 Fault Detection and Redundancy
. . . .103Fault Indicators . . . .103
Power Supply Failure. . . .104
Redundant Controllers. . . .105
Switching Conditions . . . .106
Switching Logic . . . .106
Output Connections . . . .107
Tracking Input Connections . . . .107
Serial Port Set Up . . . .107
Redundant Control Selector . . . .108
RCS Power Test . . . .108
Appendix A Configuration Parameters
. . . .109Appendix B Controller Test Sequences
. . . .115Glossary/Index
. . . .131List of Figures
Figure 1-1 Series 3 Plus Controllers share a common hardware platform . . . .13Figure 1-2 Major components of Series 3 Plus Controller . . . .15
Figure 1-3 CPU PCB Assembly . . . .16
Figure 1-4 Auxiliary PCB Assembly . . . .18
Figure 1-5 Analog PCB Assembly . . . .20
Figure 1-6 Performance and Speed Controller Front Panels . . . .21
Figure 1-7 The Engineering Panel mounts behind the Front Panel . . . .22
Figure 1-8 Basic compressor and turbine controller backs. . . .23
Figure 1-9 CPC backs for extended I/O controllers . . . .24
Figure 1-10 Field Input Module (FIM) for turbine controllers. . . .25
Figure 1-11 Field Output Module (FOM) for turbine controllers . . . .25
Figure 1-12 Field Input Output Module (FIOM) for compressor controllers . . . .25
Figure 1-13 AC Power Supply Assembly . . . .27
Figure 1-14 Using a PC to Configure Series 3 Plus Controllers . . . .30
Figure 2-1 Mounting a Series 3 Plus Controller . . . .31
Figure 2-2 Power Cable . . . .33
Figure 2-3 Power Cable connector configurations . . . .33
Series 3 Plus Hardware Reference 9
Figure 3-1 Alternate parameter set memory . . . 41
Figure 3-2 Series 3 Plus Engineering Panel . . . 44
Figure 4-1 Serial port terminals on standard Back Panels . . . 59
Figure 4-2 FTA Serial port features . . . 60
Figure 4-3 Wiring diagrams for Ports 1 and 2 . . . 61
Figure 4-4 Connecting to an RS-422/485 host port. . . 62
Figure 4-5 Connecting to an RS-232 host port . . . 63
Figure 4-6 Terminating resistor DIP switch on the CPU PCB . . . 64
Figure 5-1 Discrete I/O terminals on basic controller back panels . . . 67
Figure 5-2 Discrete I/O features of Field Termination Assemblies . . . 68
Figure 5-3 CPU PCB Discrete output jumpers . . . 69
Figure 5-4 Basic compressor controller discrete input wiring . . . 70
Figure 5-5 Basic compressor controller discrete output wiring . . . 70
Figure 6-1 Analog I/O features of Field Termination Assemblies . . . 75
Figure 6-2 Analog I/O terminals on basic controller back panels . . . 76
Figure 6-3 Early Analog PCB Assembly input configuration resistors. . . 77
Figure 6-4 Analog I/O connections for basic compressor controller . . . 78
Figure 6-5 Analog output jumpers on inside of Back Panel. . . 81
Figure 6-6 Analog PCB Assembly . . . 83
Figure 6-7 Calibration connections for basic compressor controllers . . . 84
Figure 7-1 Operation of bipolar output. . . 89
Figure 7-2 Back panel speed input and high-current output terminals . . . 91
Figure 7-3 Field Termination Assembly extended I/O terminals . . . 92
Figure 7-4 Jumper locations on the Auxiliary PCB . . . 93
Figure 7-5 Daughter card configuration jumper. . . 93
Figure 7-6 High-current output functional diagram . . . 95
Figure 8-1 Fault and Tracking LED locations . . . 103
Figure 8-2 Series 3 Plus dual-redundant fault tolerance . . . 105
Figure 8-3 Typical redundant switching relay circuit . . . 106
Figure 8-4 Switched I/O signal connections . . . 107
Figure 8-5 Typical Redundant Control Selector connections . . . 108
List of Tables
Table 2-1 Power supply voltages. . . . 40Table 3-1 Data groups and pages . . . 43
Table 7-1 Expected output readings . . . 96
10 Contents
Symbols and Acronyms
Ω ohm (electrical resistance measurement)
% percent (parts or divisions per hundred)
# generic symbol for any number or numeric key
AC Alternating Current
AD1 to AD8 Analog-to-Digital variables
ADC Analog-to-Digital Converter
ALT ALTernate readout
AUX AUXiliary readout
BCC Basic (I/O) Compressor Controller
BTC Basic (I/O) Turbine Controller
C# Capacitor (for example, C9)
CCC Compressor Controls Corporation
CH1 to CH8 analog input CHannels
COND signal CONDitioning
CPC Circular Plastic Connector
CPU Central Processing Unit
CRC Cyclic Redundancy Checksum
CR1 to CR5 Control Relays (discrete outputs)
DC Direct Current
DCS Distributed Control System
D1 to D7 compressor controller Discrete Input
DEV DEViation readout
DI01 to DI16 turbine controller Discrete Input
DIP Dual Inline Package
DO1 to DO9 Discrete Outputs (control relays)
ECC Extended (I/O) Compressor Controller
ETC Extended (I/O) Turbine Controller
EPROM Erasable Programmable Read-Only Memory
EEPROM Electrically-Erasable Programmable Read-Only Memory
F# Fuse (for example, F1)
FIM Field Input Module
Series 3 Plus Hardware Reference 11
FOM Field Output Module
FREQ1 to FREQ6 Frequency input (speed measurement)
FTA Field Termination Assembly
GRD electrical ground terminal
H electrical hot terminal
HDIC High-Density Interconnect Cable
Hz Hertz (frequency in cycles per second)
I1 to I3 analog current-loop output
I/H Current-to-Hydraulic signal converter
I/O Input and Output (circuits or signals)
IP Internet Protocol
I/P Current-to-Pneumatic signal converter
IVP Intended Valve Position
J# Jumper (for example, J3)
JB# Jumper Block (for example, JB10)
k or k- kilo (symbol or prefix for one thousand)
kW kilo-Watt
LED Light Emitting Diode
LVDT Linear Variable Differential Transformer (position input)
m or m- milli (symbol or prefix for one-thousandth)
M or M- mega (prefix for one million)
mA milli-Ampere
MPU Magnetic PickUp
N electrical neutral terminal
NEMA National Equipment Manufacturer’s Association
NO/NC Normally-Open or Normally-Closed
OUT OUTput display
OUT1 to OUT3 analog OUTputs
PC (IBM-PC compatible) Personal Computer
PCB Printed Circuit Board
PI Proportional-Integral control
PID Proportional-Integral-Derivative control
12 Contents
PLC Programmable Logic Controller
PV Process Variable readout
R# Resistor (for example, R33)
RAM Random Access Memory
RCS Redundant Control Selector
RMA Returned Material Authorization
RTU Remote Terminal Unit
RVDT Rotary Variable Differential Transformer (position input)
RX serial port reception channel (for example, RX3)
S Solenoid
SCADA Supervisory Control And Data Acquisition
SP Set Point readout
SPEC SPECial response
SV1 to SV8 Signal Variables
TB Terminal Block
TCP Transmission Control Protocol
TTC Total Train Control®
TX serial port transmission channel (for example, TX3)
V Voltage
Vac alternating-current Voltage
Vdc direct-current Voltage
V1 to V2 analog Voltage output
W Watt (electrical power measurement)
Series 3 Plus Hardware Reference 13 IM300/H Series 3 Plus Hardware Referencemanual
Chapter 1
Description
This chapter describes the controller and its major components, and discusses basic maintenance strategies and spare parts stocking.
Figure 1-1 Series 3 Plus Controllers share a common hardware platform
Components
and
Configu ations
All Series 3 Plus Controllers use a common hardware platform con-sisting of the following major components:
• The CPU PCB Assembly provides the controller’s primary com-putational, serial communication, and discrete I/O capabilities. • The Analog PCB Assembly provides most (if not all) of the
con-troller’s analog input and output circuits.
• The Auxiliary PCB Assembly provides the added I/O and com-putational capabilities needed for turbine control applications. • The Front Panel Assembly provides the controller’s operator
display and input functions.
• The Engineering Panel Assembly provides the controller’s con-figuration and tuning functions.
• The Power Supply Assembly converts the input power to the voltages required by the controller’s internal circuitry.
• The Back Panel Assemblies and optional Field Termination Assemblies (FTAs) provide wiring terminals for the controller’s
OUT SP
Series 3 Plus Controller AUX COMP CONTROLS CORPORATION
∇
∆
AUTO MANGas Turbine
Fuel and Nozzle
Controllers
Dual-Loop
and
Air Miser
Controllers
Steam Turbine
Speed and Extraction
Controllers
Compressor
Perfor-mance and Antisurge
14 Chapter 1: Description
Mounting
Configu ation
With the exception of the externally-mounted FTAs, all of the con-troller’s components are usually housed in an extruded aluminum case for mounting in a control panel cutout (see Figure 1-2). This is referred to as the panel-mounted configuration.In this configuration, the Back Panel (which will cause few mainte-nance or repair problems) can usually be treated as part of the case. The remaining components can be replaced from the front of the case without removing it from the panel.
Alternately, the components of one or more controllers can be housed in a NEMA rated enclosure. This is referred to as the enclo-sure-mounted configuration, an option most frequently used in Air Miser applications. Most enclosure-mounted controllers use FTAs. In this configuration, the Front and Engineering Panels are mounted in the door of the enclosure and connect to the CPU PCB via a rib-bon cable. The CPU and Analog PCBs, Power Supply, and Back Panel Assemblies are mounted as one unit within the enclosure, along with any FTAs, to which they connect using High-Density Interconnect Cables (HDICs).
Component
Configu ation
Series 3 Plus Controllers can be divided into four basic component configurations, depending on whether or not they are equipped with an Auxiliary PCB Assembly and whether or not the Back Panel fea-tures compression terminals or circular plastic connectors (CPCs). Compressor control applications rarely require the Auxiliary PCB, while turbine applications usually do. Thus, component combina-tions that do not include it are referred to as compressor controller configurations and those that do are referred to as turbine controller configurations. However, Antisurge and Performance Controllers can use a turbine controller configuration when the application requires Auxiliary PCB features. Similarly, a compressor controller configuration can be used for Extraction Controller applications that do not require features provided by the Auxiliary PCB Assembly. Because the I/O capabilities of turbine controller FTAs exceed those of the compression-terminal Back Panel for the same controllers, controllers that include CPC-style Back Panels are referred to as extended I/O configurations and those with compression terminal backs are referred to as basic I/O configurations. However, both the basic and extended I/O compressor controller configuration offer an essentially identical combination of inputs and outputs.Series 3 Plus Hardware Reference 15
Figure 1-2 Major components of Series 3 Plus Controller
In summary, the four basic component configurations can be referred to as:
• The Basic Compressor Controller (BCC), which has neither an Auxiliary PCB nor a CPC-style Back Panel Assembly.
• The Extended Compressor Controller (ECC), which has a CPC Back Panel Assembly but no Auxiliary PCB.
• The Basic Turbine Controller (BTC), which has an Auxiliary PCB but not a CPC-style Back Panel Assembly.
• The Extended Turbine Controller (ETC), which has both a CPC Back Panel and an Auxiliary PCB Assembly.
Each component configuration can use either an AC or DC power supply (which require different Back Panels) and can be provided in either the panel- or enclosure-mounted configuration.
Rear Panel Assembly Auxiliary PCB AssemblyPower Supply Assembly
Slide Adjuster Mounting Slide
Case Front Panel Assembly
Engineering Panel Assembly Analog PCB Assembly
CPU PCB Assembly
16 Chapter 1: Description
Figure 1-3 CPU PCB Assembly
CPU PCB
Assembly
The CPU PCB provides the controller’s central processor, memory, serial communication, and discrete I/O capabilities. The major com-ponents of this assembly (see Figure 1-3) are:• a Zilog Z80 CPU chip (central processing unit);
• a RAM chip (random access memory) in which the results of internal calculations are stored (that is, the working memory); • two EEPROM chips (electrically-erasable programmable
read-only memories) that store the control program and parameters; • two I/O chips that provide four serial ports, eight discrete inputs,
and communication between the main CPU and the micropro-cessors on the Engineering Panel and optional Auxiliary PCB; • a super-capacitor that powers the RAM during power outages,
thus preserving the working memory;
• eight electro-mechanical relays (discrete outputs), with jumpers that set their normally-open / normally-closed configurations; • isolating power supplies for the serial ports;
• terminating resistors for the serial communication networks, and a set of DIP switches for including them in those circuits; and • a speaker for audible feedback.
Storing configuration parameters in EEPROMs protects them from being lost or corrupted during power failures (see page 41), while still allowing them to be easily changed from either the Engineering Panel keyboard or via serial communication from a computer work-station running controller support software.
Similarly, storing the control program in the EEPROMs means it can also be updated from a computer running our Download software.
DO2 Jumper
Power Supply Connector
Factory-Test Jumpers Engineering Panel ConnectorSpeaker Termination Resistor DIP Switch
Analog Board Connectors
RAM CPU
EEPROM
I/O Chip
Auxiliary Board Connector
NO/NC Jumpers Discrete Output Relays
EEPROM
I/O Chip
Series 3 Plus Hardware Reference 17 In panel-mount controllers, the CPU PCB slides into grooves in the case. For enclosure-mount applications, it is mounted on the back of the enclosure. Either way, the Analog PCB, Auxiliary PCB (when present), and Power Supply are bolted to the CPU PCB and com-municate with it via connectors mounted between them.
The CPU PCB communicates with the Back Panel via a 120-pin connector along its trailing edge, and with the Engineering Panel via a 20-pin connector along its leading edge. In enclosure-mounted controllers, the CPU PCB and Engineering Panel Assemblies are connected by a ribbon cable.
Serial Ports The CPU board’s two I/O chips provide four serial ports (Ports 1 to 4) that are compatible with the EIA RS-485 standard.
Ports 1 and 2 are used for communications with other Series 3 Plus Controllers, while Ports 3 and 4 are used for communication with host computers or control systems using the Modbus protocol. Port 5 is not used.
Discrete Inputs The CPU board’s I/O chips provide eight discrete inputs that are referred to as D- or DI-1 through 8:
• Compressor controllers have terminals for and thus support only seven of these inputs.
• Turbine controllers support all eight.
Consult the configuration manual for each specific controller to determine the functions of these inputs.
Discrete Outputs The CPU board provides eight electro-mechanical relays that can be used to control external alarms or as inputs to other control or monitoring systems. These are referred to as DO- or CR-1 to 8:
• All compressor controllers have terminals for and thus support only the first five of these relays.
• Basic turbine controllers support seven relays, while extended I/O turbine controllers support all eight. All turbine controllers also support the Auxiliary PCB’s fault relay (DO/CR9).
The function of each relay can be independently selected by setting its Relay Assigned Function[MODE:D RA #] parameter. Consult the configuration manual for your controller to determine what control relay functions it provides.
CR1 is of particular interest, because it is normally energized and thus fails off. This provides an automatic indication of hardware fail-ure or power loss. In models equipped with Revision B or later CPU PCBs, CR2 can also be configured as a fault relay.
18 Chapter 1: Description
Figure 1-4 Auxiliary PCB Assembly
Auxiliary PCB
Assembly
The Auxiliary PCB provides the additional computational and I/O capacity needed for speed control and valve positioning. All turbine controllers except the Extraction Controller require this board. It can also be installed in Compressor Controllers that require its valve positioning loop, speed inputs, or high-current output circuit. The major components of this assembly (see Figure 1-4) are:• the Motorola 68332 central processing unit (CPU);
• two random access memory (RAM) chips, in which the results of internal calculations are stored (the board’s working memory); • the EPROM chip (erasable programmable read-only memory)
that stores the control program for this board;
• a super-capacitor that powers the RAM when the controller is unplugged and during power outages;
• an analog output that can provide a bipolar current-modulated signal of up to 200 mA, and the jumpers to configure it;
• a programmable input/output (PIO) chip that provides eight additional discrete inputs;
• one electro-mechanical relay (discrete output) and a jumper to configure it as normally open or closed, used for fault detection on the Auxiliary PCB; and
• a daughter board that provides the speed and position inputs. The only currently-available Daughter Board provides:
• three frequency inputs for use as rotational speed inputs; • one LVDT and one 4 to 20 mA position inputs; and
• a demodulation circuit for the frequency feedback signal of a Rosemont 3311 pneumatic transducer.
Speaker EPROM CPU RAM I/O Chip
Analog Board Connection Daughter Board
Series 3 Plus Hardware Reference 19 The Auxiliary PCB Assembly is mounted to and above the Analog PCB Assembly, which it completely covers (see Figure 1-2).
Frequency Inputs The Daughter Board provides three inputs for reading the rotational speed signals from a steam or gas turbine’s magnetic pickups:
• Basic turbine controllers have back-panel terminals for only three of these inputs (FREQ 1 to 3).
• Extended I/O controllers have FOM terminals for all three inputs (MPUs 1 through 3).
High-Current Output The Auxiliary board includes an analog output circuit that can pro-vide virtually any current-modulated signal (up to 200 mA) that might be required for control valve positioning. Thus, this circuit is usually called the High-Current Output. Its wiring terminals are located on the basic turbine controller back panel (OUT 1) or Field Output Mod-ule (Current Output 1).
This output can be jumper-configured for a maximum current of 20, 60, or 200 mA. The control program can then be configured to map its output signal to any portion of the selected current range.
Position Inputs The only currently-available Daughter Board provides one LVDT (Linear Variable Differential Transformer) and one 4 to 20 mA ana-log input for measuring the position of control valves or inlet guide vanes. These are supported only by extended I/O turbine control-lers. Terminals for these inputs (Position In 1 and the Auxiliary Input) are located on the Field Input Module (FIM).
The Daughter Board also includes circuitry to decode a frequency signal that has been modulated onto the High-Current Output. For example, it could recover the pressure feedback signal of a Rose-mont 3311 pneumatic transducer. This feature is available in both the basic and extended I/O configurations.
Discrete Inputs and
Outputs The Auxiliary PCB provides eight discrete inputs (in addition to the eight provided by the CPU PCB): • Basic turbine controller configurations support only one of these
inputs (D9).
• Extended I/O configurations support all eight (DI-9 through -16). As described in the individual controller manuals, each input can be configured to trigger specific responses when the input is active. The Auxiliary PCB also has a single discrete output (DO/CR9) that signals Auxiliary board faults in the same way that DO/CR1
indi-Note:
Early models of the Auxiliary PCB that do not include the daughter card provide two LVDT inputs but support only three MPUs.20 Chapter 1: Description
Figure 1-5 Analog PCB Assembly
Analog PCB
Assembly
The Analog PCB Assembly (see inputs and two analog outputs. It is mounted on and toward the front Figure 1-5) provides eight analog of the CPU PCB (see Figure 1-2).Analog Inputs The Analog board’s inputs are referred to as either Analog Inputs 1 to 8 or CH1 through CH8:
• Basic turbine controller configurations support only four of these inputs (CH1 to 4).
• All other controller configurations support all eight analog inputs. All eight of these circuits must be configured as either current or voltage inputs by placing all of the board’s configuration jumpers in either the C (20 mA) or V (5 Vdc) positions.
Analog Outputs For compressor controllers, the Analog PCB outputs are called OUT1 and OUT2. They are factory-set as either 20 mA or 5 Vdc cir-cuits by setting a jumper on the inside of the Back Panel Assembly. When set up for current-loop modulation, they are sometimes called I-1 and I-2. When set up for voltage-modulation, they are also
referred to as V-1 and V-2.
For turbine controllers, these outputs are referred to as OUT2 and OUT3 (OUT 1 is the High-Current Output provided by the Auxiliary PCB). The compression terminal back panel has a jumper (similar to that of the basic compressor controller) that configures them as either current (I2 and I3) or voltage (V2 and V3) outputs. In contrast, the FOM provides terminals for both the current- and voltage-modu-lated forms of these outputs. However, only one form of each output can be used at any given time.
Calibration Potentiometers
Configuration Jumpers
Note:
Early models of the Analog PCB were factory configured for all 5 Vdc or all 20 mA inputs and did not include configuration jumpers.Series 3 Plus Hardware Reference 21
Figure 1-6 Performance and Speed Controller Front Panels
Front Panel
Assembly
The Front Panel Assembly provides the primary operator interface for the Series 3 Plus Controller. It is attached to the Engineering Panel by a swing-out hinge and communicates with it via an eight conductor ribbon cable.Regardless of which model you purchase, the general features of this panel are always the same. As shown in Figure 1-6, each has:
• two five-digit numeric readouts that usually display the con-trolled variable and its set point,
• a three-digit numeric readout that displays the value of the con-troller’s output signal (in percent)
• a twelve-character alphanumeric readout for displaying process or controller variables,
• fourteen LEDs for indicating status conditions, and • eight control keys.
Each model does have a unique overlay that identifies the type of controller you have, the function of each control key, and the mean-ing of each status LED that it utilizes. The configuration manuals (IM3##) provide detailed information about each controller’s front-panel and operator interface.
COMPRESSOR CONTROLS CORPORATION SCROLL MENU
∆
∇
AUTO MAN Manual Auto Local Tracking Fault TranFail Fallback ComErr PV OUT SP Performance Controller AUX DISPLAY Remote Limit REMOTE LOCAL LOOP2 DISPLAY LOOP3 COMPRESSOR CONTROLS CORPORATION SCROLL MENU∆
∇
AUTO MAN Manual Auto Local Stop Run Fault ShutDn Limit ComErr RPM OUT SP Speed Controller AUX SET POINT MODE RESET ENTER Remote Idle Tracking Alarm Cascade OPER-ATING MODE KW= 2122 Speed/Remote50.4
50.1
90.0
3620
90.0
3620
22 Chapter 1: Description
Figure 1-7 The Engineering Panel mounts behind the Front Panel
Engineering
Panel Assembly
The chief feature of the Engineering Panel is the Engineering Key-board (see Figure 3-2), which can be used to enter and change the configuration and tuning parameters that adapt each controller to its specific application.In Series 3 Plus Controllers, the Engineering Panel is equipped with an embedded microprocessor that controls both the Engineering Keyboard and the Front Panel. Off-loading these functions from the main CPU allows the controller to run more demanding control algo-rithms while still providing a responsive user interface.
The Engineering Panel is mounted on the front of the controller, immediately behind the Front Panel (see Figure 1-7). It is accessed by loosening the screw at the bottom of the Front Panel, pulling its left side forward about an inch, and then swinging the entire assem-bly forward and to the left.
Figure 1-8 Basic compressor and turbine controller backs
Back Panel
Assemblies
All I/O wiring and the input power cable connect to the controller’s Back Panel Assembly. Each controller is equipped with one of four basic versions of this panel:• the basic compressor controller Back Panel,
• the extended I/O compressor controller Back Panel, • the basic turbine controller Back Panel, or
• the extended I/O turbine controller Back Panel.
Each of these assemblies is available for either AC or DC power supply configurations and either panel or enclosure mounting.
The I/O terminals for the basic controller configurations are mounted directly on the Back Panel (see Figure 1-8). In order to facilitate replacement of these controllers, two-piece terminals are used. After permanently attaching each wire to the removable half of its connector, you can unplug each group of wires by detaching that half of the connector from the controller.
The two extended I/O versions of the Back Panel are designed to be used with separately-mounted Field Termination Assemblies
(FTAs), to which they are connected using High-Density
Intercon-PORT 5 +TX5 RX5 2 1 4 3 NOT D + – + – CH 1 N GRD H 96-264 VAC MADE IN USA 21-32 VDC + – CH 2 + – CH 3 + – CH 4 OUT 1 + PORT 2 + – + – + – 24VDC DISCRETE + – D6 D7 PORT 1 TX/RX TX2 RX2 CR3 CR4 CR5 DISCRETE IN D1 D2 D3 D4 D5 PORT 4 +TX4– +RX4– PORT 3 +TX3– +RX3– – + OUT 2 + 1 2 1 2 1 2 CH 5 35 W max CH 6 CH 7 CH 8 CR1 CR2 1 2 1 2 + – + – + – USED – 2 1 4 3 DISCRETE D + – + – CH 1 N GRD H 96-264 VAC MADE IN USA 21-32 VDC + – CH 2 + – CH 3 + – CH 4 OUT 1 + PORT 2 + – + – + – 24VDC DISCRETE + – D6 D7 PORT 1 TX/RX TX2 RX2 CR6 CR7 CR9 DISCRETE IN D1 D2 D3 D4 D5 PORT 4 +TX4– +RX4– PORT 3 +TX3– +RX3– + – FREQ1 + OUT 2 + 1 2 1 2 1 2 OUT 3 D8 D9 + – FREQ2 FREQ3 35 W max CR1 CR2 CR3 CR4 CR5 1 2 1 2 1 2 1 2 1 2
Compressor
Turbine
24 Chapter 1: Description
Figure 1-9 CPC backs for extended I/O controllers
Extended I/O compressor controllers use a Back Panel with one CPC connector, while the Back Panel for extended I/O turbine con-trollers have two (see Figure 1-9).
For panel-mounted controllers, the Back Panel Assembly is bolted to the back of the case. In enclosure-mounted applications, the Back Panel is mounted on the back of the enclosure using angle brackets. In either case, the optional FTAs snap onto standard instrument mounting rails.
Extended I/O Controllers can be purchased without FTAs. We then supply pigtail I/O cables with CPC connectors on the controller ends only. The Series 3 Plus Compressor Controllers Field Termination Assembly data sheet [DS300/T] and Series 3 Plus Turbine Control-lers Hardware Specifications [DS307/H] list the I/O signals assigned to the color coded wires on the unterminated ends.
G 96-264 VAC 21-32 VDC H N MADE IN USA 35 W max 1 4 60 63 INPUTS 1 4 60 63 (J1) OUTPUTS (J2)
Compressor
Turbine
G 96-264 VAC 21-32 VDC H N MADE IN USA 35 W max 1 4 60 63 INPUTS/ (J1) OUTPUTSFigure 1-10 Field Input Module (FIM) for turbine controllers
Figure 1-11 Field Output Module (FOM) for turbine controllers
Analog Input Fuses and Config. Blocks 24 Vdc Fuses
and Config. Block
Terminals for
Discrete Inputs Valve Position Inputs Terminal Block for Frequency Inputs Terminals for Discrete Input Fuses and
Config. Blocks
Terminal Blocks for Analog Inputs CPC Connector for
Controller Data Cable
Terminal Blocks for
Serial Ports 1 to 4 Terminal Block for Terminal Block for 24 Vdc
CPC Connector for Discrete Output Fuses and Config. Blocks
Terminal Blocks for Controller Data Cable
Analog Outputs Discrete & Misc. Outputs (Port 5 is not used)
Discrete Output Cfg. Blocks HDIC
Connector DB-9 Connectors for
Modbus Ports Analog InputCfg. Blocks 24 VDC Cfg. Block Discrete I/O Fuses Fuses for Analog Inputs Terminal Blocks for
Analog I/O Circuits
Terminal Block for Discrete Outputs
Terminal Block for Discrete Inputs Fuses for 24 VDC
Power Circuits Terminal Block for
Serial Ports 1 to 4 (P5 is not used)
Terminal Block for 24 VDC and Instrument Ground
Serial Port Cfg. Blocks Ribbon Cable Connectors for Serial Port Bus
26 Chapter 1: Description
Field Termination
Assemblies
Because there is simply too little room on the Back Panel to provide terminals for all of their CPU, Analog, and Auxiliary PCB I/O circuits, extended I/O turbine controllers are provided with remotely-mounted Field Termination Assemblies (FTAs):• The Field Input Module (or FIM, see Figure 1-10) has terminals for all input signals.
• The Field Output Module (or FOM, see Figure 1-11) handles all output and serial communication connections.
The Series 3 Plus Turbine Controllers Field Termination Assembly
data sheet [DS307/T] lists the specifications for these FTAs.
In addition to supporting additional I/O circuits, the use of FTAs can reduce panel design and wiring costs. They also include fusing and dropping resistor options that would otherwise be quite difficult to install. Other FTA design features facilitate connecting the control-ler’s I/O signals to a DCS or other supervisory control system, and simplify wiring of the serial communication networks used to coordi-nate the actions of multiple controller systems.
Because the FTAs have no active components, they should never fail or need replacement. In the remote event one does, the terminal blocks can be disconnected and reinstalled on a replacement FTA without disturbing the field wiring.
Note:
The Field Input/Output Module (FIOM), shown in specifed in Series 3 Plus Turbine Controllers Field Termination Figure 1-12 and Assembly data sheet [DS307/T]is a discontinued part and is no longer available.Figure 1-13 AC Power Supply Assembly
Power Supply
Assembly
All Series 3 Plus Controllers are equipped with either an AC or a DC power supply that automatically adapts to a wide range of input volt-ages (Figure 1-13 illustrates the AC Power Supply):• the AC power supply accepts any voltage from 96 to 264 Vac, 50 to 60 Hz, while
• the DC power supply accepts any voltage from 21 to 32 Vdc. The Back Panel of each controller is clearly labeled to indicate which power supply it is equipped with. Either provides regulated +5, +15, –15, and +24 Vdc output voltages, and either galvanically isolates the controller’s internal circuitry from the power source. The ground conductor of the power cable should be connected to a suitable earth ground. This grounds the case (for electrical safety), provides the reference potential for internal power supply voltages and analog outputs, and serves as a sink for any high-frequency components of the analog input signals.
The 24 Vdc output, which is connected to the 24 VDC terminals on the Back Panel or FTA, can be used to power your field transmitters. This transmitter power output is isolated so that a faulty transmitter will not affect the controller’s internal voltages.
The Power Supply Assembly is mounted on and toward the rear of the CPU PCB Assembly (see Figure 1-2), to which it connects via an 18-pin connector with 15 individual conductors.
5 Vdc Potentiometer (R33)
28 Chapter 1: Description
Maintenance
Strategies
The simplest approach to maintaining Series 3 Plus Controllers is to replace suspect units with identical spares. The faulty unit can be sent to Compressor Controls Corporation for diagnosis and repair. Because Back Panel problems are extremely rare, you can usually employ the considerably easier remedy of replacing only those com-ponents that can be removed from the front of the controller.
It is often possible to determine which component is malfunctioning (for example, the Analog PCB Assembly), in which case you can replace just that component and return it for repair or replacement (we advise against attempting board-level repairs). Due to the almost complete interchangeability of parts across the entire Series 3 Plus line, this approach can significantly reduce your required spare parts inventory.
Most models of the Series 3 Plus Controller can be converted into any other by changing the Front Panel and loading the appropriate control program. You might also have to add or remove the Auxiliary PCB Assembly, and make sure the CPU PCB has enough control relays (turbine controllers generally require eight, while some com-pressor controllers have only five). If the controllers are equipped with different Back Panels, you might also have to change the Rear Panel Assembly or reuse the Case and Rear Panel from the control-ler you are replacing.
Spare Parts
If your chosen maintenance strategy is to replace malfunctioning units, one identical Series 3 Plus Controller should be stocked for every five in use. If the cost or consequences of downtime are unusually severe, a higher ratio of spares might be in order.On the other hand, if you choose to do board-level troubleshooting and replacement, you should stock spare assemblies at the same one-to-five level. One or more complete, spare controllers should also be stocked for use while troubleshooting suspect units.
The Series 3 Plus Controller Spare Parts List [DS300/P] lists the major assemblies used in Series 3 Plus Controllers. Your spare parts inventory should be based on the total number of installed controllers using each assembly.
To avoid complicating maintenance and spare parts procedures, we will normally try to configure all of your controllers to use identical Analog and Auxiliary PCBs. However, if this is impossible or you install controllers on different turbomachinery trains at different
Warning!
To prevent damage from static-electric discharges, all spare circuit boards should be stored and transported in static-resis-tant pouches.times, you may have multiple versions of these assemblies. Appro-priate care must then be taken when ordering and replacing them.
Return Procedure
To return a controller or assembly for repair, call CCC at 515-270-0857 and ask to talk to the Return Goods Coordinator. You will be asked to identify your controller model (for example, a Series 3 Plus Performance Controller), provide its serial number, and describe the problem you are experiencing. He or she will then schedule your repair and assign a Return Material Authorization (RMA) number. Package the items carefully (if needed, the Return Goods Coordina-tor will send you appropriate packing materials) and ship them prepaid and insured to:Compressor Controls Corporation ATTN: Service Department
4725 121st Street
Des Moines, IA 50323 U.S.A.
The RMA number should be clearly displayed on all shipping car-tons and noted in all correspondence. Your equipment will usually be repaired and shipped back within five days of their arrival at the factory.
Note:
If you have both compressor and turbine controllers, all of your CPU PCBs should have eight discrete output relays. If you have any with only five, contact CCC for information on replacing them.30 Chapter 1: Description
Figure 1-14 Using a PC to Configure Series 3 Plus Controllers
Support
Software
Since the Series 3 Plus Controllers were first brought to market, CCC has offered different software packages for monitoring and maintaining them using IBM-PC compatible computers. Each included utility programs that can can read, edit, and replace a Series 3 Plus Controller’s configuration parameter set and update its control program via one of its Modbus RTU serial ports (see Ports 3 and 4 on page 63):
• The Toolbox Software package was a set of Series 3 Plus sup-port programs for the MS-DOS operating system, including: • a Configurator program that could read, modify, store,
com-pare, and write configuration parameter sets, and
• a Download program that could replace the control program (application software) of a Series 3 Plus Controller.
• The Workstation Operator Interface Software (WOIS) was a group of Series 4 and 3 Plus software packages developed for 16-bit Windows 95/98/ME operating systems. The WOIS Series 3 Plus Configurator utility could read and replace controller parameter sets and update their control programs.
• The current TrainTools Software Packages are collections of programs developed for the 32-bit Windows 2000 and XP Professional operating systems. In particular, the Platform Engi-neering Utilities package includes the WOIS Series 3 Plus Configurator program, which can reprogram and reconfigure controllers via the TrainTools Series 3 OPC Server program. Instructions for doing so can be found in the Series 3 Engineer-ing Utilities user manual [UM5513].
OUT ALT Antisurge Controller AUX AUTO MAN DISPLAY SCROLL MENU SURGE COUNT ∆ ∇ RESET SAFETYON DEV DISPLAY LIMIT OUT ALT Antisurge Controller AUX AUTO MAN DISPLAY SCROLL MENU SURGE COUNT ∆ ∇ RESET SAFETYON DEV DISPLAY LIMIT OUT SP Performance Controller AUX AUTO MAN DISPLAY SCROLL MENU SURGE COUNT ∆ ∇ RESET SAFETYON PV DISPLAY LIMIT
IM300/H Series 3 Plus Hardware Referencemanual
Chapter 2
Installation and Maintenance
This chapter tells how to mount, replace, disassemble, reassemble, and convert controllers, and discusses general troubleshooting.
Figure 2-1 Mounting a Series 3 Plus Controller
Controller
Mounting
Refer to the Series 3 Plus Compressor Controllers Hardware Speci-fications [DS300/H] or Series 3 Plus Turbine Controllers Hardware Specifications [DS307/H] for panel cutout dimensions and Figure 2-1 for an illustration of the slide clamps (these are located on the top and bottom of the controller case). If your controller has Field Termination Assemblies (FTAs), refer to the Series 3 Plus Compres-sor Controllers Field Termination Assembly [DS300/T] or Series 3 Plus Turbine Controllers Field Termination Assembly [DS307/T] data sheet for information on mounting rails and data cables. Use the following procedure to mount your controller in a properly sized cutout:
Step 1: Loosen the slide clamp pressure screws, then remove the
1 2 3 Mounting Slide Pressure Slide Clamp Screw
32 Chapter 2: Installation and Maintenance
Step 2: Remove the slides from the case by sliding them to the back.
Step 3: Slide the controller case back into the panel cutout until the flanges contact the panel.
Step 4: Reinstall the slides and slide clamps from behind the panel.
Step 5: Tighten the pressure screws until the slides are tight against the panel.
Step 6: If using locally-mounted FTAs (in the same cabinet as the controller), snap them onto mounting rails, connect them to the controller with high-density interconnect cables (HDIC), and ground both of each HDIC’s shield pigtails.
If using remotely-mounted FTAs, only the controller ends of the HDICs should be grounded (grounding both ends can create an electric shock hazard if the ground potentials differ).
In order to safely comply with CE electromagnetic requirements, connect both ends of each HDIC to equal-potential grounds.
Step 7: Connect your field wiring to the appropriate terminal blocks on the Back Panel or FTAs.
Step 8: Configure and connect the power cable to the controller and an appropriate power supply (observe the caution on page 33).
Step 9: Use the Program Version [MODE TEST 2] and Program Checksum [MODE TEST 8] tests to determine the software revi-sion and CRC, then record them on a configuration form.
Step 10: If the controller was not preconfigured, enter appropriate values for all configuration and tuning parameters, as described in the controller’s instruction manual. Be sure to keep a record of these values and the resulting parameter checksum.
If your controller was preconfigured, verify that the Parameter Checksum [MODE LOCK 4] matches that recorded on the sup-plied configuration form. If not, identify and correct any changed parameters.
Caution:
Grounding both ends of a long HDIC can create a hazardous ground loop.Warning!
When mounting a Turbine Controller, make sure you connect the FOM to the Back Panel “Outputs” socket and the FIM to the “Inputs” socket.Figure 2-2 Power Cable
Power Cable
As shown in Figure 2-2, each pair of panel-mounted controllers is currently supplied with a 14-foot (4.3 meter) power cable, both ends of which are fitted with connectors that plug into the Back Panel power receptacle. This cable can be cut at any point to provide max-imum flexibility in choosing the length of the two resulting cables. The configuration of the power cable connectors depends on which power supply (AC or DC) is installed, as shown in Figure 2-3.Figure 2-3 Power Cable connector configurations
Input Power Filter
Series 3 Plus Controllers meet CE-specified electromagnetic com-patibility requirements only if each controller is equipped with a dedicated input power filter that is an exact electrical equivalent of the Corcom model 3VB3 filter.If the controller is mounted in an enclosure or cabinet, this filter must be installed within the same enclosure. Otherwise, it must be
installed within twelve inches (30 cm) of the controller.
M630
Caution:
Because the power cable connector is not designed to assure the ground conductor is the first connection made and the last broken, there is a risk of electric shock while connecting or disconnecting the cable to the controller.
Line (Black) Neutral (White) Ground (Green) Cable Controller AC Cable + (Red) – (Black) Ground (White) DC Cable Cable Controller
34 Chapter 2: Installation and Maintenance
Controller
Replacement
Use the following procedure to replace a malfunctioning controller:
Step 1: Obtain a spare unit from your company stores. If needed, convert it to the correct model by replacing the Front Panel. When converting between compressor and turbine controllers, you might also have to change the Back Panel and install or remove the Auxiliary PCB. Chapter 1 describes the potential hardware differences between controller models.
Step 2: Transfer control of your process to an alternate device.
Step 3: Unplug the power cable from the Back Panel of the malfunc-tioning controller. For FTA-equipped controllers, also disconnect the data cable(s). For those without FTAs, unplug the Back Panel terminal strips (rather than disconnecting the individual wires from the terminal blocks).
Step 4: Loosen and remove the slide clamps from the case, remove the slides and pull the controller forward from the panel cutout.
Step 5: Verify that all of the replacement unit’s internal switches and jumpers are set the same as in the controller being replaced.
Step 6: Temporarily connect a spare power cable to the Back Panel of the replacement controller.
Step 7: Connect a PC running one of our Series 3 Plus Controller support software packages (see Support Software on page 30) to a controller Modbus port (see Ports 3 and 4 on page 63).
Step 8: Power up the new controller, computer, and converter, and configure them to communicate with each other.
Step 9: Use the Program Version [MODE TEST 2] test to verify that the replacement contains the desired control program. If not, load that software using the Download or Configurator utility.
Step 10: If the replacement was not preconfigured, use the Configu-rator program to load the correct parameter set.
If the replacement has been preconfigured, use the Parameter Checksum [MODE LOCK 4] test to verify that its parameter set-tings match those of the original. If not, use the Configurator utility to determine which parameters differ and correct them.
Step 11: Use the Engineering Panel MODE COMM 0 key sequence to set the replacement’s Controller and Computer ID Numbers to match those of the original controller.
Step 12: Disconnect the temporary power cable and install the replacement controller into your panel by following steps 1 to 5 of the previously described Controller Mounting instructions.
Step 13: Reconnect the FTA data cable(s) or Back-Panel terminal strips and power cable.
Internal
Component
Access
With the exception of the Back Panel, any internal component of a panel-mounted controller can be removed from the front of the panel. The components of an enclosure-mounted unit are readily accessible by opening the enclosure door.
Disassembly
Use the following procedure to disassemble a panel-mounted Series 3 Plus Controller (if installed, it is not necessary to remove the controller from the panel):Step 1: Transfer control of your process to an alternate device.
Step 2: Disconnect the power cable from the rear of the controller.
Step 3: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left.
Step 4: To separate the Front and Engineering Panels (optional unless replacing only one of these components), unplug the cable connecting them, then squeeze the top and bottom of the wire hinge until you can pull it away from the Engineering Panel.
Step 5: Remove the Engineering Panel Assembly (and Front Panel, if still attached) from the case by removing the four galvanized screws at its corners and pulling the entire assembly forward to disengage it from the CPU PCB.
Step 6: Remove the CPU PCB, Analog PCB, Power Supply, and Auxiliary PCB (if present) as a unit by pulling them forward and out of the case. Considerable force may be required to disen-gage the CPU PCB from the connector on the Back Panel.
Step 7: To separate the Auxiliary PCB (if present), remove the four machine screws that attach it to the standoffs on the Analog PCB, then disengage the pins on its rear side from their connec-tor on the CPU PCB.
Step 8: To separate the Analog PCB, remove the four screws or standoffs that attach it to the standoffs on the CPU PCB, then disengage the connector joining those circuits boards.
Step 9: To separate the Power Supply, disengage the connector near its trailing edge and remove the four machine screws that
Caution:
Disconnect the power cable before disassembling the controller or disconnecting any internal component. Failure to do so is dangerous and can severely damage the controller.Warning!
Never disassemble a Series 3 Plus Controller or handle any of its circuit boards without taking steps to prevent static dis-charge. Spare parts must be stored in static-protective bags. Failure to follow these precautions can result in severe damage to the controller’s internal components.
36 Chapter 2: Installation and Maintenance
Reassembly
To reassemble the controller, you basically reverse the disassembly procedure:Step 1: Align the Power Supply’s mounting holes with the corre-sponding standoffs on the CPU PCB, reinstall the four machine screws that attach it to those standoffs, and re-engage the power supply connector to the pins protruding from the top side of its trailing edge.
Step 2: Align the pins on the Analog PCB’s rear side with the con-nectors on the CPU PCB, then reinstall the machine screws or standoffs that attach it to the standoffs on the CPU board.
Step 3: If the controller includes an Auxiliary PCB, align the pins on its rear side with the corresponding connectors on the CPU PCB, then reinstall the four machine screws that attach it to the standoffs on the Analog board.
Step 4: Slide the CPU PCB, Analog PCB, Power Supply, and Auxil-iary PCB (if so equipped) into the case as a unit. The CPU PCB fits into the left-most set of grooves in the top and bottom of the case. Press fairly hard until you feel the CPU PCB “pop” back into the connector on the front of the Back Panel.
Step 5: Align the tabs on the sides of the Engineering Panel’s mounting brackets with the grooves in the sides of the case, then slide it back until the front of those brackets is flush with the front of the mounting flange. Secure this assembly by reinstall-ing the four screws at its corners.
Step 6: Install the Engineering Keyboard (if necessary) by aligning its mounting holes with the standoffs on the circuit board behind it (this should align the eight pins protruding from its lower rear side with the connector on the circuit board). Then reinstall the four black screws that hold this assembly together.
Step 7: To reinstall the Front Panel (if necessary), insert either end of the wire hinge into its hole in the Engineering Panel’s mount-ing bracket, then squeeze the top and bottom of the hmount-inge together until you can insert the other tang into its hole. Then plug the ribbon cable from the Engineering Panel into the con-nector on the back of the Front Panel.
Step 8: Swing the Front Panel back and to the right until it contacts the front of the case. Pull its left edge forward about an inch, until you can engage the tab on its right rear side into the slot in the right side of the case. Push the left side back until the panel is parallel to the front of the case, then secure it by tightening the retaining screw at the bottom of the panel.
Figure 2-4 Panel-mounted controller with extender board installed
Testing and
Adjusting Internal
Components
Because the internal components of a panel-mounted controller can be accessed only by disassembling it, you can test or calibrate such controllers only by using a test bench or Extender Board.
A test bench can be constructed from a spare Back Panel, which the CPU PCB, Analog PCB, and Power Supply Assemblies can be plugged into as a unit. Ideally, it should also include Engineering and Front Panel Assemblies and a ribbon cable (like that used in enclosure-mounted units) for connecting them to the CPU boards you will be testing. This approach provides full access to both the Analog PCB and the Power Supply Assemblies.
In contrast, using the Series 3 Plus Extender Board provides access only to the Analog PCB, but does allow you to work on the controller in place. Use the following procedure to install one of these boards:
Step 1: Transfer control of your process to an alternate device.
Step 2: Disconnect the power cable from the rear of the controller.
Step 3: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left.
Step 4: Remove the Engineering Panel Assembly (and attached Front Panel) by removing the four screws at its corners and pull-ing the assembly forward to disengage it from the CPU PCB.
Step 5: Remove the CPU PCB, Analog PCB, Power Supply, and Auxiliary PCB (if present) as a unit by pulling them forward and out of the case. Considerable force may be required to
disen-Caution:
Care should be taken to minimize the unavoidable risk of electric shock while testing a powered controller.Warning!
Your test bench and work area must be fully protected against the possibility of static discharge. Failure to provide adequate grounding for both your equipment and personnel can result in severe damage to the controller’s internal components.
38 Chapter 2: Installation and Maintenance
Step 6: Slide the Extender Board into the left-most set of grooves in the top and bottom of the case (you can determine the proper orientation by comparison with the CPU PCB). Press fairly hard until you feel the CPU PCB “pop” back into its Back-Panel connector.
Step 7: Reinstall the CPU PCB, Analog PCB, and Power Supply into the case as a unit, (the CPU PCB fits into the left-most grooves in the top and bottom of the case). Press hard enough to seat the CPU PCB into its connector on the front of the Extender Board.
Step 8: If desired, reinstall the Engineering Panel (and connected Front Panel) by plugging it into the front of the CPU PCB.
Step 9: Reconnect the power cable to the Back Panel of the controller.
When you are through testing or calibrating the unit, the Extender Board can be removed by simply reversing these steps.
Model
Conversion
Although any model Series 3 Plus Controller can be converted into any other, it is easiest to interconvert those with the same Compo-nent Configuration (see page 14) so you only need to replace the Front Panel and load the desired software and parameters:
Step 1: Loosen the screw at the bottom of the Front Panel, pull its left side forward about an inch, then swing it out and to the left.
Step 2: Unplug the cable connecting the Front and Engineering Panels.
Step 3: Squeeze the top and bottom of the wire hinge together until you can pull it away from the Engineering Panel.
Step 4: Reverse steps 1 to 3 to install the new panel.
New software can then be installed using the Download module of our optional Toolbox support software. If you have that program, its Configurator module is the best tool for loading the new parameters. To convert a controller into a model having a different component configuration, you might also have to add or remove the Auxiliary PCB Assembly and make sure the CPU PCB has enough control relays (turbine controllers generally require eight, while some com-pressor controllers have only five). If the controllers have different Back Panels, you might also have to change it or reuse the Case and Rear Panel from the controller you are replacing.
General
Troubleshooting
This section contains information you will need to troubleshoot general problems with the controller. Because it is not practical to fully discuss control system troubleshooting in this manual, we are including only basic information that should be helpful to a reason-ably experienced troubleshooter.
Detailed troubleshooting information concerning each type of input or output is included in the appropriate chapter. For example, Chap-ter 4 includes information on troubleshooting serial communication. In addition, each controller provides several diagnostic tests that can be performed from the Engineering Keyboard. A general discus-sion of them can be found in Chapter 3, while Appendix B describes them in detail.
If a controller malfunction is suspected, transfer control of your pro-cess to a backup device. Then try to determine whether the problem is in this controller, another controller with which it communicates, or elsewhere in your control system (for example, a failed transmitter). If the problem is in a controller, verify that it is not due to incorrect engineering parameters. If you have an up-to-date configuration worksheet, the Parameter Checksum [MODE LOCK 4] procedure provides a quick check for changed parameters.
Additional information or assistance can be obtained by contacting the Technical Service Department at Compressor Controls.
Blank Front Panel
If a controller is inadequately protected (see Surge Suppression on page 61 and Output Isolation on page 84), excessive Port 3, Port 4, or analog output voltages can cause the Front Panel to light its Fault LED and blank all other LEDs and readouts. Normal functioning can then be restored by temporarily unplugging the controller.Visible Damage
With the controller disconnected from its power supply, examine the Front and Back Panels and all interior components for physical damage, signs of overheated components, broken wires, and such. If obvious physical damage is detected, try to identify and correct any external causes before replacing the damaged assemblies — otherwise you risk damaging the replacement parts as well.Controller Faults
Every Series 3 Plus Controller has a front-panel Fault LED and one or more fault relays that indicate various internal failures (see Fault Indicators on page 105).Caution:
Always transfer your process to a backup control device before powering down or trouble-shooting a Series 3 Plus Controller. In most cases, the process signals should also be disconnected while testing the controller.