CCC Series 3 Plus Plus Hardware Reference

U

GLOBAL

SUPPLIERS

OF

TURBINE

AND

COMPRESSOR

CONTROL

SYSTEMS

A/D

RAM

PID

ID

F

UM3300/H Series 3++ Hardware Referencemanual

#

Hardware ReferenceInstallation, Maintenance and

General Operation

Publication UM3300/H (1.1.0)Product Version: #61-001

August 2007

4725 121st Street

Des Moines, Iowa 50323, U.S.A.

Phone: (515) 270-0857

Fax: (515) 270-1331

Web: www.cccglobal.com

Documentation Feedback Form

http://www.cccglobal.com


http://www.cccglobal.com/products.asp

© 1987-2007, 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 5,609,4655,622,042 5,699,267 5,743,715 5,752,3785,879,133 5,908,462 5,951,240 5,967,7426,116,258 6,217,288 6,317,655 6,332,3366,494,672 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 described products. CCC reserves the right to alter the designs or specifications of its products at any time and without notice.

For a list of certifications, see the

Agency Certifications for Series 3

++

Controllers

technical note [TN41] at the back of this manual.

For environmental and safety recommendations, see page 14

Series 3

++

Hardware Reference

3

Document ScopeThis manual provides the information you will need to physically install and maintain Series 3++ Controllers. However, it does not tell how to configure or tune them, nor how to program a host computer or DCS to utilize their Modbus communication interface (see the Series 3++ Modbus Reference manual [UM3300/M]).

Chapter 1 describes the components of and provides safety and environmen-tal recommendations for Series 3++ Controllers.

Chapter 2 describes the parameter memory and tells how to view or alter parameter values or run tests from the engineering panel.

Chapter 3 tells how to mount Series 3++ Controllers and connect their field I/O and communication cables.

Chapter 4 describes the general operation of the controller and tells how to configure the field I/O circuits.

Chapter 5 tells how to set up and operate redundant controllers.

Chapter 6 discusses controller maintenance and troubleshooting.

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++ Controller.

The following supporting documents are included at the back of this manual:

DS3300/P lists the replaceable components of the Series 3++ Controller.

DS3300/C specifies the physical and electrical characteristics of Series 3++ Compressor Controllers.

DS3300/T specifies the physical and electrical characteristics of Series 3++ Turbine Controllers.

DS3300/N describes the built-in Modbus TCP to RTU converter options.

DS3300/R describes the Series 3++ Redundant Control Selector

DS3301/V documents controller hardware revisions.

TN41 lists the agency certifications for Series 3++ Controllers.

The configuration and operation of each turbomachinery control application is described in its user manual:

UM3301 Series 3++ Antisurge Controller

UM3302 Series 3++ Performance Controller

UM3303 Series 3++ Dual-Loop A/P Controller

UM3307 Series 3++ Speed Controller

UM3308 Series 3++ Extraction Controller

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Contents

Document Conventions

August 2007 UM3300/H (1.1.0)

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 [UM3300/H (1.1.0)], while even-page footers pro-vide the publication date (August 2007).

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 procedures or steps as instructed.

Series 3

++

Hardware Reference

5

Table of ContentsDocument Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Symbols and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 1 Hardware Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Environmental and Safety Considerations . . . . . . . . . . . . . . . . . . . . . 14Components and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Analog Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Discrete Output Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . 18Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Discrete Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19High-Current Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Frequency Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Engineering Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Back Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 24Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Chapter 2 Engineering Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Support Software Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Alternate Parameter Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Data Groups and Pages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Parameter Checksum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Configuration Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Viewing and Changing Parameter Values . . . . . . . . . . . . . . . . . . . 32Key Sequence Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Key Sequence Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Enabling Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34List Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Label Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Numeric Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Parameter Memory Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Contents

Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Bad CRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Com# POF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44CS= XXXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Error! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44No Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Chapter 3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Internal Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47CPU/IO Control Relay Switches . . . . . . . . . . . . . . . . . . . . . . . . . . .48Analog Input Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Analog Output Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Auxiliary PCB Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Fault Relay Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Inductive Load Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Maximum Output Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Daughter Board Jumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Back-Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

FTA Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57FIM 24Vdc Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57FIM Discrete Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58FIM Analog Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59FIM Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61FIM Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61FOM 24Vdc Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62FOM Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62FOM Control Relay Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Serial Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Termination Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Ports 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Port 3 and 4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66RS-232 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Ethernet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

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Chapter 4 Configuration and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69CPU/IO Board Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Machine Control Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Reloading the Control Program . . . . . . . . . . . . . . . . . . . . . . . . . 71

Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Configuring Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76CPU Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Speed Board Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Speed Board Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Speed Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80MPU Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

High-Current Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Bipolar Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Output Circuit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Loopback Circuit Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Output Loopback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Engineering and Front Panel Operation. . . . . . . . . . . . . . . . . . . . . . . 89Status Screen and Menu System Buttons . . . . . . . . . . . . . . . . . . . 90User Preferences and LED Tests. . . . . . . . . . . . . . . . . . . . . . . . . . 90

Chapter 5 Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Tracking Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Analog Output Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Redundant Control Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94Fault Relay Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Tracking Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Analog Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

RCS Power Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Unswitched Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Discrete Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Analog Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Ethernet Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Chapter 6 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Monitoring Controller Health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Internal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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Contents

Field I/O Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Compressor Controller I/O Signals . . . . . . . . . . . . . . . . . . . . . .101Turbine Controller I/O Signals . . . . . . . . . . . . . . . . . . . . . . . . . .102Analog In Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Problem Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Fault LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105CPU/IO Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Speed Board Fault Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Alarm System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106External Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

General Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108Relay Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108Modbus/OPC Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110Tracking Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110Shutdown Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113Front and Test Panel Problems . . . . . . . . . . . . . . . . . . . . . . . . . . .114Communication Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115CPU/IO Board Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117Analog Input Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118Analog Output Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118Discrete Input Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119Discrete Output Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120Speed Board Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121Speed Input Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125Front Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125Programming and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .126

Appendix A Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Appendix B Controller Test Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Glossary/Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

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++

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9

List of FiguresFigure 1-1 Series 3++ Compressor and Steam Turbine Controllers . . . . . . . . . . 13Figure 1-2 Major Components of Series 3++ Controller . . . . . . . . . . . . . . . . . . . . 15Figure 1-3 Series 3++ Panel-Mounting Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 1-4 CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Figure 1-5 Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Figure 1-6 Antisurge and Performance Controller Front Panels . . . . . . . . . . . . . 21Figure 1-7 The Engineering Panel Mounts Behind the Front Panel . . . . . . . . . . 22Figure 1-8 Compressor Controller Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . 23Figure 1-9 Turbine Controller Back Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 1-10 Field Input Module (FIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Figure 1-11 Field Output Module (FOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Figure 1-12 AC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 2-1 Alternate Parameter Set Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Figure 2-2 Series 3++ Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 3-1 Mounting a Series 3++ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Figure 3-2 CPU/IO PCB Configuration Switches. . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 3-3 CPU/IO PCB Control Relay Switches . . . . . . . . . . . . . . . . . . . . . . . . 48Figure 3-4 Analog Input Resistors and Mode Switches. . . . . . . . . . . . . . . . . . . . 49Figure 3-5 Analog Output Switches and Jumpers . . . . . . . . . . . . . . . . . . . . . . . . 50Figure 3-6 Jumper Locations on the Auxiliary PCB. . . . . . . . . . . . . . . . . . . . . . . 51Figure 3-7 Back-Panel Discrete I/O Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . 53Figure 3-8 Back-Panel Discrete Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Figure 3-9 Back-Panel Control Relay Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Figure 3-10 Back-Panel Analog I/O Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Figure 3-11 Back-Panel Analog I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . 56Figure 3-12 Back-Panel Speed Input Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . 56Figure 3-13 FIM Discrete Input Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Figure 3-14 FIM Analog Input Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Figure 3-15 FIM Speed and Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Figure 3-16 FOM Analog Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Figure 3-17 FOM Control Relay Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Figure 3-18 Communication Port Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Figure 3-19 Wiring Diagrams for Ports 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Figure 3-20 Connecting to an RS-422/485 Host Port . . . . . . . . . . . . . . . . . . . . . . 66Figure 3-21 Connecting to an RS-232 Host Port. . . . . . . . . . . . . . . . . . . . . . . . . . 66Figure 3-22 Ethernet Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Figure 3-23 Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Figure 3-24 Power Cable Connector Configurations. . . . . . . . . . . . . . . . . . . . . . . 68

Figure 4-1 Position of Loader Switch on Front of CPU/IO PCB . . . . . . . . . . . . . 71Figure 4-2 Analog Input Signal Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Figure 4-3 MPU Signal Varies With Speed, Shaft Ratio, and Tooth Count. . . . . 80Figure 4-4 High-Current Output Functional Diagram. . . . . . . . . . . . . . . . . . . . . . 82Figure 4-5 Operation of Bipolar Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Figure 4-6 General Layout of Series 3++ Front Panel . . . . . . . . . . . . . . . . . . . . . 89

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Contents

Figure 5-1 Redundant Controller Data Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Figure 5-2 Typical Redundant Switching Circuitry . . . . . . . . . . . . . . . . . . . . . . . .93Figure 5-3 Typical Redundant Control Selector Connections. . . . . . . . . . . . . . . .95Figure 5-4 Connecting Current-Loop Outputs to an RCS . . . . . . . . . . . . . . . . . . .96

Figure 6-1 Controller Status Screen and Menu Buttons . . . . . . . . . . . . . . . . . . .100Figure 6-2 Front-Panel Status LEDs and Alarm Menu . . . . . . . . . . . . . . . . . . . .104

List of TablesTable 2-1 Data Groups and Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Table 4-1 Expected Output Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Table 4-2 Expected Output Readings for Common Actuators. . . . . . . . . . . . . . .84

Table 6-1 Acceptable Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Symbols and AcronymsΩ ohm (electrical resistance measurement)

% percent (parts or divisions per hundred)

# generic symbol for any number or numeric key

AC Alternating Current

AD Analog-to-Digital variable

ADC Analog-to-Digital Converter

C# Capacitor (for example, C9)

CCC Compressor Controls Corporation

CFTA Communications Field Termination Assembly

CH analog input CHannel

COND signal CONDitioning

CPC Circular Plastic Connector

CPU Central Processing Unit

CPU/IO PCB providing the main CPU and Input/Output Circuitry

CRC Cyclic Redundancy Checksum

CR Control Relay (discrete/digital output)

D or DI Discrete/Digital Input signal or circuit

DAC Digital-to-Analog Converter

DC Direct Current

DCS Distributed Control System

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DEV antisurge control DEViation

DIP Dual Inline Package

EIA Electronic Industries Alliance

EEPROM Electrically-Erasable Programmable Read-Only Memory

F# Fuse (for example, F1)

FIM Field Input Module

FOM Field Output Module

FPGA Field Programmable Gate Array

FREQ Frequency (speed) input

FTA Field Termination Assembly

G or GRD electrical ground terminal

H electrical hot terminal

HDIC High-Density Interconnect Cable

HMI Human-Machine Interface

Hz Hertz (frequency in cycles per second)

I/H Current-to-Hydraulic signal converter

I/O Input and Output (circuits or signals)

I/P Current-to-Pneumatic signal converter

IRG Instrument Reference Ground

IVP Intended Valve Position

J# Jumper (for example, J3)

JB# Jumper Block (for example, JB10)

LCD Liquid Crystal Display

LED Light Emitting Diode

LVDT Linear Variable Differential Transformer (position input)

mA milli-Ampere

MPU Magnetic PickUp

N electrical neutral terminalalso speed (Number of revolutions per minute)

NEMA National Equipment Manufacturer’s Association

NO/NC Normally-Open or Normally-Closed

OUT OUTput

PC (IBM-PC compatible) Personal Computer

PCB Printed Circuit Board

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Contents

PI Proportional-Integral control

PID Proportional-Integral-Derivative control

PLC Programmable Logic Controller

PSA Power Supply Assembly

PV Process Variable readout

R# Resistor (for example, R33)

RAM Random Access Memory

RCS Redundant Control Selector

RMA Returned Material Authorization

RTU (Modbus) Remote Terminal Unit

RVDT Rotary Variable Differential Transformer (position input)

RX serial port reception terminals (for example, RX3)

S Solenoid

SCADA Supervisory Control And Data Acquisition

SP Set Point readout

SPEC SPECial response

SV Signal Variable

TB Terminal Block

TCP Transmission Control Protocol

TTC Total Train Control®

TX serial port transmission terminals (for example, TX3)

V Voltage

Vac alternating-current Voltage

Vdc direct-current Voltage

W Watt (electrical power measurement)

Xmtr transmitter

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Chapter 1 Hardware DescriptionThis chapter describes the components of and provides safety and environmental recommendations for Series 3++ Controllers.

Figure 1-1 Series 3++ Compressor and Steam Turbine Controllers

Introduction Series 3++ Controllers are traditional, single- or dual-loop devices that are optimized and factory-programmed to regulate and protect turbocompressors and steam turbines. Each can be configured to a specific application and operated without using an engineering or operator workstation, although Modbus communication is built in and an OPC server and client software is an available option.

This manual describes the general operation of and tells how to install and maintain Series 3++ Controllers:

• For environmental and safety recommendations and descrip-tions of the controller components, read the rest of this chapter.

• If you want to know how controllers are adapted to particular applications, see Chapter 2.

• If you want to know how to mount controllers and connect their field I/O circuits, see Chapter 3.

• If you want to understand the operation of such controllers and know how to configure their field I/O features, see Chapter 4.

• If you want to know how to set up and operate controllers in redundant pairs, see Chapter 5.

• If you want to know how to maintain, troubleshoot and repair such controllers, see Chapter 6.

Fault

Alarm

DEV

SP OUT

#A

Antisurge Controller

ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO SURGERESET

MAN

∆

∇TEST ENTER

Fault

Alarm

PV

SP OUT

#A

Performance Controller

ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO MAN

∆

∇TEST ENTER

REMT LOCALSPSP

Fault

Alarm

PV

SP OUT

#A

Dual-Loop A/P Controller

ACK MENU SCROLL

ALT LIMITAS/PF

PERF A/S

∆

∇TEST ENTER

PERF A/SMANMAN

AUTO AUTOSURGERESET

Fault

Alarm

RPM

SP OUT

#A

Speed Controller

ACK MENU SCROLL

LIMIT POWERCASC

AUTO MAN

∆

∇TEST ENTER

OP SPMODEMODE

ESDRESET

Fault

Alarm

PV

SP OUT

#A

Extraction Controller

ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO MAN

∆

∇TEST ENTER

OP SPMODEMODE

ESD

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14 Chapter 1: Hardware Description

Environmentaland Safety

Considerations

Series 3++ Controllers are intended to be permanently mounted in a dry environment that minimizes static electrical discharges and conforms to the temperature and humidity restrictions stated on the Series 3++ Compressor Controllers Hardware Specifications sheet [DS3300/C] and the Series 3++ Turbine Controllers Hardware Speci-fications sheet [DS3300/T]. Conformal coating is available as an added-cost option for corrosion resistance.

Conformance with the safety requirements of various government agencies and industry groups is tabulated in the Agency Certifica-tions for Series 3++ Controllers technical note [TN41].

All wiring and maintenance must be performed by qualified person-nel in conformance with all applicable safety codes.

The ground pin of the power connector must be connected to an earth ground. However, that connector is not designed to assure its ground is the first connection made and the last broken. If that is a concern, an alternate means of disconnection should be provided.

These devices should only be configured and operated by person-nel familiar with all applicable instructions and documentation. Due to the nature of industrial processes and controllers, they can offer no protection against settings and actions that might be ineffective or even hazardous in one application but appropriate in another.

Caution:Never disassemble a controller or handle its components without protecting them from static discharge and excessive moisture. To prevent damage, all circuit boards should be stored and transported in static-resistant, water-resistant pouches.

Warning! Disconnect the power cable before disassembling the control-ler or disconnecting any internal component.

Caution: Most test and maintenance procedures should be performed only while the process is shut down or under another means of control.

Warning!Because the power connector is not designed to assure its ground is the first connection made and last broken, there is a slight risk of electric shock while connecting or disconnecting that cable to the controller.

Caution: If a controller’s Fault relay de-energizes, its final control element should be immediately transferred to an alternate control device.

Warning!Failing to comply with the installation and use instructions in this or any other Series 3 ++ Controller manual might create unforeseen safety hazards.

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Series 3++ Hardware Reference 15

Figure 1-2 Major Components of Series 3++ Controller

Components andConfigurations

All Series 3++ Controllers use a common hardware platform that consists of the following major components:

• The CPU/IO PCB Assembly provides the controller’s primary computational, serial communication, and I/O capabilities.

• 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 generates regulated 24 Vdc power for the internal and I/O circuits from either an AC or DC source.

• The Back Panel Assemblies and optional Field Termination Assemblies (FTAs) provide wiring terminals for the controller’s field I/O circuits and communication ports.

With the exception of the optional, externally-mounted FTAs, all of these components are usually housed in an extruded aluminum case for mounting in a control panel cutout (see Figure 1-3):

• The optional auxiliary PCB assembly plugs into a connector on the face of (and is bolted to) the CPU/IO PCB.

• The CPU/IO PCB plugs into a 120-pin connector along the front edge of the power supply assembly.

• The power supply assembly plugs into a 120-pin connector on the inside of the back panel.

• The engineering panel plugs into a 20-pin connector along the front edge of the CPU/IO PCB.

• The front panel plugs in and attaches to the engineering panel.

Back Panel AssemblyPower Supply Assembly

Front Panel AssemblyEngineering Panel Assembly

Assembly Auxiliary PCB Assembly (optional)CPU/IO PCB

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Figure 1-3 Series 3++ Panel-Mounting Case

All but the back panel can be replaced from the front of the case without removing it from the panel, and the entire controller can be replaced without disturbing any of its field wiring.

The back panel and internal components can also be attached to a plate that can be mounted in a control panel, while the engineering and attached front panel are mounted on the control panel door and connected to the CPU/IO PCB using a cable. Such “plate-mounted” configurations are especially useful when the back of the control panel/rack is inaccessible.

ComponentConfiguration

Series 3++ Controllers can be divided into two basic hardware con-figurations, depending on whether or not they are equipped with an auxiliary PCB assembly:

• Because that board is needed for some (but not all) turbine con-trol applications, controllers that do include it are referred to as Turbine Controllers (see the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T]).

• Because it is rarely (if ever) required for compressor control applications, controllers that do not include it are referred to as Compressor Controllers (see the Series 3++ Compressor Con-trollers Hardware Specifications sheet [DS3300/C]).

Several different Back Panel Assemblies (see page 23) are avail-able for each of these basic configurations, depending on whether the controller is equipped for AC or a DC power, and back-panel or FTA field wiring terminals.

Slide AdjusterMounting SlideCase

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Figure 1-4 CPU/IO PCB Assembly

CPU/IO PCBAssembly

The CPU/IO PCB provides the controller’s central processor, memory, serial communication, and field I/O capabilities. The major components of this assembly (see Figure 1-4) are:

• the central processing unit (CPU) with built-in discrete I/O and serial communication circuits;

• a random access memory (RAM) chip with a backup battery, real-time clock, and watchdog timer;

• two electrically-erasable programmable read-only memory chips (EEPROM) that store the control program and parameters;

• direct current 24 to 1.2, 3.3, 5.0 and ±15 Vdc power converters;

• eight electro-mechanical relays triggered by the CPU’s discrete outputs, with NO/NC configuration switches;

• two isolated analog output circuits, with switches that configure each for voltage or current-loop operation;

• eight field analog input circuits, with switches that configure each for voltage or current-loop operation;

• eight internal analog input circuits for voltage, temperature, and analog output monitoring; and

• a speaker for audible feedback.

Storing configuration parameters in EEPROMs protects them from being lost or corrupted during power failures (see page 28), while still allowing them to be easily changed from either the Engineering Panel keyboard or via Modbus communication from a computer workstation running WOIS or TrainTools field engineering programs. Similarly, storing the control program in the EEPROMs means it can also be updated from such a computer.

Engineering Panel Connector Auxiliary PCB Connector

Power Supply Connector

CPU

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Analog InputChannels

The CPU/IO board’s analog input circuits are referred to as chan-nels (CH) 1 through 8:

• Turbine controllers with terminal-block Back Panel Assemblies (see page 23) support only four of these circuits (CH1 to CH4).

• All other controller configurations support all eight.

Each of these channels can be switch-configured for either current-loop or voltage operation and internally measures its own value.

Analog Outputs Each of the CPU/IO board’s isolated analog output circuits can be switch-configured for either current-loop or voltage operation:

• For compressor controllers, the CPU/IO board’s analog outputs are referred to as OUT 1 and 2.

• For turbine controllers, output 1 is the high-current output of the Auxiliary PCB Assembly (see page 19). The CPU/IO PCB’s analog outputs are then referred to as OUT 2 and 3.

Discrete Inputs The CPU/IO board’s boolean inputs are referred to as discrete inputs (DI) 1 through 8:

• Compressor controllers have terminals for and thus support only seven of these inputs (labeled D1 through D7).

• Turbine controllers support all eight, plus one (D9) or all eight of those provided by the Auxiliary PCB Assembly (see page 19).

Discrete OutputControl Relays

The CPU/IO board’s boolean outputs are referred to as control relays (CR) 1 through 8:

• All compressor controllers have terminals for and thus support only the first five of these circuits (CR1 through CR5).

• Turbine controllers with terminal-block Back Panel Assemblies (see page 23) support seven of these circuits (CR1 through CR7), plus the auxiliary PCB’s fault relay (CR9). Those with FTAs support all output relays provided by both boards.

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. CR2 can be switch-configured to do the same.

Serial Ports The CPU/IO board’s four serial communication circuits (Ports 1 to 4) are compatible with the EIA RS-485 standard:

• Ports 1 and 2 are used for communications with Series 3++ and other CCC controllers.

• Ports 3 and 4 are used for Modbus RTU communication with host computers or control systems.

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Figure 1-5 Auxiliary PCB Assembly

Auxiliary PCBAssembly

The auxiliary PCB (speed board) provides the added computational and I/O capacity needed for speed control and valve positioning. Its major components (see Figure 1-5) 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;

• a universal asynchronous transmitter and receiver (UART) chip that provides eight additional discrete inputs;

• one electro-mechanical relay and a jumper to configure it as a normally-open or closed indicator of auxiliary PCB malfunctions;

• an analog output that can provide a bipolar current-modulated signal of up to 200 mA, and the jumpers to configure it; and

• a daughter board that provides six frequency (rotational speed) input circuit, and one LVDT and one current-loop position input.

Discrete Inputs andOutputs

The auxiliary PCB provides eight boolean input circuits (in addition to the eight provided by the CPU/IO PCB) that are referred to as dis-crete inputs 9 through 16:

• Turbine controllers with terminal-block Back Panels support only one of these inputs (labeled D9).

• Those with FTAs support all eight.

It also provides a single control relay (CR9) that signals auxiliary board faults.

CPU

CPU/IO PCB ConnectionDaughter Board

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High-Current Output The auxiliary PCB includes an analog output circuit that can provide virtually any current-modulated signal from –200 to +200 mA. Because this greatly exceeds the usual 4 to 20 mA range, this circuit is usually called the high-current output. It includes:

• a digital-to-analog converter (DAC) that generates an inter-mediate 0 to 5 Vdc signal,

• circuitry that converts that voltage into a current signal with a jumper-selectable maximum magnitude of 20, 60, or 200 mA,

• a phase inverter that can be turned on by the auxiliary PCB’s CPU when reverse current flow is needed, and

• an analog-to-digital converter (ADC) that measures the loop-back value of this signal.

• circuitry that measures the frequency of any transducer feed-back signal modulated onto this output signal.

Frequency Inputs The daughter board provides six inputs for reading the rotational speed signals from a turbine’s magnetic pickups (MPUs):

• Turbine controllers with terminal-block Back Panels support only three of these inputs (FREQ 1 to 3).

• Those with FTAs have terminals for all six.

Each such input can read the frequency signals from either active or passive magnetic pickups:

• If active pickups are used, the controller can read any speed that produces at least a 5 Hz signal. The corresponding mini-mum speed depends on the number of teeth on the exciter and shaft ratio. For example, a 60-tooth gear mounted on the main shaft would generate a 5 Hertz signal at 5 rpm.

• If passive pickups are used, the minimum detectable speed is that at which the voltage of the MPU signal meets the minimum listed on the Series 3++ Turbine Controllers Hardware Specifica-tions sheet [DS3300/T]. This can be determined from the electrical specifications for your MPUs.

Position Inputs The daughter board provides one five-wire linear variable differential transformer (LVDT) and one bipolar 20 mA analog input, either of which can be used to measure the position of a control element. They are available only through the Field Input Module, and referred to as LVDT 1 and the Auxiliary Input (see the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T]).

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Figure 1-6 Antisurge and Performance Controller Front Panels

Front PanelAssembly

The front panel assembly provides the primary operator interface for the Series 3++ Controller. It is attached to the engineering panel by a swing-out hinge and a 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:

• The upper section has a three-digit control response readout, two five-digit controlled variable and set point readouts, and three buttons that select the displayed loop.

• The middle section has a four-by-ten character LCD status screen, three buttons for its menu system, and the Fault and Alarm LEDs;

• The lower section has eight control keys and twelve LEDs, three of which are embedded in associated keys, plus a TEST key that activates front panel test features.

The keys, buttons, and Alarm, Fault, and key status LEDs are all built into the front panel overlay, which is unique to each model. That overlay also identifies the type of controller you have and labels its readouts and LEDs. Detailed information about each con-troller’s front-panel operation can be found in its operator interface data sheet [DS330#/O].

Fault

Alarm

PV

SP OUT

9.01

50.4

#A

AUTO MAN

Performance Controller

ACK MENU SCROLL

Local

Stop

Tracking

Remote

Limit

CV Open

Fallback

Alt PV

Mode RUN

9.00LIMIT 2 LIMIT 3ALT

∆

∇TEST ENTER

SPREMT

SPLOCAL

Fault

Alarm

DEV

SP OUT

RT

Stop

POC

Tracking

Limit

Balance

Fallback

.000

9.3

Mode RUNTotlB=10.3SrgCnt=001

#A


ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO MAN SURGERESET

∆

∇TEST ENTER

Control LoopReadouts

Control LEDsand Keys

Status LEDs,Screen and

and Buttons

Buttons

August 2007 UM3300/H (1.1.0)


Figure 1-7 The Engineering Panel Mounts Behind the Front Panel

EngineeringPanel Assembly

The chief feature of the engineering panel is the engineering key-board (see Figure 2-2), which can be used to:

• enter and change the configuration and tuning parameters that adapt each controller to its specific application, and

• display diagnostic information.

In Series 3++ Controllers, the engineering panel is equipped with an embedded microprocessor that controls not only its readout and keyboard, but also the front panel. Off-loading these functions from the main CPU allows the controller to run more demanding control algorithms while still providing a responsive user interface.

The engineering panel is mounted on the front of the controller, immediately behind the front panel (see Figure 1-7). It is accessed by loosening the screw at the bottom of the front panel, pulling its right side (your left) forward about an inch, and then swinging the entire assembly forward and to your left.

August 2007 UM3300/H (1.1.0)


Figure 1-8 Compressor Controller Back Panels

Back PanelAssemblies

All I/O wiring and the input power cable connect to the controller’s back panel assembly. Each controller is equipped with one of five basic versions of this panel:

• New compressor controllers use either Modbus RTU or TCP back panels, which have serial port terminal blocks or RJ-45 ethernet connectors, respectively. Series 3++ circuit boards can also be used to upgrade Series 3 Plus Controllers that use the discontinued field input / output module (FIOM) and its single FTA-connector back panel (see Figure 1-8).

• Turbine controllers use either the FTA-Connector or Terminal-Block Back Panel (see Figure 1-9):

• Those equipped with the FTA back panel connect to external Field Termination Assemblies (see page 24) via high-density interconnect cables (HDICs). Because they provide terminals for all CPU/IO and auxiliary PCB I/O circuits, they are referred to as extended I/O turbine controllers.

• Those with back-panel terminal blocks, which support fewer I/O circuits, are called standard turbine controllers.

PORT 5

+RX5TX5

21

43

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 1TX/RX RX2TX2

CR3 CR4 CR5 DISCRETE IND1 D2 D3 D4 D5

PORT 4

+ – + –RX4TX4

PORT 3

+ – + –RX3TX3

–

+OUT 2+

1 2 1 2 1 2

CH 5

35 W max

CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ –+ –+ –

USED

–

Modbus RTU

21

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

PORT 2

+ – + – + –

24VDC DISCRETE

+ – D6 D7

PORT 1TX/RX RX2TX2

PO

RT

3P

OR

T 4

35 W max

Modbus TCP

D

+ –CH 1

+ –CH 2

+ –CH 3

+ –CH 4 OUT 1

+


+OUT 2+

1 2 1 2 1 2

CH 5 CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ –+ –+ ––

G

96-264 VAC

21-32 VDC

HN

MADE IN USA

35 W max

1 4

60 63

INPUTS/

(J1)OUTPUTS

FTA-Connector

August 2007 UM3300/H (1.1.0)


Figure 1-9 Turbine Controller Back Panels

For panel-mounted controllers, the back panel is bolted to the case and the power supply plugs into it. For plate-mounted applications, the power supply is bolted to the plate and the back panel plugs into it using a right-angle connector.

In order to facilitate controller replacement, the non-FTA versions feature two-part terminal blocks, the removable halves of which can be unplugged and reconnected to a replacement controller without disturbing the field wiring.

Field TerminationAssemblies

Because there is not enough room on the back panel to provide terminals for all I/O circuits provided by the CPU/IO and auxiliary PCBs, turbine controllers are usually equipped with two external 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 specifications for these modules are provided by the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T].

21

43

DISCRETE

D

+ –

+ –

CH1

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

+ –

CH2

+ –

CH3

+ –

CH4

OUT1

+

PORT 2

+ – + – + –

24VDC DISCRETE

+ – D6 D7

PORT 1TX/RX RX2TX2


PORT 4+ – + –RX4TX4


+ –FREQ1

+

OUT2

+

1 2 1 2 1 2

OUT 3

D8 D9

+ –FREQ2 FREQ3

35 W max

CR1 CR2 CR3 CR4 CR51 2 1 21 21 21 2

Terminal-Block

G

96-264 VAC

21-32 VDC

HN

MADE IN USA

35 W max

1 4

60 63

INPUTS

1 4

60 63

(J1)

OUTPUTS(J2)

FTA-Connector

August 2007 UM3300/H (1.1.0)


Figure 1-10 Field Input Module (FIM)

Figure 1-11 Field Output Module (FOM)

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.

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.

Analog Input Fuses and Config. Blocks

24 Vdc Fusesand Config. Block

Terminals for Discrete Inputs

Terminal Block for Valve Position Inputs

Terminals for Frequency Inputs

Discrete Input Fuses andConfig. Blocks

Terminal Blocks for Analog Inputs

CPC Connector forController Data Cable

Terminal Blocks forSerial Ports 1 to 4

Terminal Block for

Terminal Block for 24 Vdc

CPC Connector forDiscrete Output Fuses and Config. Blocks

Terminal Blocks for

Controller Data Cable

Analog Outputs Discrete & Misc. Outputs

August 2007 UM3300/H (1.1.0)


Figure 1-12 AC Power Supply Assembly

Power SupplyAssembly

Each controller has either a DC or an AC power supply assembly (PSA) with dual 24 Vdc power circuits:

• the DC assembly’s soldered-on voltage regulation circuits accept a wide range of direct current inputs (nominally 24 Vdc).

• the AC assembly’s voltage conversion daughter boards accept a range of alternating current inputs (nominally 110 to 240 Vac).

The two power circuits share a single power cord and back-panel power connector:

• one provides 24 Vdc power directly to the CPU/IO PCB’s 1.2, 3.3, 5.0 and ±15 Vdc power converters, while

• the other powers the analog outputs and external transmitter power terminals.

This design prevents faulty field devices from affecting the control-ler’s internal voltages.

The AC and DC back panels connect the power supply to different pins of their power connectors (see Figure 3-24), and are clearly labeled to indicate their required supply voltages.

CP

U/IO

PC

B C

onne

ctor

Bac

k P

anel

Con

nect

or

Power Supply 1

Power Supply 2

August 2007 UM3300/H (1.1.0)



Chapter 2 Engineering ProceduresEach Series 3++ Controller is adapted to its specific application by setting the configuration and tuning parameters that govern its oper-ation. These can be viewed or changed from the engineering panel or from a computer running our Series 3 Plus Configurator program. Each controller model also offers diagnostic tests that are run from the engineering panel.

This chapter describes the parameter memory and tells how to view or alter parameter values or run tests from the engineering panel. Detailed test procedure descriptions can be found in Appendix B.

SupportSoftware

Packages

Series 3++ Controllers can be configured and updated from a PC running the Series 3 Plus Configurator program, which can read, edit, and replace a controller’s configuration parameter set and update or change its control program via either of its Modbus com-munication ports. It is included in the following software packages:

• The TrainTools Software Packages are collections of programs developed for the 32-bit Windows 2000 and XP Professional operating systems. The Platform Engineering Utilities package includes the Series 3 Plus Configurator program, which then communicates with controllers via the TrainTools Series 3 OPC Server program. The Series 3 Engineering Utilities user manual [UM5513] tells how to use it in that fashion.

• The Workstation Operator Interface Software (WOIS) is an older group of Series 4 and 3 Plus software packages developed for 16-bit Windows 95/98/ME operating systems.

Using the Configurator program to modify a controller’s parameter set or update its control program will not change the parameters that govern the communication between them. On the other hand, using it to convert one type of controller to another (see Programming and Configuration on page 126) can change the serial port settings, which could then be restored only from the engineering panel.

August 2007 UM3300/H (1.1.0)

28 Chapter 2: Engineering Procedures

Figure 2-1 Alternate Parameter Set Memory

ParameterMemory

All Series 3++ Controllers store two copies of their configuration parameter values. The long-term set is stored in an electrically eras-able programmable read only memory (EEPROM) that retains them even if the controller is powered down for years. The present set is stored in a battery-backed up random access memory (RAM) that would retain them even if the controller was powered down for a year or more.

The controller usually keeps both parameter sets identical by contin-uously comparing the values in the present set to their long-term counterparts, and correcting any that differ. Changes can be made only by disabling that mechanism:

• When making changes from a PC, the Configurator program automatically disables and re-enables that mechanism.

• When using the engineering panel, it is disabled and re-enabled by special Parameter Memory Procedures (see page 43).

Any changes, however entered, are made to both the present and long-term parameter sets.

AlternateParameter Sets

Most Series 3++ Controllers allow you to define three alternate parameter sets, which are also stored in the EEPROM. Special Parameter Memory Procedures (see page 43) are provided for defining these parameter sets, determining which one (if any) is in use, and switching to a different one.

Some controllers also allow you to select an alternate parameter set by clearing or asserting a discrete input.

Present Set

Stored In RAM Stored in EEPROM

Long-TermSet

Alternate Set 1

Alternate Set 3

Alternate Set 2

Store 1

Store 2

Store 3

Recall 1Recall 2

Recall 3

automatic

Keyboard

Download

August 2007 UM3300/H (1.1.0)


Data Groups andPages

Each controller’s parameters are divided into data groups and pages to facilitate their entry from the engineering panel. As shown in Table 2-1, each data group has an associated key and key color, and each group/page combination has a unique abbreviation (the last character of which indicates the data page). For example, the abbreviation for PID parameters on the device page is PID:D.

In all Series 3++ documents, the key sequence used to view or enter a parameter or execute a test begins with the abbreviation for its data group and page (for example, Transmitter Status Test [MODE:D ANIN –]). Procedures that are not assigned to a specific data page indicate only the data group key (for example, Reset Con-troller [MODE COMM]).

Table 2-1 Data Groups and Pages

Data Group Key Color Data Pages Abbreviation

PID Blue

AntisurgeCascadeDevice

ExtractionGas TurbinePerformance

Speed

PID:APID:CPID:DPID:EPID:GPID:PPID:S

MODE Red



Speed

MODE:AMODE:CMODE:DMODE:EMODE:GMODE:PMODE:S

CONDitioning Green



Speed

COND:ACOND:CCOND:DCOND:ECOND:GCOND:PCOND:S

SPECial RESPonse YellowAntisurge

Gas TurbineSpeed

SPEC:ASPEC:GSPEC:S

August 2007 UM3300/H (1.1.0)


ParameterChecksum

Each parameter set has an associated cyclic redundancy checksum (CRC) that is calculated by applying a standard algebraic function to all of its parameter values. Changing any parameter will produce a new checksum.

You can tell if two parameter sets are identical by comparing their checksums. Both the engineering panel and Configurator program provide easy ways to determine these checksums.

ConfigurationForms

Two forms are available for planning and recording the configuration of each controller. Configuration Worksheets [FM33##/C] group the parameters by Data Groups and Pages, while the Configuration Planners [FM33##/L] list them according to the associated feature.

If you permanently change any parameters from the engineering panel, you should record the new values and the resulting check-sum on one of these worksheets. Determining whether or not the controller’s configuration has been changed then becomes a simple matter of comparing the current checksum to that on the worksheet.

EngineeringPanel

The engineering panel not only allows you to display or change parameter values but also provides the only method of executing the process and controller test procedures described in Appendix B. It consists of three main sections:

• an eight-character alphanumeric readout across the top,

• four data group keys across the bottom,

• and sixteen data keys in the middle.

The controller beeps and displays a confirming message as each key is pressed. If you do not complete a key sequence, the control-ler will beep and clear this display after 45 seconds of keyboard inactivity. Certain Diagnostic Messages (see page 44) may also be displayed by this panel’s readout.

To expose this panel, loosen the screw at the bottom of the front panel and swing the bezel out and to the left. This allows simulta-neous access to both the operator and configuration interfaces.

Note:Parameter checksums are displayed as hexadecimal numbers (for example, F10C), in which each digit can have any one of sixteen values. Those greater than nine are represented by the letters A (10) through F (15).

August 2007 UM3300/H (1.1.0)


Figure 2-2 Series 3++ Engineering Panel

Key Descriptions The data group keys are used only to initiate a new key sequence, at which point one of them is pressed one or more times to select the desired data page and group. Pressing a data group key at any other point in a sequence causes an error that aborts the procedure.

The two gray data keys are used primarily to end key sequences:

• Pressing CLEAR either aborts a sequence without entering any changes or, when entering a numeric value, clears the digits you have entered so you can start over.

• Pressing ENTER at the end of a parameter entry sequence records the new value. Although pressing it at any other point usually causes an error, some multi-parameter sequences allow you to press ENTER to display the value of the second parame-ter without first defining a new value for the first.

The other fourteen multi-colored data keys are divided into four sec-tions. One is gray, each of the others is the same color as a data group key. The function of each such key depends on when it is pressed in a key sequence. If pressed immediately after a data group key, it has the value labeled in the matching-colored area. Otherwise, it enters the value shown in the gray area.

ENGINEERINGPANEL

PID CONDSPECRESP MODE

∞∞∞∞∞∞∞∞

LOCK6

DISPLAY

b

TEST8

OUT

SO

MORTf 3

BIAS

REV5

ALARM

K

SSTd 2

GAIN

fDr 4

βfC

G

M

fBKr 1

CONSTfA

PB –

Q

HIGH

RA9

SP

C

AN IN•

f (X)

dCOMM

0

X

A

MVAR7

LVL

RT

ENTER

fEIN

LOWTL

CLEAR

August 2007 UM3300/H (1.1.0)


For example, consider the key in the upper right hand corner:

• Pressing the blue PID key defines this as the Tf key:

• Pressing the red MODE key defines it as the MOR key:

• Pressing the green COND key defines it as the BIAS key:

• If pressed at any other point in a sequence, it is the three key:

Viewing andChanging

Parameter Values

The parameter listings in the appendix of each instruction manual include each parameter’s engineering panel key sequence and confirming display. Pressing the indicated keys will elicit the listed display, which consists of a prompt followed by the current value:

• Enabling parameters can have the value Off and one or more others such as On, High, Low, or single digits. These ranges are indicated as “OFF/ON”, “OFF/HIGH/LOW”, or “Off/#”.

• List parameters have a limited number of possible values that are generically indicated as “Value” or “Valu”.

• Numeric parameters can have any value within the listed range, the precision of which is indicated by the number of “#” symbols used to represent its digits. The position of any decimal point is fixed. The space before a negative value is replaced by a “–”. A hexadecimal ten leading digit shows as “A” (A0.0 is 100.0).

PID PID:

Tf

Tf

MODE MODE:

MOR MOR

COND COND:

BIASBIAS

COND COND:

OUTOUT

3

OT3

August 2007 UM3300/H (1.1.0)


For parameter arrays, the prompt also includes a digit correspond-ing to the element index and represented by the character “#”.

After a parameter’s current value or status has been displayed, you can terminate the procedure and clear the display by pressing the gray CLEAR key. Or, if you have entered the

Enable Reconfigura-tion

[MODE LOCK 5 1] procedural key sequence, you can enter a new value. The required procedure depends on the parameter type:

• Enabling parameters are changed by pressing the correspond-ing key (0 for Off, 1 for On, HIGH, LOW, or a digit) followed by the ENTER key. Until you do press ENTER, you can change your mind and press as many of the allowed value keys as you need.

• List parameters are changed by pressing the decimal key until the desired value is displayed and then pressing ENTER.

• Numeric parameters are changed by pressing the indicated number of numeric keys, including any leading or trailing zeroes, then ENTER. Any decimal point is placed automatically. A negative value is defined by pressing the minus (–) key before the first digit. A hexadecimal ten leading digit is defined by pressing the HIGH key (100.0 is entered as HIGH 0 0). If you make a mistake prior to pressing ENTER, you can press CLEAR to start over.

For any parameter, pressing ENTER to finalize a value change also clears the confirming display.

Note:

You may examine the value of any configuration parameter while the controller is on line without affecting the controller output or your process, and without entering the configuration password.

If you attempt to change a parameter without enabling reconfigura-tion, the No Store diagnostic message will be displayed and the new value will be discarded.

Caution: To prevent process upsets, parameters should only be changed with the controller in manual or off-line.

August 2007 UM3300/H (1.1.0)

34

Chapter 2: Engineering Procedures

Key SequenceIllustrations

Although a confirming message is displayed as each key is pressed, key sequence illustrations (such as those shown in Appendix B) usually show only the most important of these messages (to save space). For clarity’s sake, they also show only the effective value of the data keys at each point in the sequence.

Thus, the initial steps of a sequence that might require you to press the data group key more than once (for example, the Transmitter Status Test [MODE:D ANIN –]) would be shown as:

repeat until you see

In contrast, the initial steps of a sequence that is not assigned to a specific page (for example, the Signal Values Test [MODE TEST 4]) would be shown as:

Key SequenceExamples

The following examples illustrate the procedures for viewing and changing the various types of parameters. When possible, they are device page parameters that are common to most if not all models of the controller.

EnablingParameters

Most enabling parameters are assigned to the MODE data groups and simply enable or disable a controller feature. A good example is Modbus Write Inhibit, which determines whether or not Modbus hosts can change coils and holding registers (Off allows changes, On prevents them).

The listing for this parameter gives its sequence as MODE:D LOCK 2 and its display as “LOC2 OFF/ON”. Thus, pressing those keys dis-plays the current status of that option as follows:


or

MODE MODE: D

AN IN–

AN1 GOOD

MODE TEST4

Inputs

MODE MODE: D

LOCK2

LOC2 OFF

LOC2 ON

August 2007 UM3300/H (1.1.0)


You can then press CLEAR to retain that status, enter 0 to disable that feature, or enter 1 to enable it:

or

Other enabling parameters either disable the associated feature (Off) or select one of two possible modes of operation (High or Low). An example would be the Speed Controller’s

Alternate MW Input

(Off) disables the redundant MW input, High configures the control-ler to use the highest of the two inputs, Low selects the lowest).

The listing for this parameter gives its sequence as MODE:S SS 3 and its display as “SS3 OFF/HIGH/LOW”. Thus, pressing those keys displays the current status of this option as follows:


or

or

You can then press CLEAR to leave it unchanged, or enter HIGH, LOW, or 0 to select the desired new configuration:

or

or

0

LOC2 OFF

1

LOC2 ON

ENTER

MODE MODE: S

SS3

SS3 HIGH

SS3 LOW

SS3 OFF

HIGH

SS3 HIGH

LOW

SS3 LOW

0

SS3 OFF

ENTER

August 2007 UM3300/H (1.1.0)

36


A few enabling parameters allow you to select from options that are intuitively numeric by pressing the corresponding decimal key. They usually either disable a feature or select the companion controller or analog input from which a given signal is to be obtained. An exam-ple is the Performance Controller’s Mass Flow Input, which selects the input for its mass flow rate calculation (Off disables that calcula-tion, any digit from 1 to 8 configures it to use that analog input).

The listing for this parameter gives its sequence as MODE:D fD 1 and its display as “fD1 OFF/#”. Thus, pressing those keys displays the current status of this option as follows:


or

You can then press CLEAR to leave this feature unchanged, enter 0 to disable it, or enter the desired input number:

or

where the digit key used to enter the new value is represented as #.

Parameters that define the decimal point positions for front panel display variables are a variant of this type of parameter. An example is the Measured Variable Decimal parameter arrays, of which each element defines the position of the decimal point in the correspond-ing measured variable display (Off means no decimal).

The listings for these parameters gives their sequence as COND:D DISPLAY 0 # • and their display as “0#. 4321 (selected digit is replaced by •)”. Thus, pressing those keys displays the current deci-mal position (in this example, it follows the second digit):


where the fourth key you press is the digit corresponding to the ana-log input, as is the number (#) in the resulting display.

MODE MODE: D

fD1

fD1 OFF

fD1 #

0

fD1 OFF

#

fD1 #

ENTER

COND COND: D

DISPLAY

0 # •

0#. 43.1

August 2007 UM3300/H (1.1.0)


You can then press CLEAR to leave that variable’s decimal position unchanged, or change it by pressing the numeric key (0 to 4) corre-sponding to the desired decimal position:

or

or

or

or

You can continue pressing numeric keys in any order until the desired decimal point position is displayed. Finally, press CLEAR to exit the procedure without changing the parameter, or press ENTER to accept the displayed position:

List Parameters Like enabling parameters, list parameters are usually assigned to the MODE data groups and also have a limited number of values. However, few if any of those values intuitively correspond to data keys, so they are selected by repeatedly pressing the decimal (•) key until the desired value is displayed. A universal example is the

Port 2 Baud Rate

, which defines the data transmission rate for serial Port 2 (2400, 4800, or 9600 bits per second, which appear to be numeric values but are in fact selected from a list).

The listing for this parameter gives its sequence as MODE:D COMM 2 and its display as “PT2 Valu”. Thus, pressing those keys displays the current value (2400 baud in this example):


0

0#. 4321

1

0#. 432.

2

0#. 43.1

3

0#. 4.21

4

0#. .321

ENTER

MODE MODE: D

COMM2

PT2 2400

August 2007 UM3300/H (1.1.0)

38


You can then press CLEAR to leave this baud rate unchanged, or press the decimal key (•) until the desired new rate is displayed and then press ENTER:

Some list parameters have both a sign (+ or –) and a list value. An example is the Relay Assigned Function parameter array, each element of which sets the conditions under which the corresponding discrete output is triggered (if the assigned function is positive, the relay will be energized when the associated condition exists; if the value is negative, the relay will de-energize).

The listing for these parameters gives their sequence as MODE:D RA # and their display as “RA#±Valu (press HIGH or LOW to select sign, then press • to select function)”. Thus, pressing those keys dis-plays the current value as follows:


where the third key you press is the digit corresponding to the dis-crete output number, as is the digit (RA#) in the resulting display.

To change the normally energized/de-energized circuit configura-tion, press HIGH or LOW:

or

Pressing the decimal key will advance the display to the next avail-able function (BBBB):

•

PT2 4800

•

PT2 9600

•

PT2 2400

ENTER

MODE MODE: D

RA#

RA#±AAAA

HIGH

RA#+AAAA

LOW

RA#-AAAA

•

RA#±BBBB

August 2007 UM3300/H (1.1.0)


You can press any of these keys as many times as necessary to dis-play the desired configuration.

Pressing ENTER accepts the displayed relay configuration:

Label Parameters Label parameters are entered as a series of characters individually selected from a list. An example are the Measured Variable Name and Units parameters, each of which defines the name displayed above and units displayed after a measured variable’s value when it is viewed via the status screen’s Analog In menu.

The listing for these parameters gives their sequence as COND:D DISPLAY 0 # – and their display as “AAAAAAAA then EU:AAAAA”, followed by the instruction “selected symbol (A) flashes, press • to select, then ENTER for each”. Thus, pressing those keys displays the current value as follows:


where the fourth key you press is the digit corresponding to the variable’s analog input and the first character (shown in blue above) would be flashing.

You can then press CLEAR to leave the name and units unchanged, or change the flashing character by pressing the decimal (•) key to advance it to the next possible symbol or the minus (–) key to back up to the previous possible symbol:

You can also hold either key down to scroll rapidly through the available symbols. When the desired symbol appears (P in this example), press ENTER to accept it and edit the next:

ENTER

COND COND: D

DISPLAY

0 # –

AAAAAAAA

AAAAAAAA•

BAAAAAAA

–

AAAAAAAA

•

PAAAAAAA

ENTER PAAAAAAA

August 2007 UM3300/H (1.1.0)


Repeat this procedure to edit each succeeding character. Once you have accepted a character, you cannot return to it without entering the rest of the label and starting over. For this parameter, entering the eighth character accepts the name and displays the units:

Press clear to leave the engineering units unchanged, or edit each displayed symbol as described above. Entering the fifth character accepts the new units:

Numeric Parameters Because numeric parameters have virtually continuous ranges, their desired values must be defined by pressing the corresponding digit keys. A good example is the Dual-Loop Controller’s Transmitter Failure Limit, which defines the minimum valid value (00.0 to 99.9 percent) for any offset zero inputs.

The listing for this parameter gives its sequence as MODE:D ANIN LOW and its display as “ANL ##.#”. Thus, pressing those keys dis-plays the current value as follows:


You can then press CLEAR to leave that value unchanged, or enter the desired new value:

Psuction

ENTER EU:AAAAA

•

EU: psig

ENTER

MODE MODE: D

AN INLOW

ANL ##.#

#

ANL # .

#

ANL ##.

#

ANL ##.#

ENTER

August 2007 UM3300/H (1.1.0)


where each key used to define the new value is represented as # and the decimal point is placed automatically.

The precision of such a parameter is indicated by the number of “#” symbols in its listed display. When changing its value, you must press that many digit keys, even if they correspond to leading or trailing zeroes. A hexadecimal ten leading digit is entered by press-ing the HIGH key and is displayed as “A” (100.0 is entered as HIGH 0 0 and displays as “A0.0”). A negative value is defined by pressing the minus (–) key before the first digit key. If you make a mistake prior to pressing ENTER, you can press CLEAR to start over.

Characterizing functions are arrays that define the values of one variable that correspond to ten specific values of another:

• For some functions, the independent variable (X) values are predefined in even steps from zero to one, ten, or one hundred (for example, 00.0, 11.1, 22.2, ..., 88.8, 100.0).

• For others, only the first and last X values are fixed (0 and 1.000, 10.00, or 100.0). The eight intermediate steps (which must have increasing values) are defined by an array entered using a COND X # # key sequence (the first digit is the function number, the second is the element index).

In either case, however, the values of the dependent variable (Y) are defined by the corresponding elements of an array entered using a MODE f(X) # # sequence.

An example is the Antisurge Controller’s Reported Flow Character-izer, which defines how it calculates the flow rate it reports to its companion controllers from the flow rate used in its own proximity-to-surge calculation.

The listing for this parameter gives its sequences as COND:A f(X) 2 # and X 2 # and its displays as “X2# #.##” and “Y2# #.##”. Thus, you must define both arrays for this particular characterizer.

Note:

Most numeric parameters can range from zero to some power of ten. When the routines for entering them from the keyboard do not permit you to enter a hexadecimal leading ten by pressing HIGH, the parameter listing will show the maximum value as .999, 9.99, or 99.9. However, such parameters can be given a maximum value of one, ten, or one hundred (1.000, 10.00, or 100.0) from a computer workstation and the engineering panel will consequently display them as such (.A00, A.00, or A0.0).

August 2007 UM3300/H (1.1.0)

42


Press these keys to view point N’s argument (X2,N = #.##):


where the fourth key you press is the digit corresponding to the characterizer point, as is the first digit (X2#) in the resulting display.

Press CLEAR to leave it unchanged, or enter the desired new value:

where each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically.

Press these keys to view point N’s result (Y2,N = #.##):


where the fourth key you press is the digit corresponding to the characterizer point, as is the first digit (Y2#) in the resulting display.

Press CLEAR to leave it unchanged, or enter the desired new value:

again, each numeric key used to enter the new value is represented as # and the decimal point is positioned automatically.

COND COND: A

X

2 #

X2# #.##

# # #

X2# #.##

ENTER

COND COND: A

f(X)

2 #

Y2# #.##

# # #

Y2# #.##

ENTER

August 2007 UM3300/H (1.1.0)


ParameterMemory

Procedures

Because the present parameter values stored in the controller’s working memory (RAM) are subject to random (albeit extremely rare) changes, the controller continuously compares them to their long-term counterparts and corrects any errors. Before you can change any parameters from the engineering panel, this feature must be disabled by entering the

Enable Reconfiguration

[MODE LOCK 5 1] key sequence. Otherwise, any attempt to enter a new parameter value will only elicit a

No Store

message on the panel’s alphanumeric readout.

While reconfiguration is enabled, the controller will not automatically correct any errors that might develop in its present parameter set. To restore this protection, you should enter the

Disable Reconfigu-ration

[MODE LOCK 5 0] sequence when you finish configuring the controller. If you do not, the controller will automatically disable reconfiguration after 30 minutes of keyboard inactivity.

The

Parameter Checksum

[MODE LOCK 4] procedure displays the checksum values of the controller’s various parameter sets. You can also determine which of these parameter sets (if any) agree with those recorded on your configuration forms by comparing these checksums to those recorded on those worksheets.

For controllers with Alternate Parameter Sets (see page 28), the fol-lowing procedures can be used to define these parameter sets, determine which one (if any) is in use, or switch to a different one:

• Each alternate set is defined by assigning the desired values to the present and long-term parameters and using the

Store Alter-nate Parameters

[MODE LOCK 3 •] procedure to copy them to an Alternate Set.

• You can switch to one of the alternate sets by using the

Recall Alternate Parameters

[MODE LOCK 3 • •] procedure to copy it

back to the present and long-term sets.

• You can determine which (if any) of the alternate sets is in use by using the

Parameter Checksum

[MODE LOCK 4] procedure to compare their Parameter Checksums with that for the present and long-term sets. You can also determine if any of these sets agree with those recorded on your configuration forms by com-paring these checksums to those on those worksheets.

August 2007 UM3300/H (1.1.0)

44


DiagnosticMessages

The following paragraphs explain the various messages that can appear on the engineering panel’s eight-character display.

Bad CRC This message indicates the controller has found and corrected a difference between the present and long-term Parameter Memory.

Com# POF This message indicates a low-level serial communication error (see Communication Problems on page 115).

CS= XXXX This message indicates an unreasonable parameter setting was detected and changed during a CPU Reset (see page 77), which in turn changed the parameter checksum to the indicated new value (XXXX). It usually appears only after installing a new EEPROM, downloading a new control program, or using the Configurator pro-gram to change parameter values. If the controller repetitively beeps and flashes this message, the parameter memory is probably dam-aged (see CPU/IO Board Problems on page 117).

Error! This message indicates you have entered an unrecognized key sequence. This is typically caused by:

• pressing a parameter (multi-colored) key without first pressing the correct data group (solid-colored) key,

• failing to press the data group key enough times to access the correct data page,

• pressing the wrong number of data keys,

• pressing the decimal key in sequences that automatically place the decimal point, or

• entering an out-of-range value for a numeric parameter.

If the controller repetitively beeps and flashes this message, one of the engineering panel keys is probably stuck down (see Front and Test Panel Problems on page 114).

No Store This message indicates you tried to change a parameter without first entering the Enable Reconfiguration [MODE LOCK 5 1] sequence.

Reset This message indicates a CPU Reset (see page 77), which can be manually triggered by changing critical parameters, recalling an alternate parameter set, or invoking the Reset Controller [MODE COMM] procedure. Repetitive beeping and flashing of this message indicates the control program is restarting but failing to reset the watchdog timer (see CPU/IO Board Problems on page 117).

Note: If a communication error occurs while you are entering parameter values, the controller will only beep.

August 2007 UM3300/H (1.1.0)



Chapter 3 InstallationThis chapter tells how to mount Series 3++ Controllers and connect their field I/O and communication cables.

Overview The installation of a panel-mounted Series 3++ Controller entails the following general procedures:

Step 1: Mount the controller in a properly-sized panel cutout (see Mounting on page 46).

Step 2: Remove the internal PCBs, set their switches and jumpers, then reinstall them (see Internal Settings on page 47).

Step 3: Connect your field elements to the appropriate back-panel terminals (see Back-Panel Connections on page 53), or

Mount the field termination assemblies (FTAs), connect them to the controller back panel, and connect your field wiring to the appropriate terminals (see FTA Connections on page 57).

Step 4: Connect your communication cables to the back-panel or field output module (see Communication Ports on page 64).

Step 5: Configure and connect the power cable to the controller and an appropriate power supply (see page 68). Refer to page 110 if the controller starts beeping repeatedly.

Additional considerations apply when installing Redundant Control-lers (see Chapter 5).

Refer to Chapter 2 and Appendix B for more information on the remaining steps:

Step 6: Use the Program Version [MODE TEST 2] procedure to identify the installed control program. If needed, use the Series 3 Plus Configurator to load the correct one (see page 71).

Step 7: If the controller was not preconfigured, use the Configurator utility or engineering panel to enter appropriate values for all configuration and tuning parameters, which are described in its user manual. Be sure to keep a record of these values and the resulting parameter checksum.

If your controller was preconfigured, use the Configurator utility or Parameter Checksum [MODE LOCK 4] procedure to verify that the current and recorded parameter checksums match. If not, reload the supplied parameter set or identify and correct any changed parameters using either the Configurator program or the engineering panel.

Step 8: Use the Set Clock [MODE TEST 9] key sequence to set the internal date and time (Speed Controllers only).

August 2007 UM3300/H (1.1.0)

46 Chapter 3: Installation

Figure 3-1 Mounting a Series 3++ Controller

Mounting Refer to Figure 3-1 for an illustration of the slide clamps (located on the top and bottom of the case) and to the Series 3++ Compressor Controllers Hardware Specifications sheet [DS3300/C] or the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T] for panel cutout dimensions. DS3300/T also discusses the dimen-sions and mounting options for turbine controller FTAs.

Use the following procedure to mount a Series 3++ Controller in a properly-sized panel cutout:

Step 1: Loosen the slide clamp pressure screws, then remove the clamps from the case.

Step 2: Remove the mounting slides from the case by sliding them off 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.

12 3

Mounting Slide

PressureSlide ClampScrew

Note: Panel cutouts must have specified dimensions after painting.

August 2007 UM3300/H (1.1.0)


Figure 3-2 CPU/IO PCB Configuration Switches

InternalSettings

The CPU/IO PCB, auxiliary PCB, and some back panel assemblies have configuration switches and/or jumpers whose settings might need to be changed for a specified application. To do so, you must remove the internal components from the controller case, verify or change the appropriate settings, and reassemble the controller.

Disassembly Use the following procedure to access the internal components of a newly-mounted Series 3++ Controller:

Step 1: Make sure the power cable is not connected to the rear of the controller.

Step 2: 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 3: Remove the engineering panel assembly from the case by removing the four screws at its corners and pulling the entire assembly forward to disengage it from the CPU/IO PCB.

Step 4: Pull the internal components from the case (considerable force may be required).

Step 5: Separate the auxiliary PCB (if present) by removing the four screws that attach it to the CPU/IO PCB, then disengage the pins on its rear side from their CPU/IO PCB connector.

CPU

Control Relays

Analog Inputs

AnalogOutputs

Warning! Disconnect the power cable before disassembling the control-ler or disconnecting any internal component.

Caution: Never disassemble a controller or handle its components without taking steps to prevent static discharge.

August 2007 UM3300/H (1.1.0)


Figure 3-3 CPU/IO PCB Control Relay Switches

CPU/IO ControlRelay Switches

CR1 is normally-energized for use as a fault relay, while CR3 to CR8 must be energized by the control program (see Discrete I/O on page 74). The operation of CR2 is set by its mode switch, which is located to the left of CR6 on the CPU/IO PCB:

• If it is set to its upper NORM position, CR2 will be a normally de-energized relay that is programmatically or parametrically set to indicate some process or internal condition.

• If it is set to its lower FAULT position, CR2 will be a second fault relay that only de-energizes when CR1 does.

In addition, each relay must be configured for normally-open (NO) or normally-closed (NC) operation by setting the normal position switch (DO#) located to its right:

• Setting that switch to the lower NC position connects that relay’s field terminals to its normally-closed contacts.

• Setting that switch to the upper NO position connects them to the normally-open contacts.

CR6

CR7

CR8

CR1

CR2

CR3

CR4

CR5

Normal Position Switches

DO2 Mode Switch

NORM

FAULT

NO

NC

NO

NC

NO

NC

DO2

DO2

DO1

DO3

NO

NC

NO

NC

NO

NC

DO7

DO6

DO8

NO

NC

NO

NC

DO4

DO5

Note:A relay’s NO contacts are open and its NC contacts are closed when it is de-energized. The NO contacts of normally-energized fault relay are usually selected, so the external circuit will be complete when no fault exists.

August 2007 UM3300/H (1.1.0)


Figure 3-4 Analog Input Resistors and Mode Switches

Analog InputSwitches

The eight analog inputs are individually configured to accept either current-loop (20 mA) or voltage (5 Vdc) signals by setting switches SW11/AIN1 through SW18/AIN8, which are mounted halfway up on the right side of the CPU/IO PCB (see Figure 3-4):

• Setting a switch to the upper (1/V) position configures its circuit as a voltage input.

• Setting a switch to the lower (2/I) position configures its circuit as a current-loop input.

The appropriate settings for FTA-equipped turbine controllers are discussed on page 59.

The scaling and testing of these inputs is discussed on page 75.

1

2

V

I

AIN1

2

AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 AIN7 AIN8

SW11 SW12 SW13 SW14 SW15 SW16 SW17 SW18

1

2

1

2

1

2

1

2

1

2

1

2

Note:Unlike Series 3 Plus Controllers, which had to be equipped with all 5 Vdc or all 20 mA analog inputs, Series 3++ Controllers can be set up for any desired combination of voltage and current-loop inputs. It is also not necessary to install resistors across unused voltage inputs.

August 2007 UM3300/H (1.1.0)


Figure 3-5 Analog Output Switches and Jumpers

Analog OutputSwitches

The CPU/IO PCB analog outputs are individually configured to pro-vide either current-loop (20 mA) or voltage (5 Vdc) signals by setting switches SW21/AO1 and SW22/A02, which are mounted near the top of the auxiliary PCB connector on the upper-right side of the CPU/IO PCB (see Figure 3-5):

• Setting a switch to the lower (1/I) position configures its circuit as a current-loop output.

• Setting a switch to the upper (2/V) position configures its circuit as a voltage output.

Terminal-block back panel assemblies have jumpers on the inner side of their circuit boards that can be set to either an I (current loop) or V (voltage) position. For Series 3++ Controllers, either position connects the back-panel terminals to the switch-selected signal, so you never need to change them when installing Series 3++ boards into a case that formerly housed a Series 3 Plus Controller (but the jumper positions would indicate how the switches should be set).

The turbine controller FOM provides two sets of terminals for each of these outputs. Because these are connected in parallel to the switch-selected signal, both can be used only if voltage operation is selected (although the second set of terminals could be connected to a high-impedance voltmeter even if the circuit was configured for current-loop operation.

1

2

1

2

V

I

AO2

SW22

SW21

V

I

AO1V2 I2 V1 I1

V2 I2 V1 I1

Inside Back PanelOn CPU/IO PCB

August 2007 UM3300/H (1.1.0)


Figure 3-6 Jumper Locations on the Auxiliary PCB

Auxiliary PCBJumper Settings

When installing a turbine controller or replacing its auxiliary PCB, you must verify the correct setting of several jumpers on that board. (jumper JP6 is not used).

Fault Relay Jumper Jumper JP1 configures the auxiliary PCB fault relay (CR9). Connect the center and right pins for normally-open (NO) operation, or short the center and left pins for normally-closed (NC) operation.

Inductive LoadJumper

The auxiliary PCB includes special circuitry to deal with inductive loads on the high-current output. If that output is connected to an electronic I/P transducer, you might need to bypass this circuitry by removing jumper JP3.

Maximum OutputJumpers

The high-current output’s maximum current is set to any of three val-ues by setting jumpers JP4 and JP5:

• to select a 200 mA maximum output, short the two top pins of both jumpers (labeled 200 mA),

• to select a 60 mA maximum output, short the two center pins of both jumpers (labeled 60 mA), or

• to select a 20 mA maximum output, short the two bottom pins of both jumpers (labeled 20 mA).

The selected range can be further restricted by setting the high-cur-rent output and loopback calibration parameters (see page 82).

Daughter BoardJumper

In order to use the LVDT position input, you must connect the center and left pins of jumper JP1 on the auxiliary PCB daughter board.

JP4JP5 JP1JP3

Daughter Card JP1JP6

August 2007 UM3300/H (1.1.0)


Reassembly To reassemble a Series 3++ Controller, you basically reverse the Disassembly procedure:

Step 1: To reinstall the auxiliary PCB, align the pins on its rear side with the corresponding connectors on the CPU/IO PCB, then press them together. Reinstall the four machine screws that attach the auxiliary PCB to the CPU/IO board.

Step 2: Slide the resulting assembly into the case as a unit. The CPU/IO PCB and PSA fit into the left-most set of grooves in the top and bottom of the case. Press fairly hard until you feel the PSA “pop” back into its connector on the front of the back panel.

Step 3: Align the tabs on the sides of the engineering panel’s mount-ing 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 (thus engaging it into the connector on the front edge of the CPU/IO PCB). Secure this assembly by rein-stalling the four screws at its corners.

Step 4: Swing the front panel back and to the right until it contacts the front of the case. Pull its left edge forward about an inch, until you can engage the tab on its right rear side into the slot in the right side of the case. Push the left side back until the panel is parallel to the front of the case, then secure it by tightening the retaining screw at the bottom of the panel.

Step 5: Reconnect the power cable and FTA data cables or back-panel terminal strips.

August 2007 UM3300/H (1.1.0)


Figure 3-7 Back-Panel Discrete I/O Terminals

Back-PanelConnections

This section tells how to connect field devices to a controller’s back-panel field input and output terminals.

Discrete I/O Every Series 3++ Controller’s CPU/IO PCB provides eight discrete inputs and eight control relays.

• Compressor controllers provide back-panel terminals for seven of those inputs (D1 through D7) and five relays (CR1 to CR5).

• Turbine controllers without FTAs provide terminals for all eight of those inputs (D1 to D8) and seven relays (CR1 to CR7), as well as the fault relay (CR9) and one discrete input (D9) from the auxiliary PCB.

The locations of those terminals are shown in Figure 3-7.

All discrete inputs are optically isolated from the connected signals and share a common return terminal labeled by a D in a triangle.

The discrete outputs are dry contacts that are galvanically isolated from all other controller circuits. The controller’s 24 Vdc transmitter power output could be included in their external circuitry but usually does not provide enough power for all of them.

1 2 1 21 21 21 2

DISCRETE

D6 D7

D8 D9

D

CR6 CR7 CR9 DISCRETE IND1 D2 D3 D4 D51 2 1 2 1 2

CR1 CR2 CR3 CR4 CR5

D6 D7

CR1 CR21 2 1 2

D

CR3 CR4 CR5 DISCRETE IND1 D2 D3 D4 D51 2 1 2 1 2

Turbine ControllersCompressor Controllers

DISCRETE

August 2007 UM3300/H (1.1.0)


Figure 3-8 Back-Panel Discrete Input Wiring

Figure 3-8 shows how to connect the discrete inputs to external devices:

• The left panel shows how to include external power sources.

• The right panel shows how to incorporate the controller’s 24 Vdc transmitter power output.

Figure 3-9 Back-Panel Control Relay Wiring

Figure 3-9 shows how to connect field devices to a controller’s dry-contact, non-directional, back-panel control relay terminals.

Externally Powered Internally Powered

+ – D6 D7

D

24VDC DISCRETE

DISCRETE IND1 D2 D3 D4 D5 30 Vdc

(max.)

+ – D6 D7

D

24VDC DISCRETE

DISCRETE IND1 D2 D3 D4 D5

CR3 CR4 CR51 2 1 2 1 2

CR1 CR21 2 1 2

30 Vdc, Load1.0 A. max.

Caution: The controller’s transmitter power output does not have sufficient capacity to drive the control relay circuits.

August 2007 UM3300/H (1.1.0)


Figure 3-10 Back-Panel Analog I/O Terminals

Analog I/O Every Series 3++ Controller’s CPU/IO PCB provides eight analog inputs and two analog outputs:

• Compressor controllers have terminals for both of these outputs (OUT1 and OUT2) and all of these inputs (CH1 to CH8).

• Turbine controllers without FTAs have terminals for both of these outputs (OUT2 and OUT3) but only four of these inputs (CH1 to CH4). OUT1 is provided by the auxiliary PCB.

The terminals for these circuits (see Figure 3-10) are usually con-nected to an intermediate terminal block, with the cable shields tied to an earth ground at that point.

Back-panel current-loop outputs are connected in series with their control elements (and any other load) as if they were batteries, as shown for OUT1 in the left panel of Figure 3-11. Thus, the positive (+) output terminal should be connected to the positive terminal of the first load. The negative terminal of the first should be connected to the positive of the second, and so on. The negative terminal of the last load should be connected to the negative (–) output terminal.

Voltage outputs are wired in parallel with all connected devices, as shown on the right side of Figure 3-11.

Current-loop inputs are wired in series with all connected devices, as shown for CH1 in the left panel of Figure 3-11.

Voltage inputs are wired in parallel with all connected devices, as shown in the right panel of Figure 3-11.

1+

CH 5– + – + – + –

+ –CH 1

+ –CH 2

+ –CH 3

+ –CH 4 OUT 1

+

24VDC+ –

+OUT 2+

CH 6 CH 7 CH 8

+ –

CH

+ –

CH

+ –

CH

+ –

CH

+

24VDC+ –

OUT

+21 2 3 4

OUT3


OUT

August 2007 UM3300/H (1.1.0)


Figure 3-11 Back-Panel Analog I/O Connections

Speed Inputs Turbine controllers without FTAs provide terminals for three of the auxiliary PCB’s speed inputs (FREQ1 through FREQ3), located to the left of the power connector at the bottom of the back panel.

These terminals (see Figure 3-12) should be connected to MPUs using twisted-pair cables whose shields are tied to an earth ground. By convention, the black lead of each magnetic pickup (MPU) is connected to the positive terminal and its white lead is connected to the negative terminal. However, the inputs are non-polar and will function correctly even if you do not follow this convention.

Figure 3-12 Back-Panel Speed Input Terminals

OUT 1 + + –

CH 1

FT

+ –CH 1

24VDC+ –

FYG FT+5

Current Loops Voltage Circuits

OUT 1 +

FY

Note: Twisted-pair cables are recommended for speed input signals.

+ –

TB6

+ –FREQ1

+ –FREQ2 FREQ3

August 2007 UM3300/H (1.1.0)


FTAConnections

In order to use all of the input and output circuits provided by the CPU/IO and auxiliary PCB assemblies, a turbine controller must be equipped with the optional field input and output modules (FIM and FOM), which are collectively called field termination assemblies (FTAs). Specifications and terminal lists for those modules can be found in the back of the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T].

Snap each FTA onto a DIN mounting rail and connect it to the con-troller back panel using a high-density interconnect cable (HDIC):

• Connect the field input module to the back-panel J1 connector and the field output module to the J2 connector.

• If the FTAs are located in the same cabinet as the controller, ground both of each HDIC’s shield pigtails.

Otherwise, 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.

FIM 24Vdc Bus The FIM includes a 24 Vdc bus that can be used to power discrete and analog input circuits. It can be configured to draw that power from either the controller’s transmitter power supply or any source connected to terminals 1 and 2. Although this choice could be made by selectively installing diodes and jumpers in the 24 Vdc jumper block, it is simpler to install the diodes and jumpers for both sources and either leave terminals 1 and 2 disconnected or remove the fuse for the internal power circuit:

Warning! Independently grounding both ends of a long HDIC can create a hazardous ground loop.

E

F

G

H

A

B

C

D

24 VDC(to I/O circuits)

(in controller)

1.0Amp

1 2

A C E G

B D F H

E

F

G

H

A

B

C

D


(in controller)

1.0Amp

1 2

August 2007 UM3300/H (1.1.0)


Figure 3-13 FIM Discrete Input Features

FIM DiscreteInput Circuits

Each of the FIM’s discrete input circuits has a jumper block that can configure it to draw power from the FIM 24Vdc Bus:

• To configure one of these circuits to use the onboard 24 Vdc, install jumpers between pins A and D, B and E, and C and F, and install a dry contact device across the field terminals:

• If a circuit is externally powered, configure it to bypass the onboard bus by installing jumpers between pins A and E and pins B and F (note that this reverses the polarity of the terminals from that listed by DS3300/T):

Discrete Input Fuses and Configuration Blocks

DI2/DI4

DI5/DI7

DI6/DI8

DI9/DI11

DI10/DI12

DI13/DI15

DI14/DI16

DI7 to DI13 DI14 to DI16 DI1 to DI6

DI1/DI3

14 16 1.0

Am

p

1.0

Am

p

D E F

A B CDA

B

C F

E

24 Vdc

DI

50 mA

D E F

A B CDA

B

C F

E

24 Vdc

DI

50 mA

August 2007 UM3300/H (1.1.0)


Figure 3-14 FIM Analog Input Features

FIM Analog InputCircuits

Each of the FIM’s analog inputs has an jumper block and five wiring terminals (B, C, D, H, and S). Terminals B, C, D, and H are directly connected to the corresponding pins of the configuration block, the S (shield) terminal is connected to the FIM’s earth ground. The CPU/IO PCB is switch configured (see page 49) to read the voltage drop across or current flowing between terminals C and D.

The simplest application is to connect a 5 Vdc transmitter to the C and D terminals (62 and 63, for example) and set the CPU/IO PCB switch for 5 Vdc operation:

When a 4-to-20 mA transmitter is used in a simplex application, the preferred configuration is to connect it to the C and D terminals and set the CPU/IO PCB switch for 20 mA operation (this uses the CPU/IO PCB’s precision dropping resistor):

Fuses and Configuration Blocks

Analog Inputs 4, 5, and 6

Analog Inputs 1, 2, and 3

Analog Inputs 7 and 8

AI-1 AI-7AI-5

AI-4

AI-3

AI-2 AI-6 AI-8

F

B

A E

CH

G

H

D

C

Shield

+

–

50 mA

24 V

dc

A C E G

B D F H

62

61

64

63

65

Xmtr

F

B

A E

CH

G

H

D

C

Shield

Xmtr+–50 mA

24 V

dc

A C E G

B D F H+–

67

66

69

68

70

August 2007 UM3300/H (1.1.0)


Alternately, a 250 ohm dropping resistor can be installed between the C and D terminals and the CPU/IO PCB switch can be set for 5 Vdc operation (however, this would provide less-precise, uncali-brated measurements unless a precision potentiometer was installed and precisely adjusted):

To use the FIM 24Vdc Bus to power a 4-to-20 mA transmitter, jumper pin A to B and G to F, then connect the transmitter across the B and C terminals:

To include a DCS current-loop input in a 4-to-20 mA circuit, jumper pin G to H and connect the DCS input across the D and H terminals:

F

B

A E

CH

G

H

D

C

Shield

Xmtr+–50 mA

24 V

dc

A C E G

B D F H+–

67

66

69

68

70

F

B

A E

CH

G

H

D

C

Shield

50 mA

24 V

dc

A C E G

B D F H

+

Xmtr–

82

81

84

83

85

DCS

+

F

B

A E

CH

G

H

D

C

Shield

50 mA

24 V

dc

A C E G

B D F H

+

Xmtr–

–

82

81

84

83

85

August 2007 UM3300/H (1.1.0)


Figure 3-15 FIM Speed and Position Inputs

FIM Speed Inputs Turbine controllers with FTAs provide terminals for all six of the auxiliary PCB’s speed inputs (frequency inputs 1 through 6). with the exception of the negative terminal for the rarely used sixth MPU, all of them are located on the FIM.

By convention, the black lead of each magnetic pickup (MPU) is connected to the input’s positive terminal and its white lead is con-nected to the negative terminal. However, the inputs are non-polar and will function correctly even if you do not follow this convention.

These terminals (see Figure 3-12) should be connected to MPUs using twisted-pair cables. to prevent ground loops, connect the cable shield to the FIM shield terminal and leave it ungrounded at the pickup end.

The speed input circuits are capacitively isolated from the MPUs within the controller.

FIM PositionInputs

The FIM also provides terminals for the auxiliary PCB’s LVDT and analog position inputs:

• LVDT leads have five-conductors that should be connected to the corresponding FIM terminals — two for the excitation coil (51 & 52), two for the return coil (53 & 55), plus a common (74). Connect the shield to any convenient shield terminal and make sure the left and center pins of the Daughter Board Jumper (see page 51) are connected.

• If your controller uses the bipolar 20 mA position input, connect it to the auxiliary input terminals (71, 72) and any convenient shield terminal.

MPU 4, 5, 6+

LVDT1

MPU 1 to 3

Auxiliary Input

Note: Twisted-pair cables are recommended for speed input signals.

August 2007 UM3300/H (1.1.0)


Figure 3-16 FOM Analog Output Terminals

FOM 24Vdc Bus If any relay circuits are configured to use the onboard power bus, a 24 Vdc source must be connected to terminals 29 and 30:

FOM AnalogOutputs

Current-loop OUT1, which is configured as described on page 51, should be connected in series with all loads. Its positive terminal should be connected to the positive terminal of its first load. If there is more than one load, the negative terminal of the first should be connected to the positive of the second, and so on. The negative output terminal should be connected to the negative terminal of the last (or only) load.

OUT2 and 3, which can be independently set for either current-loop or voltage operation (see page 50), have two sets of terminals each:

• If 20 mAdc operation is selected, connect all loads in series to one set of terminals. The second set should be connected (if at all) only to a high-impedance voltmeter.

• If 5 Vdc operation is selected, connect all loads in parallel using either or both sets of terminals.

OUT: 2 3 1 2 3

26 27 28 29 30

24 VDC(from controller)


Caution:The controller’s transmitter power output does not have sufficient capacity to drive the control relay circuits and thus should not be connected to FOM terminals 29 and 30.

August 2007 UM3300/H (1.1.0)


Figure 3-17 FOM Control Relay Features

FOM ControlRelay Circuits

Each of the FOM’s control relay circuits has a jumper block that can configure it to draw power from the FOM 24Vdc Bus (which draws power from terminals 29 and 30) and include the provided fuse:

• To configure a relay circuit to use the FTA’s onboard 24 Vdc, install jumpers between pins C and D and pins G and H:

• For circuits using external 24 Vdc power sources, bypass the onboard source by installing a jumper between pins C and H:

• Each circuit includes an onboard fuse that can be bypassed by installing a jumper between pins A and B of the jumper block:

CR8 and CR9

Fuses and Configuration Blocks

CR1 to CR7

CR1 CR2

CR3

CR4

CR5

CR6

CR7

CR8

CR9

24 Vdc In

Field

24 Vdc

AB

C

D G

HCR

–

1.0 A

B D F H

A C E G

Element

24 Vdc

AB

C

D G

HCR

1.0 A

B D F H

A C E G

Field Element

–

24 Vdc

AB

C

D G

HCR

1.0 A

B D F H

A C E G

Field Element

August 2007 UM3300/H (1.1.0)


Figure 3-18 Communication Port Terminals

CommunicationPorts

The CPU chip provides four EIA RS-485 serial ports (Ports 1 to 4). The controller back panel or field output module (FOM) provides compression terminals for all of them (see Figure 3-18), which in either case are galvanically isolated from the instrument ground, each other, and all other I/O circuits. The connection of those ports to other controllers or computers is discussed below.

For compressor controllers, the back-panel terminals for Ports 3 and 4 can be replaced by built-in Modbus RTU-to-TCP converters (see page 23). The connection of those ethernet ports to other controllers or computers is discussed on page 67.

In either case, Ports 2, 3 and 4 must be configured as discussed under Serial Communication on page 72.

SerialConnections

Because each serial port supports communication among several devices connected to a single cable, certain RS-485 networking considerations apply.

Cable Length Unless RS-485 repeaters are installed, the total length of the cables in each network can be no more than 4000 feet (1200 meters).

Surge Suppression All Series 3++ I/O circuits, including the serial ports, are designed to withstand electrical surges of 4000 volts or more, so external surge suppression devices are usually not needed.

TerminationResistors

The serial port transceivers used in Series 3++ Controllers do not require termination resistors at any of the available baud rates.

21

43

TB6

PORT 2

+ – + – + –

PORT 1TX/RX RX2TX2



Port 4

Port 1 Port 3Port 2

Note: Always use shielded, twisted-pair serial communication cables.

August 2007 UM3300/H (1.1.0)


Figure 3-19 Wiring Diagrams for Ports 1 and 2

Ports 1 and 2 Ports 1 and 2 are used to communicate with other Series 3++ Con-trollers using proprietary protocols. Figure 3-19 shows how to wire such networks, whose ground terminals should be interconnected using the cable shields and collectively grounded through a single small resistor (100 ohms generally works well). They should not be grounded at any other point.

Port 1 Serial Port 1 communication is used to coordinate the actions of Series 3++ Controllers regulating a single turbomachinery train. In installations where several trains are operated in parallel, there will usually be a separate Port 1 network for each train.

Under the Port 1 protocol, each device transmits in turn to all of the others. Thus, these ports are connected in parallel by a single pair of wires (all positive terminals together in one group, and all nega-tive terminals in a second).

Port 2 Port 2 is used primarily for load-sharing and performance override control. The protocol it uses designates a single primary controller (the master) that can either broadcast to the other controllers on the network or query a single secondary controller for specific informa-tion. The secondary controllers transmit only in response to such queries. Only one secondary controller can transmit at any given time, and then only to the master.

Port 2 networks are installed as shown in the right panel of Figure 3-19. The secondary controllers’ receivers are wired in parallel with the master’s transmitter and the secondary controllers’ transmitters are similarly wired in parallel to the master’s receiver.

Tx/Rx+

Tx/Rx–

Ground

Tx/Rx+

Tx/Rx–

Ground

Tx/Rx+

Tx/Rx–

Ground

Port 2Master Slaves

100 Ω

Rx –

Rx +

Gnd

Tx –

Tx +

Tx +

Tx –

Gnd

Rx +

Rx –

Tx +

Tx –

Gnd

Rx +

Rx –

100 Ω

Port 1

August 2007 UM3300/H (1.1.0)


Figure 3-20 Connecting to an RS-422/485 Host Port

Ports 3 and 4 Ports 3 and 4 are used to communicate with external devices using the Modbus RTU protocol, such as a DCS or a PC running one of our Support Software Packages (see page 27). That protocol allows a single master device and multiple slaves to be connected to each network (Series 3++ Controllers are always slaves).

These ports can be directly connected to a host’s RS-422 or RS-485 serial port using either a two-wire or four-wire connection (as shown in Figure 3-20). You should use Belden 8723 twisted-pair cable (or its equivalent), and ground the shield at one end only.

Port 3 and 4Grounding

The ground pins of interconnected Modbus serial ports must not be connected and grounded unless none of them are grounded at any other point. Although Ports 3 and 4 are isolated from all grounds, we generally advise against grounding their networks (as indicated by the lack of ground pin connections in Figure 3-20).

Figure 3-21 Connecting to an RS-232 Host Port

Tx/Rx +

Tx/Rx –

Ground

Tx +

Tx –

Gnd

Rx +

Rx –

Tx +

Tx –

Gnd

Rx +

Rx –

Rx +

Rx –

Ground

Tx +

Tx –

Gnd

Rx +

Rx –

Tx +

Tx –

Gnd

Rx +

Rx –

Tx +

Tx –

ControllersHost ControllersHost

Note:Using a two-wire connection will increase the communication load on each controller, as it would then “hear” the responses of its peers to requests the master directs to them.

Rx +Rx –Tx +Tx –Gnd

2345678

20

+–+–G

TxDRxDRTSCTSDSRGNDDCDDTR

32786514

9 25

2345678

20

pinpin

Rx +Rx –Tx +Tx –Gnd

ConverterHost ControllerController

TxDRxDRTSCTSDSRGNDDCDDTR

32786514

9 25

2345678

20

pinpin Host

August 2007 UM3300/H (1.1.0)


RS-232 Converter If your host is equipped with serial ports conforming to the more common RS-232C standard, you should connect them to the con-trollers using an RS-485/232 converter with isolated grounds (for example, the AEG OIC-422).

Because Series 3++ Controllers do not support handshaking signals (such as request-to-send/clear-to-send), you might need to cross-connect those of the host. A typical wiring diagram for this applica-tion is shown in the left panel of Figure 3-21.

In an emergency (say your converter fails and you can not wait for a replacement), you can directly connect a controller’s RS-485 port to a computer’s RS-232 port as shown in the right panel of Figure 3-21. However, you can not connect very many controllers at a time, nor use very long cables.

Figure 3-22 Ethernet Communication Ports

EthernetConnections

Compressor controllers can be equipped with Modbus TCP back panel assemblies that feature built-in Modbus RTU/TCP converters for serial Ports 3 and 4 (see Figure 3-22). Their RJ-45 jacks can be connected to the same or separate ethernet switches or hubs using standard category 5 patch cables. One or more Modbus TCP clients can then communicate with each of those ports via the associated TCP/IP networks. Alternately, a single client can be connected to each jack using an ethernet cross-over cable.

When a converter port is connected using the appropriate cable, its lower, yellow LED will light. Its upper, green LED will flash when it is sending or receiving ethernet packets

Although the converters are built into the back panel, the controller can communicate with them only as a Modbus slave that cannot send configuration instructions. So, they must be configured from a PC connected to their ethernet jacks, as described in Chapter 4 of the Series 3++ Modbus Reference manual [UM3300/M] or Appendix B of the Series 3 OPC Server user manual [UM5503].

21

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

PORT 2

+ – + – + –

24VDC DISCRETE

+ – D6 D7

PORT 1TX/RX RX2TX2

PO

RT

3P

OR

T 4

35 W max

August 2007 UM3300/H (1.1.0)


Figure 3-23 Power Cable

Power Cable As shown in Figure 3-23, each pair of panel-mounted controllers is supplied with a 14-foot (4.3 meter) power cable, both ends of which have connectors that plug into the back-panel power receptacle. This cable can be cut at any point to provide maximum flexibility in choosing the length of the two resulting cables.

The configuration of the power cable connectors depends on which power supply (AC or DC) is installed, as shown in Figure 3-24.

Figure 3-24 Power Cable Connector Configurations

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 transient voltages and high-frequency components of the analog input signals.

M630

Warning!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 dis-connecting the cable to the controller.

Line (Black)

Neutral (White)

Ground (Green)

Cable Controller

AC Cable

+ (Red)

– (Black)

Ground (White)

DC Cable

Cable Controller

August 2007 UM3300/H (1.1.0)



Chapter 4 Configuration and OperationThis chapter describes the general operation of the controller and tells how to configure the field I/O circuits. Chapter 6 describes the general operation and maintenance uses of the front panel.

Overview The operation of a compressor controller is orchestrated by two microprocessors (one each on the CPU/IO and engineering panel PCBs), which communicate via an internal parallel port. Turbine controllers have a third microprocessor (on the auxiliary PCB, which communicates with the CPU via another parallel link.

External I/O and serial communication signals pass between the back panel and CPU/IO PCB via the power supply PCB, where they are either read/written or connected to the appropriate auxiliary PCB circuits (which are read and set by its CPU).

When the controller is first powered up, each processor loads its own firmware, initializes its associated components, then initiates normal operation and communication with the others.

Each controller can be operated from any combination of:

• its front panel readouts, LEDs, buttons, and keys;

• readouts, potentiometers, indicators, and switches connected to its analog and discrete I/O channels; and/or

• operator workstations connected to its Modbus serial ports, either directly or via a Series 3 OPC server.

August 2007 UM3300/H (1.1.0)

70 Chapter 4: Configuration and Operation

CPU/IO BoardOperation

The microprocessor on the CPU/IO PCB is a field programmable gate array (FPGA) that has been programmed to duplicate the com-putational, I/O logic, and serial communication features of the Series 3 Plus Controller’s CPU and analog PCB assemblies. Thus, the only changes required to run the field-proven Series 3 Plus control pro-grams on these controllers were adaptations to the new internal PCB and front panel features.

When the FPGA powers up, it loads the stored programming and interconnections for its internal logic units from an associated flash memory chip. This has two implications:

• powering down and restarting a controller can potentially correct some CPU malfunctions, and

• the operation of the FPGA can potentially be improved by down-loading a new program to the flash memory chip.

The FPGA program configures some of its circuits to emulate:

• a microprocessor that runs the machine control program stored in the EEPROM chips;

• the parallel ports used to communicate with the front panel and optional auxiliary PCB assembly;

• the analog and discrete I/O interface; and

• the four serial communication ports.

To identify the installed FPGA firmware, enter the Program Version [MODE TEST 2] engineering keyboard sequence and then press the decimal key until the FPGA display appears.

Machine ControlProgram

The actions of the main CPU (within the FPGA) are specified by a machine control program stored in the EEPROM chips, which can be updated by the Configurator program via serial Port 4 (see page 71). Each such program (for example, version 761-001 of the anti-surge control program) defines:

• a startup sequence (see page 77);

• a main loop that runs repeatedly (subject to various interrupts), which primarily handles communication tasks and checks for differences between the present and long-term parameter sets (see page 28);

• an input/output scan (see page 75) triggered by a clocked five millisecond interrupt; and

• a process control scan initiated by every eighth I/O scan (in other words, every 40 milliseconds).

To identify the installed control program, enter the Program Version [MODE TEST 2] engineering keyboard sequence.

August 2007 UM3300/H (1.1.0)


Figure 4-1 Position of Loader Switch on Front of CPU/IO PCB

Reloading theControl Program

The machine control program can be updated via serial Port 4 from a PC running the Series 3 Plus Configurator program (see Chapter 2 of the Series 3 Engineering Utilities user manual [UM5513]).

A controller is usually prepared for that process simply by initiating manual operation, as discussed in the user manual for its currently-loaded control program. However, a Series 3++ Controller can be forced into its program loader mode using the following procedure:

Step 1: Power down the controller.


Step 3: Remove the engineering panel assembly from the case by removing the four screws at its corners and pulling the entire assembly forward to disengage it from the CPU/IO PCB.

Step 4: Move the loader switch at the front of the CPU/IO PCB (see Figure 4-1) to its FORCE (down) position.

Step 5: Align the tabs on the sides of the engineering panel’s mount-ing 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 (thus engaging it into the connector on the front edge of the CPU/IO PCB). Temporarily reinstall one of the four screws that normally secure that assembly.

Step 6: Power up the controller. The SP readout will indicate “Addr.” and the OUT readout will display the controller’s computer ID.

Step 7: Connect the controller to a PC running the Series 3 Plus Configurator program.

Loader Switch

FO

RC

EN

OR

M

Note: Port 4 must be set for 19,200 baud and odd parity in order to replace the machine control program.

August 2007 UM3300/H (1.1.0)


Step 8: Start that program and invoke its Download command.

Step 9: Click the Load BHF File button and select the desired con-trol program (.bhf) file from the resulting dialog.

Step 10: Click the Select From Port and Controller Number option, then select the PC port the controller is connected to from the Port Number menu and the computer ID displayed in the OUT readout from the Controller Number menu.

Step 11: Click the Start button to download the new program. The thirteen progress bars along the left side of the dialog will indi-cate the progress of the program download.

Step 12: When the download is finished, power down the controller, remove the engineering panel, move the loader switch back to the NORM (up) position, and replace the engineering panel.

Step 13: Reconnect the power cable, then use the Program Version [MODE TEST 2] engineering keyboard procedure to verify that the controller is now running the desired control program.

Step 14: Secure the engineering panel by reinstalling the four screws at its corners, then close and secure the front panel.

This procedure is normally used only after a failed or interrupted program download has left a controller otherwise inoperable. If that happened with a Series 3 Plus Controller, controller operation could be restored only by installing pre-programmed EEPROM chips.

SerialCommunication

The FPGA provides four EIA RS-485 serial ports:

• Ports 1 and 2 are used for communications with Series 3++ and other CCC Controllers.

• Ports 3 and 4 are used for Modbus RTU communication with host computers or control systems, using two-byte registers with a configurable significant range (as discussed in the Series 3++ Modbus Reference manual [UM3300/M]).

All four are protected against transients by the power supply PCB, and optically-isolated (from the instrument ground and each other) by the CPU/IO PCB. There are no internal termination resistors, which are not usually needed at the supported baud rates.

The occurrence of low-level (parity, framing, and overrun) errors is indicated by beeping and displaying a “Com# POF” message on the Engineering Panel (see page 110). Unless frequent or continuous, such errors are not generally serious.

If a controller is not receiving expected Port 1 or 2 transmissions, however, it will light the Alarm LED. The problematic port can then be identified by displaying the status screen alarms menu. The cor-responding Modbus bit and possibly a control relay will also be set.

August 2007 UM3300/H (1.1.0)


ConfiguringCommunications

In order for two devices to successfully communicate, both must be set up to send and receive information at the same speed and in the same basic format (for example, number of bits per character):

• There are no parameters for Port 1, which operates at 38.4k baud with even parity, 1 start, 8 data, and 2 stop bits.

• The Port 2 Baud Rate [MODE:D COMM 2] can be 2400, 4800, or 9600. It is normally set to 9600. If you wish to mix Series 3 and Series 3++ Controllers, however, you must set the Port 2 baud rate to the 2400 bps rate used by the older controllers. This port also uses even parity, 1 start, 8 data, and 2 stop bits.

• The Port 3 Baud Rate [MODE:D COMM 3] can be 4800, 9600, 19.2k, or 38.4k baud, while the Port 3 Parity can be odd, even, or none. The same options are available for the Port 4 Baud Rate [MODE:D COMM 4] and the Port 4 Parity. Both of these ports use one start bit, eight data bits, and one stop bit.

The key sequences that set these ports’ baud rates and parities also allow you to select the Port 3 Scaling and Port 4 Scaling. Each of those parameters specifies the Modbus register value that port would report for most real variables when they equal their normal maximum values (generally 100 percent):

• The 4000 setting reports 100% as 0x0FA0.

• The 4095 setting reports 100% as 0x0FFF.

• The 64k setting reports 100% as 0xFA00.

In addition, multidropped ports require a unique identifying number for each controller. The Port 1 protocol uses the Controller ID Num-ber [MODE:D COMM 0], while the Port 2 protocol and Modbus use the Computer ID Number [MODE:D COMM 0 •].

When a Modbus RTU-to-TCP converter is connected (internally or externally) to Port 3 or 4, that port must be configured to use the same baud rate and parity as the converter’s serial port. By default, the built-in converters available for compressor controllers are set for 19.2 kbaud and odd parity.

Finally, a controller can be configured to prevent Modbus hosts from setting coil and holding register values by setting the Modbus Write Inhibit [MODE:D LOCK 2] parameter to On.

Note:

The Enable Reconfiguration [MODE LOCK 5 1] key sequence must be entered before changing settings from the engineering panel.

To alter a controller’s operation from a PC workstation, you must clear the Modbus Write Inhibit [MODE:D LOCK 2] parameter. How-ever, its control program can be updated when that parameter is set.

August 2007 UM3300/H (1.1.0)


Discrete I/O The D1 through D8 input signals are routed directly to the FPGA and read by each process control scan:

• Compressor control programs associate each of those signals with a predefined controller feature.

• For turbine control programs, those associations are set by the Discrete Input Assigned Function [COND:D IN ##] parameters.

Conversely, each scan sets or clears the FPGA’s discrete outputs to indicate whether or not the conditions assigned by the correspond-ing Relay Assigned Function [MODE:D RA #] parameters exist. Those signals are routed to a clocked-latching chip, whose outputs in turn energize or de-energize the coils of the corresponding control relays (thus, those outputs will freeze rather than clear if the CPU faults or restarts):

• CR3 through CR8 energize and de-energize as their assigned functions set and clear the corresponding discrete outputs.

• CR1 is a normally-energized fault relay (see Fault Indicators on page 104).

• CR2 can be switch-configured (see page 48) to be energized by its own assigned function or to de-energize when CR1 does (in which case it should usually be assigned the same function as CR1 so its state indicators will echo those for CR1).

Compressor controllers have back-panel terminals only for CR1 through CR5. Turbine controllers have terminals for all eight, and provide another fault relay and eight more discrete inputs that are connected to the auxiliary PCB.

The monitored discrete input and intended discrete output states can be displayed by the front-panel status screen.

August 2007 UM3300/H (1.1.0)


Figure 4-2 Analog Input Signal Processing

Analog Inputs The CPU/IO PCB provides eight analog field input circuits (CH1 to CH8), whose signals are protected against transients by the power supply PCB, and filtered and isolated (from the instrument ground and each other) by the CPU/IO PCB.

The Analog Input Switches (see page 49) route each such signal to a multiplexed 14-bit analog-to-digital converter (ADC) either:

• directly (if it is connected to voltage transmitter), or

• via a precision dropping resistor (if it is connected to a current-loop transmitter).

In either case, there is no need and no provision for calibrating any such circuit, either before shipment or in the field.

Each five millisecond input scan retrieves the digital values of these signals, then triggers a logic circuit that sequences the reading of new values for the next I/O scan. Each process control scan then:

• averages the last eight values of each signal;

• compares the result to the 21.0 mA smart-transmitter fail level specified by the Namur NE 43 recommendation and a config-urable testing range set by that input’s Analog Input Low Alarm Limit [MODE:D ANIN # LOW] and Analog Input High Alarm Limit [MODE:D ANIN # HIGH] or the Dual-Loop A/P Controller’s com-mon Transmitter Failure Limit [MODE:D ANIN LOW];

AN IN ON(e.g., 4 to 20 mA)

AN IN OFF(e.g., 0 to 10 V)

SamplingHardware

CH (V)

SV = AD

AD (%)

SV (%)

Failed if: < AN IN LOW or > AN IN HIGH

MODE TEST 4

SV = 1.25 • (AD - 20%)

SamplingHardware

CH (mA)

AD (%)Failed if: < AN IN LOW or > AN IN HIGH

MODE TEST 4

MV = Min +(Span · SV)

MV

SV (%)

MV

MV = Min +(Span · SV)

August 2007 UM3300/H (1.1.0)


• calculates its signal variable value by scaling it to between 00.0 and 100.0 percent of the span selected by that input’s Offset Zero Input [MODE:D ANIN #] parameter; and

• calculates its measured variable engineering units value by lin-early scaling that signal variable within the range defined by its Measured Variable Maximum [COND:D DISPLAY 0 # HIGH], Measured Variable Minimum [COND:D DISPLAY 0 # LOW], Measured Variable Decimal [COND:D DISPLAY 0 # •], and Measured Variable Name and Units [COND:D DISPLAY 0 # –].

If its Measured Variable Display [COND:D DISPLAY 0 #] is enabled, an input’s measured variable value and alarm limits status can be displayed by the front panel status screen. The Transmitter Status Test [MODE:D ANIN –] and the Signal Values Test [MODE TEST 4] can be used to view any input’s alarm limits status and signal vari-able value from the engineering panel.

The 16-channel ADC also reads eight internal analog inputs, which are used to monitor the analog output signals, the five component-power voltages, and the internal temperature. The front panel status screen can also display all of these variables (see Monitoring Con-troller Health on page 100).

Analog Outputs The CPU/IO PCB provides two analog outputs that are powered by the isolated 24 Vdc field power circuit and internally protected against electrostatic discharge and other voltage transients.

Compressor controllers label these circuits OUT1 and OUT2, while turbine controllers label them OUT2 and OUT3 (OUT1 is the speed board’s High-Current Analog Output).

Each process control scan specifies a new normalized value for each of these outputs, which usually can be clamped and/or non-linearly scaled as appropriate for the connected field device. It then triggers a logic circuit that sequences the conversion of those values to voltage signals by the 16-bit digital-to-analog converter (DAC). The intended values are latched, so the generated voltages freeze if the CPU faults or restarts.

These output circuits are calibrated prior to shipment and cannot be adjusted in the field. The generated voltages are monitored by inter-nal analog inputs, and the intended and measured value of each can be displayed by the front-panel status screen.

Because PID control algorithms automatically adjust to inaccurately calibrated output circuits, any discrepancy between the actual and intended values is not considered a fault. However, an output failure alarm would be indicated and any output failure relays would be set.

August 2007 UM3300/H (1.1.0)


CPU Reset When a controller is first powered up, the FPGA loads the stored programming and interconnections for its internal logic units.

It then resets the emulated CPU, which:

1. Initializes the I/O circuitry and serial ports.

2. Sends a restart instruction to the engineering panel.

3. Resets its serial ports and analog input circuitry.

4. Writes the “Reset” message to the engineering panel readout.

5. Assigns default values to any configuration parameters that have unreasonable values, and instructs the engineering panel to display the resulting parameter checksum (“CS=####”).

6. Initiates a new scan of the machine control program.

A CPU reset is also initiated when the watchdog timer triggers the CPU/IO Fault Relay (see page 105), critical parameters are changed or an alternate parameter set is recalled, the controller is reconfigured from a workstation, or the Reset Controller [MODE COMM] key sequence is entered from the engineering panel.

Note that the battery-backed RAM, which stores the most recent values of all control program internal variables, is not initialized. Thus, those programs can and generally do resume control of the process from its last known state.

Most controllers always execute a soft reset, which does not change the operating state or analog output. However, the Speed Controller will execute a hard reset (which initiates an emergency shutdown) when it is powered up or detects a fault.

August 2007 UM3300/H (1.1.0)


Speed BoardOperation

The Auxiliary PCB and its daughter board provide:

• eight additional discrete input circuits and its own fault relay (see below),

• linear variable displacement transformer (LVDT) and bipolar 20 mA current-loop valve Position Inputs (see page 79),

• six Speed Inputs (see page 79) for magnetic pickup frequency signals, and

• a configurably bipolar High-Current Analog Output (see page 82) that includes loopback circuitry for measuring its own value.

It also provides a high-speed valve positioning loop that varies the high-current output in response to deviations of the LVDT input from an intended position received from the main CPU. However, that loop is supported only by the speed controller and is used primarily for upgraded Series 3 Plus systems that implemented it prior to the development of our external Digital Positioning Module (see the Valve Positioning section in Chapter 3 of UM3307).

To identify the installed auxiliary PCB firmware, enter the Program Version [MODE TEST 2] engineering keyboard sequence and then press the decimal key until the SPBD display appears. In addition, the Auxiliary PCB Error Count [MODE TEST HIGH] key sequence will dynamically display the number of times this board’s CPU has failed to respond to the main CPU since this count was last zeroed.

An Extraction Controller that does not use any of its speed board’s I/O signals can be configured to ignore or operate without it by enabling the Auxiliary PCB Lockout [MODE:E LOCK 6] parameter.

Speed BoardDiscrete I/O

The auxiliary PCB provides discrete inputs D9 through D16. All of them are supported by controllers equipped with FTAs, while those with terminal-block back panels can use only D9:

• Their states are read by the speed board microprocessor and then communicated to the main CPU.

• The associated controller features are set by the corresponding Discrete Input Assigned Function [COND:D IN ##] parameters.

The speed board provides no additional discrete outputs other than its normally-energized fault relay (CR9), which is controlled by that board’s watchdog timer (see Speed Board Fault Relay on page 105 and cannot be assigned any additional function.

August 2007 UM3300/H (1.1.0)


Position Inputs This assembly provides two inputs for valve position measurements. LVDT1 is for linear variable differential transformer measurements, while the Auxiliary Input supports bipolar 20 mA position signals.

None of the standard control programs supports the Auxiliary input, and only the Speed Controller supports LVDT1. To use it, the Daughter Board Jumper (see page 51) must configure it for an LVDT rather than a transducer feedback signal.

Speed Inputs Three of the six auxiliary PCB speed inputs are supported by the Series 3++ Speed Controller, none of the other control programs support any. They can read the frequency signals from either active or passive magnetic pickups:

• If active pickups are used, the controller can read any speed that produces at least a 5 Hz signal. The corresponding mini-mum speed depends on the number of teeth on the exciter and shaft ratio. For example, a 60-tooth gear mounted on the main shaft would generate a 5 Hertz signal at 5 rpm.

• If passive pickups are used, the minimum detectable speed is that at which the voltage of the MPU signal meets the minimum listed on the Series 3++ Turbine Controllers Hardware Specifica-tions sheet [DS3300/T]. This can be determined from the electrical specifications for your MPUs.

In addition to physically connecting them to the MPUs, these inputs must also be enabled (see below) and configured to compensate for both the number of teeth on the MPU gear and its shaft ratio (see Speed Scaling on page 80).

You enable the speed input for each installed MPU by setting its selection parameter to On:

MPU 1: Speed Input 1 [MODE:S ANIN 1]



If more than one MPU is enabled, the controller uses the following rules to decide which one to use as the speed control variable:

• If there are three good input signals, the median speed is selected.

• If there are two good input signals, the higher of those two speeds is selected.

• If there is only one good input signal, that speed is selected.

• If all MPUs fail, an emergency shutdown (ESD) is initiated.

August 2007 UM3300/H (1.1.0)


Figure 4-3 MPU Signal Varies With Speed, Shaft Ratio, and Tooth Count

Speed Scaling As shown in Figure 4-3, each MPU is positioned near a balanced gear on the turbine’s main or auxiliary shaft, and transmits a pulse to the controller each time a gear tooth rotates past.

The frequency of the MPU signals depends not only on the speed of the turbine, but also on the number of teeth on the speed gear and the ratio of the auxiliary and turbine shaft speeds. Thus, the follow-ing function is used to calculate the turbine speed from the number of pulses received during each scan:

where

C = scan rate (scans per minute)

N = rotational speed (in rpm)

P = pulse count (pulses/scan)

Rs = Shaft Speed Ratio [MODE:S ANIN 6]

T = Gear Tooth Count [MODE:S ANIN 5]

Set the Gear Tooth Count equal to the number of teeth on the speed measuring gear and the Shaft Speed Ratio equal to the number of turbine revolutions required to rotate that gear once. For example, AN IN 6 should be 1.000 if the gear is on the turbine’s main shaft. If it’s on an auxiliary shaft that turns half as fast as the turbine, AN IN 6 should be 2.000.

Auxiliary Shaft

SpeedGear

MagneticPickup

TurbineShaft

N C P Rs⋅ ⋅( ) T⁄=

Note:

If at all possible, the speed gear should be mounted on the turbine’s main shaft.

It is important to properly match the pickups to the design of the gear that excites them. Otherwise, high-speed operation may not allow enough time for their signals to decay between the passage of adjacent teeth. If a sufficiently high speed was then reached, the measured speed would suddenly fall to zero and the controller would shut down the turbine!

August 2007 UM3300/H (1.1.0)


MPU Tests Two factors affect the minimum speed that can be read by the con-troller’s frequency / magnetic pickup (MPU) inputs:

• An MPU signal frequency below 5 Hertz can not be read. The corresponding minimum speed depends on the gear tooth count and shaft ratio. For example, a 60-tooth gear mounted on the main shaft would generate a 5 Hertz signal at 5 rpm.

• An MPU signal voltage below the minimum required by the speed inputs can not be read. This is normally an issue only for passive pickups (for which the voltage is a rising function of the speed). If active (constant voltage) pickups are used, the con-troller can measure any speed above that corresponding to a 5 Hertz signal. This can be determined by comparing the electrical specifications of your MPUs to those listed on the Series 3++ Turbine Controllers Hardware Specifications sheet [DS3300/T].

MPU failures are determined by comparing the speed from each input to the Control Threshold [COND:S ALARM 1]. An input fails this test if it is below that level.

If all three speed inputs are enabled, the highest and/or lowest will also be considered to have failed if it has differed from the median speed by more than a user-defined tolerance for at least eight con-secutive scan cycles:

where

Median = median of the speeds calculated from the three inputs

Tol = MPU Tolerance [MODE:S ANIN 4]

A failure of either type generates an “MPU# Fail” alarm. If all of the enabled speed inputs fail, the turbine is shut down.

For example, assume all three inputs are enabled and the tolerance is 91 rpm. If MPU 1 indicates 3600 rpm, MPU 2 indicates 3650 rpm, and MPU 3 indicates 3700 rpm, the acceptable speed range is 3650 ± 91 (3559 to 3741) rpm. Because all three signals are in this range, all three are judged to be valid. However, if the MPU 3 signal was greater than 3741 rpm, an “MPU3 Fail” alarm would be indicated.

Note: The Control Threshold is stored as a percentage of and thus must be set after the Maximum Control Speed [COND:S DISPLAY HIGH].

Median Tol– N Median Tol+< <

August 2007 UM3300/H (1.1.0)


Figure 4-4 High-Current Output Functional Diagram

High-CurrentAnalog Output

For turbine controllers, OUT1 is provided by an auxiliary PCB circuit that can generate almost any current-loop signal from –200 to +200 mA. Because this greatly exceeds the usual 4 to 20 mA range, this circuit is usually called the high-current output. It includes:

• a digital-to-analog converter (DAC) that generates an inter-mediate 0 to 5 Vdc signal,

• circuitry that converts that voltage into a current signal with a jumper-selectable maximum magnitude of 20, 60, or 200 mA,

• a phase inverter that can be turned on by the auxiliary PCB’s CPU when reverse current flow is needed, and

• an analog-to-digital converter (ADC) that measures the loop-back value of this signal.

As shown in Figure 4-4, the high-current output signal and its loop-back measurement are calibrated by setting their scaling gains and biases, which can also restrict this signal to a portion of the range selected by the Maximum Output Jumpers (see page 51):

• The output signal’s range is specified by setting its calibration gain and bias (see Output Circuit Calibration on page 85).

• The loopback measurement is scaled to match by setting its gain and bias (see Loopback Circuit Calibration on page 87).

However, those procedures are not meant as routine maintenance tasks—the usual practice is to set the calibration parameters only when the controller is first installed.

OutF

Out1

Actuator Control Signal

I1

Outa

I1

Outt

To Valve Actuator

Yes

Signal Scaling

Output Circuitry Loopback Input

Loopback Scaling

| Act – Outt |> 5%?

August 2007 UM3300/H (1.1.0)


Figure 4-5 Operation of Bipolar Output

Once you have determined the range of the actuator control signal, you should calculate its ideal, minimum, and maximum acceptable values at 5, 50, and 95 percent of span and record them in a table similar to Table 4-1. The recommended tolerance is ±0.25 percent of the maximum output (for example, ±0.15 mA for a 60 mA output). Table 4-2 gives the recommended ranges for several of the most commonly used actuators.

The Signal Values Test [MODE TEST 4] can be used to view the raw loopback measurement (Outa in the figure, displayed as AD3) and its calibrated value (Outt in the figure, displayed as AD5).

Bipolar Operation The high-current output of a Speed Controller can be configured for bi-directional operation (for example, –200 to +200 mA) by enabling its Bipolar Output [COND:D OUT 1 –] parameter. The speed board’s CPU then calculates the magnitude of that signal as shown in the top right panel of Figure 4-5, and turns the phase inverter on when a negative current flow is needed.

Bipolar Output

0%

100%

0% 100%Control Signal

Output

PhaseInverter

Off

On

200 mA

Output

–200 mA

Unipolar Output

200 mA

–200 mA

0%

100%

0% Control Signal 100%

PhaseInverter

Off

On

toValve

Outputto

Valve

to DACOutputto DAC

Note:When checking or changing the calibration of the output or loopback circuits, record any parameter changes you make and restore the original values of all but the scaling parameters when you are done.

Caution: Calibrate this circuit only while the turbine is shut down or under some alternate form of control.

August 2007 UM3300/H (1.1.0)


Table 4-1 Expected Output Readings

Table 4-2 Expected Output Readings for Common Actuators

Actuator Range (mA):

OUT Display

Measured Current (mA)

Ideal Minimum Maximum

5.0 %

50.0 %

95.0 %

OUT Display

Measured Current (mA)

Ideal Minimum Maximum

Actuator Range: 4 to 20 mA

5.0 % 4.80 4.75 4.85

50.0 % 12.00 11.95 12.05

95.0 % 19.2 19.15 19.25

Actuator Range: 20 to 160 mA

5.0 % 27.00 26.60 27.40

50.0 % 90.00 89.60 90.40

95.0 % 153.0 152.6 153.3

Actuator Range: –20 to +20 mA

5.0 % 1.00 0.95 1.05

50.0 % 10.00 9.95 10.05

95.0 % 19.00 18.95 19.05


5.0 % 1.00 0.95 1.05

50.0 % 10.00 9.95 10.05

95.0 % 19.00 18.95 19.05


5.0 % 3.00 2.85 3.15

50.0 % 30.00 29.85 30.15

95.0 % 57.00 56.85 57.15

August 2007 UM3300/H (1.1.0)


Output CircuitCalibration

The Output Scaling Gain [COND:D GAIN 1] and Output Scaling Bias [COND:D BIAS 1] both calibrate and restrict the range of the high-current output signal. Thus, you should first enter nominal (ideal) values for those parameters based only on the desired range restriction, and then adjust them to precisely calibrate this signal.

This circuit is set up to generate a maximum current (Imax) of 20, 60, or 200 mA by setting the Maximum Output Jumpers (see page 51). Its range is then matched to that of the actuator by calculating the final output as a percentage of twice that maximum (see Figure 4-4):

where:

Act = actuator control signal, in percent

Bias1 = the Output Scaling Bias

Gain1 = the Output Scaling Gain

I1 = high-current output, in mA

Imax = maximum high-current output (20, 60, or 200 mA)

Out1 = calculated output signal (decimal)

Because the actuator control signal must be between zero and 100 percent, the actual output can never be less than (Imax · 2 · Bias1), nor more than [Imax · 2 · (Gain1 + Bias1)]. Because I1 can not exceed Imax, the sum of Gain1 and Bias1 should not exceed 0.50.

The nominal values of this gain and bias should be calculated as:

where:

Ihigh = 100 percent value of actual high-current output (mA)

Ilow = 0 percent value of actual high-current output (mA)

For bipolar outputs, Ilow (and thus the nominal bias) must be zero. Negative signals are generated as positive currents which are then reversed by the phase inverter. If Ilow is not zero, there will be a gap around the zero point of the output!

To configure a 4 to 20 mA signal, for example, set JP4 and JP5 for a 20 mA maximum signal, so Ihigh = Imax = 20, Ilow = 4, and the nominal Bias1 to 0.1 and the nominal Gain1 to 0.4:

I1 Out 1 Imax 2⋅( )⋅=

Out 1

Act Gai n1⋅100

------------------------------- Bias1+=

Gai n1 0.5Ihigh I low–

Imax---------------------------⋅= and Bias1 0.5

I low

Imax-----------⋅=

Gai n1 0.5 20 4–( ) 20⁄⋅ 0.4= =

Bias1 0.5 4 20⁄⋅ 0.1= =

August 2007 UM3300/H (1.1.0)


Use the following procedure to fine-tune the nominal gain and bias or to recalibrate this output signal:

Step 1: Disconnect the control element from the OUT1 terminals on the FOM or back panel and connect an ammeter in its place.

Step 2: Disable the Bipolar Output [COND:D OUT 1 –], Positioning Loop [MODE:D fC 1], and Output Reverse [MODE:S REV 1] features (if they exist and are enabled).

Step 3: Manually adjust the controller output to 5, 50, and 95 per-cent. Compare the resulting ammeter readings to the ranges recorded in your Expected Outputs Table (see Table 4-1). If all of them are acceptable, skip to step 10.

Step 4: Manually set the output to 25 percent and record the amme-ter reading as OUTlow.

Step 5: Manually set the output to 75 percent and record the amme-ter reading as OUThi.

Step 6: Use the following formula to calculate a new gain value:

where Gain1 is the new value, Gainp is the previous value, and Span is the span of the output range (for example, 16 for a 4 to 20 mA output). Set the Output Scaling Gain [COND:D GAIN 1] equal to this new value.

Step 7: Set the output to zero (0) percent and adjust the Output Scaling Bias [COND:D BIAS 1] until the meter reading agrees with the desired minimum output signal (generally, add the error divided by twice Imax to the bias). If that signal is zero, make sure it rises with even a slight increase of the intended output.

Step 8: Recheck the accuracy of the signal at 5 and 95 percent and repeat steps 4 to 7 until satisfactory results are obtained.

Step 9: Manually adjust the output to 50 percent. If the resulting meter reading is not in the acceptable range, the Auxiliary PCB should be replaced.

Step 10: Disconnect the ammeter, reconnect the control element, and restore the original values of any parameters you changed.

Gain1 Gai np0.5 Span⋅

Out hi Out low–----------------------------------------

⋅=

Note:If the controller reverts to automatic operation during this test, it is probably because a limiting loop or manual override was triggered. Determine which feature is responsible and disable it.

August 2007 UM3300/H (1.1.0)


Loopback CircuitCalibration

The Loopback Scaling Gain [COND:D GAIN 2] and Loopback Scal-ing Bias [COND:D BIAS 2] calibrate and adjust that measurement to the actual range of the high-current output signal. As with the output scaling parameters, you should first enter nominal (ideal) values for these parameters based only on the desired range restriction and then adjust them to precisely calibrate this measurement.

If valve positioning is supported and enabled, this gain and bias are not used and need not be set. Otherwise, they scale the internal measurement of the actual high-current output for comparison to its intended value (see Figure 4-4):

where:

Outa = raw loopback measurement, expressed as a decimal fraction of the maximum high-current output (Imax )

Outt = scaled measurement for loopback test (in percent)

Bias2 = the Loopback Scaling Bias

Gain2 = the Loopback Scaling Gain

The nominal values of this gain and bias can be calculated as:

where Ilow and Ihigh define the intended range of the output signal. For example, consider an ideal 4 to 20 mA output:

If the high-current output is accurately calibrated, you can use the following procedure to fine-tune the nominal loopback scaling or to recalibrate this measurement:

Step 1: Make sure the First Output Assigned Variable [COND:D OUT 1] is set to OUTL and the Bipolar Output [COND:D OUT 1 –] and Positioning Loop [MODE:D fC 1] are disabled.

Step 2: Use the Signal Values Test [MODE TEST 4] to display the scaled loopback signal (AD 5) on the Engineering Panel.

Step 3: Observe the AD5 value while you manually vary the dis-played output from zero to 100 percent. Although they can differ by up to 5 percent without triggering a loopback failure, they should match as closely as possible. If the calibration is satis-factory, skip to step 11.

Step 4: Set the displayed output to 25.0 percent and record the dis-played value of AD5 as Inlow.

Out t 100 Out a Bias2+( ) Gai n2⋅ ⋅=

Bias2I low–

Imax-------------= and Gai n2

Imax

Ihigh I low–---------------------------=

I low 4= Ihigh Imax 20= =

Bias24–

20------ 0.20–= = Gai n2

2020 4–---------------- 1.25= =

August 2007 UM3300/H (1.1.0)


Step 5: Set the displayed output to 75.0 percent and record the dis-played value of AD5 as Inhigh.

Step 6: Press CLEAR to terminate the Signal Values Test.

Step 7: Calculate and enter a new Loopback Scaling Gain [COND:D GAIN 2] using the following formula:

where Gain2 is the new value and Gainp is the previous value.

Step 8: Press MODE TEST 4 8 and then the decimal key (several times) to again display AD5 on the Engineering Panel. If neces-sary, adjust the output so AD5 is not zero.

Step 9: Subtract the new value of AD5 from the displayed output and record that error.

Step 10: Press CLEAR to again terminate the Signal Values Test.

Step 11: Calculate and enter a new Loopback Scaling Bias [COND:D BIAS 2] using the following formula:

where Bias2 is the new value and Biasp is the previous value.

Step 12: Set the displayed output to 0.00 and redisplay AD5. If it is zero, increase the bias enough to give AD5 a slight positive value (zero or less is always treated as a loopback failure).

Step 13: Repeat until satisfactory results are obtained, then restore the original values of any parameters you changed.

Output LoopbackTest

If the First Output Assigned Variable [COND:D OUT 1] is set to ActL or ActP, an output failure is indicated if its readback and intended values differ by more than 5.0 percent of span for a minimum time defined by the Output Failure Delay [COND:D CONST 2].

Gain2 Gai np 50 Inhigh Inlow–( )⁄⋅=

Bias2 Biasperror

100 Gain2⋅-------------------------------+=

Note:It the loopback alarm activates unnecessarily when the output is at its minimum value, make the Bias slightly less negative. If it comes on at maximum output, slightly lower the Gain.

August 2007 UM3300/H (1.1.0)


Figure 4-6 General Layout of Series 3++ Front Panel

Engineeringand Front Panel

Operation

The microprocessor on the engineering panel PCB runs an embed-ded program that displays information from the main CPU on the front panel and its own readout and sends back codes identifying the currently-pressed front and engineering panel keys and buttons.

Chapter 2 provided an operational description of the engineering panel. Chapter 6 describes the maintenance features of the front panels, which (as shown in Figure 4-6) have three main sections:

• The upper section has a three-digit control response readout, five-digit controlled variable and set point readouts, and three buttons that select the feature whose data is displayed.

• The middle section provides the Status Screen and Menu Sys-tem Buttons (see page 90), Fault LED (see page 105), and Alarm LED (see page 106).

• The lower section has eight control keys and twelve LEDs, three of which are embedded in associated keys, plus a Test key that displays the engineering panel firmware revision and activates the front-panel User Preferences and LED Tests.

Fault

Alarm

PV

SP OUT

#A

AUTO MAN

Controller Type

ACK MENU SCROLL

Tracking

Limit

LIMIT 2 LIMIT 3ALT

∆

∇TEST ENTER

Mode RUN

AlarmsTran OutF

Com1&2 24V


Control LEDsand Keys

Status LEDs,Screen and

and Buttons

Buttons

August 2007 UM3300/H (1.1.0)


Status Screenand Menu

System Buttons

The various information screens that can be displayed by the 4-line by 10-character status screen are organized into menu groups and selected by pressing the MENU and SCROLL buttons. However, the operation of the compressor and turbine controller menu systems differ somewhat:

• The top line of each compressor controller screen displays the current operating state. Pressing the MENU key displays the most recently viewed screen from the next menu / group. You can then cycle through the screens in that group by repeatedly pressing the SCROLL key.

• The top line of each turbine controller screen identifies the selected menu. Pressing the MENU key displays the first screen from the next group, which only displays the menu name (for Speed Controllers, it also displays the date and time). You can then display that menu’s first and subsequent data screens by repeatedly pressing the SCROLL key.

Turbine controllers also provide Menu and Scroll discrete input functions that can be used to remotely select the active menu and screen.

The internal clock of a Speed Controller can be reset using the

Set Clock

[MODE TEST 9] engineering panel procedure.

User Preferencesand LED Tests

Holding down the TEST key displays the installed front-panel firm-ware version (left-most screen):

• Pressing the SCROLL button while continuing to press TEST would then display a prompt (second screen above) indicating that the contrast of the LCD status screen could be adjusted by pressing the Raise or Lower key.

• Pressing SCROLL again would display a prompt (third screen above) indicating that the brightness of the control loop read-outs could be adjusted by pressing the Raise or Lower key.

• Pressing SCROLL a third time would display the right-most screen above and light every readout and indicator LED on both the front and engineering panels.

Holding down the SCROLL button and pressing the Raise or Lower key will ramp the beep frequency higher or lower.

DisplayTesting &OptionsVer. #.##

LCDContrastAdjustmentUse Î

LEDBrightnessAdjustmentUse Î

LED Test

August 2007 UM3300/H (1.1.0)


UM3300/H Series 3

++

Hardware Referencemanual

Chapter 5 Redundant Controllers

This chapter tells how to set up and operate redundant controllers.

Figure 5-1 Redundant Controller Data Flow

Overview

Series 3

++

Controllers can be installed in a dual-redundant, paired

configuration. The main controller in each pair will normally regulate your process while its “hot” backup monitors it via serial Port 1 so it can instantly take over if the main controller should fail.

Each controller pair is connected by a Redundant Control Selector (see page 94) or other switching device that:

• clears the Tracking discrete input of the active controller and connects the final control elements to its outputs, and

• asserts the Tracking discrete input of the redundant controller and excludes the final control elements from its output circuits.

Each controller is configured to track the operating state and outputs of the other only when its own tracking input is asserted by setting its

Redundant Tracking

[MODE:D fE 1] parameter to true.

Switching is triggered by the main controller’s fault relay, possibly wired in series with additional relays set up to be de-energized by other switching conditions. Each of the application manuals listed at the bottom of page 3 describes its available relay functions.

Controller

Controlled Process

REDUNDANT

CONTROL

SELECTOR

MAIN

BACK-UP

Switch toBack-Up

Switch toMain

GREENACTIVE

REDTRACK

MainControllerBackup

Fault Relays

Controller Outputs

Fault Relays

Tracking Input

SelectedOutputs

Controller Inputs Controller Inputs

Serial Port 1 Application Tracking Communications

Controller Outputs

Tracking Input

Fault

Alarm

DEV

SP OUT

.000

9.3


#A


ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO SURGERESET

MAN

∆

∇TEST ENTER

Fault

Alarm

DEV

SP OUT

.000

9.3


#A


ACK MENU SCROLL

LIMIT 2 LIMIT 3ALT

AUTO SURGERESET

MAN

∆

∇TEST ENTER

August 2007 UM3300/H (1.1.0)

92

Chapter 5: Redundant Controllers

SwitchingLogic

Typically, the switching circuitry for redundant Series 3++ Controllers provides Main and Backup buttons for manually activating either controller (provided it is healthy) and relay logic that automatically activates the backup controller if it is healthy and its main counter-part fails. Once the backup has been activated, however, control is not automatically returned to the main controller (that must be done by pressing the Main button while that controller is healthy).

Figure 5-2 shows a hardware implementation of this logic, which selects the backup controller when the SR relay is energized:

• If both controllers are healthy and neither button is pressed, the M and B relays would both be energized while S and R would both be de-energized:

• Failure of the main controller or pressing the Backup button would energize S, thus selecting the backup controller by completing and latching the SR circuit.

• Pressing the Main button would energize the R relay, thus selecting the main controller by de-energizing S and SR.

• If the backup controller was unhealthy, it could not be activated because pressing its button would not energize S. If the main controller then failed, SR would remain de-energized.

• If the main controller was unhealthy, it could not be activated because pressing its button would not energize R.

• Failure of the backup controller while active would not break the SR circuit even if the main controller was healthy.

Tracking InputCircuits

One function of the redundant switching device is to energize the tracking input of the tracking controller. For compressor controllers, that is always discrete input D1. For turbine controllers, it must be assigned to an input provided by the CPU/IO PCB (DI-1 through DI-8), but never to an auxiliary PCB input (DI-9 through DI-16).

Figure 5-2 shows how the tracking inputs of redundant controllers should be connected to their own 24 volt transmitter power terminals through normally-open and -closed switching relay contacts.

Analog OutputSwitching

Another function of the redundant switching device is to connect control elements to the output signals of only the active controller.

Current-loop outputs must also be connected in a way that main-tains their continuity when not connected to the field device:

• Figure 5-2 shows how this can be done using normally-open (NO) and -closed (NC) contacts of the switching relay (SR).

• Figure 5-4 shows the corresponding RCS terminal connections.

August 2007 UM3300/H (1.1.0)


Figure 5-2 Typical Redundant Switching Circuitry

CR11 2

Main Controller Backup Controller

B

CR11 2

M B S

M

SR

S Backup

R

R

M

Main

B

S

M

SR

S Backup

R

R

M

Main

Mai

n A

ctiv

eB

oth

Hea

lthy

B

S

M

SR

S Backup

R

R

M

Main

Bac

kup

Act

ive

Bot

h H

ealth

y

B

S

M

SR

S Backup

R

R

M

Main

Mai

n A

ctiv

eB

acku

p U

nhea

lthy

B

S

M

SR

S Backup

R

R

M

Main

Bac

kup

Act

ive

Mai

n U

nhea

lthy

D

DISCRETE IND1

24VDC–+

D

DISCRETE IND1


24VDC–+

+

–

OUT 1 +

OUT 1 +

Tracking Discretes

Current-Loop Outputs

FY

SR SR

SR SR

SR SR

SRSR


August 2007 UM3300/H (1.1.0)

94 Chapter 5: Redundant Controllers

RedundantControl

Selector

Redundant controllers require an independent device to sense main controller failures and automatically transfer control to its backup. Our Redundant Control Selector (RCS) fills that need by providing:

• two fault-sensing circuits that connect to the fault and/or other appropriate control relays of the main and backup controllers,

• sixteen isolated relay contacts that connect field devices to the main or backup controller’s analog outputs and control relays based on the states of the fault relay circuits,

• LEDs and discrete outputs that indicate which controller’s out-puts are connected to the process, and

• buttons for manually selecting that controller.

Hardware specifications for the RCS can be found on the Series 3++ Redundant Control Selector data sheet [DS3300/R].

Operation Each RCS consists of an Operator Panel that is usually mounted between the front panels of the redundant controllers and a Switch-ing Unit mounted in a less accessible location.The switching unit contains a latched master relay that controls four slave relays:

• When de-energized, they connect the main controller to the field and energize the TB6 Main Active discrete output. The Main LED is green and the Backup LED is red. Only the backup con-troller lights its green Tracking LED.

• When energized, they connect the backup controller to the field and energize the TB6 Backup Active discrete output. The Main LED is red and the Backup LED is green. Only the main control-ler lights its green Tracking LED.

The switching unit routes 24 Vdc power through the fault relay of the main controller at all times. As long as that circuit is closed and con-trol has not been manually transferred to the backup controller, the switching relays will be de-energized. If that circuit opens or the Switch to Backup button is pressed, those relays will energize if the backup controller’s fault relay circuit is closed.

Once control has been passed to the backup controller, the relays will remain energized until the Switch to Main button is pressed while the main controller’s fault relay circuit is closed. Control of the process can never be transferred to a failed controller and is never automatically transferred to the main controller, even if it is healthy and the backup is not.

August 2007 UM3300/H (1.1.0)


Figure 5-3 Typical Redundant Control Selector Connections

Fault RelayConnections

Connect the TB6 main and backup controller Fault terminals to the CR1 fault relays of the corresponding controllers. If desired, other relays that would open to indicate additional switching conditions can be connected in series with the fault relay:

• For turbine controllers, the auxiliary PCB fault relay (CR9) should be set for normally-open operation and wired in series with CR1, so an automatic switch to the backup controller will occur if either of them de-energizes.

• All controllers offer a General Failure relay function that is primarily for redundant switching.

These circuits are powered by the RCS, so its terminals indicate a polarity while the dry-contact controller relays do not.

Tracking InputConnections

Connect each controller’s tracking input (D1 for compressor and assignable for turbine controllers) to the 24 Vdc transmitter power outputs of both via a single switching relay contact (see Figure 5-3):

• Connect the 24 Vdc of each controller to its own discrete return terminal and through a diode to the RCS Common terminal.

• Connect the main controller input to the Track terminal.

• Connect the backup controller input to the Run terminal.

Each controller’s tracking input will then be asserted only when its peer is selected/active.

D

OUT 1

DISCRETE IND1

+

CR11 2

TB6

Main Controller Backup ControllerRCS Switching Unit

24VDC–

D

OUT 1

DISCRETE IND1

+

CR11 2

TB6

24VDC–+

To Transducer: +–

Note: Field Output Module fault relay circuits connected to an RCS must be set up as dry contacts.

August 2007 UM3300/H (1.1.0)


Figure 5-4 Connecting Current-Loop Outputs to an RCS

Analog OutputConnections

The current-loop output circuits of redundant controllers must be connected to the switching device in a manner that maintains the continuity of both circuits while including the transducer in only one (so neither controller will indicate an output failure). The upper panel of Figure 5-4 shows how to do so using normally-open (NO) and -closed (NC) contacts controlled by a single RCS switching relay. The other panels show how the signals are routed when each con-troller is selected:

• When the main controller is selected (middle panel), its OUT1 circuit includes the transducer (red lines) while the backup con-troller’s circuit is closed by the relay (gray lines).

• When the backup controller is selected (lower panel), its OUT1 circuit includes the transducer (red lines) while the main control-ler’s circuit is closed by the relay (gray lines).

PowerConnections

The RCS switching unit provides connectors for two independent external power supplies and automatically powers its circuits from the highest-voltage source. Connect one to a regulated 24 Vdc power converter and the other to a battery pack, with the converter adjusted to provide a voltage slightly above that of the batteries. Power will be drawn from the batteries if the power converter fails, but they will not be recharged when that source is restored.

1 2 3 4 5 6 7 8 9 10 11 12

A B C D A B C D A B C D FY

OUT 1 +

OUT 1 + RUN COMMONTRACKBackup Main

1 2 3 4 5 6 7 8 9 10 11 12

FY

OUT 1 +

OUT 1 +

1 2 3 4 5 6 7 8 9 10 11 12

FY

OUT 1 +

OUT 1 +

Backup

MainSelected

Selected

August 2007 UM3300/H (1.1.0)


RCS Power Failure If power to the RCS failed, the slave relays would de-energize and connect the main controller to the field. However, the latched master would remember which controller had been selected:

• If the main controller was in control, it would remain so when power was restored (unless it had faulted in the meantime).

• If the backup controller was in control, it would resume control when power was restored (even if it had faulted or the main con-troller had been repaired in the meantime).

When a Speed or Extraction Controller RCS is connected to two power supplies, each controller can be set up to alarm the failure of one of them by wiring a discrete input assigned the -RS24 function in parallel with the RCS and one of its power supplies. That control-ler would then energize any +RS24 relays and signal an “RS24V Fail” alarm if that input was cleared, generally indicating a total fail-ure of the corresponding power supply. If the RCS was without power, both controllers would indicate an RS24V failure.

UnswitchedConnections

Input and communication signals must be connected to both control-lers in such a way that both can monitor the process and either can be disconnected without affecting the signals to the other.

Discrete InputConnections

With the exception of the tracking input signals (see page 92), all redundant controller discrete inputs should be connected in parallel (rather than through the switching relay). Both controllers can then read them and the removal of either will not affect the other’s inputs.

Analog InputConnections

The analog inputs of redundant controllers should be configured to accept voltage signals (see Analog Input Switches on page 49). They can then be connected in parallel to 5 Vdc transmitters or across 250 ohm dropping resistors connected in series with 20 mA transmitters, so disconnecting either controller would not affect the input of the other.

For redundant turbine controllers equipped with FTAs, this can be done by installing the dropping resistors across pins C and D of the FIM jumper blocks (see FIM Analog Input Circuits on page 59):

F

B

A E

CH

G

H

D

CXmtr

+–50 mA

24 V

DC

A C E G

B D F H+–

67

66

69

68

CH

D

C50 mA67

68

August 2007 UM3300/H (1.1.0)


If the FIMs are configured to obtain their onboard 24 Vdc power from a source other than the controllers (see page 57), such a circuit can be powered from either FIM by:

• jumpering its pin A to B and connecting its B terminal to the transmitter’s positive terminal, and

• jumpering its pin G to H and connecting its H terminal to the other controller’s D terminal:

The same approach should be taken for the auxiliary current-loop input, but the resistors would have to be installed across their FIM terminals because no configuration block is provided for that circuit.

Serial Ports If Modbus While Tracking [MODE:D LOCK 0] is Off, the main and backup controllers can be given the same Computer ID Number [MODE:D COMM 0 •]. Write requests will then be implemented by both but only the active controller will respond to read requests. Redundant controllers with Modbus While Tracking enabled must either be connected to different Modbus master serial ports or be assigned unique Computer ID Numbers so both can be remotely accessed via the same master port.

Both controllers in each redundant pair must be connected to the same inter-controller serial communication networks. The backup controller does not transmit over Port 1, but does use it to track its active counterpart. Similarly, only the active controller responds to Port 2 requests. Because that port’s address is set by the Computer ID Number, redundant controllers will also have the same Modbus RTU ID. Thus, you must disable Modbus While Tracking or connect the controllers to separate host ports.

If your hosts need to know which controller is active, hard wire one of the main controller’s otherwise unused discrete inputs so that it is always asserted. The corresponding discrete input bit or variable will then be cleared only when the backup unit is active.

Ethernet Ports If Modbus RTU/TCP converters are used, there is no way they can communicate as a duplex pair because each port has to have a unique IP address. Each pair of controllers should be identified by giving them a common Computer ID Number and Modbus While Tracking should enabled even in load-sharing applications.

Modbus TCP clients can tell which of the controllers is active by monitoring their Tracking discrete inputs.

F

B

A E

CH

G

H

D

C 50 mA

24 V

DC

A C E G

B D F H

+

Xmtr–

92

91

94

93

CH

D

C50 mA92

93

August 2007 UM3300/H (1.1.0)



Chapter 6 Maintenance and RepairThis chapter discusses controller maintenance and troubleshooting.

Overview Although Series 3++ Controllers are designed to run continuously for years without requiring any maintenance, hardware problems will occasionally be encountered:

• Some developing problems can be detected by routinely review-ing various controller health variables (see Monitoring Controller Health on page 100).

• The controller will indicate internal and field element problems as discussed in the sections on Problem Indicators on page 104 and Troubleshooting on page 112.

• Most internal problems are resolved by replacing the controller or one or more of its main components (see Replacement Pro-cedures on page 123).

Although the turbine controller High-Current Analog Output (see page 82) could be routinely recalibrated, there is usually no reason to do so. No other field calibration is possible.

Whenever a malfunctioning controller or CPU/IO PCB is replaced, the original CPU’s control program and configuration parameters must be restored. Both can be downloaded from a PC running the Configurator program (see Support Software Packages on page 27), provided you have ready access to that program and:

• the downloadable file for the currently-installed version of each controller’s application software, and

• an up-to-date configuration parameter set file.

Those files are discussed in the Configurator documentation.

In addition, you should keep records of each controller’s installed program version and checksum, parameter set checksum, and Modbus port settings and ID number. These can be determined using the following engineering keyboard sequences:

• Program Version [MODE TEST 2]

• Program Checksum [MODE TEST 8]

• Parameter Checksum [MODE LOCK 4]

• Port 3 Baud Rate [MODE:D COMM 3]


• Computer ID Number [MODE:D COMM 0 •]


August 2007 UM3300/H (1.1.0)

100 Chapter 6: Maintenance and Repair

Figure 6-1 Controller Status Screen and Menu Buttons

MonitoringController

Health

The CPU/IO PCB temperature and power supply voltages and most field I/O signals can be monitored via the front-panel status screen and/or computer communications.

InternalConditions

Each compressor controller’s main menu includes two screens that display the CPU/IO PCB component power voltages. Turbine con-trollers provide those screens via a separate Diagnostic menu:

Table 6-1 lists the minimum CPU/IO PCB voltages needed for the controller to operate. If the internal 24 Vdc falls below its limits, cor-rect the input voltage or replace the power supply assembly. If any converted voltage deteriorates, replace the CPU/IO PCB.

That table also lists the acceptable input voltage ranges and the minimum 24 Vdc output voltage required by the analog outputs (any field devices connected to those terminals might require a higher voltage). If the input power is acceptable but the transmitter 24 Vdc output is not, replace the power supply assembly.

Table 6-1 Acceptable Voltages

Fault

Alarm

MENU SCROLL

Mode RUNPower: AB24V = 24.015V = 14.7

DiagnosticPower: AB24V = 24.015V = 15.0

then

Diagnostic5.0V = 5.03.3V = 3.31.2V = 1.2

PSA Range CPU/IO PCB Minimum Used By

AC Input 96 - 264 Vac 1.2 Vdc 1.15 CPU core

DC Input 21 - 32 Vdc 3.3 Vdc 3.00 RAM/clock chip

Xmtr Out 19.0 Vdc min. 5.0 Vdc 4.50 discrete I/O, serial ports, front panel

15 Vdc 14.25 analog I/O, Auxiliary PCB

24 Vdc 22.0 power converters for above voltages

August 2007 UM3300/H (1.1.0)


Scrolling past the second voltage screen displays the CPU/IO PCB’s temperature (measured near the hottest part of that board), which will generally be 20 to 25 degrees Celsius higher than that outside of the controller sleeve (controllers that have an auxiliary PCB run about five degrees hotter than those that do not):

Although temperature-related problems should not occur unless that temperature exceeds 90°C, additional ambient cooling should be provided if it routinely exceeds 80°C.

Field I/O Screens

Most field I/O signals can be monitored via the Main menu of a com-pressor controller or In/Out menu of a turbine controller.

CompressorController I/O

Signals

In addition to any application specific screens, the Main menus of all three compressor controllers include the following I/O screens:

The above screen displays the states of all seven digital inputs and all five digital outputs (digits indicate inputs and outputs that are set). The 1 for fault relay CR1 will appear unless it (and possibly CR2) are de-energized by CR1’s assigned function.

The above example indicates that only the D2 and D6 inputs are set and only the fault relays and CR4 should be energized.

The next two presses of the SCROLL button would then display the intended and measured values of the analog outputs:

If their accuracy deteriorates significantly, measure the voltage of the transmitter power circuit (which can indicate PSA malfunctions, bad input voltages, or excessive transmitter power demands). If it is okay, the controller or its CPU/IO PCB should be replaced (these outputs cannot be field calibrated). An output failure alarm would be indicated if any output used to drive a valve or other control element deviated from its intended value by more than five percent.

DiagnosticBoard Temp 050. degC

Mode RUN DigitalsIn:_2___6_Out:1__4_

Mode RUNAnalog OutOut1 =##.#Out2 =##.#

then

Mode RUNOutReadbckOut1= ##.#Out2= ##.#

August 2007 UM3300/H (1.1.0)


Turbine ControllerI/O Signals

The first In/Out menu screen of a Speed Controller lists the enabled speed readings, in rpm (Extraction Controllers skip this screen). The label for the selected input is displayed in all uppercase letters (SPD3 below), the labels for the others are capitalized (Spd#):

SCROLLing that menu then displays the digital inputs and outputs:

Each digit or letter (A for input 10, G for 16) appears if that circuit is asserted or energized, otherwise it is replaced by an underscore. The digits for fault relays appear only if they are de-energized by the assigned relay function.

The next two presses of the SCROLL button display the intended and read-back values of the analog outputs (if the optional position-ing loop is enabled, the OUT1 readback is replaced by the LVDT1 valve position measurement):

If reverse action is enabled for an output, the displayed value will be the complement of the variable it represents:

• If Out1 and RdBk1 differ significantly, try recalibrating the High-Current Analog Output (see page 82) and its loopback. If that fails, replace the auxiliary PCB.

• Out2 and 3 cannot be recalibrated. If their accuracy deteriorates significantly, you should measure the voltage of the transmitter power circuit (which can indicate PSA malfunctions, bad input voltages, or excessive transmitter power demands). If it is okay, the controller or its CPU/IO PCB should be replaced.

An output failure would be indicated only if the high-current output’s loopback test was enabled and RdBk1 differed from Out1 by more than five percent (5.0%) of span for a configured minimum time.

In/OutSpd1 4969Spd2 5001SPD3 4983

In/OutDigital InÎ:1_34___8¨:9_BC_E_G

then

In/OutDigitalOutÎ:_23__67_

In/OutOut1 =##.#Out2 =##.#Out3 =##.#

then

In/OutRdBk1=##.#RdBk2=##.#RdBk3=##.#

or

In/OutLVDT1=##.#RdBk2=##.#RdBk3=##.#

August 2007 UM3300/H (1.1.0)


Analog In Menu Each controller provides an Analog In menu, whose screens display the scaled, measured variable values and testing status of user-specified Analog Inputs (see page 75):

• For compressor controllers, these screens also identify the cur-rent operating state:

• Their turbine controller counterparts do not:

The word “Fail” is displayed after the value if the input’s unscaled value is not within its acceptable range, in which case a transmitter failure is indicated (see Analog Input Problems on page 118).

The percent-of-range signal variable value of each analog input can be viewed using the engineering panel

Signal Values Test

[MODE TEST 4] key sequence. To determine if a specific input is being read correctly, disable its

Offset Zero Input

[MODE:D ANIN #] parameter and compare the TEST 4 value to a volt or ammeter measurement of the corresponding input signal.

Mode RUNAnalog In2:D Press 250. psig

or

Mode RUNAnalog In2:D Press 0. Fail

Analog In 1:V1 Press 250. psig

or

Analog In 1:V1 Press 0. Fail

August 2007 UM3300/H (1.1.0)


Figure 6-2 Front-Panel Status LEDs and Alarm Menu

ProblemIndicators

Series 3

++

Controllers provide various indications of internal and

some external control system hardware problems:

• Microprocessor and some power problems are indicated by the Fault Indicators (see below).

• More specific problems are indicated by the Alarm System (see page 106) and optional External Alarms (see page 108).

• Problems that are indicated by beeping can be investigated using the Engineering Panel (see page 110).

• A redundant controller pair’s Tracking Indicators (see page 110) will signal the activation of the backup peer.

• Speed Controller problems that trigger emergency shutdowns are recorded in the Shutdown Log (see page 111).

Fault Indicators

Microprocessor and some power problems are indicated by the front-panel Fault LED, the CPU/IO Fault Relay, and/or the Speed Board Fault Relay. Because each is controlled by a different PCB, they do not convey the same information.

Although various main CPU and RAM/clock chip problems would de-energize the PCB/IO fault relay and also light the fault LED, a total loss of power to the controller or failure of the internal 24Vdc power would only de-energize the fault relays (the LED obviously could not light under those circumstances).

In most systems, each controller’s fault relays are connected to external logic circuits that will automatically shut down or transfer control of the compressor or turbine to a backup device when any such relay de-energizes. You can then identify and correct the cause of that action.

Fault

Alarm

MENU SCROLL

Mode RUN Alarms Tran OutFCom1&2 24V

Fault

Alarm

MENUACK SCROLL

AlarmsCom1 Error


August 2007 UM3300/H (1.1.0)


Fault LED The front-panel Fault LED is lit if the engineering panel is receiving 5Vdc power and:

• it is unable to communicate with the main CPU, in which case the status screen will display “No Comms with Main CPU” and all other LEDs and readouts will be blank/off; or

• the CPU is unable to communicate with the Auxiliary PCB, in which case the other LEDs, control loop readouts, and status screen will continue to operate.

CPU/IO Fault Relay CR1 is hard-wired as a normally-energized fault relay, and CR2 can be set to only de-energize when CR1 does (see CPU/IO Control Relay Switches on page 48). It/they will de-energize if the 3.3 Vdc power falls below its fault threshold or the control program does not periodically reset the watchdog timer. In either case, the main CPU is also reset (see page 77):

• If the CPU is able to restart, it will reset the watchdog timer and re-energize the fault relays. The speaker will beep and the engi-neering panel will display “Reset”.

• Some problems allow the CPU to restart but eventually prevent it from resetting the watchdog timer. The fault relay(s) will then toggle off and back on and the controller will beep repeatedly.

Although there is a slight chance that powering the controller down and back up would correct this condition, it is almost always indicative of a failed power converter or other compo-nent on the CPU/IO PCB.

This relay will also de-energize if the trigger condition for its relay assigned function is detected (see Relay Functions on page 108), in which case the CPU is not reset.

Speed Board FaultRelay

The auxiliary PCB’s fault relay is controlled by its watchdog timer:

• If that timer is not regularly reset by that board’s CPU, it will de-energize CR9 and reset that CPU. CR9 will not re-energize unless that restart succeeds.

• CR9 will also de-energize if the 15 Vdc power converter on the CPU/IO PCB fails.

In either case, the main CPU will be unable to communicate with its counterpart on the speed board. A Speed Controller will then light its Fault LED and initiate an emergency shutdown of the turbine, while an Extraction Controller will only indicate an “Aux. Board” alarm.

August 2007 UM3300/H (1.1.0)


Alarm System

The meaning of the front-panel Alarms LED, Modbus and OPC Alarm variables, and any relays given the Alarm function depends on the type of controller:

• Compressor controllers light their Alarm LEDs, energize any Alarm relays, and set their Modbus/OPC Alarm variables when there are uncorrected controller hardware problems. They do not automatically display the Alarms menu when new problems are detected, and provide no way to acknowledge uncorrected alarms (the ACK button is not used).

All current alarm conditions are indicated via the third and fourth lines of a single Alarms screen that you should manually display (by repeatedly pressing the MENU button) whenever the Alarm indicators are set:

• “Tran” indicates one or more analog inputs are beyond their testing ranges (see Analog Input Problems on page 118).

• “OutF” indicates the loopback reading for an analog output that is being used to drive a control element differs from its intended value by more than five percent (see Analog Output Problems on page 118).

• “Comm1”, “Comm2”, or “Com1&2” indicates expected trans-missions are not being received from companion controllers via the corresponding serial ports (see Communication Prob-lems on page 115).

• “24V”, “15V”, “5V”, or “3V” means the corresponding CPU/IO PCB voltage is unacceptably low (see Power Problems on page 113).

The Alarm LED remains lit and Alarm relays remain energized until all such problems have been corrected.

Alarm Relays

Alarm Discreteand OPC Variable

Alarm LED

Alarms Menu

ACK Button

Mode RUN AlarmsTran OutFCom1&2 24V

August 2007 UM3300/H (1.1.0)


• Turbine controllers light or flash their Alarm LEDs whenever there are unacknowledged and/or uncorrected alarm conditions, but they energize relays assigned the Alarm function and set the Modbus/OPC Alarm variables only if there are unacknowledged problems (corrected or not). Each screen of their Alarms menus list one of up to eight such conditions:

The Alarm LED will flash if the currently-displayed alarm has not been acknowledged, which can be done either by pressing the ACK button or asserting a Reset discrete input.

If a new problem is detected, the Alarm menu screen displays automatically (thus causing the LED to flash). Acknowledging that alarm or scrolling to a previously-acknowledged one would cause the LED to stop flashing, but it would remain lit as long as any alarms were uncorrected and would resume flashing if you scrolled to one that had not been acknowledged.

Those indicators are used to signal both process and controller problems (only the latter will be covered here):

• “Aux. Board” means the main CPU cannot communicate with the auxiliary PCB (see Speed Board Problems on page 121).

• “Com1 Error” or “Com2 Error” indicates the corresponding serial port is not receiving expected companion controller data (see Communication Problems on page 115).

• “FD24V Fail” indicates a field device power supply failure (see Power Problems on page 113).

• “MPU# Fail” indicates a failure of the corresponding (#) speed input (see Speed Input Problems on page 121).

• “OutputFail” indicates the high-current output loopback read-ing differs from its intended value by more than five percent (see Analog Output Problems on page 118).

• “Pwr Supply” indicates an internal power supply problem (see Power Problems on page 113).

• “PosFeedbck” indicates an unacceptable deviation of a hydraulic control element’s actuator positioning pressure (see Positioning Problems on page 122).

• “RS24V Fail” indicates a redundant control selector power supply failure (see RCS Power Failure on page 97).

• “Tran# Fail” indicates the corresponding (#) analog input is beyond its transmitter testing range (see Analog Input Prob-lems on page 118).

AlarmsCom1 Error

August 2007 UM3300/H (1.1.0)


External Alarms

In addition to its front-panel Alarms menu, each controller also pro-vides relay functions and Modbus variables that indicate individual or collective hardware problems.

General Failure All Series 3

++

Controllers provide a general failure relay function and Modbus/OPC variables that can be triggered by any of several con-ditions that would warrant switching to a backup controller:

All Controllers: output loopback or internal voltage failure

Speed Controllers: valve positioning failure, or the failure of all speed inputs

Extraction Controllers: auxiliary PCB failure

Each of these problems is also indicated by other relays and vari-ables. Redundant controller fault relays are often assigned this Fail function (see Fault Relay Connections on page 95 and Tracking Indicators on page 110).

Relay Functions Each controller’s relay outputs can operate external indicators (lights, horns, etc.) for or communicate various problems to a DCS.

FD24 This turbine controller function indicates a transmitter power test fail-ure (see Power Problems on page 113).

OutF The turbine controller OutF function indicates either an excessive readback deviation of the high-current analog output (see Analog Output Problems on page 118) or an excessive deviation of the position feedback signal (see Positioning Problems on page 122). Compressor Controllers have separate OutF and PosF functions for indicating those problems.

PSF This turbine controller function indicates a low CPU/IO PCB voltage. For compressor controllers, such problems are indicated by a Fail not accompanied by an OutF (see Power Problems on page 113).

RS24 This turbine controller function indicates a redundant control selec-tor power problem (see RCS Power Failure on page 97).

SerC This function indicates the controller has failed to detect an expected transmission on its Port 1 or 2 communication network (see Communication Problems on page 115).

Tran The Tran function indicates at least one analog input signal is not within its valid range (see Analog Input Problems on page 118).

All relays will de-energize if the 5 Vdc power to their coils fails.

PosF

August 2007 UM3300/H (1.1.0)


Modbus/OPCVariables

A TrainTools or other operator workstation can indicate the following problems when the corresponding Modbus/OPC variables are set.

Aux. Board Fail This turbine controller discrete indicates the main CPU is unable to communicate with its counterpart on the Auxiliary PCB (see Speed Board Problems on page 121).

FD 24V Fail This turbine controller discrete indicates a transmitter power test fail-ure (see Power Problems on page 113).

Low Voltage This discrete indicates a low CPU/IO PCB voltage (see Power Prob-lems on page 113).

MPU # Fail Each of these Speed Controller discretes indicates the correspond-ing MPU has failed (see Speed Input Problems on page 121).

Output Fail This discrete indicates an excessive readback deviation for the analog output used to manipulate the control element (see Analog Output Problems on page 118).

Port # Fail Each of these discretes indicates the controller has failed to detect an expected transmission on the corresponding serial communica-tion network (see Communication Problems on page 115).

Position Fail This turbine controller discrete indicates an excessive deviation of the position feedback signal (see Positioning Problems on page 122). Compressor Controllers test that signal only if a relay has been assigned the PosF function, in which case this problem would be indicated by the corresponding CR State discrete.

RS 24V Fail This turbine controller discrete indicates a redundant control selec-tor power problem (see RCS Power Failure on page 97).

TranFail The Tran discrete indicates one or more analog input signals are out of their valid ranges, in which case the corresponding TranFail # dis-cretes would also be set (see Analog Input Problems on page 118).

TranFail#

August 2007 UM3300/H (1.1.0)


EngineeringPanel

Each time an engineering panel key is pressed, the controller will beep and (unless you pressed the CLEAR key) the engineering readout will display a message. If not, see the section on Front and Test Panel Problems on page 114.

The controller will also beep if any key is “stuck”, the CPU reboots or a low-level serial communication error is detected. The engineering panel readout will then display one of the following:

Com# POF: indicates a low-level (Parity, Overrun, or Framing) error was detected by the serial port identified by the fourth character (see Communication Problems on page 115).

CS= XXXX: indicates an unreasonable parameter value has been detected and changed. If this message is accompanied by repeated beeping, the parameter memory is probably defective (see CPU/IO Board Problems on page 117).

Error! indicates an invalid engineering key sequence. If accompa-nied by repeated beeping, the cause is usually a failed keypad (see Front and Test Panel Problems on page 114).

Reset: indicates a CPU Reset (see page 77). This might indicate a power cord or connector problem (see Power Problems on page 113). However, it usually means an internal hardware or soft-ware problem is aborting the controller reset sequence (see CPU/IO Board Problems on page 117).

Although occasional errors will not affect control of your compressor or turbine, frequent or repeated beeping should be investigated.

TrackingIndicators

When a redundant pair of controllers is installed, the front-panel Tracking LED of the active peer will be off, that of the inactive peer will be continuously lit. The active controller’s Modbus/OPC Track-ing discretes will also be cleared, those of its peer will be set. In addition, the operator panel of our Redundant Control Selector (see page 94) will indicate which controller’s outputs are connected to your field elements:

• When the main controller is active, the Main LED is green and the Backup LED is red.

• When the backup controller is active, the Main LED is red and the Backup LED is green.

Thus, any problem that triggers an automatic switch to the backup controller will be indicated by the lighting of the main controller’s Tracking LED and the RCS Main LED turning red. To diagnose such a switchover, you need to know which controller relays trigger them and the functions assigned to them (see Fault Indicators on page 104 and Relay Functions on page 108).

Tracking LED

Redundant ControlSelector LEDs

August 2007 UM3300/H (1.1.0)


Shutdown Log

Speed Controller problems that trigger emergency shutdowns of the turbine are recorded and can be viewed by repeatedly pressing the Menu key until the status screen’s shutdown log menu appears.

Pressing SCROLL once displays the cause of the most recent tur-bine shutdown and the time and date at which it occurred:

• Overspd SD indicates the turbine was shut down because it exceeded a configured trip speed.

• MPULoss SD indicates the turbine was shut down because all of its speed inputs failed (see Speed Input Problems on page 121).

• Breaker SD indicates a turbine-driven generator was shut down when the generator breaker unexpectedly opened.

• DGI SD ## indicates the shutdown was initiated by Stop or ESD input number ##.

• OperatorSD indicates the shutdown was initiated from the front panel or via computer communications.

• FailsafeSD indicates a start-up aborted when the turbine failed to reach a configured minimum speed quickly enough.

• WatchdogSD indicates a power loss or controller failure caused a hard reset of the CPU, thus tripping the turbine (see CPU/IO Board Problems on page 117).

• Shutdown indicates the auxiliary PCB failed (see Speed Board Problems on page 121) or that this controller took control after a shutdown and cannot determine its cause.

Each subsequent press of the SCROLL key displays the same infor-mation for the next older of the last eight shutdowns:

If the controller has shut down the turbine fewer than eight times, the second line of the as-yet-unused log screens will display a line of dashes.

You can also determine the reasons for the most recent shutdown by reading the Modbus Last ESD register, or the last three by read-ing the corresponding OPC Last ESD# OPC variables.

SD Log 1WatchDogSD 13:52:11 12/25/06

SD Log

14:12:39 12/25/06

then

SD Log 8OperatorSD 19:43:52 01/02/05

August 2007 UM3300/H (1.1.0)


Troubleshooting

This section suggests appropriate responses to various hardware problems (whose indicators were discussed in the previous section):

• Power Problems (see page 113)

• Front and Test Panel Problems (see page 114)

• Communication Problems (see page 115)

• CPU/IO Board Problems (see page 117)

• Analog Input Problems (see page 118)

• Analog Output Problems (see page 118)

• Discrete Input Problems (see page 119)

• Discrete Output Problems (see page 120)

• Speed Board Problems (see page 121)

• Speed Input Problems (see page 121)

• Positioning Problems (see page 122)

Unless the problem is clearly external to the controller, you should replace it or its internal circuit boards and/or front-panel (see Replacement Procedures on page 123) to return it to service as quickly as possible. You can then return all replaced hardware to CCC for repair, or isolate and return only the failed components.

If you have removed a controller from service, it is usually easiest to replace suspect components one at a time until the malfunctioning one becomes obvious. Additional information or assistance can be obtained by contacting the Technical Service Department at Com-pressor Controls.

August 2007 UM3300/H (1.1.0)


Power Problems

If the controller appears to be “dead” (all display elements are off, all control relays are de-energized, all analog outputs are 0.0, and all serial communication has ceased), check the voltage across the field power output. If it is not zero, either:

• one of the CPU/IO board’s power converters has failed, or

• the power supply is not providing 24 Vdc power to that board.

Either replace both assemblies, or replace one at a time so you can identify and replace only the one that actually failed.

You should also check the field power voltage if the standard analog outputs fail but the controller otherwise seems to be okay (a turbine controller might also indicate a “FD24V Fail” alarm and energize any FD24 control relays). If it is not zero, the power supply assembly is not providing 24 Vdc field power and must be replaced.

In addition, you should replace the power supply if the controller indicates the 24 Vdc to the CPU/IO board is failing, or the CPU/IO board if any of its power converters is failing (see Internal Conditions on page 100 and Alarm System on page 106).

If the controller appears to be dead and there is no voltage across the field power terminals, disconnect the power cord from the back panel and test the voltage (see Table 6-1) across the pins for the installed power supply (see Figure 3-24). If that cable is “live”, either the power supply assembly or the back panel has failed and must be replaced. If the cable is not live, figure out why not.

If the engineering panel intermittently beeps and displays a “Reset” message, one of the power cord connections might be loose or worn (or the controller reset sequence is being aborted by a hardwired or software problem, see CPU Reset on page 77 and CPU/IO Board Problems on page 117). You can check the power-cord and back-panel connectors by connecting a different cord to the problematic controller and/or the same cord to a different controller. Depending on the result, replace the back panel or power cord.

August 2007 UM3300/H (1.1.0)


Front and TestPanel Problems

Front and engineering panel problems will not prevent a controller from continuing to control and protect your process equipment. So, if you suspect such a problem but are able to monitor and operate the controller from a computer workstation or remote operator panel, you might decide to delay correcting it.

If you suspect an LED or readout is not working, or want to verify that all of them are, hold down the TEST key and press the SCROLL button three times (see User Preferences and LED Tests on page 90). Doing so will display “LED Test” on the top row of the status screen and light every readout and indicator LED on both the front and engineering panels. If any LED or readout segment does not light, replace the corresponding (front or engineering) panel.

If you suspect a front panel key or button is not working, invoke the engineering panel

Signal Values Test

[MODE TEST 4], press the minus (–) key, and then press the key you want to test to verify that its code is being sent (see page 147). If not, replace the front panel.

If an engineering panel key is stuck on, the controller will usually beep at 0.4 second intervals and display “Error!” on the engineering panel readout. However, if the CLEAR key is stuck, the beeping will be accompanied by a blank readout. If the PID, MODE, COND, or SPEC RESP key is stuck, pressing the CLEAR key will neither elicit a beep nor clear the corresponding confirming message.

If you suspect an engineering panel key is not working, press it. The controller should beep and display the corresponding message.

If any engineering panel key is faulty, replace that panel.

If all front panel display elements are unlit/blank but the fault relay is not de-energized or you otherwise know the controller is running:

1. Open the front panel and determine whether the engineering panel is working (pressing any key should elicit a beep). If not, replace it and reinstall the front panel.

If the new engineering panel does not work, the CPU/IO circuit that powers the engineering panel is probably bad. That would necessitate replacement of the CPU/IO PCB assembly.

2. Make sure the ribbon cable between the front and engineering panels is connected and undamaged. If not, reseat or replace it.

3. Replace the front panel assembly if it is still unlit.

Caution:

Pressing a key to verify it is working might affect the operation of the controller. If possible, you should first switch to an alternate method of controlling your process.

August 2007 UM3300/H (1.1.0)


CommunicationProblems

If the controller beeps and the engineering panel shows a message of the following form:

the port indicated by the number in the fourth field (1 through 4) is detecting serial data it is unable to decode. The P, O, and/or F will appear only when the corresponding type of error occurs:

• The P will appear if a parity error was detected. This indicates that the number of set bits (ones) in a received character did not agree with the defined parity for the serial port it arrived on. Continuous parity errors usually indicate that the parity settings of the transmitting and receiving devices are different.

• The O will appear if an overrun error occurred. This means that the controller failed to read an incoming character before the next one arrived.

• The F will appear if a framing error was detected. This indicates the controller was unable to decode an incoming character due to a synchronization error. Continuous framing errors usually indicate the baud rates of the host and slave disagree.

If such errors are occurring continuously, make sure all devices on the problem network are set for the same baud rate and parity and have unique Controller (Port 1) and Computer (Ports 2, 3 and 4) ID numbers. Downloading a different control program (for example, changing a Performance into an Antisurge Controller) will frequently produce misconfigurations that trigger continuous reception errors.

For Port 3 or 4, make sure only one Modbus master is connected and is configured to use one start, one stop, and eight data bits. Some Modbus hosts, particularly older PLCs, might experience frequent synchronization errors at high baud rates. Such problems can thus be solved by reducing that setting in both the host and the controllers.

Because the communication protocols employed by the controller reject faulty messages (and often provide for their re-transmission), isolated reception errors rarely affect the operation of the controller. Frequent but not continuous errors can indicate poor connections or electromagnetic interference.

Com4 POF

August 2007 UM3300/H (1.1.0)


If a controller fails to receive expected information from another via Port 1 or Port 2, it will set its Port 1 or Port 2 Fail Modbus discrete input and OPC variable, display “Comm1”, “Comm2”, or “Com1&2” in the lower left corner of its alarms screen while energizing any SerC relays (compressor controllers), or indicate a “Com1 Error” and/or “Com2 Error” alarm (turbine controllers).

Such indications can result from:

• the failure of a controller to transmit information expected by its companions, due to misconfiguration, failure of its serial port circuit, or a more general fault;

• the failure of the receiving controller’s serial port circuit; or

• line breaks, noise, or other network problems.

In general, a transmission or line problem will cause several control-lers to indicate such problems, while reception failures are indicated only by the problem controller.

Several controller features can prove useful when troubleshooting such problems:

• Any controller’s

Port 1 Test

[MODE COMM – 3] will identify the companion controllers it is receiving data from via Port 1.

• The

Port 2 Slave Test

[MODE COMM – 2] of any load-sharing Performance, Antisurge, Dual-Loop A/P, or Extraction Controller will indicate whether it is detecting any communication on the Port 2 load-sharing network.

• A Station Performance Controller’s

Port 2 Master Test

[MODE COMM – 1] will identify the load-sharing slaves that it is commu-nicating with.

• The

Serial Port Activity Test

[MODE TEST 3] elicits a dynamic display that reveals whether a specified serial port is transmit-ting or receiving data (Port 3 in this example):

The R will be followed by a hyphen if the port is receiving a transmission, otherwise an underscore. Similarly, the T will be followed by a hyphen only when that port is transmitting. In the above example, Port 2 is receiving but not transmitting:

A lack of communication activity on ports that are connected to active networks usually indicates a serial port failure. Such fail-ures (which are rare) usually result from extreme voltage surges or the failure of the 24-to-5 volt power converter. Either problem requires replacement of the CPU/IO PCB.

MODE TEST3 2

PT2 R-T_

August 2007 UM3300/H (1.1.0)


CPU/IO BoardProblems

Any of the following symptoms can indicate that the CPU/IO PCB should be replaced:

• a de-energized main fault relay (CR1), unless:

• the controller is powered down,

• cycling the controller off and back on re-energizes CR1, or

• the digital I/O status screen shows an underscore in the first relay position, thus indicating it was de-energized by that assigned condition, which does not indicate a CPU/IO PCB failure (see External Alarms on page 108):

• a lit Fault LED or non-functional engineering and front panels that remain so even after those panels have been replaced;

• periodic beeping accompanied by a “Reset” engineering panel message (see CPU/IO Fault Relay on page 105), provided the power cord is securely connected at both ends and its back-panel connector is not loose or otherwise failing;

• repeated beeping accompanied by a “CS=” message on the engineering panel readout (this usually indicates the parameter memory is defective);

• any unacceptable power converter voltage (15, 5.0, 3.3, or 1.2), provided the 24 Vdc is good, or an excessive or unusually high difference between the internal and ambient temperatures (see Internal Conditions on page 100);

• failure of the standard analog output circuits, provided external causes have been ruled out and the transmitter power supply has not failed;

• failure of any analog input or discrete I/O circuit, provided exter-nal causes have been ruled out

Mode RUN DigitalsIn:_2___6_Out:_2__5

In/OutDigitalOutÎ:_23__67_

or

Note:

I/O circuit failures are often caused by voltage transients that can also damage power supply PCB circuit traces (especially those for analog inputs, which provide their over-voltage protection).

August 2007 UM3300/H (1.1.0)


Analog InputProblems

Transmitter fail alarms indicate that at least one analog input is below its configured low (or above its specified high) alarm limit, as discussed under Analog Inputs on page 75. They, or any obvious analog input failures, usually indicate:

• externally open or shorted circuits

• blown fuses (such as those on a turbine controller field input module, see FIM Analog Input Circuits on page 59)

• induced currents

• failed or miscalibrated transmitters

• damaged analog input circuit components

• failure of the CPU/IO PCB’s 24-to-15 volt power converter

• misconfigured circuits (see Analog Input Switches on page 49)

The problematic input(s) can be identified using the status screen’s Analog In Menu (see page 103), provided their measured variable displays are enabled (see page 75). If you suspect the problems are internal, the simplest thing to do is replace the CPU/IO PCB and power supply assemblies (damage to the CPU/IO PCB analog input circuitry is often caused by extreme voltage surges that would also damage the protective circuits on the power supply PCB).

To determine if such a problem is internal, connect a test signal in place of the transmitter and use the

Signal Values Test

[MODE TEST 4] to compare the supplied signal and resulting reading. Keep in mind that an input value reported by that procedure is in percent of span (rather than range), as specified by its

Offset Zero Input

[MODE:D ANIN #] setting. If that parameter is enabled, the TEST 4 value is determined using a 20 percent offset zero (00.0 for 4 mA or less, 50.0 for 12 mA, A0.0 for 20 mA or higher).

If the controller is reading an input correctly but seemingly ignoring it, check to make sure none of its

Input Lockout

(MODE LOCK 6) parameters have been enabled.

Analog OutputProblems

An output loopback deviation or alarm indicates that the controller is unable to maintain the intended voltage or current in a final control element’s analog output circuit. This can be caused by:

• field element problems

• poor connections or open circuits

• blown fuses (such as those on a turbine controller field output module, see FOM Analog Outputs on page 62)

• CPU/IO or auxiliary PCB component failures

• excessive loads on or failure of the transmitter power circuit (which also powers the CPU/IO PCB analog outputs)

• miscalibration of the high-current output or its loopback circuit

August 2007 UM3300/H (1.1.0)


You can determine the magnitude of the problem by using the status screen to view the intended and measured output values (see Com-pressor Controller I/O Signals on page 101 or Turbine Controller I/O Signals on page 102). Unless the deviation indicates an open circuit or is too large for the control loop to adjust to, such problems rarely require immediate correction.

To determine if the cause is internal or external:

• transfer control to another device—if it is unable to maintain the intended current or voltage, the problem is probably external to the controller; or

• connect a test load in place of the field element and disconnect the transmitter power output—if the controller is still unable to maintain the intended current or voltage, the problem is most likely internal.

An internal high-current output problem should be addressed by first trying to recalibrate it. If that fails, replace the auxiliary PCB.

Internal standard output problems should be addressed by replacing the power supply and CPU/IO PCB assembly. To isolate the prob-lem further, connect a test load and then replace those components one at a time.

Discrete InputProblems

If you suspect a discrete input circuit is malfunctioning, you can determine whether the input signal is being properly read by com-paring its displayed state (see Field I/O Screens on page 101) to the voltage between its back-panel or FIM terminals (see page 53 or page 58). The signal should be greater than 10 Vdc if the input is asserted, or less than 2 Vdc if it is cleared.

You should also compare that voltage to the state of the connected signal source to determine whether it is malfunctioning or if there might be a line break or blown fuse—especially for FIM Discrete Input Circuits (see page 58). If you use solid-state relays to control such inputs, keep in mind that they can be problematic. Ground-loop problems can also alter the effective voltages in such inputs.

If the controller is reading an input correctly but seemingly ignoring it, check to make sure none of its

Input Lockout

(MODE LOCK 6) parameters have been enabled.

August 2007 UM3300/H (1.1.0)


Discrete OutputProblems

If you suspect a discrete output/control relay malfunction, you can temporarily alternate the assigned function between On and Off to determine if the connected device responds accordingly. If it does not, check any fuse included in the suspect circuit (such as those on a turbine controller field output module, see FOM Control Relay Cir-cuits on page 63)

To directly test a relay’s operation, compare its intended coil state (energized or de-energized, see page 101) to the resistance across its back-panel or FOM terminals (see page 53 or page 63):

Step 1: Note the position of its NO/NC switch (see page 48).

Step 2: For basic I/O controllers, disconnect the field devices from the CR# circuits by unplugging their terminal blocks from the back panel.

For FTA-equipped controllers, it is easiest to connect a spare FOM or FIOM. Alternately, you could disconnect the field wiring from the FTA or temporarily replace the top half of the connec-tors (which are secured with screws).

Step 3: For compressor controllers, set MODE:D RA 1 to OFF and RA 2 through 5 to ON (be sure to note their original settings). This should energize all five relays.

For turbine controllers, set MODE:D RA 1 (and RA 9, if present) to +OFF and all other RA parameters to +ON.

Step 4: The resistance measured across each relay’s field terminals should be nearly zero for each normally-open relay and nearly infinite for each normally-closed relay.

Step 5: For compressor controllers, set MODE:D RA 1 to ON and RA 2 through 5 to OFF. This should de-energize all five relays.

For turbine controllers, set MODE:D RA 1 (and RA 9, if present) to +ON and all other RA parameters to +OFF.

Step 6: The resistance measured across each relay’s field terminals should be nearly zero for each normally-closed relay and nearly infinite for each normally-open relay.

Step 7: Restore the original values of any MODE:D RA parameters you changed in step 3 or 5.

Step 8: Restore the original field wiring connections.

If the resistance measured across a given relay was the same in both step 4 and step 6, that relay is probably not energizing or de-energizing, or else its contacts are not opening or closing properly. In either case, the CPU/IO PCB will need to be replaced.

August 2007 UM3300/H (1.1.0)


Speed BoardProblems

Unless the CPU/IO PCB’s 24-to-15 volt power converter has failed, any of the following symptoms generally indicates that the auxiliary PCB assembly (speed board) should be replaced:

• the speed board fault relay (CR9) de-energizes

• the Fault LED lights while other LEDs and readouts are lit

• an excessive deviation of the high-current analog output loop-back test, provided external causes have been ruled out (see Analog Output Problems on page 118)

• an “Aux. Board” alarm

If a Speed Controller exhibits any of those symptoms, that assembly must be immediately replaced. If an Extraction Controller does, the immediacy of the problem depends on which auxiliary I/O circuits are in use and how important they are to control of the turbine.

Speed InputProblems

MPU failure alarms are usually caused by the loss of a frequency signal due to misaligned magnetic pickups, broken leads, or high temperatures. When operating with only one healthy MPU, its failure would trigger an MPULoss shutdown. However, such a shutdown could also occur if:

• passive MPU’s are used and the speed falls below the minimum needed to generate a measurable signal; or

• the pickups are not properly matched to the gear that excites them and the speed exceeds the maximum above which their signals cannot decay between the passage of adjacent teeth.

In either case, all of the MPUs would appear to have failed.

As an aid to troubleshooting, these controllers provide two ways to display the value of each speed input:

• The signal to each input can be displayed (in rpm) by the status screen’s In/Out menu.

• The engineering panel’s

Signal Values Test

[MODE TEST 4] will display each such signal as a percentage of the

Maximum Con-trol Speed

[COND:S DISPLAY HIGH].

Either value will be accurate only if the input has been properly configured. If the inputs appear to be miscalibrated, check the con-figuration parameters to make sure you have correctly entered the number of teeth on the exciter gear and the speed ratio between the gear and turbine shafts.

August 2007 UM3300/H (1.1.0)

122

Chapter 6: Maintenance and Repair

PositioningProblems

An Antisurge, Performance, or Speed Controller can be configured to indicate a final control element positioning problem if it detects an excessive deviation between its intended control element position and a predefined or configured analog input signal (which might be an actual position measurement or a hydraulic / pneumatic actuator control pressure).

Unless that problem is caused by a concurrent output failure, the problem is external to the controller. Check for wiring problems, or miscalibration or failure of the control element or an intermediate I/H or I/P converter.

August 2007 UM3300/H (1.1.0)

Series 3

++

Hardware Reference

123

ReplacementProcedures

Series 3++ Controllers contain no user-serviceable parts. Suspect units or components should be replaced with identical spares and returned to CCC for diagnosis and repair. You can:

• replace one or more internal components, without dismounting the case and back panel (see Component Replacement); or

• replace the entire controller with a new one having the same hardware configuration, without disturbing the field wiring (see Controller Replacement).

Either way, you might need to change the front panel (see Front Panel Replacement on page 125) or update, change, or reconfigure the installed application software (see Programming and Configura-tion on page 126).

Spare Parts If your chosen maintenance strategy is to replace malfunctioning units, at least one controller with identical components should be stocked for every five in use, along with a selection of front panels.

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++ Controller Parts List [DS3300/P] lists the assemblies you might wish to stock. Your spare parts inventory should be based on the total number of controllers using each assembly.

Return Procedure To return any item 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++ Performance Con-troller), 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 (appropriate packing materials can be sent to you if needed) and ship them prepaid and insured to:

Compressor Controls CorporationATTN: Service Department4725 121st StreetDes Moines, IA 50323 U.S.A.

The RMA number should be clearly displayed on all cartons and noted in all correspondence. The equipment will usually be repaired and shipped back within five days of its arrival at the factory.

Warning!To prevent damage from static-electric discharges, all spare circuit boards should be stored and transported in static-resis-tant pouches.

August 2007 UM3300/H (1.1.0)


ComponentReplacement

Most controller malfunctions can be fixed by replacing some or all of the internal components from the front of the case:

Step 1: Transfer control of your process to the malfunctioning con-troller’s online backup or other alternate device.

Step 2: Disconnect the power cable from the rear of the controller.


Step 4: Separate the engineering panel assembly by removing the four galvanized screws at its corners and pulling it forward to disengage it from the CPU/IO PCB and case.

Step 5: Pull the internal components from the case.

Step 6: Decide which components to replace, obtain them from your company stores, and verify their switch and jumper settings (see page 48, page 49, and page 51).

Step 7: To separate the auxiliary PCB, remove the four screws that attach it to the standoffs on the CPU/IO PCB, then disengage the pins on its rear side from their CPU/IO PCB connector.

Step 8: To replace only the CPU/IO PCB or power supply, remove the two clips from the connector joining them, replace the defec-tive assembly, and re-install the clips.

Step 9: To reinstall or replace the auxiliary PCB, align the pins on its rear side with the corresponding connectors on the CPU/IO PCB, then press them together. Reinstall the screws.

Step 10: Slide the internal components into the case (the CPU/IO PCB and PSA fit into the left-most set of grooves). Press fairly hard until you feel the PSA “pop” back into its connector.

Step 11: Align the tabs on the sides of the engineering panel’s mounting brackets with the grooves in the case, then slide it back into the connector on the front of the CPU/IO PCB. Secure this assembly by reinstalling the four screws at its corners.

Step 12: Reinstall or replace the front panel with one having the same overlay as the original (see page 125).

Step 13: Reconnect the power cable to the back panel.

Step 14: Verify or reload the control program, then reload its config-uration parameters (see page 126).

Step 15: Transfer control of the process to the reassembled unit.

Warning! Disconnect the power cable before disassembling a controller.

Caution: Never disassemble a controller or handle its components without taking steps to prevent static discharge.

August 2007 UM3300/H (1.1.0)


ControllerReplacement

If you suspect the inside of the back panel or case are corroded or contaminated with foreign materials, use the following procedure to replace the entire controller rather than just its internal components:

Step 1: Transfer control of your process to the controller’s online backup or other alternate device.

Step 2: Unplug the power cable from the controller’s back panel. Unplug the field wiring terminal strips or FTA cables (rather than disconnecting individual wires).

Step 3: Loosen and remove the slide clamps from the case, remove the slides and pull the controller forward from the panel cutout.

Step 4: Obtain a spare unit having the same hardware configuration from your company stores.

Step 5: Verify that all of the replacement unit’s internal switches and jumpers are set the same as in the controller being replaced (see Internal Settings on page 47).

Step 6: Remove the slide clamps from the replacement controller, then slide it into the panel cutout. Reinstall its slides and slide clamps and tighten the pressure screws.

Step 7: If needed, replace the front panel with that of the original controller or a new one having the same overlay (see below)

Step 8: Reconnect the FTA data cables or back-panel terminal strips and power cable.

Step 9: Verify or reload the control program and configuration parameters (see Programming and Configuration on page 126).

Step 10: Transfer control of your process to the new controller.

Front PanelReplacement

To replace a front panel that has failed or no longer matches a newly-installed control program:


Step 2: Unplug the cable connecting the front panel to the engineer-ing panel.

Step 3: Squeeze the top and bottom of the wire hinge together until you can pull it away from the engineering panel.

Step 4: Insert either end of the new panel’s wire hinge into its hole in the engineering panel’s mounting bracket, then squeeze the top and bottom of the hinge together until you can insert the other tang into its hole.

Step 5: Plug the ribbon cable from the engineering panel into the connector on the back of the front panel.

Step 6: Close the front panel after completing any needed configu-ration or other engineering procedures.

August 2007 UM3300/H (1.1.0)


Programming andConfiguration

Whenever you replace a controller or its CPU/IO PCB, you must make sure the control program and configuration parameters of the new CPU match those of the original:

Step 1: Retrieve the needed program information and serial commu-nication settings from your records (see Overview on page 99).

Step 2: Enter the Enable Reconfiguration [MODE LOCK 5 1] key sequence from the engineering panel, then assign the original values to the following parameters:

• Computer ID Number [MODE:D COMM 0 •]


• Port 4 Baud Rate [MODE:D COMM 4].

Step 3: Connect a PC running the Configurator program.

Step 4: Use the Program Version [MODE TEST 2] test to determine if the replacement is running the desired control program. If not, reload it (see Reloading the Control Program on page 71).

Step 5: Download a saved copy of the original parameter set and verify the resulting parameter checksum.

Step 6: Disconnect the Configurator program.

Step 7: Use the Set Clock [MODE TEST 9] key sequence to set the internal date and time (Speed Controllers only).


August 2007 UM3300/H (1.1.0)



Appendix A Configuration ParametersThis appendix describes each configuration or tuning parameter dis-cussed in the body of this manual, including:

• its functional name and a description of that function,

• the range of values it can be given,

• the sequence of keys you must press to view or change it from the engineering panel (often used as an alternate name),

• its confirming display prompt,

• any restrictions on the order in which it must be entered, and

• cross-references to the sections of this manual in which the parameter is discussed.

Keyboard Entry As discussed in Chapter 2, pressing the indicated keys will produce the listed confirming display, which consists of a prompt followed by the current value. For array parameters, that prompt will include a “#” representing the digit corresponding to the array element.

Values that are selected from a list by pressing the decimal key are shown as “Value” or “Valu”. OFF/ON or OFF/HIGH/LOW choices are shown as such and are selected by pressing the corresponding key (0, 1, HIGH, or LOW). Values that are entered by pressing one or more numeric keys are shown as a series of “#” symbols repre-senting digits, possibly including an automatically-placed decimal point. The space before a negative value is replaced by a “–”. A hexadecimal ten leading digit is entered by pressing HIGH and dis-plays as “A” (100.0 is entered as HIGH 0 0 and displays as A0.0).

August 2007 UM3300/H (1.1.0)

128 Appendix A: Configuration Parameters

COND:A f(X) 2 #and X 2 #

These parameters characterize an Antisurge Controller’s reported flow measurement in multisection compressor applications.

Range: 0.00 to 9.99 percent [X]0.00 to 9.99 percent [f(X)]

Display: X2# #.## [X]Y2# #.## [f(X)]

Reference: Numeric Parameters . . . . . . . . . . . . . . . . . . . 41

COND:D BIAS 1 For controllers equipped with an auxiliary PCB, this parameter sets the bias used to scale and calibrate the high-current output signal.

Range: .0000 to .9999

Display: B1 .####

Reference: Output Circuit Calibration. . . . . . . . . . . . . . . . 85

COND:D BIAS 2 For controllers equipped with an auxiliary PCB, this parameter sets the bias used to scale and calibrate the high-current output’s loop-back input signal.

Range: –.9999 to .9999

Display: B2 .####

Reference: Loopback Circuit Calibration . . . . . . . . . . . . . 87MODE TEST 4 . . . . . . . . . . . . . . . . . . . . . . . 146

COND:D CONST 2 This parameter defines the number of seconds the output or posi-tion feedback test deviation can be above its threshold before the corresponding alarm is signaled.

Range: 0.00 to 9.96 seconds (multiples of .04)

Display: CO2 #.##

Reference: Output Loopback Test . . . . . . . . . . . . . . . . . . 88

Reported FlowCharacterizer

Output Scaling Bias

Note: BIAS 1 and 2 can only be changed via the Engineering Panel.

Loopback Scaling Bias

Output Failure Delay

August 2007 UM3300/H (1.1.0)


COND:D DISPLAY0 #

Each of these parameters determines whether or not the corre-sponding measured variable can be viewed via the status screen’s Analog In menu.

Range: Off variable cannot be displayedOn variable can be displayed

Display: D0# OFF/ON

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75

COND:D DISPLAY0 # –

Each of these parameters defines the name and engineering units shown when the corresponding measured variable is viewed.

Range: up to eight name and five units symbols

Display: AAAAAAAA, then EU:AAAAAselected symbol (A) flashespress • to select, then ENTER for each

Reference: Label Parameters . . . . . . . . . . . . . . . . . . . . . . 39Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75

COND:D DISPLAY0 # HIGH

Each of these parameters defines the value the Analog In menu would display for the corresponding measured variable if the value of its signal variable was 100.0 percent.

Range: –9999 to 9999

Display: 0#H ####


COND:D DISPLAY0 # LOW

Each of these parameters defines the value the Analog In menu would display for the corresponding measured variable if the value of its signal variable was zero.

Range: –9999 to 9999

Display: 0#L ####


COND:D DISPLAY0 # •

Each of these parameters defines the position of the decimal point in the corresponding measured variable display.

Range: 0 #### (no decimal)1 ###. (trailing decimal)2 ##.#3 #.##4 .### (leading decimal)

Display: 0#. 4321 (selected digit is replaced by •)

Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 36Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75

Measured VariableDisplay

Measured VariableName and Units

Measured VariableMaximum

Measured VariableMinimum

Measured VariableDecimal

August 2007 UM3300/H (1.1.0)


COND:D GAIN 1 For controllers equipped with an auxiliary PCB, this parameter sets the gain used to scale and calibrate the high-current output signal.

Range: .0000 to .9999

Display: G1 .####


COND:D GAIN 2 For controllers equipped with an auxiliary PCB, this parameter sets the gain used to scale and calibrate the high-current output’s loop-back input signal.

Range: 00.00 to 99.99

Display: G2 ##.##

Reference: Loopback Circuit Calibration . . . . . . . . . . . . . 87MODE TEST 4 . . . . . . . . . . . . . . . . . . . . . . . 146

COND:D IN ## For turbine controllers, each of these parameters selects the func-tion assigned to the corresponding discrete input. If the value is positive, the input is asserted by raising its voltage above the neutral zone. If it is negative, the input is asserted by lowering that voltage below the neutral zone.

Range: see UM3307 and UM3308

Display: ##+Value (press HIGH or LOW to select sign,then press • to select function)

Reference: Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 74

COND:D OUT 1 This parameter selects the signal from which the high current output signal is calculated and enables or disables the current and position feedback tests.

Range: Act actuator control signal, no testsActL Act plus current Loopback test onlyActP ActL plus position feedback testOff constant, minimum signal

Display: OT1 Valu

Reference: Loopback Circuit Calibration . . . . . . . . . . . . . 87Output Loopback Test . . . . . . . . . . . . . . . . . . 88

Output Scaling Gain

Note: GAIN 1 and 2 can only be changed via the Engineering Panel.

Loopback Scaling Gain

Discrete InputAssigned Function

First Output AssignedVariable

August 2007 UM3300/H (1.1.0)


COND:D OUT 1 – For controllers that support valve positioning via the high-current output, this parameter determines whether that output is generated as a unipolar or bipolar electrical signal.

Range: Off unipolar outputOn bipolar output

Display: OT1- OFF/ON

Reference: Bipolar Operation . . . . . . . . . . . . . . . . . . . . . . 83Output Circuit Calibration . . . . . . . . . . . . . . . . 86Loopback Circuit Calibration. . . . . . . . . . . . . . 87

COND:S ALARM 1 This parameter defines the minimum rotational speed below which the signal from a magnetic pickup is considered unreliable.

Range: 00000 to Maximum Control Speed

Display: A1 #####

Enter After: COND:S DISPLAY HIGH

Reference: MPU Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

COND:S DISPLAYHIGH

This parameter serves as a reference value for converting the abso-lute speeds (in rpm) obtained from the speed inputs and displayed on the front-panel readouts to the percent-of-range values the con-troller uses internally. It should be set equal to or slightly greater than the maximum rotational speed your turbine could ever reach.

Range: 00000 to 64000 rpm

Display: HI #####


MODE:D ANINLOW

For a Dual-Loop A/P Controller, this parameter defines the minimum value for any offset-zero input’s analog-to-digital variable, below which that input is considered to have failed.

Range: 00.0 to 99.9 percent

Display: ANL ##.#

Reference: Numeric Parameters. . . . . . . . . . . . . . . . . . . . 40Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75MODE:D ANIN –. . . . . . . . . . . . . . . . . . . . . . 141

Bipolar Output

Control Threshold

Maximum ControlSpeed

Transmitter FailureLimit

August 2007 UM3300/H (1.1.0)


MODE:D ANIN # Each of these parameters identifies the zero level of the corre-sponding analog input signal (relative to its hardware configuration).

Range: Off actual zero (for example, 0 to 5 Vdc)On 20 percent offset zero (e.g., 4 to 20 mA)

Display: A# OFF/ON

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75Analog In Menu . . . . . . . . . . . . . . . . . . . . . . 103MODE TEST 4 . . . . . . . . . . . . . . . . . . . . . . . 145

MODE:D ANIN #HIGH

Each of these parameters defines the maximum value for the corre-sponding analog input’s analog-to-digital variable, above which that input is considered to have failed.


Display: A#H ##.#

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75MODE:D ANIN – . . . . . . . . . . . . . . . . . . . . . 141

MODE:D ANIN #LOW

Each of these parameters defines the minimum value for the corre-sponding analog input’s analog-to-digital variable, below which that input is considered to have failed.


Display: A#L ##.#

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 75MODE:D ANIN – . . . . . . . . . . . . . . . . . . . . . 141

MODE:D COMM 0 This parameter identifies the controller in the network connected to its serial Port 1. With the exception of redundant controllers, this ID must be unique within that network.

Range: 1 to 8

Display: Ctrl# #

Reference: Configuring Communications. . . . . . . . . . . . . 73Engineering Panel . . . . . . . . . . . . . . . . . . . . 110

Offset Zero Input

Analog Input HighAlarm Limit

Analog Input LowAlarm Limit

Controller ID Number

Note: COMM 0 and 0 • can only be changed via the Engineering Panel.

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MODE:D COMM 0 • This parameter identifies the controller in the networks connected to its serial Ports 2, 3, and 4. With the possible exception of redundant controllers, this ID must be unique within each of those networks.

Range: 01 to 64

Display: Comp# ##

Reference: Configuring Communications . . . . . . . . . . . . . 73Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Programming and Configuration. . . . . . . . . . 126

MODE:D COMM 2 This parameter defines the data transmission rate for the Port 2 serial communication channel.

Range: 2400, 4800, 9600

Display: PT2 Valu (press • to select, then ENTER)

Reference: List Parameters . . . . . . . . . . . . . . . . . . . . . . . 37Configuring Communications . . . . . . . . . . . . . 73

MODE:D COMM 3 These parameters define the data transmission rate, parity setting, and Modbus register scaling for the Port 3 communication channel.

Range: 4800, 9600, 19k2 (baud)Even, Odd, None (parity)4000, 4095, 64k (100% value)

Display: PT3 Valu (press • to change, then ENTER)PT3 Valu (press • to change, then ENTER)PT3 Valu (press • to change, then ENTER)

Reference: Configuring Communications . . . . . . . . . . . . . 73Programming and Configuration. . . . . . . . . . 126

MODE:D COMM 4 These parameters define the data transmission rate, parity setting, and Modbus register scaling for the Port 4 communication channel.

Range: 4800, 9600, 19k2 (baud)Even, Odd, None (parity)4000, 4095, 64k (100% value)

Display: PT4 Valu (press • to change, then ENTER)PT4 Valu (press • to change, then ENTER)PT4 Valu (press • to change, then ENTER)

Reference: Configuring Communications . . . . . . . . . . . . . 73Programming and Configuration. . . . . . . . . . 126

Computer ID Number

Port 2 Baud Rate

Port 3 Baud Rate

Port 3 Parity

Port 3 Scaling

Port 4 Baud Rate

Port 4 Parity

Port 4 Scaling

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MODE:D fC 1 This parameter enables or disables the optional valve positioning loop and the display of its input signal value (LVDT1).

Range: Off valve positioning disabledOn valve positioning enabled

Display: fC1 OFF/ON

Reference: Output Circuit Calibration. . . . . . . . . . . . . . . . 86Loopback Circuit Calibration . . . . . . . . . . . . . 87

MODE:D fD 1 This parameter selects the analog input for the flow signal (∆Po) used to compute a Performance Controller’s measured total flow.

Range: Off measured total flow not calculated1 to 8 selects corresponding analog input

Display: fD1 OFF/#

Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 36

MODE:D fE 1 This parameter determines whether the controller will operate in its redundant mode when a Track discrete input is asserted.

Range: Off redundant tracking disabledOn redundant tracking enabled

Display: fE1 OFF/ON

Reference: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

MODE:D LOCK 0 If redundant controllers are given the same Computer ID Number [MODE:D COMM 0 •], this parameter must be disabled so that only one of them will respond to Modbus data requests to that address. If they are given different ID numbers, enabling this parameter allows the Modbus host to monitor both controllers.

Range: Off host cannot monitor tracking controllerOn host can monitor tracking controller

Display: LOC0 OFF/ON

Reference: Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . 98

MODE:D LOCK 2 This parameter defines the level of access (read/write or read-only) that a host device has to the controller’s coils and holding registers.

Range: Off read and write accessOn read access only


Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 34Configuring Communications. . . . . . . . . . . . . 73

Positioning Loop

Mass Flow Input

Redundant Tracking

Modbus While Tracking

Modbus Write Inhibit

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MODE:D RA # Each of these parameters selects the conditions under which the corresponding discrete output is triggered. If the assigned function is positive, the relay will be energized when the associated condition exists. If the value is negative, the relay will de-energize.

Range: see chapter 3 of each configuration manual

Display: RA#±Valu (press HIGH or LOW to select sign, then press • to select function)

Reference: List Parameters . . . . . . . . . . . . . . . . . . . . . . . 38Discrete I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

MODE:E LOCK 6 An Extraction Controller that does not use the high-current analog output or discrete inputs of it auxiliary PCB assembly can be config-ured to ignore or operate without it by enabling this parameter.

Range: Off functioning auxiliary PCB requiredOn auxiliary PCB ignored (if present)


Reference: Speed Board Operation . . . . . . . . . . . . . . . . . 78Alarm System . . . . . . . . . . . . . . . . . . . . . . . . 106

MODE:S ANIN 1 This parameter specifies whether the controller calculates a speed from the frequency of the first magnetic pickup input signal.

Range: Off MPU1 not readOn MPU1 enabled

Display: P1 OFF/ON

Reference: Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . 79

MODE:S ANIN 2 This parameter specifies whether the controller calculates a speed from the frequency of the second magnetic pickup input signal.


Display: P2 OFF/ON


MODE:S ANIN 3 This parameter specifies whether the controller calculates a speed from the frequency of the third magnetic pickup input signal.


Display: P3 OFF/ON


Relay AssignedFunction

Auxiliary PCB Lockout

Speed Input 1

Speed Input 2

Speed Input 3

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MODE:S ANIN 4 When all three magnetic pickup inputs are enabled, this parameter defines their maximum acceptable deviation from the median speed. Any input that deviates from the median by more than this amount is considered to have failed.

Range: 01 to 99 rpm

Display: WIN ##


MODE:S ANIN 5 This parameter defines the number of speed input pulses the con-troller will expect to receive per revolution of the MPU gear shaft.

Range: 000 to 999 teeth

Display: GR ###

Reference: Speed Scaling . . . . . . . . . . . . . . . . . . . . . . . . 80

MODE:S ANIN 6 This parameter defines the number of times the MPU gear shaft rotates per revolution of the turbine.

Range: 0.000 to 9.999

Display: Ri #.###

Reference: Speed Scaling . . . . . . . . . . . . . . . . . . . . . . . . 80

MODE:S REV 1 This parameter matches the direction of the actuator control signal to that of your steam control valve.

Range: Off signal-to-open valveOn signal-to-close valve

Display: REV1 OFF/ON


MODE:S SS 3 This parameter specifies how a Speed Controller’s megawatt droop algorithm selects its analog input (signal variable SV7 or SV8).

Range: Off always select SV7High select highest of two signalsLow select lowest of two signals

Display: SS3 OFF/HIGH/LOW

Reference: Enabling Parameters . . . . . . . . . . . . . . . . . . . 35

MPU Tolerance

Gear Tooth Count

Shaft Speed Ratio

Output Reverse

Alternate MW Input

August 2007 UM3300/H (1.1.0)



Appendix B Controller Test SequencesThis appendix describes the controller test procedures that can be executed from the engineering panel of a Series 3++ Controller.

As described in Chapter 2, each such key sequence begins with a data group key that selects the function of the second key. Unlike the key sequences used to enter configuration parameters, most of these procedural key sequences are not assigned to specific data pages. A data page letter is indicated only when you must press the data group key as many times as needed to display the letter at the end of the first step confirming display. For example, the Transmitter Status Test [MODE:D ANIN –] is assigned to the Device page, as indicated by the MODE:D notation and its “MODE: D” first step con-firming display.

Pressing the CLEAR key will terminate any of these procedures and clear the display. Otherwise, they time out and automatically clear the display after 45 seconds of keyboard inactivity.

LIMIT LOWER The Machine Control Program (see page 70) scans the controller’s inputs and outputs every five milliseconds, and ideally executes the control loop after every eighth I/O scan (in other words, at 40 milli-second intervals). That loop is interrupted by serial communication tasks and subsequent I/O scans, but should complete before the next eighth such scan.

To display the number of I/O scans that are being run between con-trol loop executions on the engineering readout, press the following Front Panel keys (for Dual-Loop A/P and Speed Controllers, the first key is instead labelled ALT or LIMIT):

If a control loop execution takes more than the allotted eight I/O scans, the displayed Lp will be zero. The CPU will then reset if the loop takes more than 120 more milliseconds to complete. To display the number of I/O scans (out of 16) that remained before that would have happened, press the following front panel keys (for Dual-Loop and Speed Controllers, the first key would be LIMIT or POWER):

CPU Loading

LIMIT 2 ∇ Lp 5

LIMIT 3 ∇ Wp 16

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138 Appendix B: Controller Test Sequences

MODE LOCK 5 1 To enable alteration of the controller’s configuration and tuning parameters from the engineering panel, press the following keys:

If you make a mistake entering this sequence, the controller will beep and display an Error! message on the confirming display.

When you finish reconfiguring your controller, enter the Disable Reconfiguration [MODE LOCK 5 0] sequence to disable further changes (otherwise, reconfiguration will be automatically disabled after thirty minutes of keyboard inactivity):

MODE LOCK 5 0 To disable alteration of the controller’s configuration and tuning parameters from the engineering panel, press the following keys:

If you make a mistake entering this sequence, the controller will beep and display an Error! message on the confirming display.

Enable Reconfiguration

MODE LOCK5 1

LOC5 ON

ENTER

DisableReconfiguration

MODE LOCK5 0

LOC5 OFF

ENTER

August 2007 UM3300/H (1.1.0)


MODE LOCK 3 • This procedure copies the controller’s current parameters into any of its three alternate sets.

To initiate this procedure, which you can abort at any time by press-ing CLEAR, press the following keys:

This display indicates which alternate set the current parameters will be copied into. To select a different set, press the decimal (•) key:

Pressing ENTER will then copy the current parameters to the indi-cated alternate set and briefly display that set’s new checksum:

MODE LOCK 3 • • This procedure copies any of the three alternate parameter sets into the controller’s current set.

To initiate this procedure, which you can abort at any time by press-ing CLEAR, press the following keys:

This display indicates which alternate set will be copied into the working memory. To select a different set, press the decimal (•) key:

Pressing ENTER will then initiate a recall of the selected alternate parameter set. If it is valid, it is copied into the current set and the controller executes a soft reset. If the selected set is invalid (which probably means it was never defined), “No Match” is displayed to inform you that the recall has been aborted:

or

Store AlternateParameters

MODE LOCK3 •

ENTER Store1?

•

Store2?

ENTER CS= F882

Recall AlternateParameters

MODE LOCK3 • •

ENTER Recall1?

•

Recall2?

ENTER Reset

No Match

August 2007 UM3300/H (1.1.0)

140

Appendix B: Controller Test Sequences

MODE LOCK 4 This procedure displays the checksum values of the controller’s various parameter sets. You can determine which (if any) of the alternate parameter sets is currently in use by comparing the check-sum of the present and long-term sets to those for the alternate sets. You can also tell if any of these parameter sets agree with those recorded on a parameter worksheet by comparing these checksums to those recorded on that worksheet.

To view the parameter checksums, press the following keys:

or

If the confirming display beings with CS, the present parameter set is the same as that stored in long-term memory. If that display begins with P, the two sets differ and the checksum shown is for the present set. In that case, you can display the long-term parameter checksum by pressing the decimal key:

If the two parameter sets are different, you should use the Disable Reconfiguration [MODE LOCK 5 0] procedure to disable reconfigu-ration. The controller will then correct any errors that occur in the present parameter set.

To display the alternate parameter set checksums, continue to press the decimal (•) key:

You can cycle through the displays of all four (or five) checksums by continuing to press the decimal (•) key as many times as you want.

Parameter Checksum

MODE LOCK4

CS= A3C2

P = A76F

•

L = A3C2

•

CS1=B94A

•

CS2=632E

•

CS3=44FC

August 2007 UM3300/H (1.1.0)


MODE:D ANIN – This procedure can be used to identify which analog input signal(s) triggered a transmitter failure alarm, which is indicated by lighting the front panel’s Alarm LED and displaying “TranFail” on its Alarms status screen.

To initiate this test, press the following keys:


or

or

The digit in this display is the analog input channel number (AN1). HIGH indicates that signal is above its Analog Input High Alarm Limit, LOW indicates it is below its Analog Input Low Alarm Limit, or GOOD indicates it is between those limits.

For a Dual-Loop Controller only, the inputs are checked against a common Transmitter Failure Limit and only test as GOOD or LOW.

You can determine the status of each consecutive input signal by pressing the • key:

or

or

This allows you to repetitively cycle through all the inputs.

The status of the displayed input is updated continuously. With pre-vious versions, the conditions of all eight inputs were checked only at the instant that this test was initiated and not updated thereafter.

MODE COMM To restart the control program without initializing its operating state and variables, press the following keys:

Doing so will increment both the CPU Reset Count [MODE TEST 6] and the Front-Panel Reset Count [MODE TEST 7].

Transmitter Status Test

MODE MODE: D

AN IN–

AN1 GOOD

AN1 HIGH

AN1 LOW

•

AN1 GOOD

AN1 HIGH

AN1 LOW

Reset Controller

MODE COMM ENTER Reset

August 2007 UM3300/H (1.1.0)

142


MODE COMM – 1 A Station Controller periodically requests information from each Load-Sharing Performance Controller. To determine whether or not those controllers are responding, press the following keys:

or

where the number following the minus sign is the first designated load-sharing controller’s Computer ID Number (08 in the above example). The confirming display will be GOOD if that controller is responding to Station Controller requests, or BAD if it is not.

Pressing the decimal key then advances this display through the list of designated Load-Sharing Controllers, in the following order:

The confirming display The End will appear after the status of all the designated secondary controllers has been reviewed.

MODE COMM – 2 To determine if the controller has detected any Port 2 serial commu-nications activity within the past second, press the following keys:

or

where the confirming display will be GOOD if a serial transmission has been received during the previous second.

Port 2 Master Test

08 decrementing to 0116 decrementing to 0924 decrementing to 1732 decrementing to 2540 decrementing to 3348 decrementing to 4156 decrementing to 4964 decrementing to 57

MODE COMM– 1

-08 GOOD

-08 BAD

Port 2 Slave Test

MODE COMM– 2

-2 GOOD

-2 BAD

Note:

Unless this port is used for performance or extraction load-sharing, it is usually not even connected to any other controllers and a BAD result for this test is of no consequence.

August 2007 UM3300/H (1.1.0)


MODE COMM – 3

Each controller can be configured to expect Port 1 transmissions from other Series 3

++

Controllers by enabling any of several features (for example, redundant controller tracking). This procedure reveals whether or not this controller is receiving Port 1 transmissions from the associated controllers.

To identify the companion controllers from which Port 1 transmis-sions are being received, press the following keys:

where the digit is a controller ID number. GOOD indicates data is being received from that controller, BAD indicates it is not. Subse-quently pressing the decimal key displays the same information for the next possible companion controller. You can cycle through all eight possible ID numbers (including this controller’s own) by press-ing that key as many times as you like:

MODE TEST 3

To view a dynamic display of a specified serial port’s communica-tions activity, press the following keys:

where # is the numeric key corresponding to the port number. The bar after the R will be in the high position if that port is currently receiving a transmission, otherwise it will be low. Similarly, the bar after the T will be high only when that port is transmitting. The port in the above example is receiving but not transmitting.

You can then check for communications activity on any other port by pressing the corresponding numeric key (for example, press 4 to view Port 4’s activity):

Port 1 Test

MODE COMM– 3

-1 GOOD

-1 BAD

•

-8 BAD

•

-1 GOOD

Note:

Although transmissions are normally received from all controllers connected to Port 1 (including this one), only those from specified companion controllers are normally of any concern.

Serial Port Activity Test

MODE TEST3 #

PT# R-T_

4

PT4 R-T_

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144


MODE TEST 2 This procedure displays the installed control program and the FPGA and auxiliary PCB firmware revision numbers.

To determine which revision of the control program is installed in your controller, press the following keys:

If the confirming display is blank, production software has not yet been loaded into this controller.

Pressing the decimal key (•) will then display the installed version of the FPGA or auxiliary PCB firmware:

or

or

The SPBD (speedboard/auxiliary PCB) version is displayed only by Speed and Extraction Controllers with installed auxiliary PCBs, while the line of dashes is displayed by turbine controllers that are not so equipped. In either case, pressing the decimal key (•) a sec-ond time would then display the FPGA firmware version.

Program Version

MODE TEST2

1061-001

•

FPGA0202

SPBD-010

--------

August 2007 UM3300/H (1.1.0)


MODE TEST 4 This procedure can display the current values of the analog, speed (frequency), position, and discrete input signals, the intended states of the control relays, and the currently-pressed front-panel buttons and control keys.


To display the measured value of any analog input, press the corre-sponding numeric key. For example, pressing 1 displays the current value of the CH1 input:

where the number in the display is the corresponding signal variable (values above 99.9 percent display as A0.0). Or, you can display the value of each consecutive input by pressing the decimal key (•).

To determine if an input is being read accurately, disable its Offset Zero Input [MODE:D ANIN #] parameter and compare the resulting TEST 4 value to a volt or ammeter measurement of the correspond-ing input signal.

To display a turbine controller’s speed/frequency inputs (MPUs), press the decimal key to scroll past the CH8 input display:

Each input is displayed as a percentage of the defined maximum speed for the corresponding turbine shaft. Because the Extraction Controller does not use these inputs, their values are meaningless.

Signal Values Test

Note:The internal analog inputs for the output loopback measurements, CPU/IO board power supply voltages and temperature can only be monitored via the via the front-panel status screen.

MODE TEST4

Inputs

1

CH1 45.8

Note: The engineering-units value of each enabled input can be displayed via the Analog In menu of the front-panel status screen.

CH8 50.8•

PU1 00.0

Note: The revolutions-per-minute value of each enabled speed input can be displayed via the In/Out menu of the front-panel status screen.

August 2007 UM3300/H (1.1.0)


To display the auxiliary PCB’s valve position and output loopback signals (see Loopback Circuit Calibration on page 87), scroll past the display for MPU 3:

These values represent:

LV1 unscaled LVDT1 input, displayed as a percentage of its maximum range

AD3 raw value of the output loopback signal, in percent of 200 mA.

AD4 auxiliary analog input (00.0 = -20, A0.0 = +20 mA)

AD5 output loopback value, after applying the Loop-back Scaling Bias and Loopback Scaling Gain

To determine the status of the discrete inputs, press zero (0). Press-ing the decimal key (•) then repeatedly toggles the display between inputs 1 to 8 and 9 to 16:

Each character will be the input number if that input is asserted or an underscore if it is not. Digits above nine are shown in a modified hexadecimal notation (A=10, B=11, …, G=16). The above examples show only inputs DI2, 5, 10 (A), 13 (D), and 14 (E) are asserted.

PU3 00.0•

LV1 35.2

•

AD3 50.3

•

AD4 00.0

•

AD5 01.1

0

_2__5___

•

_A__DE__

•

_2__5___

August 2007 UM3300/H (1.1.0)


To determine which discrete outputs are energized, press nine (9):

where each character will be either the relay number (if that relay is energized) or an underscore (if it is not). The 1 for fault relay CR1 will appear unless it (and possibly CR2) are de-energized by CR1’s assigned function. In the above example, only relays CR1 and CR4 should be energized.

To display a group of digits indicating which front-panel keys and buttons are pressed, press the minus (–) key:

If no keys are pressed, a line of eight underscores is displayed. If a single key is pressed or stuck, one of the following unique groups of digits will appear (for example, the group 1/2/5 shown above would indicate that only the Menu button is pressed or stuck down):

9

1__4____

Note: The status of the Auxiliary PCB Fault relay (DO9) cannot be viewed via this procedure.

–

12__5___

12512456 5

81356 4

12346 127

237 7

6235 346

1

2

Caution:This procedure does not disable the normal operation of the front panel keys and buttons, so pressing them to verify that they are working can affect the operation of the controller.

August 2007 UM3300/H (1.1.0)


MODE TEST 6 Resetting the main CPU restarts its control program. This occurs when the controller is powered up, a hardware or software fault causes a watchdog time out, critical parameters are changed or alternate parameter sets are recalled, the controller is reconfigured from a workstation, or the Reset Controller [MODE COMM] proce-dure is executed.

This procedure checks the controller’s parameters to make sure they are reasonable, resets its serial ports and analog inputs, and begins a new scan cycle. Most controllers always execute a soft reset, which does not change the operating state or analog output. However, a Speed Controller will execute a hard reset (which trips the turbine) when it powers up or detects a fault.

To display the number of times the control program has restarted since this count was last zeroed, press the following keys:

where #### is the hexadecimal reset count, which can then be reset by pressing the zero key:

MODE TEST 7 To display the number of times the front-panel microprocessor has reset since this count was last zeroed, press the following keys:

where #### is its current hexadecimal value, which can then be reset by pressing the zero key:

Resetting or powering up the controller will usually increment this count by two.

CPU Reset Count

MODE TEST6

Z80 ####

0

Z80 0000

Front-Panel ResetCount

MODE TEST7

Mot ####

0

Mot 0000

August 2007 UM3300/H (1.1.0)


MODE TEST 8 This procedure initiates the calculation and display of a four-digit, hexadecimal (for example, 1AF4) checksum for the controller’s internal binary operating instructions. It is used primarily to verify the successful downloading of a new operating program.


This message indicates the controller is calculating the requested checksum. After a brief pause, it will be replaced by:

where #### is the hexadecimal checksum for the installed software. The correct CRCs for the standard releases of each control applica-tion are listed on its revisions data sheet DS33##/V].

MODE TEST 9 This procedure sets a Speed Controller’s clock to a specified month, day, year, hour and minute, which it displays in that order. As the current value of each field is displayed, you can:

• press the decimal key (•) to leave it unchanged and display the next field’s value,

• enter a new value by pressing the corresponding two numeric keys and then the ENTER key, or

• press the CLEAR key to terminate this procedure.

If you make a mistake while specifying a new value, press the CLEAR key once to start over or twice to abort this procedure and leave the original value unchanged. If you specify an invalid value and then press ENTER, the procedure aborts after briefly displaying an “Error!” message. Once you have entered a change, making an error or aborting the procedure will not undo it.

To initiate this procedure, press the following keys to display the cur-rent month-of the-year setting (01≤##≤12):

Either pressing the decimal key (•) or entering a new month will then display the current day-of-the-month (01≤##≤days in month):

Program Checksum

MODE TEST8

CRC BusY

CRC ####

Set Clock

MODE TEST9

Month?##

# #

Month?##

ENTER Day? ##

August 2007 UM3300/H (1.1.0)


where each numeric key used to specify the new month is repre-sented as # (you must press the leading zero for most months).

Either pressing the decimal key (•) or entering a new day will then display the current year (20##):

Either pressing the decimal key (•) or entering a new year will then display the current hour-of-the-day (00≤##≤59):

Pressing the CLEAR key or entering a new minute (00≤##≤59) will then terminate this procedure. Entering a new minutes value will also set the seconds counter to zero:

MODE TEST HIGH For Speed and Extraction Controllers, this procedure dynamically displays the number of times the auxiliary PCB has failed to respond to the main CPU since this count was last zeroed.

To display this count, press the following keys:

where #### is the communication error count, which can then be reset by pressing the zero key:

# #

Day? ##

ENTER Year? ##

# #

Year? ##

ENTER Hour? ##

# #

Minut?##

ENTER

Auxiliary PCB ErrorCount

MODE TESTHIGH

332=####

0

332=0000

August 2007 UM3300/H (1.1.0)

Series 3

++

Hardware Reference

151


Glossary/IndexThis combined glossary and index defines and references various topics discussed in this manual.

Alarms are undesirable control system conditions indicated by the front-panel Alarms LED, Modbus and OPC Alarm variables, and any control relays assigned the Alarm function.

Reference: Compressor Controllers . . . . . . . . . . . . . . . . . . . 106External Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 108Turbine Controllers . . . . . . . . . . . . . . . . . . . . . . . 107

AlternateParameter Set

is one of three sets of configuration and tuning parameter values that the controller can store in addition to its primary (working) set. Recalling an alternate parameter set causes a Controller Reset.

Reference: Alternate Parameter Set . . . . . . . . . . . . . . . . . . . . 28Displaying Checksums . . . . . . . . . . . . . . . . . . . . 140Parameter Memory Procedures . . . . . . . . . . . . . . 43Storing and Recalling . . . . . . . . . . . . . . . . . . . . . 139

Analog Input is a circuit that measures the electrical signal from a process variable transmitter, or the value of such a signal.

Reference: Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . 20Back Panel Connections. . . . . . . . . . . . . . . . . . . . 55CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . 18Current/Voltage Switch Settings . . . . . . . . . . . . . . 49FIM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 59Measured Variable Screens . . . . . . . . . . . . . . . . 103Measured Variable Value . . . . . . . . . . . . . . . . . . . 76Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Redundant Controllers . . . . . . . . . . . . . . . . . . . . . 97Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . 145Signal Variable Value . . . . . . . . . . . . . . . . . . . . . . 76Transmitter Status Test . . . . . . . . . . . . . . . . . . . 141Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 118

see also: Position Input, Transmitter Failure

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152 Glossary/Index

Analog Output is a circuit that generates an electrical signal that is used to manipulate a final control element, or the value of such a signal.

Reference: Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . .20Back Panel Connections . . . . . . . . . . . . . . . . . . . .55CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . .18Current/Voltage Switch and Jumper . . . . . . . . . . .50FOM Connections . . . . . . . . . . . . . . . . . . . . . . . . .62General Operation . . . . . . . . . . . . . . . . . . . . . . . . .76Monitoring Intended and Actual Signals. . . . 101–103Redundant Controllers . . . . . . . . . . . . . . . . . . . . . .92Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .118

see also: High-Current Output, Output Loopback Failure

Auxiliary PCB is a circuit board that provides the High-Current Output, Position Inputs, Speed Inputs, and Discrete Inputs 9 to 16.

Reference: Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . .19Failure Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105General Operation . . . . . . . . . . . . . . . . . . . . . . . . .78Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .51Program Version Test . . . . . . . . . . . . . . . . . . . . .144Replacement Procedure . . . . . . . . . . . . . . . . . . .124Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .121

Back Panel is one of several different assemblies that can be used to provide the power cord and field wiring or Field Termination Assembly connections.

Reference: Back Panel Assemblies . . . . . . . . . . . . . . . . . . 23–24Component Configuration . . . . . . . . . . . . . . . . . . .16Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 53–56Ethernet Converters . . . . . . . . . . . . . . . . . . . . . . . .23Serial Port Connections . . . . . . . . . . . . . . . . . . . . .64

Baud Rate see: Serial Port

Beep Frequency is the frequency of the beep sound, which can be varied by pressing the Raise or Lower Key while holding down the Scroll button.

Reference: User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . .90

Bipolar Output is a feature of the High-Current Output that can generate bi-directional (forward and reverse) current flows.

Brightness,Readouts

see: LED Brightness

Buttons see: Control Keys, Control Loop Buttons, Menu System Buttons

Cable Length is the total of the lengths of all cables within any given RS-485 serial com-munication network.

Reference: Serial Communication Networks . . . . . . . . . . . . . .64

August 2007 UM3300/H (1.1.0)


Calibration is only possible for the high-current output circuit of the Auxiliary PCB. All CPU/IO PCB I/O signals are permanently calibrated at the factory.

Reference: High-Current Output . . . . . . . . . . . . . . . . . . . . 85–88

Case MountingSlides

are slides along top and bottom of controller case that pull its front flanges back against the panel, thus holding it rigidly horizontal.

Reference: Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . 46Controller Replacement . . . . . . . . . . . . . . . . . . . 125

Checksum see: Parameter Checksum, Program Checksum

Circuit Isolation see: Isolation

CommunicationError

is an error in the reception of information from a companion Series 3++ Controller or a Modbus host.

Reference: Compressor Controller Alarm . . . . . . . . . . . . . . . 106External Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 108Modbus/OPC Alarm Bit. . . . . . . . . . . . . . . . . . . . 109Serial Port 1 Test . . . . . . . . . . . . . . . . . . . . . . . . 143Serial Port 2 Test . . . . . . . . . . . . . . . . . . . . . . . . 142Serial Port Activity Test. . . . . . . . . . . . . . . . . . . . 143Serial Port Troubleshooting . . . . . . . . . . . . . . . . . 72Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 115Turbine Controller Alarm. . . . . . . . . . . . . . . . . . . 107

ComponentReplacement

is the repair of a malfunctioning controller by replacing only circuit boards that are believed to be malfunctioning.

Reference: CPU Program and Configuration . . . . . . . . . 99, 126Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Internal Circuit Boards . . . . . . . . . . . . . . . . . . . . 124Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . 123

see also: Controller Replacement, Spare Parts Stocking

CompressorController

Configuration

is a hardware configuration that does not include an Auxiliary PCB.

Reference: Component Configuration. . . . . . . . . . . . . . . . . . . 16

CompressorControllers

are Series 3++ Controllers (Antisurge, Performance, Dual-Loop A/P) that control and protect a centrifugal or axial compressor.

Reference: Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

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154 Glossary/Index

ComputerCommunications

and Control

is the monitoring and control of a Series 3++ Controller by a Modbus host or a client of the Series 3 OPC Server Program.

Reference: Ethernet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Limiting Modbus Access . . . . . . . . . . . . . . . . . . . .73Operational Overview. . . . . . . . . . . . . . . . . . . . . . .69Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Problem Indicator Variables . . . . . . . . . . . . . . . . .109Redundant Controllers . . . . . . . . . . . . . . . . . . . . . .98Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18, 72

see also: Ethernet Port, Remote Control, Serial Port

Computer IDNumber

is a number between 1 and 64 that identifies a Series 3++ Controller over it Port 2, 3, and 4 communication networks.

see: Ethernet Port, Serial Port

Configuration is the adaptation of a Series 3++ Controller to a specific application by set-ting its Configuration Parameters.

Reference: Alternate Parameters . . . . . . . . . . . . . . . . . . . . . .139CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . .17Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . .44Enabling and Disabling . . . . . . . . . . . . . . . . . . . .138Key Sequence Examples . . . . . . . . . . . . . . . . . 34–42Key Sequence Illustration . . . . . . . . . . . . . . . . . . .34Parameter Memory Procedures . . . . . . . . . . . . . . .43Planner and Worksheet Forms . . . . . . . . . . . . . . .30Viewing and Changing Parameter Values . . . . . . .32

see also: Alternate Parameter Set, Engineering Panel, Parameter Checksum

ConfigurationParameters

are a set of numeric and other values that enable, disable, or otherwise adapt a Series 3++ Controller to a specific application.

Reference: Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . .28

Configurator see: Series 3 Plus Configurator Program

Connections see: Installation

Contrast, LCD see: LCD Contrast

Control Keys are areas of the front panel with raised white outlines, which can be pressed to initiate various process control actions.

Reference: Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . .147

see also: Control Loop Buttons, Menu System Buttons

Control LEDs are the light emitting diodes in the left-lower portion of the Front Panel and embedded in the top row of Control Keys, which generally indicate the status of process control features.

see: Status LEDs

August 2007 UM3300/H (1.1.0)


Control LoopButtons

are raised, labelled areas in the upper portion of the Front Panel that can be pressed to change the data displayed by the Control Loop Readouts.

Reference: Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . 147


are the numeric LED readouts (PV or DEV or RPM, SP, and OUT) in the upper portion of the Front Panel, which generally display the control vari-able, set point, and response of a primary or limiting control loop selected by pressing one of the Control Loop Buttons.

Control Program is a Series 3++ Controller’s (Antisurge, Performance, Dual-Loop, Speed, or Extraction) machine control application software, which is stored in the CPU/IO PCB’s EEPROMs.

Reference: Controller Replacement . . . . . . . . . . . . . . . . . . . 125General Operation . . . . . . . . . . . . . . . . . . . . . . . . 70Main CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Program Checksum Test . . . . . . . . . . . . . . . . . . 149Program Version Test. . . . . . . . . . . . . . . . . . . . . 144

see also: Program Version

Control Relay is a relay that can be included in an external circuit and energizes or de-energizes to indicate the state of an internal variable or condition that can have one of two values.

Reference: Assigned Functions . . . . . . . . . . . . . . . . . . . . . . . 74Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . 19, 78Back Panel Connections. . . . . . . . . . . . . . . . . . . . 53CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . 18FOM Connections. . . . . . . . . . . . . . . . . . . . . . . . . 63Monitoring Intended State. . . . . . . . . . . . . . 101–103Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . 147Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 120

ControllerConversion

see: Model Conversion

ControllerDisassembly

see: Disassembly

Controller Faults see: Fault

Controller IDNumber

is a number between 1 and 8 that identifies a Series 3++ Controller on its Port 1 serial communication network.

see: Serial Port

ControllerInstallation

see: Installation

ControllerMounting

see: Installation

ControllerRemoval

see: Deinstallation

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156 Glossary/Index

ControllerReplacement

is the installation of a functionally identical controller in place of one that is malfunctioning.

Reference: Dismounting Old and Mounting New . . . . . . . . . .125Programming and Configuration . . . . . . . . . . 99, 126Return Procedure. . . . . . . . . . . . . . . . . . . . . . . . .123

see also: Component Replacement, Spare Parts Stocking

Controller Reset is a sequence of actions the controller executes when it is powered up, detects a Fault, or is reconfigured using the Series 3 Plus Configurator Program, or when critical parameters are changed from the Engineering Panel, an Alternate Parameter Set is recalled, or the MODE COMM key sequence is entered.

Reference: CPU Reset Count. . . . . . . . . . . . . . . . . . . . . . . . .148CPU/IO Fault Relays . . . . . . . . . . . . . . . . . . . . . .105Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . .44Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . .141

ControllerTroubleshooting

see: Troubleshooting

Converter see: Ethernet Port, Serial Port

CPU/IO PCB is a circuit board that includes the controller’s central processing unit, serial ports, and basic field inputs and outputs.

Reference: CPU Reset Count. . . . . . . . . . . . . . . . . . . . . . . . .148Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Fault Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Machine Control Program . . . . . . . . . . . . . . . . . . .70Monitoring Voltages . . . . . . . . . . . . . . . . . . . . . . .100Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . .28Replacement Procedure . . . . . . . . . . . . . . . . . . .124Startup and Operation . . . . . . . . . . . . . . . . . . . . . .70Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . 47–50Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .117

CyclicRedundancy

Checksum

is a four-digit hexadecimal number calculated by applying a standard mathematical function to a group of numbers.

see: Parameter Checksum, Program Checksum

Data Groups are configuration and tuning parameter subsets identified by the first key in the associated key sequence.

Reference: Data Groups and Pages. . . . . . . . . . . . . . . . . . . . .29

Data Pages are basic categories of configuration and tuning parameters that roughly correspond to the type of feature (hardware or control algorithm) they govern.

Reference: Data Groups and Pages. . . . . . . . . . . . . . . . . . . . .29

August 2007 UM3300/H (1.1.0)


Deinstallation is accomplished by removing the slide clamps and case slides and pull-ing the case out from the front of the control panel.

Reference: Controller Replacement . . . . . . . . . . . . . . . . . . . 125

Diagnostic Menu are the status screens Turbine Controllers use to display power converter voltages, internal temperatures, and output loopback measurements. Compressor Controllers include those screens in their main menus.

Reference: Internal Conditions . . . . . . . . . . . . . . . . . . . . . . . 100

Disassembly of a panel-mounted controller can be accomplished without removing the case from the control panel.

Reference: Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Discrete Input is a signal from another device that can have one of two values, or a cir-cuit that determines the state of such a signal.

Reference: Associated Functions . . . . . . . . . . . . . . . . . . . . . . 74Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . 19, 78Back Panel Connections. . . . . . . . . . . . . . . . . . . . 53CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . . . . 18FIM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 58Monitoring State . . . . . . . . . . . . . . . . . . . . . 101–103Redundant Controllers . . . . . . . . . . . . . . . . . . . . . 97Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . 146Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 119

Discrete Output see: Control Relay

Engineering Panel is an assembly that provides a keyboard and alphanumeric display for controller configuration, tuning, and troubleshooting.

Reference: Diagnostic Messages . . . . . . . . . . . . . . . . . . . . . . 44General Operation . . . . . . . . . . . . . . . . . . . . . . . . 89Key Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 31Operational Overview . . . . . . . . . . . . . . . . . . . . . . 69Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Problem Messages . . . . . . . . . . . . . . . . . . . . . . . 110Replacement Procedure . . . . . . . . . . . . . . . . . . . 124Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 114Using. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–44

see also: Configuration

EnvironmentalRequirements

Series 3++ Controllers are intended to be permanently mounted in a dry environment that minimizes static electrical discharges and conforms to specified temperature and humidity restrictions.

Ethernet Port is a converter that allows Modbus TCP clients to communicate with a Series 3++ Controller’s Modbus RTU serial ports (3 and 4).

Reference: Back-Panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . 67Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Controller Back Panels . . . . . . . . . . . . . . . . . . . . . 23Redundant Controllers . . . . . . . . . . . . . . . . . . . . . 98

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158 Glossary/Index

Extended I/OTurbine Controller

is a controller equipped with an Auxiliary PCB, CPC Back Panel, Field Input Module and Field Output Module.

External Alarms are control system conditions indicated by control relays assigned the corresponding functions.

Reference: Relay Functions . . . . . . . . . . . . . . . . . . . . . . . . . .108

Fault is an internal malfunction that causes the Fault LED to light and the fault relays to de-energize.

Reference: Auxiliary PCB Fault Relay . . . . . . . . . . . . . . . . . .105CPU/IO Fault Relays . . . . . . . . . . . . . . . . . . . . . .105Discrete Output Switches. . . . . . . . . . . . . . . . . . . .48Fault Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . .104Fault LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Fault Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Field Input Module is an external module that provides wiring terminals for turbine controller field input signals, used in combination with the CPC Back Panel.

Reference: 24 Vdc Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Analog Input Connections . . . . . . . . . . . . . . . . . . .59Discrete Input Connections . . . . . . . . . . . . . . . . . .58Field Termination Assemblies . . . . . . . . . . . . . . . .24Position Input Connections . . . . . . . . . . . . . . . . . .61Speed Input Connections. . . . . . . . . . . . . . . . . . . .61

see also: DS3300/T

Field Input/OutputModule

is an external module that provides wiring terminals for compressor con-troller field I/O signals. It is not available for new Series 3++ but can be retained when upgrading from Series 3 Plus Controllers.

Reference: Field Termination Assemblies . . . . . . . . . . . . . . . .24

Field OutputModule

is an external module that provides wiring terminals for turbine controller field output signals, used in combination with the CPC Back Panel.

Reference: 24 Vdc Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Analog Output Connections . . . . . . . . . . . . . . . . . .62Control Relay Connections . . . . . . . . . . . . . . . . . .63Field Termination Assemblies . . . . . . . . . . . . . . . .24Serial Port Connections . . . . . . . . . . . . . . . . . . . . .64

see also: DS3300/T

FieldProgrammable

Gate Array

is the microprocessor on the CPU/IO PCB, which has been programmed to duplicate the computational, I/O logic, and serial communication fea-tures of the Series 3 Plus Controller’s CPU and analog PCB assemblies.

Reference: CPU/IO PCB Processor . . . . . . . . . . . . . . . . . . . . .70Firmware Revision . . . . . . . . . . . . . . . . . . . . . . . .144

August 2007 UM3300/H (1.1.0)


Field TerminationAssembly

is a generic term for any external module that provides wiring terminals that augment or replace those on the controller Back Panel.

Reference: Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 57–63

see also: Field Input Module, Field Output Module, Field Input/Output Module.

Firmware Version is the revision level (for example, FPGA0202) of the stored programs that govern the operation of the Engineering Panel, Field Programmable Gate Array, and the optional Auxiliary PCB.

Reference: Auxiliary PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . 90Field Programmable Gate Array . . . . . . . . . . . . . . 70Program Version Test. . . . . . . . . . . . . . . . . . . . . 144

see also: Program Version

Frequency, Beep see: Beep Frequency

Frequency Inputs see: Speed Input

Front Panel is an assembly that provides the Control Keys, Control LEDs, Control Loop Buttons, Control Loop Readouts, Menu System Buttons, Status LEDs, and Status Screen.

Reference: Fault LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Front Panel Assembly. . . . . . . . . . . . . . . . . . . . . . 21Front-Panel Reset Count . . . . . . . . . . . . . . . . . . 148General Operation . . . . . . . . . . . . . . . . . . . . . . . . 89Operational Overview . . . . . . . . . . . . . . . . . . . . . . 69Preferences and Tests . . . . . . . . . . . . . . . . . . . . . 90Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 114

Front PanelOverlay

is a label that covers the Front Panel and identifies the functions of its LEDs, keys, buttons and readouts.

Grounding is accomplished by connecting the power cable ground conductor and one or both shield pigtails of any High-Density Interconnect Cable to an earth ground.

Reference: Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Serial Ports 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . 65Serial Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . 66

see also: Isolation

High-CurrentOutput

is the Auxiliary PCB Analog Output, which can generate uni- or bi-polar current-loop signals up to 200 mA.

Reference: Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . 20Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 85–88High-Current Analog Output . . . . . . . . . . . . . . . . . 82

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160 Glossary/Index

High-DensityInterconnect

Cable

is a cable for connecting a Field Termination Assembly to a controller Back Panel.

Reference: Back Panel Assemblies . . . . . . . . . . . . . . . . . . . . .23Field Termination Assemblies . . . . . . . . . . . . . . . .24Mounting Configuration . . . . . . . . . . . . . . . . . . . . .15

ID Numbers are parameters that identify a Series 3++ Controller to other devices on a serial communications network.

see: Serial Port

Indicator Lights see: Ethernet Port, Status LEDs

Installation is the mounting of a controller and connection of its I/O terminals to the corresponding field devices.

Reference: Back Panel Connections . . . . . . . . . . . . . . . . . 53–56Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . .46Ethernet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .67FTA Connections . . . . . . . . . . . . . . . . . . . . . . . 57–63Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64–67Switch and Jumper Settings. . . . . . . . . . . . . . . 47–52

see also: Analog Input, Analog Output, Discrete Input, Discrete Output, High-Current Output, Position Input, Serial Port, Speed Input

InterfacePreferences

see: Beep Frequency, LCD Contrast, LED Brightness

Internal Clock is an auxiliary function of the CPU/IO board’s random access memory (RAM) chip that keeps track of the current date and time, which is used to timestamp entries in the Speed Controller Shutdown Log.

Reference: CPU/IO PCB Components . . . . . . . . . . . . . . . . . . .17Speed Controller Set Clock Procedure . . . . . . . .149

InternalConditions

see: Output Loopback Failure; Temperature, Internal; Voltages, Internal

Isolation is the use of magnetic, optical, and capacitive techniques to prevent inter-actions between electrical circuits.

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Analog Output Installation . . . . . . . . . . . . . . . . . . .50Discrete I/O Installation . . . . . . . . . . . . . . . . . . . . .53Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 72Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

see also: Grounding

August 2007 UM3300/H (1.1.0)


Jumper Settings are hardware options that are selected by installing small electrical con-nectors on one of the controller’s circuit boards.

Reference: Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . 51Back Panel Assembly . . . . . . . . . . . . . . . . . . . . . . 50

see also: Switch Settings

Key Sequence is an Engineering Panel procedure for examining or changing a configu-ration or tuning parameter or executing a controller test.

Reference: Key Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 31Key Sequence Examples . . . . . . . . . . . . . . . . 34–42Key Sequence Illustrations . . . . . . . . . . . . . . . . . . 34

Keyboard Test is a diagnostic procedure that can be run by entering an associated Key Sequence from the Engineering Panel.

Reference: Configuration and Testing. . . . . . . . . . . . . . . . . . . 27Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 114

Keys see: Control Keys, Control Loop Buttons, Engineering Panel, Menu System Buttons

LCD Contrast is the adjustable difference between the light and dark areas of the Status Screen’s liquid crystal display element.

Reference: User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . 90

LED see: Alarms, Control LEDs, Ethernet Port, Fault, Status LEDs

LED Brightness is the adjustable brightness of the Control Loop Readouts.

Reference: User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . 90

LED Test is the ability to turn on all LEDs and alphanumeric readout segments on the Front and Engineering Panels to see if any are not working.

Reference: User Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Linear VariableDifferential

Transformer

is a device for measuring the linear displacement of an object (such as the head of a valve stem) from some reference position.

LVDT Input is an input for a Linear Variable Differential Transformer signal.

see: Position Input

Machine ControlProgram

see: Control Program

Magnetic Pickup is a device that generates a frequency signal proportional to the speed of a rotating shaft.

see: Speed Input

MaintenanceStrategy

is a user’s basic response to controller malfunctions, which is usually to either replace them completely or to identify and replace only their mal-functioning component assemblies.

Reference: Maintenance and Repair Overview. . . . . . . . . . . . 99Maintenance Strategies . . . . . . . . . . . . . . . . . . . 123

August 2007 UM3300/H (1.1.0)

162 Glossary/Index

MeasuredVariable

is a scaled representation of an Analog Input signal that can be displayed by the Status Screen.

Reference: Analog Input Processing . . . . . . . . . . . . . . . . . . . .76

Menu SystemButtons

are raised, areas (labelled ACK, MENU and SCROLL) in the center of the Front Panel that can be pressed to change the information displayed by the Status Screen.

Reference: General Operation . . . . . . . . . . . . . . . . . . . . . . . . .90Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . .147

Modbus is a protocol that allows master devices to read and write variables within Series 3++ Controllers and other slave devices via serial (Modbus RTU) or ethernet (Modbus TCP) communication networks.

Reference: Serial to Ethernet Converters. . . . . . . . . . . . . . . . .23

see also: Computer Communications and Control

Model Conversion is the transformation of one Series 3++ Controller model into another by replacing its Front Panel, Control Program, and perhaps altering the hardware configuration.

Mounting see: Installation

MountingConfiguration

is the mounting of a controller’s CPU/IO, Auxiliary, and Power Supply Assemblies within an extruded case or on a flat plate (usually within a NEMA rated enclosure).

Reference: Controller Components . . . . . . . . . . . . . . . . . . 15–16

Operator Panel see: Front Panel

Output LoopbackFailure

is an excessive deviation of an analog output signal’s measured and intended values.

Reference: Compressor Controller Alarm. . . . . . . . . . . . . . . .106External Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . .108High-Current Analog Output. . . . . . . . . . . . . . . . . .88Internal Loopback Inputs . . . . . . . . . . . . . . . . . . . .76Loopback Circuit Calibration . . . . . . . . . . . . . . . . .87Modbus/OPC Alarm Bit . . . . . . . . . . . . . . . . . . . .109Turbine Controller Alarm . . . . . . . . . . . . . . . . . . .107

Panel MountedController

is one whose internal components are contained in an aluminum case for mounting in a control panel.

Reference: Mounting Configuration . . . . . . . . . . . . . . . . . . . . .15

ParameterChecksum

is a Cyclic Redundancy Checksum calculated from the controller’s Con-figuration Parameters.

Reference: Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . .45Parameter Checksum . . . . . . . . . . . . . . . . . . . . . .30Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . .140

see also: Configuration

Parity see: Serial Port

August 2007 UM3300/H (1.1.0)


Plate MountedController

is one whose internal components have been mounted on a plate or wall or within an enclosure other than the standard panel-mounting case.

Reference: Mounting Configuration. . . . . . . . . . . . . . . . . . . . . 16

Position Input is the Auxiliary PCB’s LVDT Input or Analog Input, one of which might be used to measure the position of a control valve.

Reference: Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . 20Daughter Board Jumpers . . . . . . . . . . . . . . . . . . . 51Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79External Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 108FIM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 61Input Signal Values. . . . . . . . . . . . . . . . . . . . . . . 146Modbus/OPC Alarm Bit. . . . . . . . . . . . . . . . . . . . 109Positioning Alarm . . . . . . . . . . . . . . . . . . . . . . . . 107Troubleshooting Positioning Problems . . . . . . . . 122

see also: Output Loopback Failure

Power Cable is the cable that supplies electrical power to the controller.

Reference: Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Power SupplyAssembly

is a circuit board that provides regulated 24 Vdc power to the controller’s other circuit boards. Other needed component power voltages are gener-ated by converters on the CPU/IO board.

Reference: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Monitoring Voltage . . . . . . . . . . . . . . . . . . . . . . . 100Replacement Procedure . . . . . . . . . . . . . . . . . . . 124

ProgramChecksum

is a Cyclic Redundancy Checksum calculated from the controller’s Con-trol Program.

Reference: Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . 45Program Checksum Test . . . . . . . . . . . . . . . . . . 149

Program Version is the revision level (for example, 1061-001) of the Control Program loaded in a Series 3++ Controller.

Reference: Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . 45Controller Replacement . . . . . . . . . . . . . . . . . . . 126Machine Control Program. . . . . . . . . . . . . . . . . . . 70Program Version Test. . . . . . . . . . . . . . . . . . . . . 144

see also: Firmware Version

Reassembly is usually accomplished by installing new or repaired internal compo-nents into a still-mounted case from the front of control panel.

Reference: Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

August 2007 UM3300/H (1.1.0)

164 Glossary/Index

RedundantControllers

are Series 3++ Controllers installed in pairs in which one serves as an on-line backup to the other.

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97Analog Output Connections and Switching . . . . . .92Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .97Ethernet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . .98General Failure Relays . . . . . . . . . . . . . . . . . . . .108Modbus Communication . . . . . . . . . . . . . . . . . . . .98MPU Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Redundant Control Selector. . . . . . . . . . . . . . . 94–97Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . .92Tracking Indicators. . . . . . . . . . . . . . . . . . . . . . . .110

Remote Control is the monitoring and operation of a controller via electro-mechanical and/or electronic indicators, readouts, potentiometers, and switches con-nected to some of its analog and discrete inputs and outputs.

Reference: Operational Overview. . . . . . . . . . . . . . . . . . . . . . .69Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . .108

see also: Computer Communications and Control

Removal see: Deinstallation

Replacement see: Controller Replacement, Component Replacement

ResettingController

see: Controller Reset

Return Procedure tells how to return a malfunctioning controller or assembly to CCC for repair or replacement.

Reference: Return Procedure. . . . . . . . . . . . . . . . . . . . . . . . .123

Rotary VariableDifferential

Transformer

is a device for measuring the angular displacement of an object (such as a guide vane linkage) from some reference position.

Rotational Speed see: Speed Input

SafetyConsiderations

All wiring and maintenance must be performed by qualified personnel in conformance with all applicable safety codes.

SerialCommunication

Error

see: Communication Error

August 2007 UM3300/H (1.1.0)


Serial Port is a circuit used to exchange digital information with other devices.

Reference: Baud Rate and Parity . . . . . . . . . . . . . . . . . . . . . . 73CPU/IO PCB Assembly . . . . . . . . . . . . . . . . . 17, 18Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64–67Network Cable Lengths . . . . . . . . . . . . . . . . . . . . 64Redundant Controller ID Numbers . . . . . . . . . . . . 98Redundant Controllers . . . . . . . . . . . . . . . . . . . . . 98RS-232 Converters . . . . . . . . . . . . . . . . . . . . . . . . 67Setting ID Numbers . . . . . . . . . . . . . . . . . . . . . . . 73Station Controller Port 2 Test . . . . . . . . . . . . . . . 142Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . 64Termination Resistors Not Needed. . . . . . . . . . . . 64

see also: ID Numbers

Series 3 OPCServer Program

is a TrainTools program that provides OPC online data access to a superset of the Modbus data from Series 3, 3 Plus, and 3++ Controllers.

see: Series 3 OPC Server user manual [UM5503]

Series 3 PlusConfigurator

Program

is a PC program that can read, edit, and replace a Series 3* Controller’s configuration parameter set and update or change a Series 3 Plus or 3++ Controller’s control program via its Modbus communication ports.

Reference: Configuration and Testing. . . . . . . . . . . . . . . . . . . 27Controller and Component Replacement . . . 99, 126

Shutdown Log is a Speed Controller Status Screen menu that displays the time, date, and cause of the last eight turbine shutdowns.

Signal Isolation see: Isolation

Signal Variable is an internal variable representing the percent-of-range value of an Analog Input signal.

Reference: Analog Input Processing. . . . . . . . . . . . . . . . . . . . 76

Slide Clamps are adjusting screws mounted behind the case mounting slides that push them against the control panel, thus pulling the controller back.

Reference: Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . 46Controller Replacement . . . . . . . . . . . . . . . . . . . 125

SoftwareChecksum

see: Program Checksum

Software Version see: Program Version

Spare PartsStocking

is simplified and reduced by the use of a standard hardware platform for all Series 3 Controller models.

Reference: Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Speed Board see: Auxiliary PCB

August 2007 UM3300/H (1.1.0)

166 Glossary/Index

Speed Input is an input circuit used to measure the frequency of the signal from a Magnetic Pickup speed sensor.

Reference: Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . .20Back Panel Connections . . . . . . . . . . . . . . . . . . . .56Configuration and Operation . . . . . . . . . . . . . . . . .79FIM Connections . . . . . . . . . . . . . . . . . . . . . . . . . .61Modbus/OPC Alarm Bits . . . . . . . . . . . . . . . . . . .109MPU Fail Alarm . . . . . . . . . . . . . . . . . . . . . . . . . .107MPU Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81Scaling and Normalization . . . . . . . . . . . . . . . . . . .80Signal Values Test . . . . . . . . . . . . . . . . . . . . . . . .145Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .121

Standard TurbineController

is a turbine controller that is not equipped with the CPC Back Panel, Field Input Module and Field Output Module, and thus has fewer field I/O chan-nels than an Extended I/O Turbine Controller.

Status LEDs are front-panel indicator lights for controller and process conditions.

Status Screen is the ten-character by four-line liquid crystal display element in the cen-ter of the Front Panel, which displays a set of controller status variables or operator prompts selected by pressing the Menu System Buttons.

Reference: Changing Contrast . . . . . . . . . . . . . . . . . . . . . . . . .90General Operation . . . . . . . . . . . . . . . . . . . . . . . . .90

SurgeSuppression

is the protection of the controller’s electronic components by shunting high voltage transients to ground.

Reference: Modbus Serial Ports. . . . . . . . . . . . . . . . . . . . . . . .64

Switch Settings are hardware options that are selected by position small switches on one of the controller’s circuit boards.

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . .50Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

see also: Jumper Settings

Temperature,Internal

Is the temperature inside the controller case, as measured by a sensor on the CPU/IO PCB.

Reference: Internal Analog Input . . . . . . . . . . . . . . . . . . . . . . .76Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

TerminationResistors

are installed at the ends of high-frequency electrical buses in order to keep reflected signals from disrupting communication signals. Series 3++ serial communication networks rarely if ever need them.

Reference: Serial Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Testing see: Fault, Keyboard Test, Output Loopback Failure, Transmitter Failure, Troubleshooting

August 2007 UM3300/H (1.1.0)


TrainTools is a group of PC software packages whose programs can be used to monitor and maintain CCC Controllers.

Reference: Updating and Configuring Controllers. . . . . . . . . . 17

see also: TrainTools Product Overview and Setup manual [UM5500]

TransmitterFailure

is an alarm condition that is indicated when any analog input signal is not within user-specified limits or exceeds the 21.0 mA smart-transmitter fail signal specified by the Namur NE 43 recommendation.

Reference: Compressor Controller Alarm . . . . . . . . . . . . . . . 106External Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 108Input Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Modbus/OPC Alarm Bits. . . . . . . . . . . . . . . . . . . 109Transmitter Status Test . . . . . . . . . . . . . . . . . . . 141Turbine Controller Alarm. . . . . . . . . . . . . . . . . . . 107

Troubleshooting is the investigation of controller problems in order to identify and correct the cause.

Reference: Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 118Auxiliary PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . 121Communication Errors . . . . . . . . . . . . . . . . . . . . 115CPU/IO Board Problems. . . . . . . . . . . . . . . . . . . 117Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 119Discrete Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 120Front and Engineering Panel . . . . . . . . . . . . . . . 114Positioning Problems . . . . . . . . . . . . . . . . . . . . . 122Speed Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

see also: Analog Input, Analog Output, Discrete Input, Discrete Output, High-Current Output, Position Input, Power Supply Assembly, Serial Port, Speed Input

Turbine ControllerConfiguration

is a hardware configuration that includes the Auxiliary PCB.

Reference: Component Configurations . . . . . . . . . . . . . . . . . . 16

TurbineControllers

are Series 3++ Controllers (Speed, Extraction, Fuel) programmed to con-trol and protect a steam or gas turbine.

Reference: Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

User Preferences see: Beep Frequency, LCD Contrast, LED Brightness

Valid SpeedRange

the minimum and maximum rotational speeds that can be read by the controller’s frequency / magnetic pickup (MPU) inputs.

Reference: MPU Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Scaling and Normalization . . . . . . . . . . . . . . . . . . 80

August 2007 UM3300/H (1.1.0)

168 Glossary/Index

Voltages, Internal are the internally-monitored component power voltages from the Power Supply Assembly and the CPU/IO PCB voltage converters.

Reference: Compressor Controller Alarm. . . . . . . . . . . . . . . .106External Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . .108Internal Analog Inputs . . . . . . . . . . . . . . . . . . . . . .76Modbus/OPC Alarm Bit . . . . . . . . . . . . . . . . . . . .109Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100Turbine Controller Alarm . . . . . . . . . . . . . . . . . . .107

Watchdog TimeOut

is a feature that forces a Controller Reset if a power interruption or certain internal errors are detected.

see: Fault

August 2007 UM3300/H (1.1.0)

UDS3300/C Series 3++ Compressor Controllers Hardware Specificationssheet

This data sheet specifies the physical and operating characteristics of Series 3++ Controllers that do not include the optional Auxiliary PCB Assembly (Speed Board).

Figure 1 Controller Dimensions

GeneralSpecifications

This section lists various general characteristics of this device, whose dimensions are illustrated in Figure 1.

MountingDimensions

Cutout Width: 2.70 in. (68.6 mm), +0.02 in. (0.5 mm)/–0.00Cutout Height: 5.60 in. (142.2 mm), +0.03 in. (0.8 mm)/–0.00Cabinet Depth: 22 in. (56 cm) from front of panel

Weight 5.0 lb (2.3 kg)

Ambient Conditions Operating Temperature: -4 to 140°F (-20 to 60°C)Storage Temperature: -22 to +185°F (-30 to +85°C)Relative Humidity: 0 to 95% (if free from condensation)

Ratings andCertifications

see: Agency Certifications for Series 3++ Controllers [TN41]

Design Life 15 years (continuous operation)

Design MTBF 45 years

Program Updatingand Configuration

Front panel swings out to expose configuration and testing panel. Optional PC software can load, configure, and tune control program.

#

Compressor Controllers Hardware Specifications

1.026

2.9675.2

2.6868.1

5.506.00153

19.04484

dimensions in inches and millimeters

140

August 2007 Page 1 of 4 DS3300/C (1.1.0)

Figure 2 Power Cable Connector Configurations

Power Supplies The internal power supply PCB mounts twin third-party 24 Vdc power modules that separately power the internal circuitry and external transmitters. AC conversion or DC regulation modules can be specified, either option requires a back panel with a matching power cable connector:

Input Voltage 21 to 32 Vdc or 96 to 264 Vac, 50 to 60 Hz

Output Power 24.0±1.2 Vdc, 6.0W maximum, isolated and regulated

Maximum PowerConsumption

30W (includes 6W output power)

Power Cable One 14 ft. (4.3 m) cable with AWG 18 (0.8 mm2) conductors is supplied per pair of controllers. Both ends are plug-compatible with the specified PSA. Custom length cables are available.

Power FailureProtection

Configuration data stored in non-volatile EEPROMProcess data stored in RAM with a backup battery (minimum battery life is 1 year @ 70 °C).

CommunicationPorts

Two serial ports for communicating with other CCC controllers

• Port 1: three-wire, EIA RS-485

• Port 2: five-wire, EIA RS-485

Two Modbus RTU or TCP ports (3 and 4) for communicating with support PCs or third-party supervisory systems:

• RTU: five-wire serial ports are EIA RS-422/485 compatible

• TCP: RJ45 ethernet ports are IEEE 802.3 10/100Base-T compatible (see the Series 3++ Modbus TCP Ethernet Options data sheet [DS3300/N])

Table 1 Serial Communication Formats

Line (Black)

Neutral (White)

Ground (Green)

Cable ControllerAC Cable

+ (Red)

– (Black)

Ground (White)

Cable ControllerDC Cable

Port 1 Port 2 Ports 3 and 4Baud Rate 38400 2400, 4800, 9600 4800, 9600, 19200

Parity Even Even odd, even, none

Start/Data/Stop Bits 1/8/2 1/8/2 1 / 8 / 1

Cable Length up to 4000 feet (1200 meters)

Transceivers (1) One Two1 Up to 32 transceivers can be connected to each RS-485 network


Figure 3 Back Panel Terminal Blocks

I/O Circuits All wiring terminals are located on the Back Panel (see Figure 3).

Terminals Removable back-panel compression terminals accept AWG 18 to AWG 14 (0.8 to 2.0 mm2) wire.

Scan Time Inputs are sampled every 5 milliseconds.Outputs are updated every 40 milliseconds.

Static Protection design protection to 4,000 volts, lab tested to 7,000 volts


Eight 0.1% accuracy analog inputs, each switch-selected as:

Extended I/O controller has eight and standard controller has four 0.1% accuracy analog inputs, each internally switch-selected as:• 20 mAdc (100 Ω impedance), 30 Vdc over-voltage protection; or• 5 Vdc (400 kΩ impedance), 300 Vdc over-voltage protectionFloating-ground isolation to 270 Vdc (adjacent channels), 540 Vdc (lowest to highest channel).Each signal is tested against Namur NE 43 high failure (21 mA) and independently-configurable high and low alarm limits.

21

43

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


+ – D6 D7

PORT 1TX/RX RX2TX2


PORT 4

+ – + –RX4TX4

PORT 3

+ – + –RX3TX3

+OUT 2+

1 2 1 2 1 2

CH 5

35 W max

CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ –+ –+ –

USED

TB6

–

21

D

+ –CH 1

+ –CH 2

+ –CH 3

+ –CH 4 OUT 1

+

PORT 2


+ – D6 D7

PORT 1TX/RX RX2TX2


+OUT 2+

1 2 1 2 1 2

CH 5 CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ –+ –+ ––

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

PO

RT

3P

OR

T 4

35 W max


Analog Outputs Two isolated, internally-verified, factory-calibrated outputs. Each is independently switch-selectable for either:• 20 mAdc signals (0 to 750 Ω impedance)• 5 Vdc signals (2 kΩ minimum impedance)

Discrete Inputs Seven 2.2 kΩ discrete inputs with common return• Energized state: +10 to +30 Vdc• De-energized state: 0 to +2 Vdc.


Five single-pole electromechanical relay circuits rated 1 A at 30 Vdc, each switch-selectable as normally-open or normally-closed:

• CR1 is hard-wired to always indicate hardware faults.• CR2 can be switch-configured to also indicate faults.


Printed in U.S.A.

COMPRESSOR CONTROLS CORPORATION

4725 121st Street, Des Moines, IA 50323, USAL Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com

U

DS3300/T Series 3

++

Turbine Controllers Hardware Specificationssheet

This data sheet specifies the physical and operating characteristics of Series 3

++

Controllers that do include the optional auxiliary PCB assembly (speed board).

Figure 1 Controller Dimensions


This section lists various general characteristics of this device, whose dimensions are illustrated in Figure 1.

MountingDimensions

Cutout Width: 2.70 in. (68.6 mm), +0.02 in. (0.5 mm)/–0.00Cutout Height: 5.60 in. (142.2 mm), +0.03 in. (0.8 mm)/–0.00Cabinet Depth: 22 in. (56 cm) from front of panel

Weight 5.5 lb (2.5 kg), not including FTAs

Ambient Conditions Operating Temperature: -4 to 140°F (-20 to 60°C)Storage Temperature: -22 to +185°F (-30 to +85°C)Relative Humidity: 0 to 95% (if free from condensation)

Ratings andCertifications

see:

Agency Certifications for Series 3

++

Controllers

[TN41]

Design Life 15 years (continuous operation)

Design MTBF 45 years

Program Updatingand Configuration

Front panel swings out to expose configuration and testing panel. Optional PC software can load, configure, and tune control program.

#

Turbine Controllers Hardware Specifications

1.026

2.9675.2

2.6868.1

5.506.00153

19.04484

dimensions in inches and millimeters

140

August 2007 Page 1 of 8 DS3300/T (1.1.0)

Figure 2 Power Cable Connector Configurations

Power Supplies

The internal power supply PCB mounts twin third-party 24 Vdc power modules that separately power the internal circuitry and external transmitters. AC conversion or DC regulation modules can be specified, either option requires a back panel with a matching power connector:

Input Voltage 21 to 32 Vdc or 96 to 264 Vac, 50 to 60 Hz

Output Power 24.0±1.2 Vdc, 6.0W maximum, isolated and regulated

Maximum PowerConsumption

30W (includes 6W output power)

Power Cable One 14 ft. (4.3 m) cable with AWG 18 (0.8 mm

2

) conductors is supplied per pair of controllers. Both ends are plug-compatible with the specified PSA. Custom length cables are available.

Power FailureProtection

Configuration data stored in non-volatile EEPROMProcess data stored in RAM with a backup battery (minimum battery life is 1 year @ 70 °C).

CommunicationPorts

Two serial ports for communicating with other CCC controllers

• Port 1: three-wire, EIA RS-485

• Port 2: five-wire, EIA RS-485

Two five-wire, RS-422/485 compatible Modbus RTU serial ports for communicating with support PCs or third-party distributed control and supervisory systems.

Table 1 Serial Communication Formats

Line (Black)

Neutral (White)

Ground (Green)

Cable ControllerAC Cable

+ (Red)

– (Black)

Ground (White)

Cable ControllerDC Cable

Port 1 Port 2 Ports 3 and 4Baud Rate 38400 2400, 4800, 9600 4800, 9600, 19200

Parity Even Even odd, even, none

Start/Data/Stop Bits 1/8/2 1/8/2 1 / 8 / 1

Cable Length up to 4000 feet (1200 meters)

Transceivers (1) One Two1 Up to 32 transceivers can be connected to each RS-485 network


I/O Circuits Extended I/O Turbine Controllers provide terminals for every input and output circuit on external Field Termination Assemblies (see page 5). Standard Turbine Controllers provide back-panel terminals (see Figure 3) for most but not all I/O circuits.

Terminals Removable back-panel compression terminals accept AWG 18 to AWG 14 (0.8 to 2.0 mm2) wire.

Static Protection Design protection to 4,000 volts, lab tested to 7,000 volts.

Frequency Inputs Extended I/O controller has six frequency inputs for 0-to-30 kHz magnetic pickup speed signals, standard controller has three: • minimum 1.5 V peak-to-peak signal for passive pickups• minimum 8.0 V peak-to-peak signal for active pickups• impedance: 100 kΩ nominal, 20 kΩ minimum @ 1 kHz


Extended I/O controller has eight and standard controller has four 0.1% accuracy analog inputs, each internally switch-selected as:• 20 mAdc (100 Ω impedance), 30 Vdc over-voltage protection; or• 5 Vdc (400 kΩ impedance), 300 Vdc over-voltage protectionFloating-ground isolation to 270 Vdc (adjacent channels), 540 Vdc (lowest to highest channel).Each signal is tested against Namur NE 43 high failure (21 mA) and independently-configurable high and low alarm limits.

Position Inputs Extended I/O controller has one five-wire LVDT and one bipolar 20 mA, 250 Ω position input. Standard controller has neither.

Analog Outputs OUT1: Current-loop driver that can be configured to generate any needed signal up to 200 mAOUT2 and OUT3: independently switch-selectable for either:• 20 mAdc signals (0 to 750 Ω impedance)• 5 Vdc signals (2 kΩ minimum impedance)All three circuits provide internal reliability tracking

Discrete Inputs Extended I/O controller has sixteen inputs: DI 1 to 8 have individual grounds, DI 9 to 16 share a common return. Standard controller has nine such inputs, all of which share a common ground.• Energized state: +10 to +30 Vdc• De-energized state: 0 to +2 Vdc• Resistance: 2.2 kΩInput functions are user-defined and can be redundant.


Extended I/O controllers have nine single-pole, electromechanical control relays, standard controllers have eight (all but CR8):• 1 to 8: switch-selectable as normally-open or normally-closed;

rated 1A at 30 Vdc• 9: jumper-selectable as normally-open or normally-closed;

rated 1A at 30 Vdc

CR1 and CR9 are hard-wired to always indicate hardware faults. CR2 can be switch-configured to also indicate faults.


Figure 3 Standard and Extended I/O Back Panels

Figure 4 FTA Mounting Options

21

43

DISCRETE

D

+ –

+ –

CH1

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

TB6

+ –

CH2

+ –

CH3

+ –

CH4

OUT1

+

PORT 2

+ – + – + –

24VDC DISCRETE

+ – D6 D7

PORT 1TX/RX RX2TX2




+ –FREQ1

+

OUT2

+

1 2 1 2 1 2

OUT 3

D8 D9

+ –FREQ2 FREQ3

35 W max

CR1 CR2 CR3 CR4 CR51 2 1 21 21 21 2

G

96-264 VAC

21-32 VDC

HN

MADE IN USA

35 W max

1 4

60 63

INPUTS

1 4

60 63

(J1)

OUTPUTS(J2)

DIN EN 50 035 (TS 32)

3.25" (82 mm)

DIN EN 50 022 (TS 35)

3.0" (76 mm)


Field TerminationAssemblies

Extended I/O controllers are supplied with two rail-mounted Field Termination Assemblies that connect to the controller using High-Density Interconnect Cables (HDICs) with CPC-23/63 connectors:

• The field input module (FIM) provides the analog, discrete, frequency, and position input terminals.

• the field Output Module (FOM) provides the analog output, control relay, and serial communication port terminals.

Mounting Options DIN EN 50 035 or EN 50 022 (see Figure 4)

Field Terminals Compression terminals accepting AWG 18 (0.8 mm2) to AWG 12 (3.3 mm2) wire.

Jumper Blocks Jumper blocks use soldered-in AWG 22 jumper wires.

Fuses Plug-in, 125 V microfuses (Littel Fuse PN 273-XXX or equiv.).

Weight Field Output Module: 2.0 lb (0.9 kg).Field Input Module: 2.5 lb (1.1 kg).

Cable Length Standard HDICs are 10 ft. (3 m) long. Custom cables can be made in any length up to 100 ft. (30 m).

24 Vdc PowerOptions

The FIM’s analog and discrete input circuits can be powered from an internal bus that draws power either from the controller or an external source connected to terminals 1 and 2. If an external source is connected, remove the CD jumper from the 24 Vdc jumper block or the corresponding fuse:

The FOM’s control relay circuits can be powered from an internal bus that draws power from an external source connected to termi-nals 29 and 30:

The controller’s transmitter power output (terminals 26 and 27) does not have sufficient capacity to drive the relay circuits and should not be connected to these terminals.

E

F

G

H

A

B

C

D


(in controller)

1.0Amp

1 2

A C E G

B D F H

E

F

G

H

A

B

C

D


(in controller)

1.0Amp

1 2

26 27 28 29 30

24 VDC(from controller)



Discrete InputCircuits

Each FIM discrete input circuit has a configuration block, 50 mA fuse, and two field wiring terminals (labelled as + and – on page 7):

Configuration block options are discussed in the FIM Discrete Input Circuits section in Chapter 3 of UM3300/H.

Analog InputCircuits

Each FIM analog input circuit has a configuration block, 50 mA fuse, and five field wiring terminals (labelled as B, C/E, D/F, H, and S on page 7):

Configuration block options are discussed in the FIM Analog Input Circuits section in Chapter 3 of UM3300/H.

Control RelayCircuits

Each FOM control relay circuit has a configuration block, 1.0 amp fuse, and two field wiring terminals (labelled as + and – on page 8):

Configuration block options are discussed in the FOM Control Relay Circuits section in Chapter 3 of UM3300/H. Terminal polarity mark-ings must be observed only for circuits powered by the FOM.

Analog OutputCircuits

Each FOM analog output circuit has dedicated positive, negative, and shield terminals:

• OUT1 is a current-loop signal with a configurable range.

• OUT2 and OUT3 have CPU PCB switches that select current-loop or voltage operation. If an output is set for 20 mA operation, its parallel redundant terminals can only be connected to a high-impedance voltmeter.

D E F

A B CDA

B

C F

E

24 Vdc

DI

50 mA

–

+

F

B

A E

CH

G

H

D

C 50 mA24

Vdc

A C E G

B D F H

C/E

B

H

D/F

S

24 Vdc

AB

C

D G

HCR

1.0 A

B D F H

A C E G

–

+


Figure 5 Field Input Module Dimensions and Terminals

5

7

6

8

50 mA

9

11

10

12

50 mA

13

15

14

16

50 mA

Analog InputJumpers and Fuses

78

56

34

12

Discrete InputJumpers and Fuses

1

3

2

4

123456789

101112131415

161718192021222324252627282930

313233343536373839404142434445

464748495051525354555657585960

616263646566676869707172737475

767778798081828384858687888990

919293949596979899

100101102103104105

Terminal Blocks

24 VDC In +24 VDC In –Discrete Input 1 +Discrete Input 1 –Discrete Input 2 +Discrete Input 2 –Discrete Input 3 +Discrete Input 3 –Discrete Input 4 +Discrete Input 4 –Discrete Input 5 +Discrete Input 5 –Discrete Input 6 +Discrete Input 6 –Unused

Discrete Input 7 +Discrete Input 7 –Discrete Input 8 +Discrete Input 8 –Discrete Input 9 +Discrete Input 9 –Discrete Input 10 +Discrete Input 10 –Discrete Input 11 +Discrete Input 11 –Discrete Input 12 +Discrete Input 12 –Discrete Input 13 +Discrete Input 13 –Unused

Discrete Input 14 +Discrete Input 14 –Discrete Input 15 +Discrete Input 15 –Discrete Input 16 +Discrete Input 16 –Frequency Input 1 +Frequency Input 1 –ShieldFrequency Input 2 +Frequency Input 2 –ShieldFrequency Input 3 +Frequency Input 3 –Shield

UnusedUnusedUnusedDo Not UseDo Not UseLVDT 1 Exc +LVDT 1 Exc –LVDT 1 Ret +Do Not UseLVDT 1 Ret –Frequency Input 5 –Frequency Input 5 +Frequency Input 4 –Frequency Input 6 +Frequency Input 4 +

Input Channel 7 BInput Channel 7 C/EInput Channel 7 D/FInput Channel 7 HShieldInput Channel 8 BInput Channel 8 C/EInput Channel 8 D/FInput Channel 8 HShieldAuxiliary Input –Auxiliary Input +ShieldLVDT 1 CommonEarth Ground

Input Channel 4 BInput Channel 4 C/EInput Channel 4 D/FInput Channel 4 HShieldInput Channel 5 BInput Channel 5 C/EInput Channel 5 D/FInput Channel 5 HShieldInput Channel 6 BInput Channel 6 C/EInput Channel 6 D/FInput Channel 6 HShield

24 Vdc Jumpers

4.3" 10.9 cm

Input Channel 1 BInput Channel 1 C/EInput Channel 1 D/FInput Channel 1 HShieldInput Channel 2 BInput Channel 2 C/EInput Channel 2 D/FInput Channel 2 HShieldInput Channel 3 BInput Channel 3 C/EInput Channel 3 D/FInput Channel 3 HShield

TB2 TB1

The Shield terminals are tied to the Earth Groundterminal, which should be connected to an external earth ground.

Frequency Input 6 – is on Field Output Module.

1.0 Amp

1.0 Amp

50 mA

50 mA

16.0

"40

.7 c

m

50 mA

50 mA

50 mA

50 mA

TB7 TB6

TB4 TB3

TB5


Figure 6 Field Output Module Dimensions and Terminals

TB7

Port 1 Tx/Rx +Port 1 Tx/Rx –Port 1 CommonUnusedUnused

Port 3 Tx +Port 3 Tx –Port 3 CommonPort 3 Rx +Port 3 Rx –


Do Not UseDo Not UseNo connectionDo Not UseDo Not Use


+ 24 VDC (Out)– 24 VDC (Out)Unused+ 24 VDC (In)– 24 VDC (In)

12345

2122232425

1112131415

1617181920

678910

2627282930

Analog Output 2 +Analog Output 2 –ShieldAnalog Output 3 +Analog Output 3 –ShieldCurrent Output 1 +Current Output 1 –ShieldAnalog Output 2+Analog Output 2–ShieldAnalog Output 3 +Analog Output 3 –Shield

313233343536373839404142434445

616263646566676869707172737475

Control Relay 8 +Control Relay 8 –Control Relay 9 +Control Relay 9 –+15 VDCGround– 15 VDCFrequency Input 6 –Spare –ShieldDiagnostic Port +Diagnostic Port –ShieldEarth GroundEarth Ground

464748495051525354555657585960

Control Relay 1 +Control Relay 1 –Control Relay 2 +Control Relay 2 –Control Relay 3 +Control Relay 3 –Control Relay 4 +Control Relay 4 –Control Relay 5 +Control Relay 5 –Control Relay 6 +Control Relay 6 –Control Relay 7 +Control Relay 7 –Unused

Terminal Blocks

1

6

8

4

2

7

9

5

3

Control RelayJumpers and Fuses

Both sets of terminals for

1.0 Amp

12.8

"32

.5 c

m

4.3" 10.9 cm

1.0 Amp

1.0 Amp

1.0 Amp

1.0 Amp

TB9 TB8

TB2

TB6

TB1

TB4 TB3

TB5

analog output 2 or 3 can be connected only if its PCBswitch is set to V position.

The Shield terminals are tied to the Earth Ground terminals, which should be connected to an external earth ground.

The Ground terminals are tied to the controller

Commons for Ports 1 to 4 are isolated.

digital ground.


Printed in U.S.A.



U

DS3300/PSeries 3

++

Controller Parts List

Assembly Part Number Assembly Part Number

Complete Electronics Assembly (note 1):CPU/IO PCB and AC Power Supply . . . . 15-500000-002CPU/IO PCB and DC Power Supply. . . . 15-500010-002

Auxiliary PCB (Speed Board):Assembly with Daughter Card . . . . . . . . 15-300600-C01

Back Panel, Compressor Controller (note 2):AC, serial Modbus. . . . . . . . . . . . . . . . . . 15-300500-002AC, wired ethernet . . . . . . . . . . . . . . . . . 15-300500-006DC, serial Modbus . . . . . . . . . . . . . . . . . 15-300500-D02DC, wired ethernet . . . . . . . . . . . . . . . . . 15-300500-D06

Back Panel, Turbine Controller (note 2):AC, Back-panel terminals . . . . . . . . . . . . 15-300500-004AC, Back-panel terminals, plate mount. . 15-300500-005AC, for FIM & FOM . . . . . . . . . . . . . . . . . 15-300500-003DC, Back-panel terminals . . . . . . . . . . . . 15-300510-004DC, for FIM & FOM. . . . . . . . . . . . . . . . . 15-300510-003

Back Panel Terminal Block (note 2):6 terminals . . . . . . . . . . . . . . . . . . . . . . . 20-002568-F0612 terminals . . . . . . . . . . . . . . . . . . . . . . 20-002568-F12

Case:Assembly with Slides and Clamps . . . . . 15-300300-001Mounting Slide . . . . . . . . . . . . . . . . . . . . 50-002422-001Slide Clamp . . . . . . . . . . . . . . . . . . . . . . 50-002420-001

CPU/IO PCB (note 1) . . . . . . . . . . . . . . . . . 18-211656-001

Engineering Panel:Assembly with Keypad. . . . . . . . . . . . . . .15-500400-001 Keypad only . . . . . . . . . . . . . . . . . . . . . . .50-002551-001

Field Termination Assemblies, Turbine (note 2):Field Input and Output Modules. . . . . . . .50-203130-148Fuse, 50 mA . . . . . . . . . . . . . . . . . . . . . .20-401830-500Fuse, 100 mA . . . . . . . . . . . . . . . . . . . . .20-401830-101Fuse, 250 mA . . . . . . . . . . . . . . . . . . . . .20-401830-251Fuse, 1.0 A . . . . . . . . . . . . . . . . . . . . . . .20-401830-102Fuse, 5.0 A . . . . . . . . . . . . . . . . . . . . . . .20-401830-502HDIC (note 3) . . . . . . . . . . . . . . . . . . . . .18-002830-210

Front Panel Assembly (without overlay):with hinge. . . . . . . . . . . . . . . . . . . . . . . . .15-500200-003hinge only . . . . . . . . . . . . . . . . . . . . . . . .50-002431-001

Front Panel Overlays:Antisurge Controller . . . . . . . . . . . . . . . . .50-001280-005Performance Controller . . . . . . . . . . . . . .50-001290-005Dual-Loop A/P Controller. . . . . . . . . . . . .50-001291-005Speed Controller . . . . . . . . . . . . . . . . . . .50-001270-005Extraction Controller . . . . . . . . . . . . . . . .50-001271-005

Power Cables (note 4):for AC Power Supply . . . . . . . . . . . . . . . .18-002542-120for DC Power Supply . . . . . . . . . . . . . . . .18-002542-024

Power Supply Assembly:21-to-32 Vdc . . . . . . . . . . . . . . . . . . . . . .18-211657-1DC96-to-264 Vac. . . . . . . . . . . . . . . . . . . . . .18-211657-1AC

1. Series 3

++

CPU/IO PCB includes all field I/O circuits but not the power supplies (unlike Series 3 Plus, the analog circuits are not on a separate PCB but the 24 Vdc power supplies or regulators are).

2. Detachable terminal blocks are included with complete controllers and all FTAs, but not with replacement back panels.

3. Standard high-density interconnect cable is 10 feet long with two right-angle connectors. Two are required for each turbine controller (one for FIM, one for FOM). Custom lengths will be quoted on request.

4. Standard power cables are 14 feet long with two back-panel connectors, which will yield one long or two short cables. Longer cables will be quoted on request.

#

Controller Spare Parts List

August 2007 Page 1 of 2 DS3300/P (1.1.0)

Side Views of Series 3++ Controller Showing Locations of Major Assemblies

Slide AdjusterMounting SlideCase

Back Panel AssemblyPower Supply Assembly

Front Panel AssemblyEngineering Panel Assembly

Assembly Auxiliary PCB Assembly (optional)CPU/IO PCB Auxiliary PCB

Daughter Card

August 2007 Page 2 DS3300/P (1.1.0)

Printed in U.S.A.


4725 121st Street, Des Moines, IA 50323, USA L Phone: (515) 270-0857 • Fax: (515) 270-1331 • Web: www.cccglobal.com

U

DS3300/N Series 3

++

Modbus TCP Ethernet Optionsdata sheet

This data sheet specifies the built-in Modbus TCP/RTU converter options for Series 3

++

Controllers. Connection and configuration instructions can be found in Chapter 4 of the

Series 3

++

Modbus Reference

manual [UM3300/M] or Appendix B of the

Series 3 OPC Server

user manual [UM5503].

Figure 1 Ethernet Back Panel

Overview

Series 3

++

Compressor Controllers can be purchased with two Digi Connect ME ethernet to serial port converters built into their back panels, which allow Modbus TCP clients (masters) to communicate directly with their Modbus RTU serial ports (3 and 4).

No built-in option is currently available for Turbine Controllers, but they can be similarly connected using external converters that are available from numerous vendors. For example, the Digi One IA and IAP are Digi International’s rail-mounted equivalents to the Connect ME, and they also offer modules with multiple serial ports.

#

Modbus TCP Ethernet Options

21

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

PORT 2

+ – + – + –

24VDC DISCRETE

+ – D6 D7

PORT 1TX/RX RX2TX2

PO

RT

3P

OR

T 4

35 W max

D

+ –CH 1

+ –CH 2

+ –CH 3

+ –CH 4 OUT 1

+


+OUT 2+

1 2 1 2 1 2

CH 5 CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ –+ –+ ––

August 2007 Page 1 of 2 DS3300/N (1.0.0)

http://www.digi.com/products/serialservers

http://www.digi.com/products/serialservers/digioneia.jsp

http://www.digi.com/products/serialservers/digioneiap.jsp

http://www.digi.com/products/embeddedsolutions/digiconnectme.jsp

http://www.digi.com/products/embeddedsolutions/digiconnectme.jsp

Modbus TCP Each converter can service simultaneous requests from multiple clients, each communicating via either the transmission control or user datagram protocol (TCP or UDP). Such requests are queued for a configurable maximum time, after which they are flushed.Each converter’s Modbus node number is configurable, and the Modbus TCP exception responses (0A and 0B) can be disabled.

Bandwidth The data transfer capacity of each converter is limited to that of the 19200 baud, odd-parity Modbus RTU controller port it connects to, (approximate maximum is 1700 data bytes per second).

IP Settings Compatible with Internet Protocol versions IPv4 and IPv6.Default static IP addresses and subnet masks can be changed, or modules can be set to obtain them from a DHCP server.

Status LEDs Lower, yellow LED lights when electrically connected.Upper, green LED flashes three times while converter is booting, then intermittently to indicate data communication.

Configuration andMaintenance

Each converter can be configured, monitored, and/or updated using a web browser or the Series 3 OPC Server program.Each converter has a recessed reset switch, and can also be rebooted via its configuration interface.

Security Options Secure Sockets Layer/Transport layer Security (SSL/TLS)

HTTP configuration interface can be disabled, or its default user name and password can be changed.

RegulatoryApprovals

The following certifications have been obtained by the converter’s manufacturer (Digi International):• FCC Part 15 Class B, EN 55022 Class B• EN 61000-3-2 and EN 61000-3-3• ICES-003 Class B, VCCI Class II, AS 3548• FCC Part 15 Sub C Section 15.247• IC RSS-210 Issue 5 Section 6.2.2(o)• EN 300 328, EN 301 489-17• UL 60950-1, EN60950 (EU)• CSA C22.2, No. 60950• EN 55024

Ambient Conditions Relative humidity: 5 to 90% (non-condensing)Temperature limits exceed those of Series 3++ Controllers

August 2007 Page 2 of 2 DS3300/N (1.0.0)

Printed in U.S.A.



http://www.digi.com

U

DS3300/R Series 3

++

Redundant Control Selectordata sheet

This data sheet specifies the Redundant Control Selector for duplex Series 3

++

Control Systems. For usage information, see Chapter 5 of the

Series 3

++

Hardware Reference

manual [UM3300/H].

Overview andOperation

Each Redundant Control Selector (RCS) has two main components:

• an operator panel that is usually mounted between the operator panels of a redundant pair of controllers, and

• a switching unit that can be mounted in an inaccessible location.

The switching unit includes a latched master relay that controls four 4PDT slave relays:

• When de-energized, the slave relays connect their COMMON and RUN terminals, thus selecting the main controller.

• When energized, they connect their COMMON and TRACKING terminals, thus selecting the backup controller.

Both the operator panel and switching unit have LEDs that indicate which controller is currently selected and buttons for transferring control of the process to the other. In addition, the master relay is connected to the fault (and possibly other) relays of the main and backup controllers. If each of those circuits is set up to open when the corresponding controller should not be in control:

• Either healthy controller can be manually selected by pressing one of the corresponding buttons.

• If the main controller is selected and the backup is healthy, con-trol is transferred to the backup if the main controller faults or the Switch to Backup (or Trip) button is pressed.

• If the backup is selected and the main controller is healthy, con-trol can be transferred to the main controller only by pressing the Switch to Main (or Reset) button.

Note that control of the process can never be transferred to a failed controller and is never automatically transferred to the main control-ler, even if it is healthy and the backup is not.

If power to the RCS failed, the slave relays would de-energize, thus selecting the main controller. However, the latched master would remember which controller had been selected and return control to it when power was restored.

#

Redundant Control Selector

July 2007 Page 1 of 4 DS3300/R (1.0.0)

Figure 1 Operator Panel Dimensions and Connector Pinouts

Figure 2 Switching Unit Dimensions

dimensions in inches

1.025.4

1.333.0

5.25133.4

6.0152.4

2.9675.2

2.0050.8

1.2531.8

3.12579.4

.6316

Ground

+24VTrip

ResetBackup

Main

REDUNDANT

CONTROL

SELECTOR

MAIN

BACK-UP

Switch toBack-Up

Switch toMain

GREENACTIVE

REDTRACK

and millimeters

1.025.4

2.871

7.25184

6.75171

4.25108

8.75222

dimensions in inchesand millimeters

July 2007 Page 2 of 4 DS3300/R (1.0.0)


The dimensions of the operator panel and switching unit are shown in Figure 1 and Figure 2.

Switching Relays Four 4PDT electro-mechanical slave relays controlled by a magnetically-latched master relay. Slave relay contacts are rated at:

3 A. @ 28 Vdc (resistive) or 3 A. @ 120 Vac

Discrete Outputs Either the Main or the Backup discrete output is connected to the supplied power when the corresponding controller is selected.

Status LEDs Main and Backup LEDs on operator panel and switching unit are green when corresponding controller is active, otherwise red.The switching unit also has five red LEDs, one for each slave relay and one that lights when the main controller faults.

Operator PanelSwitches

Momentary-contact, push-button switches for selecting the main or backup controller are shrouded to prevent inadvertent operation.

Wiring Terminals Removable compression terminals accept AWG 18 (1.0 mm) to AWG 14 (1.6 mm) wire.

MaximumSeparation

Cable connecting operator panel to switching unit can be up to 300 ft. (90 m) in length.

Weight Switching Unit: 2.75 lb (1.25 kg)Operator Panel: 0.25 lb (0.11 kg)

Figure 3 Power Connector Pinouts

Power Inputs The switching unit has connectors for two independent external power supplies and automatically powers its circuits from the source providing the highest voltage.

Required Voltage 24 Vdc (± 10%)

Protective Features Each power supply circuit includes a 2.0 A., slow-blow fuse and surge-suppression circuitry.

Pass-ThroughPower

Two pass-through power circuits are provided on terminal block TB5. Total pass-through load should not exceed 5 W.

Power Consumption 7 W, excluding pass-through loads

Power Cable One 14 ft. (4.3 m.) cable with AWG 18 (0.8 mm2) conductors is supplied per pair of controllers. Both ends are equipped with compatible connectors as shown in Figure 3.Custom length cables are available.

+ (Red or Orange)

— (Black or Brown

Ground (White)

Cable Connector End-Panel Connector

July 2007 Page 3 of 4 DS3300/R (1.0.0)

Figure 4 Switching Unit Components

Figure 5 Switching Unit Terminal Blocks

Fuses

ManualSelectionSwitches

Terminal TerminalBlock TB5Block TB6

Power CordConnectors

MainLED

BackupLED

Terminal Block TB1Terminal Block TB2

Terminal Block TB3Terminal Block TB4

TB

1 th

roug

h T

B4

12

34

56

78

910

1112

operatorpanel

pass-through

isolated sparespass-through

isolated

Ground

+24VTrip

ResetBackup

Main

COMMON terminals

TRACK terminals

RUN terminals

A

TB

5

+–+–

+–+–

12

34

56

78

910

1112

TB

6

12

34

56

78

910

1112

BCDABCDABCD

(to field devices)

(to backup controller outputs)

(to main controller outputs)

to Main Fault

Backup Active DO

to Backup Fault

Main Active DO

connections

grounds

+24 Vdc

spares

July 2007 Page 4 of 4 DS3300/R (1.0.0)

Printed in U.S.A.



U

DS3301/V. Series 3

++

Controller Hardware Revisionsdata sheet

This data sheet describes the new and modified hardware changes documented by the corresponding release of the

Series 3

++

Hardware Reference

manual [UM3300/H].

Manual Version1.1.0

This release of the hardware reference manual incorporated the changes described below.

Modbus TCP Option The optional Modbus TCP Back Panel for compressor controllers replaces the Port 3 and 4 terminal blocks of the Modbus RTU Back Panel with built-in ethernet-to-serial port converters (see page 23, page 67, page 98, and the

Series 3

++

Modbus TCP Ethernet Options

data sheet [DS3300/N]).

HardwareSpecifications

The communication port, analog input over-voltage, and maximum power consumption specifications were revised (see the

Series 3

++

Compressor Controllers Hardware Specifications

sheet [DS3300/C] and the

Series 3

++

Turbine Controllers Hardware Specifications

sheet [DS3300/T]).

#

Controller Hardware Revisions

August 2007 Page 1 of 2 DS3301/V (1.1.0)

August 2007 Page 2 of 2 DS3301/V (1.1.0)

Printed in U.S.A.



TN41 (1.0)

U
TN41Agency Certifications for Series 3++ Controllerstechnical note
Agency Certifications for Series 3 ++ Controllers

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This document documents the current agency certifications for Control-lers and related components, which have been determined to be compli-ant with the following safety, environmental, and EMC standards.

Electrical Safety

Industrial Process Measurement and Control

Compliant Standard Certification Level

EN 61010-1IEC 1010-1 (2005)(Low-Voltage Directive)

Safety Requirements for Electrical Equipment for Measure-ment, Control, and Laboratory use – General Requirements

Note:

Other agency certifications are in process and will be added to this publi-cation when certificates are issued.

Environmental

Industrial Process Measurement and Control


IEC 60654-1 (2003)(IEC 654, Part 1)

Operating Conditions for Industrial Process Measurement and Control Equipment, Part 1: Temperature, Humidity, and Barometric Pressure

IEC 60654-2 (2001)(IEC 654, Part 2)

Operating Conditions for Industrial Process Measurement and Control Equipment, Part 2: Power

MIL-PRF-28800F (1996)(Class 3 and 4)

Equipment for use with Electrical and Electronic Equipment, General Specifications for Navy Ship Systems – Vibration

April 2007


Agency Certifications for Series 3++ Controllers

Electromagnetic Capability (EMC) European Union: 73/23/EEC Low Voltage Directive and89/336/EEC Electromagnetic Compatibility Directive


IEC 61326 A3:2003Electrical Equipment For Measurement, Control, and Laboratory Use -- EMC

Requirements.

BS EN 55011 A2:2002(CISPR 11 (2004))(FCC part 15 subpart B)

Industrial, scientific and medical (ISM) radio-frequency equipment emissions – Electromagnetic disturbance characteristics – Limits and methods of measurement

IEC 61000-4-2 (2001)Electromagnetic Compatibility (EMC), Part 4: Testing and Measurement

Techniques Section 2: Electrostatic Discharge Immunity Tests

IEC 61000-4-3 (2002)Electromagnetic Compatibility (EMC), Part 4-3: Testing and Measurement Tech-

niques - Radiated, Radio-Frequency, Electromagnetic Field Immunity Test


Techniques Section 4: Electrical Fast Transient/Burst Immunity Test


Techniques Section 5: Surge Immunity Test


Techniques Section 6: Immunity to conducted disturbances, induced by radio-fre-quency fields

IEC 61000-4-8 (2004)Electromagnetic Compatibility (EMC), Part 4: Testing and Measurement Tech-

niques Section 8: Power frequency magnetic field immunity test


Techniques Section 11: Voltage dips, short interruptions, and voltage variations immunity tests

Page 2TN41 (1.0)April 2007

Phone: (515) 270-0857

•

Fax: (515) 270-1331

•

Web: www.cccglobal.com4725 121st Street, Des Moines, Iowa 50323-2316, U.S.A.


The TTC and impeller logos, Air Miser, Guardian, Recycle Trip, Reliant, Safety On, SureLink, TTC, Total Train Control, TrainTools, TrainView, TrainWare, Vanguard, Vantage, and WOIS are registered trademarks; and the Series 3

++

and Series 5 logos, COMMAND, and TrainPanel are trademarks of Compressor Controls Corp. © 2007


U

May 2006 FM73 (3.0)

FM73

If you have questions or comments concerning the information provided in this user manual or in any of our technical documents please contact CCC’s Technical Documentation Department:

E-mail: [email protected]

Which Series of Controllers do you have, and are you using our TrainTools software?

Series 3+/3++ Series 4 Series 5 TrainTools Guardian Vantage Air Miser

Some additional information we would like to know: Printed Online

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You may also fax your questions or comments to:

Fax: (515) 334-2500

ATTN: Manager, Technical Documentation

Comments:

Documentation Feedback FormPublication Title: Series 3++ Hardware Reference Manual

Publication No.: UM3300/H (1.1.0) Publication Date: August 2007

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