Bailey Infi 90 IISAC01 Manuale utente

Process Control and

Automation Solutions

from Elsag Bailey Group

E96-117

Analog Control Station

(IISAC01)

WARNING notices as used in this instruction apply to hazards or unsafe practices that could result in

personal injury or death.

CAUTION notices apply to hazards or unsafe practices that could result in property damage.

NOTES highlight procedures and contain information that assists the operator in understanding the

information contained in this instruction.

WARNING

INSTRUCTION MANUALS

DO NOT INSTALL, MAINTAIN, OR OPERATE THIS EQUIPMENT WITHOUT READING, UNDERSTANDING,

AND FOLLOWING THE PROPER Elsag Bailey INSTRUCTIONS AND MANUALS; OTHERWISE, INJURY OR

DAMAGE MAY RESULT.

RADIO FREQUENCY INTERFERENCE

MOST ELECTRONIC EQUIPMENT IS INFLUENCED BY RADIO FREQUENCY INTERFERENCE (RFI). CAU-

TION SHOULD BE EXERCISED WITH REGARD TO THE USE OF PORTABLE COMMUNICATIONS EQUIP-

MENT IN THE AREA AROUND SUCH EQUIPMENT. PRUDENT PRACTICE DICTATES THAT SIGNS

SHOULD BE POSTED IN THE VICINITY OF THE EQUIPMENT CAUTIONING AGAINST THE USE OF POR-

TABLE COMMUNICATIONS EQUIPMENT.

POSSIBLE PROCESS UPSETS

MAINTENANCE MUST BE PERFORMED ONLY BY QUALIFIED PERSONNEL AND ONLY AFTER SECURING

EQUIPMENT CONTROLLED BY THIS PRODUCT. ADJUSTING OR REMOVING THIS PRODUCT WHILE IT IS

IN THE SYSTEM MAY UPSET THE PROCESS BEING CONTROLLED. SOME PROCESS UPSETS MAY

CAUSE INJURY OR DAMAGE.

AVERTISSEMENT

MANUELS D’OPÉRATION

NE PAS METTRE EN PLACE, RÉPARER OU FAIRE FONCTIONNER L’ÉQUIPEMENT SANS AVOIR LU,

COMPRIS ET SUIVI LES INSTRUCTIONS RÉGLEMENTAIRES DE Elsag Bailey. TOUTE NÉGLIGENCE À

CET ÉGARD POURRAIT ÊTRE UNE CAUSE D’ACCIDENT OU DE DÉFAILLANCE DU MATÉRIEL.

PERTURBATIONS PAR FRÉQUENCE RADIO

LA PLUPART DES ÉQUIPEMENTS ÉLECTRONIQUES SONT SENSIBLES AUX PERTURBATIONS PAR

FRÉQUENCE RADIO. DES PRÉCAUTIONS DEVRONT ÊTRE PRISES LORS DE L’UTILISATION DU MATÉ-

RIEL DE COMMUNICATION PORTATIF. LA PRUDENCE EXIGE QUE LES PRÉCAUTIONS À PRENDRE

DANS CE CAS SOIENT SIGNALÉES AUX ENDROITS VOULUS DANS VOTRE USINE.

PERTURBATIONS DU PROCÉDÉ

L’ENTRETIEN DOIT ÊTRE ASSURÉ PAR UNE PERSONNE QUALIFIÉE EN CONSIDÉRANT L’ASPECT

SÉCURITAIRE DES ÉQUIPEMENTS CONTRÔLÉS PAR CE PRODUIT. L’AJUSTEMENT ET/OU L’EXTRAC-

TION DE CE PRODUIT PEUT OCCASIONNER DES À-COUPS AU PROCÉDÉ CONTRÔLE LORSQU’IL EST

INSÉRÉ DANS UNE SYSTÈME ACTIF. CES À-COUPS PEUVENT ÉGALEMENT OCCASIONNER DES

BLESSURES OU DES DOMMAGES MATÉREILS.

NOTICE

The information contained in this document is subject to change without notice.

Elsag Bailey, its affiliates, employees, and agents, and the authors and contributors to this publication specif-

ically disclaim all liabilities and warranties, express and implied (including warranties of merchantability and

fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the information

contained herein and/or for the fitness for any particular use and/or for the performance of any material and/

or equipment selected in whole or part with the user of/or in reliance upon information contained herein.

Selection of materials and/or equipment is at the sole risk of the user of this publication.

This document contains proprietary information of Elsag Bailey, Elsag Bailey Process Automation, and

is issued in strict confidence. Its use, or reproduction for use, for the reverse engineering, development

or manufacture of hardware or software described herein is prohibited. No part of this document may be

photocopied or reproduced without the prior written consent of Elsag Bailey.

I-E96-117B1 15 August 1994

Preface

The IISAC01 Analog Control Station provides an operator inter-

face for INFI 90® system applications. It is a panel mounted

device that interfaces directly with a manual/auto transfer sta-

tion block configured in a multi-function processor module.

The analog control station (SAC) displays process variables,

allows set point adjustment and provides analog output man-

ual control. It also provides analog output backup in the event

of other system faults.

This instruction explains the station features, specifications,

and operation. It includes installation procedures and explains

how to troubleshoot station failures.

The system engineer or technician using the SAC station

should read and understand this instruction before installing

and operating the station. In addition, a complete understand-

ing of the INFI 90 system is beneficial.

This update covers error code 16 and contains information on

hardware and software improvements.

® INFI 90 is a registered trademark of Elsag Bailey Process Automation.

15 August 1994 I-E96-117B1

List of Effective Pages

Total number of pages in this instruction is 94, consisting of the following:

Page No. Change Date

Preface 31 August 1994

List of Effective Pages 31 August 1994

iii through viii 31 August 1994

1-1 through 1-9 Original

2-1 through 2-19 Original

3-1 through 3-6 Original

3-7 31 August 1994

3-8 Original

3-9 through 3-10 31 August 1994

3-11 through 3-23 Original

4-1 through 4-3 31 August 1994

4-4 through 4-9 Original

5-1 through 5-2 Original

5-3 31 August 1994

5-4 through 5-13 Original

6-1 through 6-4 Original

7-1 through 7-2 Original

8-1 Original

A-1 through A-2 Original

B-1 Original

C-1 Original

Index-1 through Index-2 31 August 1994

When an update is received, insert the latest changed pages and dispose of the super-

seded pages.

NOTE: On an update page, the changed text or table is indicated by a vertical bar in the outer mar-

gin of the page adjacent to the changed area. A changed figure is indicated by a vertical bar in the

outer margin next to the figure caption. The date the update was prepared will appear beside the

page number.

I-E96-117B1 15 August 1994 vii

Safety Summary

GENERAL

WARNINGS Equipment Environment

All components, whether in transportation, operation or storage,

must be in a noncorrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with

energized parts is avoided when servicing.

Special Handling

This module uses electrostatic sensitive devices.

SPECIFIC

WARNING Wear eye protection whenever working with cleaning solvents.

When removing solvents from printed circuit boards using com-

pressed air, injury to the eyes could result from splashing solvent as

it is blown off the printed circuit board. (p. 6-1)

SPECIFIC

CAUTION Remove a station from its housing before installing or removing the

station cable to the station housing. Failure to observe these pre-

cautions could result in equipment damage. (p. 3-22)

viii 15 August 1994 I-E96-117B1

Sommaire de Sécurité

AVERTISSEMENTS

D’ORDRE

GÉNÉRAL

Environnement de l’équipement

Ne pas soumettre les composants à une atmosphère corrosive lors

du transport, de l’entreposage ou l’utilisation.

Possibilité de chocs électriques durant l’entretien

Débrancher l’alimentation ou prendre les précautions pour éviter

tout contact avec des composants sous tension durant l’entretien.

Precautions de Manutention

Ce module contient des composantes sensibles aux décharges

électrostatiques.

AVERTISSEMENT

D’ORDRE

SPÉCIFIQUE

Portez toujours des lunettes de protection lorsque vous utilisez des

solvants de nettoyage. L'air comprimé servant à enlever le solvant

des cartes de circuits imprimés provoque des éclaboussures qui ris-

quent d'atteindre les yeux. (p. 6-1)

ATTENTION

D’ORDRE

SPÉCIFIQUE

Retirer le poste de son boitier avant d’installer ou de retirer le câble

du poste du boitier. Un manquement à cette précaution pourrait

causer des dommages à l’équipement. (p. 3-22)

Table of Contents

Page

I-E96-117B1 15 August 1994 iii

SECTION 1 - INTRODUCTION....................................................................................................1-1

INTRODUCTION...........................................................................................................1-1

INTENDED USER.........................................................................................................1-1

HARDWARE DESCRIPTION..........................................................................................1-1

HARDWARE APPLICATION...........................................................................................1-2

FEATURES...................................................................................................................1-2

INSTRUCTION CONTENT .............................................................................................1-3

HOW TO USE THIS INSTRUCTION ...............................................................................1-4

GLOSSARY OF TERMS AND ABBREVIATIONS .............................................................1-4

REFERENCE DOCUMENTS..........................................................................................1-6

NOMENCLATURE ........................................................................................................1-7

SPECIFICATIONS.........................................................................................................1-8

SECTION 2 - DESCRIPTION AND OPERATION........................................................................2-1

INTRODUCTION...........................................................................................................2-1

SYSTEM OPERATION...................................................................................................2-1

Analog Control Station Functions...........................................................................2-4

MODES OF OPERATION ..............................................................................................2-5

Initialization...........................................................................................................2-6

Stand-Alone Operation...........................................................................................2-6

Bypass Operation ..................................................................................................2-6

Manual Override Operation ....................................................................................2-7

Normal Operation ..................................................................................................2-8

Computer and Local Mode .....................................................................................2-8

Local Level.......................................................................................................2-9

Computer Level ...............................................................................................2-9

Basic Station .........................................................................................................2-9

Cascade Station ...................................................................................................2-10

Ratio Station........................................................................................................2-12

SAC STATION I/O CIRCUITRY ...................................................................................2-13

Bypass Circuitry ..................................................................................................2-14

Electric Drive Circuitry ........................................................................................2-16

Analog Output Circuitry.......................................................................................2-18

Analog Input Circuitry .........................................................................................2-18

SECTION 3 - INSTALLATION.....................................................................................................3-1

INTRODUCTION...........................................................................................................3-1

SPECIAL HANDLING ....................................................................................................3-1

UNPACKING AND INSPECTION ....................................................................................3-2

SELECTING OPTIONS ..................................................................................................3-2

Diagnostics (SW1, Position 1) .................................................................................3-3

Communication Rate (SW1, Position 2) ..................................................................3-3

Station Address (SW1, Positions 3 through 8) .........................................................3-4

Auto Bypass (SW2, Position 1) ...............................................................................3-4

Demand Output (SW2, Position 2) ..........................................................................3-5

Electric Drive Option (SW2, Position 3 and JP2) .....................................................3-5

DISPLAY OPTIONS .......................................................................................................3-6

Stand-Alone Mode Display Options (SW3) ..............................................................3-7

Square Root Enable (SW4, Position 1) ....................................................................3-7

Normal Mode Display Options (SW4, Positions 2, 3 and 4) ......................................3-8

Bypass/Manual Override Mode Display Options (SW4, Positions 5, 6, 7 and 8) ......3-8

Manual Override (JP1) ...........................................................................................3-9

iv 15 August 1994 I-E96-117B1

Table of Contents (continued)

Page

SECTION 3 - INSTALLATION

(continued)

ELECTRIC DRIVE MODE DISPLAY OPTIONS (SW3 AND SW4) ................................... 3-10

MICROCOMPUTER MODE OF OPERATION (JP3) ....................................................... 3-11

MOUNTING THE STATION HOUSING......................................................................... 3-11

Cable Lengths ..................................................................................................... 3-11

Termination Unit Cable and Wiring Installation (Single or Double Station) ........... 3-15

Termination Unit Cable Installation (Interconnected Stations).............................. 3-15

Cable Connections for the NTRL03 Termination Unit ........................................... 3-16

Cable Connections for the NIRL03 Termination Module ....................................... 3-16

Termination Module Cable Installation (without Bypass) ...................................... 3-17

Termination Module Cable Installation (with Bypass) ........................................... 3-19

Connecting Termination Cables to Station Housing ............................................. 3-22

INSERTING AND REMOVING THE ANALOG CONTROL STATION ............................... 3-22

Inserting the Analog Control Station .................................................................... 3-22

Removing the Analog Control Station................................................................... 3-23

FUNCTION CODE CONFIGURATION.......................................................................... 3-23

SECTION 4 - OPERATING PROCEDURES................................................................................4-1

INTRODUCTION .......................................................................................................... 4-1

FACEPLATE OPERATION............................................................................................. 4-1

Alphanumeric Display ........................................................................................... 4-1

Annunciators ........................................................................................................ 4-4

Bar Graph Displays ............................................................................................... 4-4

Membrane Pushbuttons ........................................................................................ 4-4

Manual Override Switch ........................................................................................ 4-4

STATION START-UP AND OPERATION......................................................................... 4-6

Stand-Alone .......................................................................................................... 4-7

Normal Operation.................................................................................................. 4-8

Changing Control Strategies in Normal Operation .................................................. 4-8

Bypass/Manual Override Operation....................................................................... 4-9

Acknowledging Alarms........................................................................................... 4-9

SECTION 5 - TROUBLESHOOTING...........................................................................................5-1

INTRODUCTION .......................................................................................................... 5-1

HOW TO USE THIS SECTION ...................................................................................... 5-1

ERROR CODES ........................................................................................................... 5-1

GENERAL FAILURES................................................................................................... 5-1

SECTION 6 - MAINTENANCE.....................................................................................................6-1

INTRODUCTION .......................................................................................................... 6-1

PREVENTIVE MAINTENANCE SCHEDULE................................................................... 6-1

EQUIPMENT AND TOOLS REQUIRED ......................................................................... 6-2

PREVENTIVE MAINTENANCE PROCEDURES .............................................................. 6-2

Printed Circuit Board Cleaning .............................................................................. 6-3

General Cleaning and Washing........................................................................ 6-3

Edge Connector Cleaning ................................................................................ 6-3

Female Edge Connector Cleaning .................................................................... 6-4

Checking Connections ........................................................................................... 6-4

SECTION 7 - REPAIR/REPLACEMENT PROCEDURES...........................................................7-1

INTRODUCTION .......................................................................................................... 7-1

STATION FUSE (F1) REPLACEMENT............................................................................ 7-2

I-E96-117B1 15 August 1994 v

Table of Contents (continued)

Page

SECTION 8 - SUPPORT SERVICES...........................................................................................8-1

INTRODUCTION...........................................................................................................8-1

REPLACEMENT PARTS AND ORDERING INFORMATION ..............................................8-1

TRAINING ....................................................................................................................8-1

TECHNICAL DOCUMENTATION ...................................................................................8-1

APPENDIX A - NTCS04 CONTROLLER/STATION TERMINATION UNIT................................A-1

INTRODUCTION.......................................................................................................... A-1

APPENDIX B - NICS01 CONTROLLER/STATION TERMINATION MODULE..........................B-1

INTRODUCTION.......................................................................................................... B-1

APPENDIX C - NIDS01 STATION TERMINATION MODULE....................................................C-1

INTRODUCTION.......................................................................................................... C-1

List of Tables

No. Title Page

1-1. Glossary of Terms and Abbreviations .....................................................................1-5

1-2. Reference Documents ............................................................................................1-6

1-3. Nomenclature ........................................................................................................1-7

1-4. IISAC01 Analog Control Station Specifications .......................................................1-8

2-1. Bypass Circuit Functions and Specifications ........................................................2-15

3-1. Dipswitch SW1 Positions 1 and 2 ...........................................................................3-3

3-2. Dipswitch SW1 Address Positions 3 through 8 .......................................................3-4

3-3. Dipswitch SW2 Positions 1 through 3 ....................................................................3-5

3-4. SAC Station Jumper Settings .................................................................................3-6

3-5. Dipswitch SW3 Positions 1 through 3 ....................................................................3-7

3-6. Dipswitch SW4 Position 1 ......................................................................................3-8

3-7. Dipswitch SW4 Positions 2 through 8 ....................................................................3-9

3-8. Dipswitch SW3 Electric Drive Mode Display Options ............................................3-10

3-9. Dipswitch SW4 Electric Drive Mode Display Options ............................................3-10

3-10. Termination Device and SAC Station Designator Relationship ..............................3-12

3-11. Cable Applications, Connections and Length Requirements..................................3-13

3-12. INFI 90 Power System Maximum Cable Length .....................................................3-14

3-13. Network 90 Power System Maximum Cable Length ..............................................3-15

4-1. Special Characters on the Alphanumeric Display ...................................................4-2

4-2. Analog Control Station Error Codes and Alarms .....................................................4-2

4-3. Annunciators.........................................................................................................4-4

4-4. Membrane Pushbutton Operation ..........................................................................4-5

5-1. Corrective Action for SAC Error Codes....................................................................5-2

5-2. Troubleshooting General Failures.........................................................................5-12

6-1. Preventive Maintenance Schedule ..........................................................................6-2

7-1. Recommended Spare Parts List ..............................................................................7-1

A-1. NTCS04 Termination Unit Dipshunt Configuration ............................................... A-1

vi 15 August 1994 I-E96-117B1

No. Title Page

List of Figures

1-1. Example Analog Control Station within the INFI 90 Hierarchy ............................... 1-3

2-1. SAC Station Application Example .......................................................................... 2-2

2-2. Flow Diagram of SAC Station Operation from Power Up to Normal Operation ......... 2-5

2-3. SAC Station Normal Operating Modes.................................................................... 2-8

2-4. Basic Station Configuration ................................................................................. 2-10

2-5. Module Configuration with Cascade Set Point from External Source .................... 2-11

2-6. Ratio Station Configuration ................................................................................. 2-12

2-7. Block Diagram of SAC Station Circuitry ............................................................... 2-13

2-8. Station Bypass Circuitry...................................................................................... 2-15

2-9. Electric Drive Circuit ........................................................................................... 2-17

2-10. Analog Output Circuitry ...................................................................................... 2-18

3-1. Dipswitch and Jumper Locations on the SAC Station Circuit Board ....................... 3-2

3-2. Station Housing Panel Cutout and Mounting Dimensions .................................... 3-12

3-3. Cable Connections for Two Analog Control Stations on One

TCS Termination Unit.......................................................................................... 3-16

3-4. Cable Connections for TCS Termination Unit with Multiple Interconnected

SAC Stations ....................................................................................................... 3-17

3-5. Cable Connections for the NTRL03 Termination Unit ........................................... 3-18

3-6. Cable Connections for the NIRL03 Termination Module ....................................... 3-19

3-7. Cable Connections for the ICS Termination Module with One Station,

No Bypass ........................................................................................................... 3-20

3-8. Cable Connections for the ICS and IDS Modules with Interconnected Stations

and Bypass ......................................................................................................... 3-21

4-1. SAC Faceplate ....................................................................................................... 4-1

5-1. Error Code E01 Troubleshooting Flowchart ........................................................... 5-5

5-2. Error Codes E03, E04, E05 and E06 Troubleshooting Flowchart ............................ 5-6

5-3. Error Codes E07 and E08 Troubleshooting Flowchart ............................................ 5-7

5-4. Error Code E17 Troubleshooting Flowchart ........................................................... 5-8

5-5. Error Code E18 Troubleshooting Flowchart ........................................................... 5-9

5-6. Error Code E19 Troubleshooting Flowchart ......................................................... 5-10

5-7. Error Code E20 Troubleshooting Flowchart ......................................................... 5-11

5-8. Troubleshooting Flowchart for General Operational Failures ................................ 5-13

A-1. NTCS04 Terminal Assignments..............................................................................A-2

B-1. NICS01 Terminal Assignments ..............................................................................B-1

C-1. NIDS01 Terminal Assignments ..............................................................................C-1

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