1. Manuals
  2. Brands
  3. Symphony Manuals
  4. Control Unit
  5. BRC-100
  6. Instruction

Symphony BRC-100 Instruction

Harmony series/bridge controller and processor bus adapter
Hide thumbs
Table of Contents

Advertisement

Quick Links

Instruction
Harmony Series
Bridge Controller and Processor Bus Adapter
BRC-100 and PBA-100

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BRC-100 and is the answer not in the manual?

Questions and answers

Summary of Contents for Symphony BRC-100

  • Page 1 Instruction Harmony Series Bridge Controller and Processor Bus Adapter BRC-100 and PBA-100...
  • Page 2 Preface The BRC-100 Harmony Bridge Controller is a high-perfor- mance, high-capacity process controller. It is a rack controller designed to interface with both Harmony I/O blocks and Har- mony rack I/O in the Symphony Enterprise Management and Control System. The Harmony bridge controller is fully com- ®...
  • Page 3 List of Effective Pages Total number of pages in this instruction is 99, consisting of the following: Page No. Change Date Preface 04 December 2000 List of Effective Pages 04 December 2000 iii through x 04 December 2000 1-1 through 1-8 04 December 2000 2-1 through 2-8 04 December 2000...

  • Page 4: Table Of Contents

    Table of Contents Section 1 Introduction ....................1-1 Overview ........................1-1 Intended User ......................1-2 Hardware Description ....................1-2 Faceplate ......................1-3 Circuit Board ....................... 1-3 Hardware Application....................1-3 Features ........................1-3 Instruction Content....................1-4 How to Use this Instruction ..................1-4 Glossary of Terms and Abbreviations................
  • Page 5 Table of Contents (continued) Section 3 Installation ..................(continued) Dipswitch SW4 - Module Options ................3-8 Jumpers .......................3-8 Module Mounting Unit Preparation ................3-9 Module Slot Assignments ..................3-9 Dipshunts ......................3-10 Controlway Cable....................3-10 PBA Board Installation..................3-11 Mounting Bracket ...................3-11 Cable and Terminator ..................3-12 Mounting ......................3-13 BRC Redundancy Kit Installation ................3-16 Module Installation....................3-18...
  • Page 6 Table of Contents (continued) Section 6 Maintenance ..................(continued) Printed Circuit Board Cleaning ................6-2 General Cleaning and Washing ................. 6-3 Edge Connector Cleaning.................. 6-3 Checking Connections ..................6-4 Section 7 Repair and Replacement ................7-1 Introduction......................7-1 Module Replacement ....................7-1 PBA Board Replacement...................
  • Page 7 List of Figures (continued) Title Page 5-1. Troubleshooting Flowchart (Serial Port) .............5-6 5-2. Troubleshooting Flowchart (Status LED) ............5-7 5-3. LEDs - Pass/Fail ..................5-12 A-1. Backup Cycle ................... A-6 A-2. Primary Cycle ................... A-8 B-1. DTE Jumper Configuration (NTMP01) ............B-2 B-2.
  • Page 8 List of Tables (continued) Title Page 5-13. P3 Pin Assignments (PBA) ............... 5-20 5-14. P4 Pin Assignments (PBA) ............... 5-20 5-15. P5 Pin Assignments (PBA) ............... 5-21 5-16. P5 Pin Assignments (Hood Connection Assembly) ........5-22 6-1. Preventive Maintenance Schedule.............. 6-2 8-1.
  • Page 9 Safety Summary GENERAL Equipment Environment WARNINGS 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.
  • Page 10 Support Services ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be made to your nearest sales or service office. ABB can also pro- vide installation, repair and maintenance contract services. When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals.
  • Page 11 Trademarks and Registrations Registrations and trademarks used in this document include: ® INFI 90 Registered trademark of ABB Process Automation. ® INFI-NET Registered trademark of ABB Process Automation. ® Network 90 Registered trademark of ABB Process Automation. WBPEEUI230017B1...

  • Page 12: Section 1 Introduction

    C, Basic, Batch 90, and Ladder. The Symphony system uses a variety of analog, control, and digital I/O devices to interface with the process. Control input/ output is available from I/O blocks using the Harmony com- munication network (Hnet) or from Harmony rack I/O modules using the I/O expander bus.

  • Page 13: Intended User

    Installation requires an engineer or technician with experience handling electronic circuitry. Formal training in Symphony system con- figuration (especially function codes) is helpful when configur- ing the BRC module.

  • Page 14: Hardware Description

    Hardware Description Hardware Description The Harmony bridge controller consists of a circuit board and a faceplate. Faceplate The BRC faceplate measures 35.56-millimeters wide by 177.80-millimeters high (1.4-inches wide by 7.0-inches high). Two latching screws, one at the top, the other at the bottom, lock the module assembly in a module mounting unit (MMU).

  • Page 15: Features

    Features application requirements of supervisory control, optimization routines, performance assessment, and process modeling. Features The Harmony bridge controller retains all of the features of the INFI 90 OPEN multifunction processor modules. Additional features of the Harmony bridge controller include: Simultaneous Hnet bus and I/O expander bus communi- •...

  • Page 16: How To Use This Instruction

    How to Use this Instruction Maintenance Covers scheduled module maintenance. Describes how to repair and replace the module. Repair and Replacement Replacement and Spare Provides a list of part numbers and nomenclatures. Parts Appendices Provide quick reference information for NTMP01 hardware configuration and step-by-step instructions for performing online configuration.

  • Page 17: Reference Documents

    Table 1-2. Reference Documents Number Title WBPEEUI200502?? Module Mounting Unit (IEMMU11, IEMMU12, IEMMU21, IEMMU22) WBPEEUI210504?? Function Code Application Manual, Symphony WBPEEUI230022?? Analog Control Station (IISAC01) WBPEEUI240751?? Harmony Input/Output System WBPEEUI240762?? IMDSO14 Digital Output Module WBPEEUI260039?? NTMP01 Multifunction Processor Termination Unit...

  • Page 18: Related Nomenclatures

    Related Nomenclatures Related Nomenclatures Table lists nomenclatures related to the BRC module. Table 1-3. Related Nomenclatures Nomenclature Description IEMMU11, IEMMU12, Module mounting unit IEMMU21, IEMMU22 IISAC01 Analog control station NTMP01 Field termination panel Specifications Table lists the specifications for the BRC module, process bus adapter board and BRC redundancy kit.
  • Page 19 Specifications Table 1-4. Specifications (continued) Property Characteristic/Value Communication ports 2 RS-232-C or 1 RS-232-C and 1 RS-485, 1 SAC channel (128 SACs maximum Ambient temperature 0° to 70°C (32° to 158°F) Relative humidity 0% to 95% relative humidity up to 55°C (131°F) noncondensing 0% to 45% relative humidity at 70°C (158°F) noncondensing Atmospheric pressure Sea level to 3 km (1.86 mi)

  • Page 20: Section 2 Description And Operation

    Description and Operation Section 2 Introduction This section explains the functionality of the Harmony bridge controller (BRC) using block diagrams and text. Block dia- grams divide the operation of the Harmony bridge controller. Operation The BRC module incorporates the power of a second genera- tion 32-bit microprocessor operating at 32 megahertz.

  • Page 21: Circuitry

    The BRC module uses a control I/O block (CIO) on Hnet to support a station link that can handle up to 128 IISAC01 stations and is compatible with the Symphony system. Two auxiliary RS-232-C ports and a serial station link are available through a cable connection via the PBA board to an NTMP01 Multifunction Processor Termination Unit.

  • Page 22: Clock And Real-Time Clock

    Circuitry C L O C K M IC RO P R O C E S S O R M AC H IN E L E D s, FA U LT S W IT C H ES , TIM E R DATA BU FF ER S S T E E R IN G 32 -B IT D ATA PAT H...

  • Page 23: Direct Memory Access

    Circuitry and UDF applications. NVRAM memory retains whatever infor- mation it has, even when it loses power. Direct Memory Access The DMA section enables the various communication links to do direct data transfers to and from RAM memory without pro- cessor intervention.

  • Page 24: Redundancy Link

    Circuitry disconnects -30 VDC from pin four of connector P2 on the BRC module. Redundancy Link The redundancy link is a dual parallel link between a primary and backup BRC module in redundant configurations. As the primary module executes, the backup module waits in standby mode and receives a copy of block outputs over this link.

  • Page 25: I/O Expander Bus

    Circuitry Physical connection is provided by a direct connection from the BRC module P3 connector to the processor bus adapter board P5 connector. The processor adapter board mounts on the rear of a module mounting unit with the proper adapter brackets installed.

  • Page 26: Station Link

    Circuitry board supplies the serial channels with handshaking signals. Clock signals for the baud rate generator are derived from an on-board, 7.3728-megahertz oscillator. The PBA board connects to an NTMP01 Multifunction Proces- sor Termination Unit. Input/output signals enter or leave the PBA board through a cable connection to the termination unit.

  • Page 27: Power

    Circuitry Support for bypass stations requires a Harmony control I/O module (IMCIS12, IMQRS12) configured on the I/O expander bus. Power Power requirements are 5 VDC for logic power and for line driv- ers/receivers. The Hnet interface derives all other power requirements from the 5 VDC logic power.

  • Page 28: Section 3 Installation

    Earlier Network 90 systems applied -30 VDC to pins three and four of the module connector P1. This voltage is not required for Symphony and INFI 90 OPEN modules. In Symphony and INFI 90 OPEN systems, pin four is used for the Controlway bus.

  • Page 29: Special Handling

    Special Handling Special Handling Observe these steps when handling electronic circuitry: NOTE: Always use ABB's field static kit (part number 1948385?1 - consisting of two wrist straps, ground cord assembly, alligator clip and static dissipative work surface) when working with the modules. The kit grounds a technician and the static dissipative work surface to the same ground point to prevent damage to the modules by electrostatic discharge.

  • Page 30: Dipswitches And Jumpers

    Dipswitches and Jumpers 3. File a claim for any damage with the transportation com- pany that handled the shipment. 4. Use the original packing material and container to store the hardware. 5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes.

  • Page 31: Dipswitch Sw5 - Module Address

    Dipswitches and Jumpers Jumpers J1, J2, J3, and J4 define module functions and oper- ation. Jumper J1 enables or disables the machine fault timer (MFT). Jumper J2 sets the diagnostic RS-232-C port for opera- tion as data communication equipment (DCE) or data terminal equipment (DTE).

  • Page 32: Dipswitch Sw2 - Normal Operating Options

    Dipswitches and Jumpers Table 3-1. Dipswitch SW5 Settings (Operation) (continued) User Pole Setting Function Setting Controlway (1 Mbaud) Module bus (83.3 kbaud) or -30 VDC operation NOTE: 0 = closed or on, 1 = open or off. 1. The module bus setting is for support of existing INFI 90 OPEN and Network 90 systems. Dipswitch SW2 - Normal Operating Options Dipswitch SW2 sets module options that are available when the BRC module is in normal operation.

  • Page 33: Dipswitch Sw2 Settings (Operating Options)

    Dipswitches and Jumpers Table 3-3. Dipswitch SW2 Settings (Operating Options) User Pole Setting Function Setting Disable special operations. Enable special operations. Refer to Dipswitch SW2 - Special Opera- tions. Disable online configuration. Enable online configuration. Perform NVRAM checksum routine. Inhibit NVRAM checksum routine. Perform flash ROM checksum routine and file system check.

  • Page 34: Dipswitch Sw2 Settings (Special Operations)

    Dipswitches and Jumpers Poles two through eight select the special operation. The fol- lowing steps explain how to set the BRC module for special operations and reset it for normal operation. Table shows the dipswitch settings and explains each special operation. To use special operations: 1.

  • Page 35: Dipswitch Sw3 - Module Options

    Dipswitches and Jumpers 7. When all special operations are complete, reset pole one on dipswitch SW2 to the closed (on) position. 8. Poles two through eight (module options) should be set for the desired BRC operation per Table 3-4. 9. Insert the BRC module in its slot. It will begin normal operation.

  • Page 36: Module Mounting Unit Preparation

    Module Mounting Unit Preparation ate in a module mounting unit that uses -30 VDC. Refer to Table for an explanation of the functions set by jumpers. NOTE: Jumper J1 is for ABB development personnel usage only. It is used to disable the machine fault timer circuit.

  • Page 37: Dipshunts

    Module Mounting Unit Preparation Dipshunts Disconnect power before installing dipshunts on the module WARNING mounting unit backplane. Failure to do so will result in contact with cabinet areas that could cause severe or fatal shock. No dipshunts are required if only Hnet is being used. If Hnet and the I/O expander bus are being used or only the I/O expander bus is being used, dipshunts are required to main- tain bus continuity between all BRC modules associated with...

  • Page 38: Pba Board Installation

    Module Mounting Unit Preparation T 0 0 06 3 A Figure 3-2. Controlway Cable Installation PBA Board Installation Hnet is the communication path between a BRC module and Harmony I/O blocks. A PBA board is required to connect a BRC module to Hnet, connect redundant Hnet to redundant BRC modules, and provide a connection point for the NTMP01 termination unit (TU).

  • Page 39: Cable And Terminator

    Module Mounting Unit Preparation To install the PBA mounting bracket: 1. Turn off power to the cabinet. 2. Install one PBA mounting bracket to the top of the module mounting unit backplane assembly using five screws, flat washers, and spacers. Refer to Figure 3-3. 3.

  • Page 40: Mounting

    Module Mounting Unit Preparation e. Attach the final cable connector to the I/O column after the PBA boards have been mounted. Continue to Mounting in this section to mount the redundant PBA boards. NOTE: Termination unit cables for the direct station link can be installed at any time after the PBA boards are installed.

  • Page 41: Pba Installation

    Module Mounting Unit Preparation N O TE : M M U C AR D C AG E N O T SH O W N . M M U BAC K PLA N E PB A M O U N T IN G BR AC KE T (PART O F PB A M O U N TIN G K IT ) 5-40 x 0.50 IN .

  • Page 42: Pba Connector Identification

    Module Mounting Unit Preparation TO R E D U N DA N T P B A R E D U N DA N T B R ID G E C O N TR O LLE R LIN K C A B LE PA RT N O .

  • Page 43: Brc Redundancy Kit Installation

    Module Mounting Unit Preparation 4. Align the two holes on each PBA mounting bracket with the matching holes in the MMU backplane assembly mounting bracket. Install two M3 × 8-mm long, Phillips pan head screws and tighten to secure each PBA assembly to the PBA mounting brackets on the MMU backplane assembly.

  • Page 44: Brc Redundancy Kit Installation

    Module Mounting Unit Preparation N OT E : M M U C A R D C A G E N OT S H OW N . M M U B AC K P L A N E P B A M O U N T IN G B R A C K E T (PA RT O F P B A M O U N T IN G K IT ) 5-40 x 0 .50 IN .

  • Page 45: Module Installation

    Module Installation R E D U N DA N T P R O C E S S O R B U S A DA P T E R C A B LE TO P 3 O F TO R E D U N DA N T P B A B R C -100 M O D U LE T 04 45 4A...

  • Page 46: Installation

    Module Installation 3. If -30 VDC is present, set jumper J3 and dipswitch SW5 to the appropriate positions. Installation Before installing BRC modules: 1. Check all module dipswitch, and jumper settings (normal and special operation). 2. Verify that the PBA board is attached to the proper slot on the module mounting unit backplane.
  • Page 47 WBPEEUI230017B1...

  • Page 48: Section 4 Operating Procedures

    Operating Procedures Section 4 Introduction The first part of this section explains Harmony bridge control- ler (BRC) startup, LED indications, and stop/reset. The last part explains the three modes of operation. Startup When power is applied to the BRC module, it does an internal check, checks its configuration, and builds the necessary data- bases.

  • Page 49: Module Leds

    Module LEDs Module LEDs There are 17 LEDs visible through the faceplate window. Eight group A and eight group B LEDs relate to processor status, and one is the module status LED (Fig. 4-1). B R C -100 R E D /G R E E N S TAT U S LE D G RO U P A LE D S...

  • Page 50: Red/Green Status Led

    Stop/Reset Switch LED turns red and the group A LEDs light up to display the error code (Table 5-1). NOTE: Both groups of LEDs one through eight are on when the system is first coming up. This is normal. It means that the BRC module is not yet online. Red/Green Status LED The status LED is a red/green LED.

  • Page 51: Modes Of Operation

    Modes of Operation operation. Always stop the BRC module before removing it from the module mounting unit. Stopping the BRC module this way causes it to: Save and lock the BRC module configuration. • Complete any nonvolatile memory write operations in •...
  • Page 52 Modes of Operation Configure Use the configure mode to enter control strategies. The BRC module receives configuration commands over Controlway and changes the data in the NVRAM memory. NOTE: The process of configuring the BRC module requires information from at least two documents. The Function Code Application Manual contains all of the information needed to design a control strategy.
  • Page 53 WBPEEUI230017B1...

  • Page 54: Section 5 Troubleshooting

    Troubleshooting Section 5 Introduction This section contains Harmony bridge controller (BRC) trou- bleshooting information. Included is information on module error codes, troubleshooting flowcharts, diagnostic routines, and the module status summary. Error codes provide specific module fault information and appropriate corrective action. Troubleshooting flowcharts pro- vide a quick look at hardware associated problems that may occur during module installation and startup.
  • Page 55 Error Codes Table 5-1. Error Codes (continued) Code Condition Corrective Action 8 7 6 5 4 3 2 1 0 0 0 0 0 1 1 0 Configuration error (data type Check module status (data type) modules. mismatch) 0 0 0 0 1 0 0 0 Trip block activated Check module status.
  • Page 56 Error Codes Table 5-1. Error Codes (continued) Code Condition Corrective Action 8 7 6 5 4 3 2 1 0 0 1 0 0 0 1 0 Invoke C error Check C program and invoke C blocks, correct and rerun. 0 0 1 0 0 0 1 1 User write violation Check C program, correct and rerun.

  • Page 57: Status Led And Other Conditions

    Error Codes Table 5-1. Error Codes (continued) Code Condition Corrective Action 8 7 6 5 4 3 2 1 0 0 1 1 1 1 1 1 Normal stop None. 0 1 0 0 0 0 0 0 Backup - cold takeover ready 1 0 0 0 0 0 0 0 Backup - hot takeover ready 1 1 0 0 0 0 0 0...

  • Page 58: Flowcharts

    Flowcharts Table 5-2. Status LED and Other Conditions (continued) Condition Corrective Action Group A Check power. Check module seating. If power and seating are okay, remove the module and replace with identically configured module. None - indicates backup module in redundant configuration.

  • Page 59: Troubleshooting Flowchart (Serial Port)

    Diagnostics S TA RT S TAT U S S TAT U S LE D S TAT U S LE D S TAT U S LE D L E D O FF ? O R A N G E ? R E D ? G R EE N ? Y E S Y E S...

  • Page 60: Troubleshooting Flowchart (Status Led)

    Diagnostics S TA RT R S -2 3 2-C LIN E E R RO R S D O N E O N B R C LE D s (C O D E 15 )? Y ES +2 4 V D C R E FE R TO N T M P 01 O P E N O N C O N N E C T E D TO...

  • Page 61: Dso And Brc Setup For I/O Expander Bus Test

    1 2 3 4 5 6 7 8 IMDSO14 0 0 0 0 1 1 1 1 BRC-100 0 0 0 0 1 1 1 1 NOTE: 0 = closed or on, 1 = open or off. 3. There must be continuity between the DSO and BRC mod- ules on the I/O expander bus (i.e., I/O expander bus dip-...
  • Page 62 Diagnostics On dipswitch SW2, poles three through eight select the diag- nostic test. Pole eight is the least significant bit (binary weight one); pole three is the most significant bit (binary weight 32). Refer to Table for test ID values. Pole one selects a special operations feature.
  • Page 63 Diagnostics Table 5-5. Diagnostic Tests (continued) Test Name Test-ID Description I/O expander bus BRC module performs status read and verifies the IMDSO14 test (address 15) responds over I/O expander bus. IMDSO14 LEDs count successful tests. Unused — SAC link 13/23 Test station link (IISAC01) communication between a BRC module controller/station acting as a controller and another BRC module acting as a station.

  • Page 64: Led Display

    Diagnostics Table 5-5. Diagnostic Tests (continued) Test Name Test-ID Description NVRAM retention - Stores a known data pattern in NVRAM for testing by the NVRAM data storage retention - data check test 27. Halts with LED pattern 0x55 if test has completed writing data.

  • Page 65: Module Status Summary

    Module Status Summary LE D 1 LE D 2 LE D 3 T E S T N U M B E R LE D 4 G RO U P A LE D s LE D 5 LE D 6 LE D 7 N O T U S E D T E S T N U M B E R LE D 8...

  • Page 66: Status Report

    Module Status Summary status report. Table lists the definition of each field within the module status report. Refer to the appropriate human sys- tem interface (HSI) instruction for an explanation of how to access the module status report. Table 5-6. Status Report Byte Mode Type...
  • Page 67 Module Status Summary Table 5-7. Status Report Field Descriptions (continued) Field Size or Byte Field Description Value Summary NVRAM initialized state: 0 = no, 1 = yes. (continued) Digital station status: 0 = good, 1 = bad. 3 - 5 Error code NVRAM error: Byte 3 is...

  • Page 68: Status Report Field Descriptions

    Module Status Summary Table 5-7. Status Report Field Descriptions (continued) Field Size or Byte Field Description Value Error code 2B (1) (2) Missing UDF declaration: (1), (2) = block number making reference. (continued) 2C (1) (2) Wrong UDF type: (1), (2) = block number making reference. 2D (1) (2) Missing UDF auxiliary block: (1), (2) = block number making reference.
  • Page 69 Module Status Summary Table 5-7. Status Report Field Descriptions (continued) Field Size or Byte Field Description Value — — Unused. (continued) — — Unused. — — Unused. Module is primary versus backup; set to 1 in the primary module. Configuration current (latched until backup is reset). Set when LED 7 is enabled (1 = on or blinking) on the backup module.

  • Page 70: Card Edge Connectors

    1. This pin connects the BRC module to -30 VDC when it is used in -30 VDC Network 90 systems. When the BRC module is used in newer Network 90, INFI 90 OPEN, and Symphony systems, this pin connects the module to the redundant Controlway channel.

  • Page 71: P2 Pin Assignments (Brc)

    Card Edge Connectors Table 5-9. P2 Pin Assignments (BRC) Signal Signal Data bit 1 Data bit 0 Data bit 3 Data bit 2 Data bit 5 Data bit 4 Data bit 7 Data bit 6 Bus clock - BCLK Sync Unused Unused NOTE: All data bits are true low.

  • Page 72: P4 Pin Assignments (Brc)

    Card Edge Connectors 1,2 (continued) Table 5-10. P3 Pin Assignments (BRC) Signal Signal Red2 busy Hnet transmit clock B 5 VDC Hnet receive clock B DCS/SAC link A (-) Hnet transmit enable A DCS/SAC link A (+) Hnet transmit enable B DCS/SAC link B (-) PBA/Hnet relay A DCS/SAC link B (+)

  • Page 73: P4 Pin Assignments (Pba)

    Card Edge Connectors Table 5-13. P3 Pin Assignments (PBA) Signal Signal SAC/DCS link A (–) SAC/DCS link A (+) SAC/DCS link B (–) SAC/DCS link B (+) 3 - 6 18 - 21 NC Receive data A (–) Receive data A (+) Receive data B (–) Receive data B (+) Clear to send A (–)
  • Page 74 Card Edge Connectors Table 5-14. P4 Pin Assignments (PBA) (continued) Signal Signal Red1 BCLK Common NOTE: 1. Data bit or signal is true low. Table 5-15. P5 Pin Assignments (PBA) Signal Signal Common Receive data A (+) Digital output 1 Receive data B (-) Red1 data7 Receive data B (+)

  • Page 75: P5 Pin Assignments (Pba)

    Card Edge Connectors Table 5-15. P5 Pin Assignments (PBA) (continued) Signal Signal DCS/SAC link B (-) PBA/Hnet relay A DCS/SAC link B (+) PBA/Hnet relay B Receive data A (-) Common NOTES: 1. Data bit or signal is true low. 2.
  • Page 76 Card Edge Connectors Table 5-16. P5 Pin Assignments (Hood Connection Assembly) Red2 busy Hnet transmit clock B 5 VDC Hnet receive clock B DCS/SAC link A Hnet transmit enable A DCS/SAC link A Hnet transmit enable B DCS/SAC link B PBA/Hnet relay A DCS/SAC link B PBA/Hnet relay B...
  • Page 77 WBPEEUI230017B1...

  • Page 78: Section 6 Maintenance

    Maintenance Section 6 Introduction The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB recom- mends that all equipment users practice a preventive mainte- nance program that will keep the equipment operating at an optimum level.

  • Page 79: Preventive Maintenance Procedures

    Preventive Maintenance Procedures Antistatic vacuum. • Clean, lint-free cloth. • Compressed air. • Non-abrasive eraser. • Fiberglass or nylon burnishing brush. • Foam tipped swab. • Bladed screwdriver suitable for terminal blocks. • Isopropyl alcohol (99.5 percent electronic grade). • Natural bristle brush.

  • Page 80: General Cleaning And Washing

    Preventive Maintenance Procedures washing, cleaning edge connectors and circuit board laminate between edge connectors. Use the procedures that meet the needs of each circuit board. Remove all dust, dirt, oil, corrosion or any other contaminant from the circuit board. Do all cleaning and handling of the printed circuit boards at static safe work stations.

  • Page 81: Checking Connections

    Preventive Maintenance Procedures 3. Do not use excessive force while burnishing. Use only enough force to shine the contact surface. Inspect the edge connector after cleaning to assure no loss of contact surface. Checking Connections Check all signal wiring, power and ground connections within the cabinet to verify their integrity.

  • Page 82: Section 7 Repair And Replacement

    Repair and Replacement Section 7 Introduction Repair procedures are limited to module replacement. If the Harmony bridge controller (BRC) module or processor bus adapter (PBA) board fails, remove and replace it with another. Verify that firmware revision levels match and that the replace- ment module switch and jumper settings are the same as those of the failed module.

  • Page 83: Pba Board Replacement

    PBA Board Replacement connector (for BRC modules controlling rack I/O modules via the I/O expander bus). 5. Turn the two latching screws on both modules ½-turn to lock the module in place. The module is locked into the module mounting unit when the open end of the slots on the latching screws faces the center of the module faceplate.
  • Page 84 PBA Board Replacement replacement PBA board. The terminator must stay attached to the cable. Figure shows the location of the terminator. A terminator should be installed on the last PBA board in a redundant configuration. 8. Insert the replacement processor adapter assembly (circuit board and mounting bracket) into position on the module mounting unit.
  • Page 85 WBPEEUI230017B1...

  • Page 86: Section 8 Replacement And Spare Parts

    Replacement and Spare Parts Section 8 Parts Order parts without commercial descriptions from the nearest ABB sales office. Contact ABB for help determining the quan- tity of spare parts to keep on hand for your particular system. Tables through list Harmony bridge controller (BRC) related parts.
  • Page 87 WBPEEUI230017B1...

  • Page 88: Appendix A Online Configuration

    Online Configuration Appendix A Introduction Using online configuration in conjunction with redundant Har- mony bridge controller (BRC) modules enables making configu- ration changes without affecting the primary BRC module or interrupting the control process. Composer provides functions to guide the user through the online configuration process.

  • Page 89: Operation

    Operation of the backup BRC module is at five during online configura- tion.) Set position two on the options dipswitch (SW2) of the backup and primary BRC modules to the open position to enable online configuration. Operation This appendix provides a step-by-step procedure for perform- ing online configuration.

  • Page 90: Backup Cycle

    Operation original primary BRC module. When the roles are reversed for either unit, their status is carefully noted. Table A-1. Legend of Symbols Description Primary Backup Module address Second module status byte 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 0 1 x x 0 x 0 x 1 0 x x 1 x 0 x...
  • Page 91 Operation Table A-2. Backup Cycle (continued) Primary Backup Procedure 2. (continued) 01xx0x0x 00xx1x0x When changes are being made to the backup module, LED 7 blinks and bit 3 of the backup module is set indicating that the configurations of the backup and primary modules do not match.
  • Page 92 Operation Table A-2. Backup Cycle (continued) Primary Backup Procedure 5. When the checkpoint data for the old configuration is received from the 01xx0x0x 10xx1x0x primary module, the reconfigured backup module can assume the role of the primary module if a failure is detected in the old configuration (Step 8). However, the primary module still indicates that no backup is available when the configuration is different.

  • Page 93: Primary Cycle

    Operation C F G T H E N EX T B A CK U P P RIM A RY E RR E RR B A CK U P EX T IN IT IA L IZ E I/O IN T E R FA C E E ER O M C F G E XT...

  • Page 94: Backup Cycle

    Operation Table A-3. Primary Cycle Primary Backup Procedure 1. The primary module is actively controlling the process. This repre- 01xx0x0x 10xx1x0x sents the same juncture as Step 4 of the backup cycle. 2. When the shutdown request is received from the backup module 01xx0x0x 11xx1x0x (Step 7 of the backup cycle), the primary module stops executing and...

  • Page 95: Primary Cycle

    Operation SH U TD O W N R E Q U E S TE D P R IM A RY P R IM A RY E X T E X T S H U TD O W N C O M PL E TE I/O IN TE R FAC E I/O IN TE R FAC E H OT...

  • Page 96: Appendix B Ntmp01 Termination Unit

    NTMP01 Termination Unit Appendix B Description The Harmony bridge controller (BRC) and processor bus adapter (PBA) combination uses an NTMP01 termination unit to connect two auxiliary serial I/O ports and IISAC01 Analog Control Stations. Jumpers on the NTMP01 termination unit configure the two RS-232-C ports for data terminal equipment (DTE) or data communication equipment (DCE).

  • Page 97: B-1. Dte Jumper Configuration (Ntmp01)

    Description J1 AN D J2 R X D D B 2 5 -3 T XD -A R X D -A T XD D B 2 5 -2 RT S-A RT S D B 2 5 -4 C T S D B 2 5 -5 C T S-A T 01 35 5 A Figure B-1.

  • Page 98: B-3. Nonhandshake Jumper Configuration (Ntmp01)

    Description J1 AN D J2 R X D D B 2 5 -3 T XD -A T XD R X D -A D B 2 5 -2 RT S RT S-A D B 2 5 -4 C T S D B 2 5 -5 C T S-A T 01 35 7 A Figure B-3.

  • Page 99: B-5. Jumpers J3 Through J10 Configuration (Ntmp01)

    Description + 12 V J6 A N D J 8 D S R D B 25-6 J5 A N D J 9 D C D D B 25-8 J7 A N D J 10 D T R D B 25-20 J4 A N D J 3 P R OT-G N D D B 25-1...

  • Page 100: B-6. Ntmp01 Board Layout

    Description STAT IO N BR C C O M . B AC TIV E LE D N TM P 0 1 B R C TER M IN A L + 24 V J 16 PO RT J 17 C R 1 R S -48 5 P O R T J 12 F U SE F1...

  • Page 101: B-7. Ntmp01 Cable Connections (Redundant Brc Modules/Pba Boards)

    Description R E D U N DA N T B R ID G E C O N T R O L LE R LIN K C A B L E PA R T N O . P -M K -H R M -P B A 200 0A N K T U 01 TO N T C S 04 O R N K T U 11...

  • Page 102: B-8. Cable Connections (Redundant Brc Modules Using Brc Redundancy Kit)

    Description B R C -1 00 R E D U N DA N T P RO C E S S O R B U S A DA P T E R C A B LE B R C -1 00 T 04 45 5A Figure B-8.
  • Page 103 WBPEEUI230017B1...
  • Page 104 For the latest information on ABB visit us on the World Wide Web at http://www.abb.com Our worldwide staff of professionals is ready to meet your needs for process automation. For the location nearest you, please contact the appropriate regional office. Americas Asia/Pacific Germany...

This manual is also suitable for:

Pba-100

Table of Contents