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Siemens QUADLOG Installation And Service Instructions Manual

Critical analog input module
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Siemens
Energy & Automation, Inc.
QUADLOG
Critical Analog Input Module (CAI)
Installation and Service Instruction
®
SDQLCAI-1
Rev: 4
September 2005

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Summary of Contents for Siemens QUADLOG

  • Page 1 Siemens Installation and Service Instruction Energy & Automation, Inc. SDQLCAI-1 Rev: 4 September 2005 ® QUADLOG Critical Analog Input Module (CAI)
  • Page 2 Trademarks ProcessSuite, QUADLOG, 4-mation, and APACS+ are trademarks of Siemens Energy & Automation, Inc. Other names in this publication might be trademarks, the use of which by third parties for their own purposes may violate the rights of the registered holder.

  • Page 3: Table Of Contents

    SDQLCAI-1 Contents Table of Contents Section Title Page Introduction........................1-1 Product Description ......................1-1 Product Support ......................1-3 Related Literature ......................1-5 Installation........................2-1 Hardware Identification....................2-1 2.1.1 Module Identification.....................2-1 2.1.2 Marshalled Termination Assembly Identification..........2-2 Preparations ........................2-2 Environmental Considerations ..................2-2 Equipment Delivery and Handling ................2-3 2.4.1 Predelivery Test .....................2-3 2.4.2 Factory Shipment ....................2-3...
  • Page 4 Contents SDQLCAI-1 3.7.2 Replacement......................3-5 Spare and Replacement Parts..................3-5 Maintenance Records ....................3-6 Circuit Description ......................4-1 Isolated Power Supply ....................4-1 IOBUS Modem......................4-1 Multiplexers/Converters ....................4-1 CPU ..........................4-2 Model Designation ......................5-1 Options .........................5-1 Accessories ........................5-2 Specifications........................6-1 Module Specifications ....................6-1 Environmental Specifications..................6-1 Electrical Classification ....................6-3 6.3.1 Approvals .......................6-3 6.3.2...
  • Page 5 SDQLCAI-1 Contents 2–3 Standard CAI/SAI Marshalled Termination Assembly ...........2-7 2–4 Installing or Removing a Marshalled Termination Assembly .........2-8 Marshalled Termination Assembly ⎯ Mounting Ear Installation........2-9 2–5 2–6 Keying an Interconnect I/O Cable Assembly for CAI Use..........2-11 2–7 Module and Rack Keying ....................2-13 2–8 CAI I/O Wiring Connections on Marshalled Resistor Termination Assembly ....2-18 2–9...
  • Page 6 Contents SDQLCAI-1 PREFACE Conventions and Symbols The following symbols may appear in this manual and may be applied to the equipment. The reader should become familiar with the symbols and their meaning. Symbols are provided to quickly alert the user to safety related situations, issues, and text. Symbol Meaning Indicates an immediate hazardous situation which, if not avoided, will result in...

  • Page 7: Contents

    The sales contract contains the entire obligation of Siemens. The warranty contained in the contract between the parties is the sole warranty of Siemens. Any statements continued herein do not create new warranties or modify the existing warranty.
  • Page 8 A properly grounded conductive wrist strap must be worn whenever an electronics module or circuit board is handled or touched. A service kit with a wrist strap and static dissipative mat is available from Siemens (PN15545-110). Equivalent kits are available from both mail order and local electronic supply companies.
  • Page 9 SDQLCAI-1 Contents September 2005...

  • Page 11: Introduction

    1.1 Product Description The QUADLOG Critical Analog Input Module (CAI) is part of the QUADLOG family of safety critical control and I/O modules. It is ideally suited for such applications as emergency shutdown or burner management. The CAI uses standard QUADLOG module packaging. It plugs into any of the standard module racks, where it operates in conjunction with a QUADLOG resource module such as a Critical Control Module (CCM) as part of a data acquisition and control system.
  • Page 12 Introduction SDQLCAI-1 Figure 1–1 Critical Analog Input Module (CAI) and Associated Hardware May 2002...

  • Page 13: Product Support

    The Process Automation User Connection is a secure site. Registration is open to all verified users of Siemens process automation systems. If you are not already, and would like to become a member, please visit our Process Automation User Connection web page at: http://www.sea.siemens.com/process/support/papauc.html...
  • Page 14 8:00 AM to 5:00 PM Telephone:+1 (423) 262 2522 Fax:+49 (180) 5050-223 Phone:+86 10 64 75 75 75 or +1 (800) 333-7421 (USA only) E-Mail: ad.support@siemens.com Fax:+86 10 64 74 74 74 Fax:+1 (423) 262 2289 GMT:+1:00 Mail to:ad.support.asia@siemens.com Mail to: techsupport.sea@siemens.com...

  • Page 15: Related Literature

    CD supplied with your system. • Using the 4-mation Configuration Software (document number CG39-20) • QUADLOG I/O Module Configuration (document number CGQL-4) • QUADLOG CCM/ACM+ Standard Function Blocks (document number CGQL-3) • MODULPAC 1000 Installation and Service Instruction (document number SD39MODULPAC-1) May 2002...
  • Page 16 Introduction SDQLCAI-1 May 2002...

  • Page 17: Installation

    IMPORTANT The CAI installation should be in accordance with the National Electrical Code (NEC), other applicable construction, and electrical codes. The CAI is only to be used for the purposes described by Siemens. 2.1 Hardware Identification 2.1.1 Module Identification The CAI is identified by the three-letter “CAI”...

  • Page 18: Marshalled Termination Assembly Identification

    Installation SDQLCAI-1 2.1.2 Marshalled Termination Assembly Identification The CAI can be used with the CAI/SAI Marshalled Termination Assembly. This assembly is identified by the following information printed on its surface. CAI/SAI MARSHALLED TERMINATION P/N 16428-1 2.2 Preparations 1. Install the MODULRAC (SIXRAC, or Remote I/O Rack) in the cabinet where the CAI is to be installed.

  • Page 19: Equipment Delivery And Handling

    If it is found that some items have been damaged or are discovered missing, refer to sections 2.4.4 or 2.4.5 and notify Siemens immediately, providing full details. In addition, damages must be reported to the carrier with a request for their on-site inspection of the damaged item and its shipping carton.

  • Page 20: Return Of Equipment Outside North America

    Canadian customers: Contact Siemens Canada. 2.4.5 Return of Equipment outside North America Contact your Siemens Representative. 2.4.6 Equipment Handling and Storage The CAI is completely enclosed and can be safely handled without undertaking special ESD (electrostatic discharge) handling procedures provided the bezel compartment door is closed and secured. DO NOT touch the connector pins on the back of the module.
  • Page 21 SDQLCAI-1 Installation marshalling cabinet. A customer-fabricated panel is typically mounted in a customer-supplied cabinet. Refer to Figure 2–2 and Figure 2–3 for dimensions of the Utility Panel and Marshalled Termination Assemblies. 1) Determine the mounting layout for DIN rails, wire ducts, and Marshalled Termination Assemblies.
  • Page 22 Installation SDQLCAI-1 Figure 2–2 Marshalling Utility Panel Dimensions May 2002...

  • Page 23: Standard Cai/Sai Marshalled Termination Assembly

    SDQLCAI-1 Installation Figure 2–3 Standard CAI/SAI Marshalled Termination Assembly May 2002...

  • Page 24: Installing Or Removing A Marshalled Termination Assembly

    Installation SDQLCAI-1 Figure 2–4 Installing or Removing a Marshalled Termination Assembly May 2002...

  • Page 25: Optional (Flat Surface) Marshalled Termination Assembly Installation

    SDQLCAI-1 Installation 2.5.2 Optional (Flat Surface) Marshalled Termination Assembly Installation Removing the DIN rail mounting feet from the Marshalled Termination Assembly, in conjunction with the installation of four mounting ears (accessory item), permits the assembly to be flat-mounted to a panel or bulkhead.

  • Page 26: Interconnect I/O Cable Installation

    Installation SDQLCAI-1 2.5.3 Interconnect I/O Cable Installation An Interconnect I/O Cable (Figure 2-6) is used to connect each CAI to a Marshalled Termination Assembly. The cable-to-module connector J1 is installed at the slot location of a CAI module. It is assumed that (as part of the site preparation procedure) all tagged Interconnect I/O Cables have been routed and pulled into their respective cabinets and they are ready for connection.

  • Page 27: Keying An Interconnect I/O Cable Assembly For Cai Use

    SDQLCAI-1 Installation Figure 2–6 Keying an Interconnect I/O Cable Assembly for CAI Use May 2002 2-11...

  • Page 28: Cai Installation

    Installation SDQLCAI-1 5. Connect the free end of the I/O Cable Assembly to its respective I/O termination assembly. Perform the appropriate procedure depending on cable type: For Interconnect I/O Cable Assembly (P2 installed) 1) Connect cable connector P2 (Figure 2-6) to the J1 connector on the Marshalled Termination Assembly (Figure 1-1).

  • Page 29: Module And Rack Keying

    SDQLCAI-1 Installation Figure 2–7 Module and Rack Keying May 2002 2-13...

  • Page 30: Module Rack Mechanical Keying

    Installation SDQLCAI-1 2.6.1 Module Rack Mechanical Keying 1. Get the rack Keying Kit supplied with the rack. 2. Refer to Figure 2-7 and note the rack-keying pattern applicable to the CAI. Also, locate the rack’s top and bottom rails. 3. Press the stop plugs into the appropriate key holes of the top and bottom rails as identified by the solid dot keying patterns in the figure.

  • Page 31: Electrical Installation

    SDQLCAI-1 Installation 2.7 Electrical Installation DANGER Explosion hazard Will cause death, serious injury or property damage • In potentially hazardous atmosphere, remove power from equipment before connecting or disconnecting power, signal, or other circuit, or extracting/inserting module. • Observe all pertinent regulations regarding installation in hazardous area. •...

  • Page 32: Field Wire Selection

    Installation SDQLCAI-1 The CAI supports the following channel types: • CAI Analog Input Channel (CAIC) • Critical Discrete Supervised Input (CDSI) • Critical Analog Input, Programmable Limits (CAIP) Wiring examples are provided in this section. WARNING Non-isolated inputs. Analog input channels share a common ground. All I/O connected to this equipment must operate at extra low voltage or all equipment must be inaccessible to the user.
  • Page 33 SDQLCAI-1 Installation To make wiring connections to a CAI/SAI Marshalled Termination Assembly: 1. From your system’s documentation and wiring diagrams, identify each channel and its assigned field cable ID. 2. Prepare the field cable ends as needed. 3. Identify each channel to be wired. Consult your system’s wiring diagrams and connect the field cable wires to the appropriate terminals.

  • Page 34: Cai I/O Wiring Connections On Marshalled Resistor Termination Assembly

    Installation SDQLCAI-1 Figure 2–8 CAI I/O Wiring Connections on Marshalled Resistor Termination Assembly 2-18 May 2002...

  • Page 35: Unterminated I/O Cable Assembly Connections

    SDQLCAI-1 Installation 2.7.3 Unterminated I/O Cable Assembly Connections Connect field devices to user-supplied termination hardware (e.g. terminal blocks). Table 2–2 lists the wire color and identification information needed for I/O wiring termination. Refer to your system’s wiring diagrams as necessary. When an unterminated I/O cable assembly is used, it is recommended that you to manually wire the I/O Supply Monitor (sense) line for the I/O power supply.

  • Page 36: Configuration

    Microsoft Windows-based personal computer (PC). It is a graphical software tool for configuring control, communication, and I/O modules within a QUADLOG process control or safety system. When the configuration is complete, it is to be transferred to the control module. Once transferred, the CAI-portion of the configuration is automatically forwarded from the control module to the CAI module.
  • Page 37 SDQLCAI-1 Installation Table 2–2 Unterminated I/O Cable Assembly P1 PIN JI PIN WIRE/STRIPE P1 PIN JI PIN WIRE/STRIPE (Engages Color (Engages Color WIRE Terminated P2 of WIRE Terminated P2 of Cable) Module) Cable) Module) CH 1 + WHT/BLK Supply BLU/VIO Monitor Cable Missing...

  • Page 39: Maintenance

    SDQLCAI-1 Maintenance 3 Maintenance DANGER Explosion hazard Will cause death, serious injury or property damage • In potentially hazardous atmosphere, remove power from equipment before connecting or disconnecting power, signal, or other circuit, or extracting/inserting module. • Observe all pertinent regulations regarding installation in hazardous area. •...

  • Page 40: Troubleshooting

    Maintenance SDQLCAI-1 Cleaning a CAI/SAI Marshalled Termination Assembly involves careful brushing and vacuuming to remove accumulated dust and dirt harboring chemical particulate that can accelerate terminal or connector contact corrosion. When cleaning the termination hardware area, be careful not to disturb the wiring. WARNING Electrical shock hazard.

  • Page 41: Cai Removal/Replacement

    SDQLCAI-1 Maintenance A digital multimeter can be used to test I/O wiring and I/O signals to the termination assembly. Power- off continuity tests can be used to test for correct wiring. When performing tests with power applied, refer to section 6 for the signal levels required at CAI input terminals. Another way to troubleshoot the CAI is develop a test configuration using the 4-mation configuration software.

  • Page 42: Marshalled Termination Assembly Removal/Replacement

    Maintenance SDQLCAI-1 IMPORTANT To avoid possibly damaging the bezel, do not use the captive mounting screws to seat the module. 3.6 Marshalled Termination Assembly Removal/Replacement 3.6.1 Removal Refer to the mechanical details of Figure 2–3and Figure 2–5. 1. As necessary, take appropriate steps to shutdown the processes monitored or controlled by the field devices connected to the Marshalled Termination Assembly.

  • Page 43: Replacement

    One spare Critical Analog Input Module should be stocked for every 1 to 10 in service. Spare and replacement assemblies can be ordered from one of the addresses in the Warranty statement or through a local Siemens representative. Assembly part numbers are stated in section 5 and printed on most modules.

  • Page 44: Maintenance Records

    Maintenance SDQLCAI-1 3.9 Maintenance Records An accurate record keeping system for tracking maintenance operations should be established and kept up to date. Data extracted from the record can serve as a base for ordering maintenance supplies, including spare parts. The record can also be useful as a troubleshooting tool. In addition, maintenance records may be required to provide documentary information in association with a service contract.

  • Page 45: Circuit Description

    4 Circuit Description The Critical Analog Input Module (CAI) receives signals from 2, 3 or 4 wire field devices connected to 32 channels. Input signals are digitized by the CAI and transferred to a QUADLOG control module (CCM/ACM+) via the IOBUS.

  • Page 46: Cpu

    Circuit Description SDQLCAI-1 4.4 CPU There are two central processing units (CPUs) to provide extensive coverage of CPU faults. Both CPUs read the input signals independently and compare the results. If either side detects a data mismatch, an error is reported. Figure 4–1 CAI Block Diagram May 2002...

  • Page 47: Cai Channel Circuit

    SDQLCAI-1 Circuit Description Figure 4–2 CAI Channel Circuit May 2002...
  • Page 48 Circuit Description SDQLCAI-1 May 2002...

  • Page 49: Model Designation

    SDQLCAI-1 Model Designation 5 Model Designation Refer to the following legend to decode the CAI model designation: QLCAI AAN QUADLOG Critical Analog Input Module (CAI) │││ │││ ││└──── NOT USED │└───── HARDWARE COMPATIBILITY CODE └────── FIRMWARE COMPATIBILITY CODE 5.1 Options Table 5-1 lists the available CAI options.

  • Page 50: Accessories

    Model Designation SDQLCAI-1 5.2 Accessories Table 5-2 lists the available CAI accessories. Table 5–2 CAI Accessories PART NUMBER DESCRIPTION 16114-97 Marshalling Utility Panel (see Figure 2-2) — Features mounted wire ducts and DIN rails for Marshalled Termination Assemblies. It is intended for installation in a MODULPAC cabinet.

  • Page 51: Specifications

    SDQLCAI-1 Specifications 6 Specifications This section lists specifications for the QUADLOG Critical Analog Input Module (CAI). 6.1 Module Specifications Table 6-1 lists the CAI’s mechanical and electrical specifications. Table 6–1 CAI Specifications DATA DATA CATEGORY SPECIFICATION (Module w/ Marshalled (Standalone)
  • Page 52 Specifications SDQLCAI-1 SPECIFICATIONS DATA REFERENCE STANDARDS Vibration 10-150 Hz IEC 68-2-6 Test F 2 g. max Mechanical Shock: 15 g11 ms IEC 68-2-27 Test E Acceleration Duration Corrosives Class GX ANSI / ISA S71.04 Radiated Emission, E-Field 30 MHz to 230 MHz EN 55011, EN 50081-2 30 db (uV/m) at 30 m CISPIR 16...

  • Page 53: Electrical Classification

    This section provides certification agency ratings and hazardous locations precautions. 6.3.1 Approvals A listing of safety agency approvals is provided in Table 6-3. Refer to the module’s nameplate or contact Siemens for the most current information regarding agency approvals. Table 6–3 Agency Approvals For CAI AGENCY STANDARDS...
  • Page 54 Specifications SDQLCAI-1 DANGER Explosion hazard Will cause death, serious injury or property damage • In potentially hazardous atmosphere, remove power from equipment before connecting or disconnecting power, signal, or other circuit, or extracting/inserting module. • Observe all pertinent regulations regarding installation in hazardous area. •...

  • Page 55: Index

    CPU faults, 4-2 part numbers DIN rail, 2-4, 2-5, 2-9, 3-4 options, 5-1 E-mail QUADLOG, 1-1, 1-7, 2-18, 4-1, 5-1, 6-1 Siemens, 1-5 ESD (electrostatic discharge), 2-4, 2-14 rack address, 2-5, 2-10 redundancy, 2-5, 2-12, 4-2 hazardous location precautions, 6-5...
  • Page 56 Index SDQLCAI-1 Technical Information Center (TIC), 1-4 transition board, 2-14 troubleshooting, 1-1, 3-2, 3-3, 3-6 TÜV, 6-4 Unterminated I/O Cable, 2-2, 2-10, 2-12, 2-18, 2-19 Unterminated Interconnect I.O Cable, 5-1, 5-2 user-serviceable parts, 3-6 web site technical services, 1-4 wire colors unterminated i/o cable assembly, 2-19 wiring gague, 2-2, 2-15...

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