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Bailey infi 90 IISAC01 Instruction

Analog control station
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E96-117
®
®
Analog Control Station
(IISAC01)
Process Control and
Automation Solutions
from Elsag Bailey Group

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Summary of Contents for Bailey infi 90 IISAC01

  • Page 1 E96-117 ® ® Analog Control Station (IISAC01) Process Control and Automation Solutions from Elsag Bailey Group...
  • Page 2 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...
  • Page 3 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. I-E96-117B1 15 August 1994...
  • Page 4 ® 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...
  • Page 5 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 6 ® Sommaire de Sécurité AVERTISSEMENTS Environnement de l’équipement D’ORDRE Ne pas soumettre les composants à une atmosphère corrosive lors GÉNÉRAL 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.

  • Page 7: Table Of Contents

    Table of Contents Page 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...
  • Page 8 ® 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) ......
  • Page 9 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......................
  • Page 10 ® List of Figures Title Page 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.

  • Page 11: Section 1 - Introduction

    SECTION 1 - INTRODUCTION INTRODUCTION The IISAC01 Analog Control Station provides process loop con- trol and monitoring capabilities for a single loop. The analog control station (SAC), while functionally compatible with the NDCS03 Digital Control Station, includes additional features not found on earlier digital control stations, including: Additional analog input display with square root option.

  • Page 12: Hardware Application

    INTRODUCTION ® The front panel pushbuttons: Select the alphanumeric display mode. • Select the station operational mode. • Raise/lower set point and control output (demand output). • Select manual override. • Acknowledge the alarms. • HARDWARE APPLICATION The SAC station enables monitoring a process or controlling a process manually.

  • Page 13: Instruction Content

    INTRODUCTION I/O EXPANDER BUS (MMU BACKPLANE) TO OTHER STATIONS (32 STATIONS MAX PER COMMUNICATIONS LINK, 64 TOTAL STATIONS MAX) (SEE NOTE) 4 STATIONS MAX NOTE: B DENOTES BYPASS- PER CONNECTOR CAPABLE STATION. LEGEND: CIS = CONTROL I/O MODULE MFP = MULTI-FUNCTION PROCESSOR MMU = MODULE MOUNTING UNIT SAC = ANALOG CONTROL STATION TCS = CONTROLLER/STATION TERMINATION UNIT...

  • Page 14: How To Use This Instruction

    Repair/Replacement Explains how to repair and replace the SAC station. Procedures Support Services Explains the services and training that Bailey Controls Com- pany makes available to their customers. Appendices Supply quick reference information on the termination devices. HOW TO USE THIS INSTRUCTION Read this instruction in sequence.
  • Page 15 INTRODUCTION Table 1-1. Glossary of Terms and Abbreviations Term Definition A/D Conversion Analog-to-digital conversion. Process of generating a digital representation of the mag- nitude of an analog signal. Basic Station An analog control station configuration that allows the operator to adjust the set point in the automatic mode (closed-loop control) and the control output in the manual mode (open-loop control).

  • Page 16: Reference Documents

    NIDS01 Station Termination Module I-E96-413 NIMF01/02 Multi-Function Controller Termination Module I-E96-415 NIRL03 Remote Link Termination Module I-E96-427 NTMF01 Multi-Function Controller Termination Unit ® Network 90 is a registered trademark of Elsag Bailey Process Automation. REFERENCE DOCUMENTS 1 - 6 I-E96-117B...

  • Page 17: Nomenclature

    INTRODUCTION Table 1-2. Reference Documents (continued) Number Title I-E96-428 NTMP01 Multi-Function Processor Termination Unit I-E96-429 NTRL02 and NTRL03 Fiber Optic Remote Link and Electrical Remote Link Termination Units I-E96-442 NTCS04 Controller Station Termination Unit I-E96-500 Site Planning and Preparation NOMENCLATURE Table is a list of related hardware.

  • Page 18: Specifications

    INTRODUCTION ® Table 1-3. Nomenclature (continued) Nomenclature Hardware NKDS13 DCS cable with connector non-PVC NKSE01 Station serial extension cable NKSE02 Station serial extension cable non-PVC NKTD01/02 Termination station cable NKTD11 /12 Termination station cable non-PVC NKTU01 Termination unit cable NKTU11 Termination unit cable non-PVC NTCS04 Control I/O termination unit...
  • Page 19 INTRODUCTION Table 1-4. IISAC01 Analog Control Station Specifications (continued) Property Characteristic/Value Analog input: Voltage range +0.75 VDC to +5.25 VDC maximum Impedance >10 MΩ Accuracy 1.5% of span at 25°C (77°F) A/D resolution 8 bit Normal mode rejection 75 dB minimum at 60 Hz Common mode rejection 90 dB minimum at 60 Hz ±5 VDC maximum...

  • Page 20: Section 2 - Description And Operation

    SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION This section contains an explanation of the operation of the IISAC01 Analog Control Station. It gives an overview of station operation within a control system. SYSTEM OPERATION A control strategy using analog control stations (SAC) is accomplished by using function blocks configured within a module.

  • Page 21: Sac Station Application Example

    DESCRIPTION AND OPERATION ® CONTROLWAY I/O EXPANDER BUS RS-485 SERIAL LINK 4-20 mA I/O RS-485 SERIAL RS-485 LINK AND SERIAL LINK 4-20 mA I/O LEGEND: CIS = CONTROL I/O MODULE MFP = MULTI-FUNCTION PROCESSOR MODULE PROCESS SAC = ANALOG CONTROL STATION TCS = CONTROL I/O TERMINATION UNIT SIGNALS TMP = MULTI-FUNCTION PROCESSOR MODULE...
  • Page 22 DESCRIPTION AND OPERATION The SAC station can be forced to take control of the analog out- put under three conditions. 1. The MFP module directs the SAC station to bypass mode. 2. The SAC station goes into bypass mode when the auto bypass option is enabled.

  • Page 23: Analog Control Station Functions

    DESCRIPTION AND OPERATION ® Analog Control Station Functions The functions of the SAC station are to: 1. Provide process variable, set point and analog output dis- plays (bar graph and alphanumeric). 2. Provide set point adjustment. 3. Allow M/A selection of the control loop. 4.

  • Page 24: Modes Of Operation

    DESCRIPTION AND OPERATION station out of manual override. The station still sends set point and target demand output values to the MFP module as in bypass mode. MODES OF OPERATION The MFP module configuration combined with the option set- tings on the SAC station determine how the station will operate in each operational mode.

  • Page 25: Initialization

    DESCRIPTION AND OPERATION ® Initialization Upon power up, the station enters the initialization operational mode. Initialization prepares the station hardware for opera- tion. It starts the watchdog timer and runs a test sequence on the faceplate displays. The MFP module reads the station option dipswitch settings and interprets how the station will operate.

  • Page 26: Manual Override Operation

    DESCRIPTION AND OPERATION being forced into bypass, refer to Section 5 for corrective action. NOTE: The associated analog output is specified by S28 of function code 80 and must reference one of the analog outputs (N+4 or N+5) of function code 79. Once in the bypass mode, the SAC station cannot return to normal operation until all of the following conditions are met: 1.

  • Page 27: Normal Operation

    DESCRIPTION AND OPERATION ® transfers to either normal mode or reverts back to bypass mode as directed by the MFP module. Normal Operation Normal operation begins after the MFP module establishes communication with the SAC station. In normal operation, the set point, process variable, control output and analog inputs appear on the appropriate bar graph on the SAC station face- plate.

  • Page 28: Local Level

    DESCRIPTION AND OPERATION LOCAL LEVEL The local level of supervisory control is the most common. It is used in PID control loops that require occasional monitoring and adjustment of an operator. When the station is at the local level, the operator can control the process from the SAC station or from a console by changing the station mode, station level, control output, set point, and ratio index values.

  • Page 29: Cascade Station

    DESCRIPTION AND OPERATION ® while in automatic mode. Figure shows an example of how function code 80 works as a basic station. Cascade Station Cascade station operation is similar to automatic basic station operation except that the set point of the cascade station is from an external source.

  • Page 30: Module Configuration With Cascade Set Point From External Source

    DESCRIPTION AND OPERATION modes. When the SAC station transfers to manual operation from cascade, it enters manual basic operation. Figure shows an example of how function code 80 generates a cascade set point from an external variable. CISI/O PRODUCT TEMPERATURE (79) MFC/P (80)

  • Page 31: Ratio Station

    DESCRIPTION AND OPERATION ® Ratio Station A variable controlled by another process variable determines the set point for a ratio station. The MFP module calculates the set point by multiplying the wild variable by a ratio index set in function code 80. The operator can change the ratio index through the set raise/lower pushbutton.

  • Page 32: Sac Station I/O Circuitry

    DESCRIPTION AND OPERATION ratio index has a range from zero to 100. If the set point track specification of function code 80 is set, the ratio index value remains fixed until the set point track is disabled. SAC STATION I/O CIRCUITRY The analog control station interfaces an MFP module to a pro- cess.

  • Page 33: Bypass Circuitry

    DESCRIPTION AND OPERATION ® Bypass circuitry. • Electric drive circuitry. • Analog output circuitry. • Analog input circuitry. • Switching power supply. • The microprocessor provides the station with intelligence and communication capability. It supports one serial port, a four-channel A/D conversion, general I/O lines, and an address/data bus that interfaces the microprocessor to mem- ory and peripheral devices.

  • Page 34: Bypass Circuit Functions And Specifications

    DESCRIPTION AND OPERATION Table 2-1. Bypass Circuit Functions and Specifications Function Purpose Specification Analog input Monitors position feedback or any external analog Differential: 0.75 to 5.25 V signal. Analog output Position control. 3 to 21 mA 0 to 600 Ω max load impedance 8-bit resolution CIS override Electronically disconnects AO of CIS and station...
  • Page 35 DESCRIPTION AND OPERATION ® on, reverse biasing D1 and turns Q2 and Q3 off. Q1 sinks the SAC station output to ground and the CIS module output drives the load through D2 and D3. In bypass or manual over- ride, the BYPASS N.H. signal is a logic zero. This state causes Q1 to turn off while Q2 and Q3 turn on.

  • Page 36: Electric Drive Circuit

    DESCRIPTION AND OPERATION I/O POWER SUPPLY M/A_PWR N.O. RELAY K1 N.C. M/A_COM SELECT M/A_PWR ELEC_DRV ~ RAISE/LOWER PUSHBUTTONS LOCATED ON FACEPLATE RELAY K1 M/A_COM ELEC_DRV ~ 1 = NO EFFECT - Q1 IS ON AND K1 CAUSES N.O. CONTACT CLOSURE AND MA SIGNAL FLOATS. 0 = Q1 IS OFF AND K1 IS OFF CAUSING N.C.

  • Page 37: Analog Output Circuitry

    DESCRIPTION AND OPERATION ® Analog Output Circuitry Figure 2-10 shows a schematic of the analog output circuit. The microprocessor sends the desired control output value to a dig- ital to analog converter (DAC). The DAC generates a corre- sponding zero to five VDC signal (VDAC). The VDAC signal is the set point for the current loop error amplifier.
  • Page 38 DESCRIPTION AND OPERATION to five VDC level. An on-board analog to digital converter (ADC) translates this zero to five VDC signal to a digital value. Analog input two has a square root display option. When enabled (dipswitch SW4, position one), it takes the square root of the zero to 100 percent input signal.

  • Page 39: Section 3 - Installation

    SPECIAL HANDLING Observe these steps when handling electronic circuitry: NOTE: Always use Bailey Controls field static kit (part number 1948385A1 - consisting of two wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with the modules.

  • Page 40: Unpacking And Inspection

    SAC station. 1. Examine the hardware immediately to verify that it has not been damaged in transit. 2. Notify the nearest Bailey Controls sales office of any such damage. 3. File a claim for any damage with the transportation com- pany that handled the shipment.

  • Page 41: Diagnostics (Sw1, Position 1)

    INSTALLATION jumpers on the station circuit board. Tables through show the SAC station dipswitch and jumper settings. Diagnostics (SW1, Position 1) The diagnostics setting (dipswitch SW1, position one) is used only by the factory. Check this dipswitch setting and verify that it is in the correct position for normal operation.

  • Page 42: Station Address (Sw1, Positions 3 Through 8)

    INSTALLATION ® 2. Refer to Table and set SW1, position 2 for the desired communication rate and record the dipswitch setting in the space provided in Table 3-1. Station Address (SW1, Positions 3 through 8) Each station must have a unique address. A SAC station (con- figured for 40 kilobaud communication rate) can have any address from zero to 63 when supported by an IMMFP01 or IMMFP02 module revision C.0 firmware or higher or an...

  • Page 43: Demand Output (Sw2, Position 2)

    INSTALLATION disabled, the station enters the stand-alone mode upon a mod- ule communication failure. To set the auto bypass option: 1. Refer to Table for dipswitch SW2, position 1 settings. 2. Set dipswitch SW2, position 1 to enable or disable the auto bypass option and record the dipswitch setting in the space provided in Table 3-3.

  • Page 44: Display Options

    INSTALLATION ® control output in manual override or bypass operation. To enable the electric drive option: 1. Determine the drive type required for your application. 2. See Figure for the location of JP2 and dipswitch SW2. 3. Refer to Table for the dipswitch SW2, position 3 set- tings.

  • Page 45: Stand-Alone Mode Display Options (Sw3)

    INSTALLATION causes an error code to appear on the alphanumeric display regardless of the present operating mode display options. NOTE: Analog inputs AI1 and AI2 are not available with the ICS ter- mination module. AI1 may be displayed with the ICS/IDS pair. AI2 is not available with the ICS/IDS pair.

  • Page 46: Normal Mode Display Options (Sw4, Positions 2, 3 And 4)

    INSTALLATION ® root of AI2. This value is displayed as zero to 100 percent. To set the square root option: 1. Refer to Table for the dipswitch SW4, position 1 dipswitch setting. 2. Set dipswitch SW4, position 1 to enable or disable the square root option and record the dipswitch setting in the space provided in Table 3-6.

  • Page 47: Manual Override (Jp1)

    INSTALLATION 3. Set dipswitch SW4, positions 5 through 8 to the positions that enable the desired display options and record the dipswitch settings in the space provided in Table 3-7. Table 3-7. Dipswitch SW4 Positions 2 through 8 Position User Display Options ALPHA Setting...

  • Page 48: Electric Drive Mode Display Options (Sw3 And Sw4)

    INSTALLATION ® 2. Set JP1 to enable or disable manual override switch and record the jumper setting in the space provided in Table 3-4. ELECTRIC DRIVE MODE DISPLAY OPTIONS (SW3 AND SW4) There are three stand-alone mode display options and three bypass/manual override mode display options that determine how the display operates when the station is in electric drive mode.

  • Page 49: Microcomputer Mode Of Operation (Jp3)

    INSTALLATION When the station exits electric drive bypass mode to normal mode operation, the new control output value is the value of the analog input as defined in Tables and 3-9. At the time of transfer, either AI1 or AI2 becomes the control output in normal mode.

  • Page 50: Termination Device And Sac Station Designator Relationship

    INSTALLATION ® NOTES: 1. MINIMUM CLEARANCE REQUIRED TO REMOVE STATION FROM HOUSING IS × (72.0 MM NO. UNITS) – 5.8 MM 250.0 MM (9.84 IN.). × (2.83 IN. NO. UNITS) – 0.23 IN. 2. MINIMUM CLEARANCE BEHIND PANEL IS 457.0 MM (18.00 IN.). 3.

  • Page 51: Cable Applications, Connections And Length Requirements

    INSTALLATION cabling applications, connections and length restrictions. Refer to the appropriate termination unit manual for complete hard- ware descriptions. NOTES: The maximum cable length for the NKCS01, NKCS02 and NKTD02 cables also depends on the number of stations intercon- nected and the type of power system used. Tables 3-12 3-13 define the cable lengths depending on the power system and the...
  • Page 52 INSTALLATION ® Table 3-11. Cable Applications, Connections and Length Requirements (continued) Connections Maximum Length Cable From Meters Feet Device Connector Device Connector NKSE01 and TCS termination unit P5 61.0 200.0 NKSE02 termination unit TCS termination unit P4 termination unit NKTD01 and IDS termination mod- SAC station KDS cable...

  • Page 53: Termination Unit Cable And Wiring Installation (Single Or Double Station)

    INSTALLATION Table 3-13. Network 90 Power System Maximum Cable Length Maximum Length Number of Cable Stations Meters Feet NKCS01, NKCS02, NKDS01, NKDS02 or NKTD02 NKCS02, NKDS02 or NKTD02 NKCS02, NKDS02 or NKTD02 NKCS02, NKDS02 or NKTD02 The ICS termination module with the NKTD02 cable supplies only the power and the serial link to the SAC station.

  • Page 54: Cable Connections For The Ntrl03 Termination Unit

    INSTALLATION ® TO ADDITIONAL NTCS04 AS REQUIRED IISAC01 (32 STATIONS MAX) (WITH BYPASS) NKSE01/11 NKDS01/11 NKCS01/11 NKTU01/11 IMCIS02 NTCS04 NKDS01/11 NKCS01/11 NKSE01/11 NKTU01/11 IISAC01 NTMP01 IMMFP01/02/03 (WITH BYPASS) NKTU01/11 NKSE01/11 REDUNDANT TO SECOND GROUP OF UP TO 32 STATIONS T00298A Figure 3-3.

  • Page 55: Termination Module Cable Installation (Without Bypass)

    INSTALLATION TO NEXT STATION (4 STATIONS MAX) IISAC01 TO ADDITIONAL NTCS04 (NO BYPASS) AS REQUIRED NKSE01/11 NKDS03/13 IISAC01 NKTU01/11 NTCS04 IMCIS02 (NO BYPASS) NKDS02/12 NKCS02/12 NKDS03/13 NKSE01/11 NKTU01/11 IISAC01 NTMP01 IMMFP01/02/03 (WITH BYPASS) NKTU01/11 NKSE01/11 TO REDUNDANT MFP IF REQUIRED TO SECOND GROUP OF UP TO 32 STATIONS...

  • Page 56: Cable Connections For The Ntrl03 Termination Unit

    INSTALLATION ® NKCL01/11 USE EITHER COAXIAL OR NKTL01 TWINAXIAL CABLE, BUT NOT NTRL03 BOTH AT THE SAME TIME (END NODE) LOCAL IMRIO02 NKLM01/11 (RMP) NKPL01/11 NKSE01/11 NDIS01 NTCS04 NDCS03 NKLM01/11 IISAC01 IMCIS02 NKCS02/12 NDIS01 NKDS02/12 NDCS03 IISAC01 ANALOG OUTPUT BYPASS CAPABILITY NKDS03/13 NO ANALOG OUTPUT NTRL03...

  • Page 57: Termination Module Cable Installation (With Bypass)

    INSTALLATION NKPL03/04 USE EITHER COAXIAL OR TWINAXIAL CABLE, BUT NOT BOTH AT THE SAME TIME NKCL01/02 NIRL03 NIRL03 NKTL01 LOCAL IMRIO02 NKTU02/12 NKTL01 (RMP) NO ANALOG OUTPUT BYPASS CAPABILITY NKTD02 NKID12 SERIAL LINK WIRE NDIS01 NDCS03 NKTU02/12 REMOTE IMRIO02 IISAC01 (RSP) NO ANALOG OUTPUT BYPASS CAPABILITY NKTD02...

  • Page 58: Cable Connections For The Ics Termination Module With One Station, No Bypass

    INSTALLATION ® NIMP01 NKTM01 NKTU02 IMMFP01/02/03 DCSA SERIAL LINK NKTM01 NKTU02 IMCIS02 NICS01 UP TO 32 NKTD02/12 STATIONS IISAC01 (NO BYPASS) T00302A Figure 3-7. Cable Connections for the ICS Termination Module with One Station, No Bypass 2. Connect the end of the NKTD01 with 1 connector to the slot on the TMU backplane that is assigned to the IDS termination module.

  • Page 59: Cable Connections For The Ics And Ids Modules With Interconnected Stations And Bypass

    INSTALLATION b. Connecting an NKDS01 cable to the NKTD01 connector provides a single station with bypass. c. Connecting an NKDS02 cable to the NKTD01 connector provides the ability to interconnect up to 4 stations. Only the station connected to the NKDS02 cable has bypass capability.

  • Page 60: Connecting Termination Cables To Station Housing

    INSTALLATION ® Connecting Termination Cables to Station Housing The termination cable edge connector snaps securely into place in the back of the station housing. Partially remove the station from the housing before fastening the cable to the housing. Viewing the station housing from the rear, the cable fastens to the right side of the station housing.

  • Page 61: Removing The Analog Control Station

    INSTALLATION 4. Use a straight blade screwdriver to turn the captive screw behind the legend door, locking the station in place. Removing the Analog Control Station To remove the SAC station from its housing: NOTE: Extended grounds allow disconnection of the station from the front of the station housing without damage.

  • Page 62: Section 4 - Operating Procedures

    SECTION 4 - OPERATING PROCEDURES INTRODUCTION This section covers IISAC01 Analog Control Station (SAC) start-up and operation. It identifies station faceplate displays, special alphanumeric characters, error codes and explains how they function in relation to the membrane pushbuttons. FACEPLATE OPERATION The operator monitors and initiates actions through the station faceplate.

  • Page 63: Special Characters On The Alphanumeric Display

    OPERATING PROCEDURES ® letters (A through Z), and two special characters (refer to Table 4-1). NOTE: The alphanumeric display is capable of displaying a range of values between the values of -9999 and +9999. Values not within these limits will be displayed as either -9999 or +9999 on the alpha- numeric display.
  • Page 64 OPERATING PROCEDURES Table 4-2. Analog Control Station Error Codes and Alarms (continued) Code Meaning Alarm - Analog Input 2 (AI2) Low - Occurs when the second analog input signal falls below 0.75 V (less than -5%). This error condition does not disrupt station operation. It warns the operator that the analog input signal is out of the specified operating range (1 to 5 VDC).

  • Page 65: Annunciators

    OPERATING PROCEDURES ® Annunciators There are nine annunciators on the station faceplate. They are located above the control output (CO) bar graph. Table lists the function of the annunciators. Table 4-3. Annunciators Annunciator Indicates The station is operating as an automatic basic station. The station is operating as a cascade station.

  • Page 66: Membrane Pushbutton Operation

    OPERATING PROCEDURES Table 4-4. Membrane Pushbutton Operation Pushbutton Action Selects the variable that appears on the alphanumeric display. It cycles through the pro- cess variable, set point and control output. The PV and SP are displayed as decimal val- ues in engineering units, the CO is displayed as a decimal value in percent. The annunciators to the left of this pushbutton indicate which variable appears on the alpha- numeric display.

  • Page 67: Station Start-Up And Operation

    OPERATING PROCEDURES ® The manual override switch is behind the legend door at the top of the analog control station faceplate (see Figure 4-1). NOTE: Toggling the M/A switch to reset the CIS/MFP/SAC combi- nation when there is a faulty CIS module, bad cabling or field termi- nation causes a potential loss of control.

  • Page 68: Stand-Alone

    OPERATING PROCEDURES the faceplate display is operating properly. Upon completion of the faceplate display test the station enters the stand-alone mode. Stand-Alone After successful initialization, station enters stand-alone mode while the module attempts to establish com- munication with the station. From the stand-alone mode the station can: Enter normal operation after the module establishes com- •...

  • Page 69: Normal Operation

    OPERATING PROCEDURES ® 2. When the CO and DO are approximately the same value, place the manual override switch in the manual ( M) position (Figure shows the location of the manual override switch). Once the station transfers to manual override, the station exits the stand-alone mode.

  • Page 70: Bypass/Manual Override Operation

    OPERATING PROCEDURES pushbutton is pressed, the station transfers to basic/auto- matic. Additional depressions of the AUTO pushbutton causes the station to toggle between the other available control strate- gies. To return to basic/manual, press the MAN pushbutton. Refer to Table for a description of pushbutton operation in relation to function code 80.

  • Page 71: Section 5 - Troubleshooting

    To avoid creating additional problems while troubleshooting, always use Bailey Controls field static kit (part number 1948385A1) when working with the SAC station. The kit connects a technician and the static dissipative work surface to the same ground point to prevent damage to the station circuit by electrostatic discharge.

  • Page 72: Corrective Action For Sac Error Codes

    TROUBLESHOOTING ® Table 5-1. Corrective Action for SAC Error Codes Condition Problem Cause Corrective Action Loss of Poor or open Check cable connections. communication. cable connection. For termination units: 1. Verify that the station cable connects P1 on the station to P2 or P3 on the TCS termination unit. 2.
  • Page 73 TROUBLESHOOTING Table 5-1. Corrective Action for SAC Error Codes (continued) Condition Problem Cause Corrective Action E07 with SAC Analog output Load removed 2. If the load was open and restored, remove the station in low. from AO, bad CIS loop from bypass by placing the M/A switch in the M position, then to the A position.
  • Page 74 TROUBLESHOOTING ® Table 5-1. Corrective Action for SAC Error Codes (continued) Condition Problem Cause Corrective Action Configuration Station firmware Reset the station. register failure. unable to config- 1. If the station is in bypass operation, secure ure micro-proces- control of the process loop through some other sor for normal source.

  • Page 75: Error Code E01 Troubleshooting Flowchart

    TROUBLESHOOTING E R ROR CO DE E0 1 O N ALP HAN UM E RIC DISP LAY REFER TO M AS TER INSTALLATION SECTION M ODU LE AN D STATION B AUD R ATE MATCH ? CORRECTIVE ACTION YE S CHECK STATION TO TU/TM CABLE CONNECTION...

  • Page 76: Error Codes E03, E04, E05 And E06 Troubleshooting Flowchart

    ERROR CODE REMAINS? YE S VOLTAGE WITHIN YE S SPEC? REPLACE STATION CABLE ERROR CODE DONE REMAINS? YE S CONTACT BAILEY CONTROLS T00 306A Figure 5-2. Error Codes E03, E04, E05 and E06 Troubleshooting Flowchart GENERAL FAILURES 5 - 6 I-E96-117B...

  • Page 77: Error Codes E07 And E08 Troubleshooting Flowchart

    CODE REMAINS? DONE Y E S REMOVE ASSOCIATED IMCIS02 ERROR REPLACE CODE REMAINS? IMCIS02 Y E S REMOVE REPLACEMENT STATION CONTACT BAILEY CONTROLS INSTALL REPLACE ORIGINAL TU/TM STATION YE S ERROR ERROR Y ES REPLACE DONE DONE CODE REMAINS? CODE REMAINS?

  • Page 78: Error Code E17 Troubleshooting Flowchart

    TROUBLESHOOTING ® ERROR CODE E17 ON ALPHANUMERIC DISPLAY STATION IN BYPASS OR MANUAL OVERRIDE? SECURE CONTROL RESET OF LOOP THROUGH STATION SOME OTHER SOURCE ERROR CODE DONE REMAINS? REPLACE STATION DONE T00308A Figure 5-4. Error Code E17 Troubleshooting Flowchart GENERAL FAILURES 5 - 8 I-E96-117B...
  • Page 79 TROUBLESHOOTING ERROR CODE E18 ON ALPHANUMERIC DISPLAY REMOVE STATION JUMPER PINS PINS 1 AND 2 1 AND 2 ON JUMPERED ON JP3? INSERT STATION ERROR CODE REMAINS? REPLACE STATION DONE T00309A Figure 5-5. Error Code E18 Troubleshooting Flowchart GENERAL FAILURES I-E96-117B 5 - 9...
  • Page 80 TROUBLESHOOTING ® ERROR CODE E19 ON ALPHANUMERIC DISPLAY CHECK STAND-ALONE DISPLAY OPTIONS AND SET FOR USE WITH ELECTRIC DRIVES CHECK BYPASS/ MANUAL OVERRIDE DISPLAY OPTIONS AND SET FOR USE WITH ELECTRIC DRIVES DISPLAY OPTIONS SET CORRECTLY? REPLACE ERROR CODE STATION REMAINS? DONE T00310A...
  • Page 81 TROUBLESHOOTING ERROR CODE E20 ON ALPHANUMERIC DISPLAY PLACE M/A SWITCH IN ‘A’ POSITION M/A SWITCH IN CORRECT POSITION? ERROR CODE DONE REMAINS? REMOVE STATION P5 SEATED SEAT P5 PROPERLY ON CONNECTOR STATION? ON STATION REPLACE ERROR CODE STATION REMAINS? DONE T00311A Figure 5-7.

  • Page 82: Troubleshooting General Failures

    3. Check the station fuse F1. If it is open replace it with a 1.0 A/250 V fuse (Bailey part number 1948182A21001). 4. If the station fuse is good, check F1 and F3 on the TCS termination unit.

  • Page 83: Troubleshooting Flowchart For General Operational Failures

    TROUBLESHOOTING ERROR CODE E20 ON ALPHANUMERIC DISPLAY PLACE MANUAL MANUAL OVERRIDE SWITCH OVERRIDE SWITCH IN THE -A- IN -A- POSITION? POSITION Y ES ALL LEDs Y ES REPLACE THE ALL LEDs DONE OFF? STATION ILLUMINATE? Y ES YELLOW STATION CHECK STATIO N BARG RAPHS MANUAL LED WILL NOT EXIT...

  • Page 84: Section 6 - Maintenance

    SECTION 6 - MAINTENANCE INTRODUCTION The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. Bailey Controls Company recommends that all equipment users practice a pre- ventive maintenance program that will keep the equipment operating at an optimum level.

  • Page 85: Equipment And Tools Required

    MAINTENANCE ® Table 6-1. Preventive Maintenance Schedule Task Frequency Check SAC faceplate, circuit board and housing for dust. 3 months Clean as necessary using an antistatic vacuum. Check all signal, power and ground connections associated with the SAC station and its termination device; verify that they are secure.

  • Page 86: General Cleaning And Washing

    MAINTENANCE Printed Circuit Board Cleaning There are several circuit board cleaning procedures in this sec- tion. These procedures cover circuit board cleaning, cleaning edge connectors and circuit board edge connector contacts. 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.

  • Page 87: Female Edge Connector Cleaning

    There must not be any motion done to loosen the connection. NOTE: Bailey Controls Company recommends this preventive main- tenance task be performed during power supply preventive mainte- nance while the power to the cabinet is off.

  • Page 88: Section 7 - Repair/Replacement Procedures

    (SAC). Table lists the recommended spare parts for the SAC station. NOTE: Always use the Bailey field static kit (part number 1948385A1) when working with the station. This kit connects the static dissipative work surface and technician to the same ground point.

  • Page 89: Station Fuse (F1) Replacement

    3. Remove F1 from the fuse holder (see Figure for the location of F1). 4. Replace F1 by installing a 1.0 A/250 V fuse (Bailey part number 1948182A21001) in the fuse holder. 5. Insert the station in the station housing. Push on the left edge of the faceplate until P1 on the SAC station circuit board seats in the cable connector at the rear of the housing.

  • Page 90: Section 8 - Support Services

    SECTION 8 - SUPPORT SERVICES INTRODUCTION Bailey Controls Company is ready to assist in the use of its products. Requests for sales, applications services, installa- tion, repair, overhaul and maintenance contract services should be made to the nearest sales office.

  • Page 91: Appendix A - Ntcs04 Controller/Station Termination Unit

    APPENDIX A - NTCS04 CONTROLLER/STATION TERMINATION UNIT INTRODUCTION The IISAC01 Analog Control Station uses the NTCS04 Control- ler/Station Termination Unit for termination. Configure the termination unit dipshunts according to the assembly revision level you are using. All NTCS04 termination units have two analog inputs available to each station connector.

  • Page 92: Introduction

    NTCS04 CONTROLLER/STATION TERMINATION UNIT ® RAISE 2 COMMON – RAISE 1 DI2 (XU6) R/L COMMON 2 +24 VDC R/L COMMON 1 LOWER 2 – – LOWER 1 ELECTRIC ELECTRIC DI1 (XU5) DI3 (XU7) DRIVE DRIVE ONLY M/A POWER 2 M/A POWER 1 ONLY M/A SELECT 2 –...

  • Page 93: Appendix B - Nics01 Controller/Station Termination Module

    APPENDIX B - NICS01 CONTROLLER/STATION TERMINATION MODULE INTRODUCTION The IISAC01 Analog Control Station can use the NICS01 Con- troller/Station Termination Module termination. dipswitch settings on the controller/station termination mod- ule (ICS) relate to the IMCIS02 Control I/O Slave Module. Refer to the IMCIS02 Control I/O Slave Module product instruction for more information.

  • Page 94: Appendix C - Nids01 Station Termination Module

    APPENDIX C - NIDS01 STATION TERMINATION MODULE INTRODUCTION The IISAC01 Analog Control Station (SAC) can use the NIDS01 Station Termination Module (IDS) for termination. The IDS termination module used in conjunction with the NICS01 Controller/Station Termination Module provides bypass capability and an electric drive termination for SAC sta- tions.
  • Page 95 Index E13................5-3 E17..............5-3, 5-8 Alarms ................ 4-2 E18..............5-4, 5-9 Analog control station functions ......... 2-4 E19...............5-4, 5-10 Annunciators .............. 4-4 E20...............5-4, 5-11 Application ..............2-2 Example configuration ..........1-3 Cable Faceplate operation ............4-1 Applications ............3-13 Alphanumeric display ..........4-1 Connections............3-13 Annunciators ............4-4 ICS and IDS termination modules....
  • Page 96 ® Index (continued) Maintenance ...............6-1 SAC station I/O circuitry ........... 2-13 Maximum number of stations ........1-2 Analog input ............2-18 Microcomputer mode of operation ......3-11 Analog output............2-18 Modes of operation .............2-5 Bypass circuitry........... 2-14 Basic station ............2-9 Electric drive ............2-16 Bypass operation...........2-6 Scheduled maintenance ..........
  • Page 97 ASIA/PACIFIC EUROPE, AFRICA, MIDDLE EAST Graefstrasse 97 Form I-E96-117B1 Litho in U.S.A. 994 Copyright © 1994 by Elsag Bailey Process Automation, As An Unpublished Work ® Registered Trademark of Elsag Bailey Process Automation ™ Trademark of Elsag Bailey Process Automation...

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