Related Manuals for Bailey Infi 90 IMHSS02
Summary of Contents for Bailey Infi 90 IMHSS02
- Page 1 E96-315 ® ® Hydraulic Servo Slave Module (IMHSS02) 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 Preface The Hydraulic Servo Slave Module (IMHSS02) is a position con- trol module. It interfaces a servo valve to the Multi-Function Processor (IMMFP01/02/03) or Multi-Function Controller (IMMFC03/04/05). The MFP or MFC controls the position of a steam or gas turbine throttle valve by sending a position demand to the HSS.
- Page 4 ® List of Effective Pages Total number of pages in this manual is 61, consisting of the following: Page No. Change Date Preface Original List of Effective Pages Original iii through vii Original 1-1 through 1-7 Original 2-1 through 2-9 Original 3-1 through 3-8 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 ensure that contact with energized parts is avoided when servicing. Special Handling This module uses Electrostatic Sensitive Devices (ESD).
- Page 6 Sommaire de Sécurité AVERTISSEMENTS Environment de l'equipment D’ORDRE Ne pas soumettre les composants a une atmosphere corrosive lors GÉNÉRAL du transport, de l'entreposage ou de l'utilisation. Risques de chocs electriques lor de l'entretien S'assurer de debrancher l'alimentaion ou de prendre les precau- tions necessaires a eviter tout conatact avec des composants sours tension lors de l'entretien.
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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...................1-1 INSTRUCTION CONTENT .....................1-2 HOW TO USE .......................1-3 NOMENCLATURE ......................1-4 GLOSSARY OF TERMS AND ABBREVIATIONS .............1-4 REFERENCE DOCUMENTS..................1-6 SPECIFICATIONS ......................1-6 SECTION 2 - DESCRIPTION AND OPERATION................2-1 INTRODUCTION......................2-1 CONTROL LOOP OPERATION..................2-1 Hydraulic Servo Slave ....................2-1... - Page 8 ® Table of Contents (continued) Page SECTION 3 - INSTALLATION (continued) Switch S6 - Demodulator Gain ................3-7 Switch S7 - LVDT Oscillator Frequency ..............3-7 SLAVE MODULE INSTALLATION ................. 3-7 CONFIGURATION ......................3-8 SECTION 4 - CALIBRATION.......................4-1 INTRODUCTION ......................4-1 INITIAL CALIBRATION ....................
- Page 9 List of Figures Title Page 1-1. The HSS within the INFI 90 Hierarchy ..............1-2 2-1. Turbine Speed Control Loop ...................2-2 2-2. HSS Functional Block Diagram ................2-4 2-3. Position Demand and Output Circuit ..............2-6 2-4. Position Feedback Circuit ..................2-8 2-5. Typical Digital Input Circuit ...................2-9 3-1.
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Page 10: Section 1 - Introduction
FCS to calculate turbine speed. The configuration within the MFP uses the calculated speed to drive the servo valve out- puts according to the control strategy of the user. ® INFI 90 is a registered trademark of the Bailey Controls Company. INTRODUCTION I-E96-315B... -
Page 11: Instruction Content
INTRODUCTION ® INFI-NET NIS NPM CONTROLWAY MFP POSITION DEMAND SLAVE EXPANDER BUS TURBINE CONTROL FIELD I/O SPEED LEGEND: FCS = FREQUENCY COUNTER SLAVE HSS = HYDRAULIC SERVO SLAVE MFP = MULTI-FUNCTION PROCESSOR NIS = NETWORK INTERFACE SLAVE NPM = NETWORK PROCESSOR MODULE OIS = OPERATOR INTERFACE STATION TP50202A Figure 1-1. -
Page 12: How To Use
The maintenance section contains a table of scheduled mainte- Maintenance nance procedures. Support Services This section explains the services and training that Bailey Con- trols makes available to their customers. Appendices There are three appendices that provide a quick reference of... -
Page 13: Nomenclature
INTRODUCTION ® NOMENCLATURE Hardware Nomenclature IEMMU01/02/04 Module Mounting Unit IMFCS01 Frequency Counter Slave Module IMMFP01/02/03 Multi-Function Processor Module IMMFC03/04/05 Multi-Function Controller Module NIDI01 Digital Input Termination Module NTDI01 Digital Input Termination Unit NKTM01, Termination Cable, NIDI01 to IMHSS02 NKTU02/12 NKTU01/12 Termination Cable, NTDI01 to IMHSS02 GLOSSARY OF TERMS AND ABBREVIATIONS Term... - Page 14 INFI 90/Network 90 modules. Termination Unit. Provides input/output connection between plant equip- ment and the INFI 90/Network 90 modules. ® Network 90 is a registered trademark of the Bailey Controls Company. GLOSSARY OF TERMS AND ABBREVIATIONS (continued) I-E96-315B...
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Page 15: Reference Documents
INTRODUCTION ® REFERENCE DOCUMENTS Number Document I-E92-501-2 Configuration/Tuning Terminal (CTT02) I-E93-903 Configuration/Tuning Module (NCTM01) I-E96-100 Operator Interface Station (IIOIS20) Operation/Configuration I-E96-200 Function Code Application Manual I-E96-201 Multi-Function Processor Module (IMMFP01) I-E96-202 Multi-Function Processor Module (IMMFP02) I-E96-203 Multi-Function Processor Module (IMMFP03) I-E96-211 Multi-Function Controller Module (IMMFC03) I-E96-212... - Page 16 INTRODUCTION SPECIFICATIONS (continued) OPERATING LVDT Supply Primary 1 kHz, 2.5 kHz or 10 kHz (selectable), 4 to 12 volts peak-to-peak Excitation Output adjustable in steps. Minimum LVDT primary impedance 500 ohms. 30 volts peak-to-peak, ±10 VDC common mode, 20k ohms (differ- LVDT Secondary Two Position Inputs ential input) impedance...
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Page 17: Section 2 - Description And Operation
SECTION 2 - DESCRIPTION AND OPERATION INTRODUCTION This section explains the operation of the hydraulic servo slave (HSS). It gives an overview of the slave and related modules within a process control system and explains the operation of key module circuitry. CONTROL LOOP OPERATION The hydraulic servo slave, frequency counter slave (FCS) and multi-function processor (MFP) form the controlling segment of... -
Page 18: Frequency Counter Slave
DESCRIPTION AND OPERATION ® FUEL HYDRAULIC SERVO THROTTLE ACTUATOR VALVE VALVE LVDT SECONDARY LVDT MAGNETIC TURBINE PICKUP PRIMARY TURBINE SPEED POSITION FEEDBACK DATA POSITION MODULE STATUS REQUEST DEMAND MODULE STATUS ALARMS MONITOR CONFIGURE TURBINE SPEED SYSTEM MANUAL CONTROL ALARMS OPERATOR INTERFACE TP25013A Figure 2-1. -
Page 19: Multi-Function Processor
DESCRIPTION AND OPERATION For the MFP to work with the FCS, it requires function code 145 in its configuration. Function code 145 defines the slave address, high/low speed alarms and high/low rate of change alarms. The block output is frequency of input pulses in hertz. The frequency counter slave continuously checks itself and notifies the MFP if a failure occurs. -
Page 20: Hss Module Circuitry
DESCRIPTION AND OPERATION ® RAISE/LOWER CONTACT INPUTS DIGITAL I/O EMERGENCY ISOLATION/ MANUAL OUTPUT DEBOUNCE POSITION FEEDBACK DEMODULATOR LVDT SECONDARIES SAMPLE/HOLD MICRO- A/D CONVERTER CONTROLLER LVDT LVDT OSCILLATOR PRIMARY XBUS STATUS AND POSITION DEMAND SLAVE EXPANDER BUS DATA STORAGE D/A CONVERTER OUTPUTS TO SERVO VALVE POSITION ERROR... -
Page 21: Slave Expander Bus Interface
HSS. This communica- tion channel is a an eight bit parallel data bus with two control lines. A Bailey Controls designed integrated circuit performs the communications protocol for interfacing the data and sta- tus information to the processor module. It performs address compare, R/W strobe generation and contains bus drivers and receivers. -
Page 22: Status And Data Buffers
DESCRIPTION AND OPERATION ® STATUS AND DATA BUFFERS The status and data buffers hold status information and pro- cess data traveling between the microcontroller and the slave expander bus I/O. This allows the two asynchronous busses to operate together and exchange information using handshake signals. -
Page 23: Digital-To-Analog Converter
DESCRIPTION AND OPERATION Digital-to-Analog Converter The DAC receives the position demand from the microcontrol- ler. It converts the data from a digital word to an equivalent analog signal. The DAC outputs the analog position demand to the position error circuit. Position Error The position error circuit compares position demand with posi- tion feedback. -
Page 24: Sample Hold Circuit
DESCRIPTION AND OPERATION ® the LVDT secondary inputs (which are out of phase) and the result is a DC offset that represents the actuator position. The position feedback signal passes from the demodulator output to the sample hold circuit. Sample Hold Circuit The sample hold circuit samples the demodulator output 1000 times per second. -
Page 25: Digital I/O
DESCRIPTION AND OPERATION DIGITAL I/O If the HSS loses communication with the MFP, the manual control circuitry enables the operator to manually change actuator position. The HSS provides two +24 VDC isolated dig- ital inputs as raise/lower commands from a manual station (pushbuttons, contacts, etc.). -
Page 26: Section 3 - Installation
Section HANDLING NOTE: Always use Bailey's Field Static Kit (P/N 1948385A1 - wrist strap, ground cord assembly, alligator clip) when working with mod- ules. The kit connects a technician and the static dissipative work surface to the same ground point to prevent damage to the modules by electrostatic discharge. -
Page 27: Installing The Process Hardware
INSTALLATION ® INSTALLING THE PROCESS HARDWARE To install the throttle valve, hydraulic actuator, servo valve and LVDT: Only qualified personnel should install the throttle valve, hydraulic actuator, servo valve and linear variable differential CAUTION transformer. Improper installation can cause damage to plant equipment, reduce plant performance and compromise the safety of plant personnel. -
Page 28: Termination Module Installation
INSTALLATION 6. Connect a 14 AWG wire from E1 or E2 to a source of +24 VDC within the cabinet. Termination Module Installation 1. Configure the jumpers on the termination module. 2. Connect one end of NKTM01 or NKTU02/12 cable to the rear of the termination mounting unit (TMU) slot for the termi- nation module. -
Page 29: Switch S2 - Controller Gain
INSTALLATION ® Table 3-1. Slave Expander Bus Address - Example Settings Example Settings Switch Position Example Address Binary Value 128 64 User Settings Switch Position Assigned Address Binary Value 128 64 NOTE: 1 = Open (off), 0 = Closed (on) STATUS EXPANDER CONTROLLER... -
Page 30: Switch S3 - Dither Oscillator Frequency
INSTALLATION Table 3-2. S2 Controller Gain Close Switch For a Gain of User Setting 20.50 18.25 15.05 13.10 10.00 5.00 2.01 1.10 NOTE: Closing a switch position will select the corresponding gain. Close only one switch at a time. All other switch positions must remain open. -
Page 31: Switch S4 - Dither Oscillator Current Amplitude
INSTALLATION ® Switch S4 - Dither Oscillator Current Amplitude Switch S4 is a two position switch that sets the current ampli- tude of the dither circuit. Set the dither oscillator current amplitude to the value the manufacturer of the servo valve rec- ommends. -
Page 32: Switch S6 - Demodulator Gain
INSTALLATION Switch S6 - Demodulator Gain Switch S6 is an eight position switch that sets the demodulator gain. The demodulator gain amplifies the feedback signal so that the peak to peak span of the feedback signal is the full range of the 16 bit resolution analog-to-digital converter (ADC). The calibration procedure in Section 4 explains how to set the demodulator gain to operate over the range of ADC resolution. -
Page 33: Configuration
INSTALLATION ® Table 3-7. S7 LVDT Oscillator Frequency Switch Position Frequency User Setting Open Open 1000 Hz Open Closed 2500 Hz Closed Open 10 kHz NOTE: 1 = Open (off), 0 = Closed (on) 2. Check the slave expander bus dipshunt socket on the backplane of the MMU. -
Page 34: Section 4 - Calibration
SECTION 4 - CALIBRATION INTRODUCTION This section covers the module calibration procedure, analog control loop tuning theory and the controller gain tuning pro- cedure. Completing the steps in this section ensures accurate positioning of the turbine throttle valve and the best possible frequency response. - Page 35 CALIBRATION ® are fast cycle times and are not recommended if the turbine is on-line. 3. Go to the block address specified in S3. Set the calibration command bit to 1. This places the HSS in the calibrate mode. 4. Read the value of S8 with the valve in the 0 percent posi- tion (closed).
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Page 36: Controller Tuning
The practi- cal method finds the gain that is one level below the gain that causes instability (oscillation). 1. Ralph K. Johnson, Analog Control Techniques and Tuning, TP89-2 (Wickliffe: Bailey Controls Co., 1989). CONTROLLER TUNING I-E96-315B... -
Page 37: Tuning The Controller Gain
CALIBRATION ® Tuning the Controller Gain The practical method of setting controller gain requires an indi- vidual with turbine control experience. The individual tuning the system should be familiar with plant operation under nor- mal conditions, know turbine start-up procedures and have experience in tuning control systems. -
Page 38: On-Line Calibration
CALIBRATION 3. Check valve operation. a. If the valve operates smoothly at all demand levels. 1. Remove the HSS and raise the controller gain (switch 2) • to the next setting. For example, if the gain is 1 (position 8 is closed), change the gain to 2 (close position 7, open posi- tion 8). -
Page 39: Controller Tuning Log
CALIBRATION ® Table 4-1. Controller Tuning Log Date Time Gain Setting Names of Personnel ON-LINE CALIBRATION 4 - 6 I-E96-315B... -
Page 40: Section 5 - Operating Procedures
SECTION 5 - OPERATING PROCEDURES INTRODUCTION This section explains how to place the hydraulic servo slave (HSS) in operation. This section includes information about the HSS faceplate indicators, system start-up and operation and manual operation. FACEPLATE INDICATORS Two LEDs are visible through the faceplate of the HSS, the sta- tus LED and the emergency manual LED. -
Page 41: Manual Operation
OPERATING PROCEDURES ® MANUAL OPERATION Emergency Manual Mode Operation enters the emergency manual mode when a MFP communication failure occurs. The emergency manual LED on the module faceplate indicates that the module is in the man- ual mode of operation. Refer to Table to determine the module status using the faceplate LEDs. -
Page 42: Emergency Trip
OPERATING PROCEDURES contacts. The raise contact opens the valve while the lower contact closes the valve. NOTE: The HSS enters the emergency manual mode when it loses communications with the MFP. When the MFP re-establishes com- munication with the HSS, a bumpless transfer of operation occurs and causes the HSS to exit the emergency manual mode. -
Page 43: Section 6 - Troubleshooting
To avoid creating additional problems while troubleshooting, always use Bailey Controls Field Static Kit (P/N 1948385A1) when working with the modules. The kit is designed to connect a technician and the static dissipative work surface to the same ground point to pre- vent damage to the modules by electrostatic discharge. -
Page 44: Off-Line Failure Troubleshooting Flowchar
Table 6-1, replace the hydraulic servo slave module. 4. If replacing the module does not correct the problem call Bailey Controls for assistance. ON-LINE FAILURE This part of the troubleshooting section covers on-line failures and how to troubleshoot them. -
Page 45: Module Failure
TROUBLESHOOTING CORRECTLY EXPANDER INSTALL SLAVE BUS DIPSHUNT EXPANDER BUS CORRECT? DIPSHUNT SET SWITCHES HSS SWITCH ON HSS TO THE SETTINGS SETTINGS FOR CORRECT? INSTALLATION INSERT HSS MODULE IN MMU OPERATING? SECURE CABLE TU/TM CABLE CONNECTION CONNECTED? FROM MMU TO TU/TM OPERATING? TP25255A Figure 6-1. - Page 46 INSTALLED PROPERLY? INSTALLATION LVDT, CHECK ACTUATOR ACTUATOR AND LVDT INSTALLED INSTALLATION PROPERLY? AND CABLE REPLACE HSS OPERATING? MODULE CONTACT BAILEY TECHNICAL DONE SUPPORT TP25256A Figure 6-1. Off-Line Failure Troubleshooting Flowchart (Page 3 of 3) ON-LINE FAILURE 6 - 4 I-E96-315B...
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Page 47: Troubleshooting On-Line Failures
TROUBLESHOOTING Table 6-1. Troubleshooting On-Line Failures Problem Cause Action HSS fails to calibrate Configuration Check the specifications for function code 150. errors Verify that function code 150 is set for calibration. HSS fails to calibrate Improper Check the installation of the HSS and related hardware. and there are no installation 1. -
Page 48: Troubleshooting On-Line Failures
HSS fails to cali- HSS failure Replace the HSS module. brate, all process hardware checks good, there are no configuration errors Replacing the HSS Contact Bailey Controls for assistance. fails to correct the calibration failure ON-LINE FAILURE 6 - 6 I-E96-315B... -
Page 49: Restoring Operation
3. If the HSS module continues to fail after completing steps 1 and 2, replace the module. 4. If replacing the module does not correct the problem con- tact Bailey Controls for assistance. ON-LINE FAILURE I-E96-315B 6 - 7... -
Page 50: On-Line Failure Troubleshooting Flowchart
LOSS OF RESET HSS POWER? MODULE CHECK SYSTEM POWER CORRECT POWER SYSTEM POWER FAILURE, REFER CHECKS GOOD? TO I-E96-506 REPLACE OPERATING? MODULE OPERATING? CONTACT BAILEY DONE TECHNICAL SUPPORT TP25054A Figure 6-2. On-Line Failure Troubleshooting Flowchart ON-LINE FAILURE 6 - 8 I-E96-315B... - Page 51 TROUBLESHOOTING Table 6-3. Troubleshooting On-Line Failures Condition LED States Action Machine fault timer Status - Red Reset the module. timeout Emerg. Man. - Off 1. Turn the thumbscrews on the faceplate a half turn to unlock the module. 2. Pull on the module faceplate until the module disconnects from the MMU backplane connector.
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Page 52: Section 7 - Maintenance
SECTION 7 - MAINTENANCE INTRODUCTION The hydraulic servo slave requires minimal maintenance. The following maintenance schedule will ensure troublefree service. NOTE: Only qualified personnel should perform maintenance. MAINTENANCE The HSS maintenance schedule is shown in Table 7-1. Perform these tasks at the specified intervals. Table 7-1. -
Page 53: Section 8 - Support Services
SECTION 8 - SUPPORT SERVICES INTRODUCTION Bailey Controls is ready to assist in the use and repairs of its products. Requests for sales and/or applications services along with installation, repair, overhaul and maintenance con- tract services should be made to the nearest sales office. -
Page 54: Edge Connector P1 (Module Power) Pin Assignments
APPENDIX A - QUICK REFERENCE MATERIAL INTRODUCTION Tables through list edge connector pin assignments for the hydraulic servo slave module. Table A-1. Edge Connector P1 (Module Power) Pin Assignments Signal Signal +5 VDC +5 VDC Unused Unused Common Common +15 VDC -15 VDC Unused Unused... -
Page 55: Appendix A - Quick Reference Material
QUICK REFERENCE MATERIAL ® Table A-3. Edge Connector P3 (Process Interface) Pin Assignments (continued) Signal Signal LVDT Secondary 2_2 LVDT Secondary 2_1 Simulation Mode COM Simulation Mode OUT Lower ~ Lower_P Emerg Manual Common Emergency Manual ~ INTRODUCTION A - 2 I-E96-315B... -
Page 56: Appendix B - Digital I/O Termination Unit (Ntdi01
APPENDIX B - DIGITAL I/O TERMINATION UNIT (NTDI01) INTRODUCTION The IMHSS02 uses an NTDI01 termination unit to terminate I/ O signals. Dipshunts on the termination unit configure the I/O signals. The hydraulic servo slave (HSS) module provides one digital and four analog outputs, and three digital and two ana- log inputs for control of hydraulic actuators. -
Page 57: Introduction
DIGITAL I/O TERMINATION UNIT (NTDI01) ® Table B-1. NTDI01 Dipshunt Configuration for the HSS Application/ Signal Type Dipshunt Configuration XU17 All Types Analog Inputs LVDT Secondary 1 XU2, XU3 LVDT Secondary 2 Analog Outputs XU1, XU4, XU13, XU14 LVDT Primary Drive Simulation Mode Servo 1 Drive Servo 2 Drive Digital Inputs... - Page 58 DIGITAL I/O TERMINATION UNIT (NTDI01) DIPSHUNT DIPSHUNT DIPSHUNT DIPSHUNT USED USED USED USED LVDT PRI SERVO 1 RAISE LOWER XU13 OUTPUT INPUT INPUT DRV OUT LVDT SEC. 1 SERVO 2 XU14 OUTPUT INPUT TERMINAL NUMBER LVDT TRIP EMER. SEC. 2 BIAS XU11 MAN.
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Page 59: Appendix C - Digital Input Termination Module (Nidi01
APPENDIX C - DIGITAL INPUT TERMINATION MODULE (NIDI01) INTRODUCTION The IMHSS02 uses an NIDI01 termination module to terminate I/O signals. Jumpers on the termination module configure the I/O signals. The hydraulic servo slave (HSS) module provides one digital and four analog outputs, and three digital and two analog inputs for control of hydraulic actuators. - Page 60 DIGITAL INPUT TERMINATION MODULE (NIDI01) ® USED EMER LOWER LVDT LVDT LVDT TRIP RAISE SERVO SERVO USED USED MODE SEC 2 SEC 1 PRI DRV USED BIAS USED USED TP25314A Figure C-2. I/O Signal Terminal Assignments for the HSS NKTM01 OR NKTU02/12 NIDI01 TP25316A...
- Page 61 Index A/D Conversion ............1-4 Glossary of Terms and Abbreviations......1-4 ADC ..............1-4, 2-8 Handling Circuitry..........3-1, 6-1 Calibration ..............4-1 Hydraulic Actuator..........1-5, 2-1 Failure..............6-1 Calibration .............4-1 Function Code Specifications ....... 4-1 Operation ..............2-1 Initial ..............4-1 Hydraulic Servo Slave..........1-1 LVDT..............
- Page 62 ® Index (continued) Position Feedback ............2-7 Maintenance ...............7-1 MCU ................1-5 MFC ................1-5 Quick Reference Material ...........A-1 MFP ................1-5 Microcontroller.............2-6 MMU................1-5 Reference Documents..........1-6 Module Bus ..............1-5 Replacement Parts ............. 8-1 Module Edge Connector Pin Assignments....A-1 Module Switch Settings..........3-3 Multi-Function Processor Configuration ............2-3 Sample Hold Circuit............
- Page 63 Index (continued) Terminal Assignments ..........C-1 Off-line Failure............6-1 Termination Unit ............B-1 On-line Failure........6-1, 6-2, 6-7 Cable Connection ..........B-1 TU ................1-5 Throttle Valve ............. 2-1 Tuning .................4-4 TM ................1-5 Controller Gain ............4-4 TMU................1-5 Function Code Specifications........4-4 Training ..............8-1 Log ................4-6 Troubleshooting............
- Page 64 Telefax 39-10-6582-941 Telephone 49-69-799-0 Telefax 65-292-9011 Telefax 49-69-799-2406 Form I-E96-315B Litho in U.S.A. 492 Copyright © 1992 by Elsag Bailey Process Automation, As An Unpublished Work ® Registered Trademark of Elsag Bailey Process Automation ™ Trademark of Elsag Bailey Process Automation...