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Emerson ROC364 Instruction Manual

Emerson ROC364 Instruction Manual

Remote operations controller
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Form A4193
Part Number D301060X012
June 2005
ROC364 REMOTE OPERATIONS CONTROLLER
Instruction Manual
Flow Computer Division
Website: www.EmersonProcess.com/flow

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Summary of Contents for Emerson ROC364

  • Page 1 Form A4193 Part Number D301060X012 June 2005 ROC364 REMOTE OPERATIONS CONTROLLER Instruction Manual Flow Computer Division Website: www.EmersonProcess.com/flow...
  • Page 2 All Pages May/02 FloBoss and ROCLINK are marks of one of the Emerson Process Management companies. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners. © Fisher Controls International, Inc. 1992-2005. All rights reserved.

  • Page 3: Table Of Contents

    2.2 Product Description ........................2-1 2.3 Installation............................2-7 2.4 Connecting the MCU to Wiring...................... 2-9 2.5 Troubleshooting and Repair......................2-12 2.6 ROC364 Specifications......................... 2-20 Section 3 – Input and Output Modules ................ 3-1 3.1 Scope............................... 3-1 3.2 Product Descriptions........................3-1 3.3 Initial Installation and Setup ......................
  • Page 4 ROC364 Instruction Manual Section 5 – I/O Converter Card ..................5-1 5.1 Scope............................... 5-1 5.2 Product Description ........................5-1 5.3 Initial Installation and Setup ......................5-2 5.4 Troubleshooting and Repair......................5-3 5.5 I/O Converter Card Specification ....................5-4 Appendix A – Lightning Protection Module ...............A-1 A.1 Product Description ........................

  • Page 5: Section 1 - General Information

    SECTION 1 – GENERAL INFORMATION 1.1 Scope of Manual This manual focuses on the hardware aspects of the ROC364 Remote Operations Controller (ROC) manufactured by Flow Computer Division of Emerson Process Management. For software aspects, such as configuration, refer to the respective ROCLINK configuration user manual.
  • Page 6 Discrete Inputs, Discrete Outputs, Analog Inputs, Analog Outputs, and Pulse Inputs. The modular design of the ROC364 makes it cost-effective for both small and large applications. You can select from a variety of communications and operator interface options to customize the installation for a given system.
  • Page 7 OUT 1 ® I/O Modules I/O Module Wiring / Termination A B C A B C A B C A B C A B C I/O Rack ROC364 Figure 1-1. ROC364 Controller Components Mounted on Backplate General Information Rev Jun/05...
  • Page 8 However, provide adequate vehicle access to aid monitoring and maintenance. 1.4.3 Compliance with Hazardous Area Standards The ROC364 hazardous location approval is for Class I, Division 2, Groups A, B, C, and D. The class, division, and group terms are defined as follows: Class defines the general nature of the hazardous material in the surrounding atmosphere.
  • Page 9 Power supply and converter accessories can minimize the number of separate power sources required for an installation. The ROC364 can operate from either a 12-volt or a 24-volt nominal power source. If 24-volt transmitter power is required when operating on 12-volt power, the ROC364 requires an I/O Converter Card to be installed.

  • Page 10: Power Supply Requirements

    Table 1-1 and Table 1-2 provide information to assist in determining power supply requirements. Table 1-1 lists the power consumption of the ROC364 and the optional devices available for it. Include in the power consumption calculations of all device relays, meters, solenoids, radios, and other devices that receive DC power from the ROC (excluding those connected to the I/O modules).
  • Page 11 Total power consumption value in Table 1-1. Refer to Section 1.5.3, Totaling Power Requirements, on page 1-9. Table 1-1. Power Consumption of the ROC364 and Powered Devices Power Consumption (mW)
  • Page 12 ROC364 Instruction Manual Table 1-2. Power Consumption of the I/O Modules Power Consumption (mW) Sub- Duty I/O Module Total 12 Volt 24 Volt Cycle (mW) AI Loop AI Differential AI Source AO Source RTD Input: P is at –50°C (–58°F); P is at 100°C (212°F)

  • Page 13: Startup And Operation

    ROC364 Instruction Manual 1.5.3 Totaling Power Requirements To adequately meet the needs of the ROC system, it is important to determine the total power consumption to size the solar panel and battery backup requirements accordingly. For total power consumption, add the device values in Table 1-1.
  • Page 14 For proper startup, the minimum input voltage level must be 12.5 volts or more for a 12- NOTE: volt unit, and 25 volts or more for a 24-volt unit. Once the ROC364 has been successfully started, the ROC continues to operate normally over the specified input voltage range. If you are unsure of the input voltage setting for your ROC, refer to the paragraphs on setting the input voltage jumpers in Section 2.

  • Page 15: Section 2 - Master Controller Unit, I/O Module Rack, And Wiring

    SECTION 2 – MASTER CONTROLLER UNIT, I/O MODULE RACK, AND WIRING 2.1 Scope This section describes the core of the ROC364 components, including the Master Controller Unit (MCU), the FlashPAC module, wiring, the I/O Module rack, the backplate, and the front panel. Topics covered include:...
  • Page 16 The NEC V25+ is a 16-bit Complementary Metal Oxide Semiconductor (CMOS) microprocessor featuring dual 16-bit internal data buses and a single 8-bit external data bus. The ROC364 can address up to one megabyte of memory and features high-speed direct memory access.
  • Page 17 ROC364 Instruction Manual Power fusing is accessible from the front of the MCU. Fuses are used for the input power and auxiliary power outputs. Terminal blocks provide terminations for the input and auxiliary output power. The source of auxiliary power is the input power, which can be a nominal 12 or 24 volts, depending on the setting of jumpers located on the MCU.
  • Page 18 Operating System Firmware 2.2.3 Diagnostic Inputs and Auxiliary Outputs The ROC364 MCU monitors the power input voltages, transmitter output voltage, and the board temperature with diagnostic Analog Inputs designated as “E” points by the configuration software. The inputs can be calibrated by using ROCLINK configuration software.
  • Page 19 ROC364 Instruction Manual 2.2.4 I/O Module Rack The I/O module rack provides sockets for up to 16 I/O modules. Refer to Figure 2-3. Up to 64 I/O modules can be used in any combination of Discrete Inputs, Discrete Outputs, Analog Inputs, Analog Outputs, and Pulse Inputs.
  • Page 20 ROC364 Instruction Manual 2.2.5 Backplate The ROC364 backplate is a mounting panel for an MCU and one or more I/O module racks. Backplates are available in three sizes to accommodate the indicated number of I/O racks: one rack, two racks, and three or four racks.

  • Page 21: Installation

    The following procedures describe installation of a ROC. If you are installing the ROC364 into a ROC enclosure, fasten the backplate to the mounting studs or tapped mounting holes provided in the enclosure. If you installing the ROC364 on a wall panel or in some other enclosure, refer to Figure 2-4 for the recommended size and location of mounting studs.
  • Page 22 ROC364 Instruction Manual 2.3.2 Mounting an I/O Module Rack to a Backplate Each I/O module rack has a male and female connector on opposite sides of the rack. The first I/O module rack plugs directly into the MCU I/O module rack connector. Additional racks plug into each other.

  • Page 23: Connecting The Mcu To Wiring

    ROC364 Instruction Manual 2.3.4 Installing a FlashPAC Module Use the following procedure to add a FlashPAC module. This procedure assumes the first-time installation of a FlashPAC module in an out-of-service ROC. For an in-service ROC, refer to the Section 2.5.10, Replacing a FlashPAC, on page 2-16.
  • Page 24 The watchdog timer resets the system when power voltage is not met or exceeds the limitations of the ROC. The two sets of AUX PWR OUT 2 terminals are internally connected in parallel. The output voltage and current supplied by these terminals is specified in Section 2.6, ROC364 Specifications, on page 2-20.
  • Page 25 ROC364 Instruction Manual The switches employed in the auxiliary outputs are solid-state relays and exhibit a voltage drop proportional to the current load, typically in the range of 0 to 2 volts dc. The relays can be controlled automatically using an FST that has been set up to determine the switching conditions. If a FlashPAC is installed, the auxiliary outputs are switched by using the Status parameter of Discrete Output Point Number E3 or E4.

  • Page 26: Troubleshooting And Repair

    ROC364 Instruction Manual 2.5 Troubleshooting and Repair The troubleshooting and repair procedures help identify and replace faulty boards, fuses, and FlashPACs. Refer to Section 3 for troubleshooting I/O modules or Section 4 for troubleshooting and replacing a communications card. Return faulty boards and FlashPACs to your local sales representative for repair or replacement.
  • Page 27 ROC364 Instruction Manual Table 2-2. MCU LED Indicators Indicator Meaning Power is applied to the MCU. MCU does not have power. Possible causes are: ♦ Power not present at power terminals. ♦ Power switch is off if so equipped (older units only).
  • Page 28 Save the FSTs to disk using Utilities > FST Editor > FST > Write function in the FST Editor. Refer to the FST Editor in the applicable configuration software user manual. 2.5.3 Replacing Fuses The types of fuses used for the ROC364 and their rating values are listed in Table 2-3. Table 2-3. ROC Fuses Fuse...
  • Page 29 ROC364 Instruction Manual Remove the battery located at B1 on the top right of the MCU. Measure the voltage of the terminals of the removed battery. If the voltage reading is less than 3.6 volts, the battery must be replaced. Refer to Section 2.5.11, Replacing the Battery, on page 2-18.
  • Page 30 ROC364 Instruction Manual 2.5.8 Performing a Cold Start A Cold Start allows you to reset your ROC based on the selected option. If your ROC is semi-functional, refer to Section 2.5.2, RAM Backup Procedure, on page NOTE: 2-13 before removing power from your ROC.
  • Page 31 ROC364 Instruction Manual To replace a FlashPAC module: When repairing units in a hazardous area, change components only in an area known to be non- hazardous. There is a possibility of losing the ROC configuration and historical data held in RAM while performing the following procedure.

  • Page 32: Replacing The Battery

    ROC364 Instruction Manual 2.5.11 Replacing the Battery This section details how to replace the ROC battery. When repairing units in a hazardous area, change components only in an area known to be non- hazardous. There is a possibility of losing the ROC configuration and historical data held in RAM while performing the following procedure.
  • Page 33 ROC364 Instruction Manual 2.5.12 Removing and Replacing the MCU Assembly Remove and replace the MCU assembly as instructed in the following procedure. When repairing units in a hazardous area, change components only in an area known to be non- hazardous.

  • Page 34: Roc364 Specifications

    ROC364 Instruction Manual 2.6 ROC364 Specifications ROC364 Specifications PROCESSOR MEMORY I/O POWER CONVERTER (OPTIONAL) NEC V25+ running at 8 MHz. Input: 11 to 16 V dc, 15 mA with no load or shorted output. On-Board: 128 KB battery-backed SRAM for data.

  • Page 35: Section 3 - Input And Output Modules

    3-30 3.2 Product Descriptions The I/O modules plug into the ROC364 I/O module rack sockets and accommodate a wide range of process inputs and outputs. The I/O module rack provides sockets for up to 16 I/O modules. Up to 64 I/O modules can be used in any combination of Discrete Inputs, Discrete Outputs, Analog Inputs, Analog Outputs, and Pulse Inputs.
  • Page 36 ROC364 Instruction Manual STATIC SENSITIVE DOC0034C Figure 3-1. Typical I/O Module 3.2.1 Analog Input Loop and Differential Modules The Analog Input Loop (AI Loop) and Analog Input Differential (AI Differential) modules are used for monitoring current loop and voltage output devices. Each AI module uses a scaling resistor for scaling loop current to achieve the proper input voltage.
  • Page 37 ROC364 Instruction Manual 3.2.4 Discrete Input Source and Isolated Modules The Discrete Input Source (DI Source) and Discrete Input Isolated (DI Isolated) modules monitor the status of relays, solid-state switches, or other two-state devices. Each module can accommodate one DI.
  • Page 38 ROC364 Instruction Manual 3.2.8 Slow Pulse Input Source and Isolated Modules The Slow Pulse Input Source (SPI Source) and Slow Pulse Input Isolated (SPI Isolated) modules count the changes in the status of relays, solid-state switches, or other two-state devices. Each module can accommodate one Pulse Input.

  • Page 39: Initial Installation And Setup

    ROC364 Instruction Manual 3.3 Initial Installation and Setup Each I/O module installs in the ROC in the same manner. Any I/O module can be installed into any I/O module socket. To install a module on a ROC that is not in service, perform the following steps. For an in-service ROC, refer to Section 3.5, Troubleshooting and Repair, on page 3-21.
  • Page 40 ROC364 Instruction Manual 3.4.1 Analog Input Loop Module The Analog Input Loop module monitors either loop current or output voltage from field devices. The module provides source power at terminal A for the loop. The AI Loop module operates by measuring the voltage at terminals B and C.
  • Page 41 ROC364 Instruction Manual 3.4.2 Analog Input Differential Module A schematic representation of the field wiring connections to the input circuit of the Analog Input Differential module is shown in Figure 3-4, Figure 3-5, and Figure 3-6. The Analog Input Differential module measures either output voltage (V or loop current (I) from externally-powered devices only.
  • Page 42 ROC364 Instruction Manual For current loop devices, scaling resistor R1 generates a voltage across terminals B and C that is proportional to the loop current. When connecting current loop devices, the value of R1 must be selected such that the 5-volts input limit of the module is not exceeded under maximum operating current conditions.
  • Page 43 ROC364 Instruction Manual For example, a 250-ohms scaling resistor would accommodate either 0 to 20 milliamps, or 4 to 20 milliamps current loop transmitters (the transmitter must be able to operate on 10 volts dc or be powered from another source). This translates to a maximum operating input voltage of 5 volts dc, which is the upper limit of the module.
  • Page 44 ROC364 Instruction Manual R1=0 AO SRC ROC-POWERED VOLTAGE DEVICE LEVEL DOC0159A = OUTPUT VOLTAGE FROM MODULE = 0 TO 5 VDC, 5 mA Figure 3-10. Analog Output Source Module Field Wiring for Voltage Devices 3.4.5 Discrete Input Source Module A schematic representation of the field wiring connections to the input circuit of the Discrete Input Source module displays in Figure 3-11.
  • Page 45 ROC364 Instruction Manual 3.4.6 Discrete Input Isolated Module A schematic representation of the field wiring connections to the input circuit of the Discrete Input Isolated module displays in Figure 3-12. The Discrete Input Isolated module is designed to operate only with discrete devices NOTE: having their own power source, such as “wet”...
  • Page 46 ROC364 Instruction Manual When using the Discrete Output Source module to drive an inductive load, such as a relay coil, a suppression diode should be placed across the input terminals to the load. This protects the module from the reverse Electro-Motive Force (EMF) spike generated when the inductive load is switched off.
  • Page 47 ROC364 Instruction Manual 3.4.9 Discrete Output Relay Module A schematic representation of the field wiring connections to the output circuit of the Discrete Output Relay module displays in Figure 3-15. The Discrete Output Relay module is designed to operate only with discrete devices NOTE: having their own power source.
  • Page 48 ROC364 Instruction Manual A 10-ohms scaling resistor (R1) is supplied by the factory and accommodates a source voltage (V ) of 11 to 30 volts dc and a pulse source with a 50% Duty Cycle. The source voltage is the input voltage to the ROC.
  • Page 49 ROC364 Instruction Manual R1=10 PI ISO 2.2K SELF-POWERED PULSE DEVICE – – TO OPTIMIZE SCALING RESISTOR R1: DOC0149A – 1 R1 = – R – 2.2K R1 + R + 2.2K = LOOP RESISTANCE = 3.4K OHMS I = LOOP CURRENT = 5 mA TYPICAL...
  • Page 50 ROC364 Instruction Manual R1=10 SPI SRC 3.3K ROC-POWERED DISCRETE DEVICE TO OPTIMIZE SCALING RESISTOR R1: DOC0151 V - 1 Modified - 3.3K R1 + Rw + 3.3K = LOOP RESISTANCE = 4.5K OHMS I = LOOP CURRENT = 3 mA...
  • Page 51 ROC364 Instruction Manual 3.4.14 Low-Level Pulse Input Module A schematic representation of the field wiring connections to the input circuit of the Low-Level Pulse Input module is shown in Figure 3-20. The field wiring connects through a separate terminal block that plugs in next to the module allowing replacement of the module without disconnecting field wiring.
  • Page 52 ROC364 Instruction Manual The RTD module input can be calibrated before installing it in the field when short wire NOTE: runs will be used, but if the RTD module is used as a temperature input to a flow calculation, then the RTD should be calibrated at the same time as the pressure inputs.
  • Page 53 ROC364 Instruction Manual 3.4.15.2 Connecting RTD Module Field Wiring The RTD sensor connects to the RTD module with ordinary copper wire. To avoid a loss in accuracy, sensor wires should be equal in length, of the same material, and the same gauge. To avoid possible damage to the RTD module from induced voltages, sensor wires should be kept as short as possible.
  • Page 54 ROC364 Instruction Manual RTDs with four wires normally have the compensation loop separate from the active element loop to increase the accuracy of the probe. Various colors are used for the probe wires. For example, some probes have wire colors of red and white for the RTD element loop and black leads for the compensation loop, while other probes use two red leads for the active element loop and two white leads for the compensation loop.

  • Page 55: Troubleshooting And Repair

    ROC364 Instruction Manual HART MODULE LIMIT ROC-POWERED HART DEVICE 1 MODEM ROC-POWERED DOC0295A HART DEVICE 2 ROC-POWERED ROC-POWERED HART DEVICE HART DEVICE 5 CHANNEL 1, MULTI-DROP MODE CHANNEL 2, POINT-TO-POINT MODE Figure 3-26. Field Wiring for a HART Interface Module 3.5 Troubleshooting and Repair...
  • Page 56 ROC364 Instruction Manual 3.5.1 Analog Input Modules Equipment Required: Multimeter To determine if an Analog Input module is operating properly, its configuration must first be known. Table 3-2 shows typical configuration values for an Analog Input: Table 3-2. Analog Input Module Typical Configuration Values...
  • Page 57 ROC364 Instruction Manual 3.5.2.1 Check AO Current Loop Source Installations Equipment Required: Multimeter Personal Computer running ROCLINK configuration software Taking appropriate precautions, disconnect the field wiring going to the AO module terminations. Connect a multimeter between the B and C terminals of the module and set the multimeter to measure current in milliamps.
  • Page 58 ROC364 Instruction Manual 3.5.3 Discrete Input Source Module Equipment Required: Jumper wire Place a jumper across terminals B and C. The LED on the module should light and the Status as read by ROCLINK configuration software should change to “On.”...
  • Page 59 ROC364 Instruction Manual 3.5.7 Discrete Output Relay Module Equipment Required: Multimeter Personal Computer running ROCLINK configuration software Place the Discrete Output in manual mode (Scanning Disabled) using ROCLINK configuration software. Set the output Status to “Off” and measure the resistance across terminals B and C. A reading of 0 ohms should be obtained.
  • Page 60 ROC364 Instruction Manual To verify low-speed operation of the PI Isolated module: Alternately supply and remove an input voltage across terminals B and C. The module LED should cycle on and off, and the total accumulated count (Accumulated Pulses) should increase.
  • Page 61 ROC364 Instruction Manual 3.5.12 RTD Input Module The RTD module is similar in operation to an AI module and uses the same troubleshooting and repair procedures. The RTD module can accommodate two-wire, three-wire, or four-wire RTDs. If two-wire RTDs are used, terminals B and C must be connected together. If any of the input wires are broken or not connected, ROCLINK configuration software indicates the “Raw A/D Input”...

  • Page 62: Removal, Addition, And Replacement Procedures

    ROC364 Instruction Manual 3.5.13.2 Verify HART Communications Equipment Required: Dual-trace Oscilloscope In this test, the HART module and the ROC act as the host and transmit a polling request to each HART device. When polled, the HART device responds. Use the oscilloscope to observe the activity on the two HART communication channels.
  • Page 63 ROC364 Instruction Manual For example, if you have AI modules installed in slots A7, A10, and A11, adding another AI module in slot A8 changes the point numbers of the Analog Inputs for modules in slots A10 and A11. If one or more FSTs, or higher level points, such as a PID loop or AGA Flow, have been configured in the ROC, be sure to reconfigure them according to the changes in I/O modules.

  • Page 64: I/O Module Specifications

    ROC364 Instruction Manual If you changed the configuration, including the history database, FSTs, and ROC Displays, save them to disk. Refer to Section 2, Troubleshooting and Repair, for more information on performing saves. 3.7 I/O Module Specifications The specifications for the various I/O modules are given in this section.
  • Page 65 ROC364 Instruction Manual Analog Input Modules—Loop and Differential Common Specifications SCALING RESISTOR CASE 250 Ω (supplied) for 0 to 20 mA full scale. 100 Ω Solvent-resistant thermoplastic polyester, meets for 0 to 50 mA (externally-powered only). UL94V-0. Dimensions are 15 mm D by 32 mm H by 43 mm RESOLUTION W (0.60 in.
  • Page 66 ROC364 Instruction Manual 3.7.2 Analog Input Source Module Analog Input Source Specifications FIELD WIRING TERMINALS FILTER A: 10 V dc. Single pole, low-pass, 40 ms time constant. B: Analog Input. CONVERSION TIME C: Common. 30 µs typical. INPUT VIBRATION Type: Single-ended, voltage sense; can be current 20 Gs peak or 0.06 in.
  • Page 67 ROC364 Instruction Manual Analog Output Source Specifications (Continued) CURRENT OUTPUT VIBRATION Type: Current loop. 20 Gs peak or 0.06 in. double amplitude, 10 to 2,000 Hz, per MIL-STD-202 method 204 Range: 4 to 20 mA with 0 to 22 mA overranging, condition F.
  • Page 68 ROC364 Instruction Manual Discrete Input Isolated Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENTS A: Not used. 4.9 to 5.1 V dc, 1 mA maximum (supplied by ROC). B: Positive Discrete Input. INPUT ISOLATION C: Negative Discrete Input. Isolation: 100 Ω minimum, input to output, and input or output to case.
  • Page 69 ROC364 Instruction Manual 3.7.5 Discrete Output Modules—Source and Isolated Discrete Output Source Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENTS A: Not used. Output Source: 11 to 30 V dc, 57 mA maximum B: Positive (to field device). from ROC power supply.
  • Page 70 ROC364 Instruction Manual 3.7.6 Discrete Output Relay Module Discrete Output Relay Module Specifications FIELD WIRING TERMINALS VIBRATION A: Normally-open contacts. 21 G peak or 0.06" double amplitude, 10-2000 Hz B: Common. per MIL-Std-202, Method 204, Condition F. C: Normally-closed contacts.
  • Page 71 ROC364 Instruction Manual Pulse Input Isolated Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENTS A: Not used. 4.9 to 5.1 V dc, 2 mA maximum (supplied by ROC). B: Positive Pulse Input. INPUT ISOLATION C: Negative Pulse Input. Isolation: 100 MΩ minimum, input to output, and INPUT input or output to case.
  • Page 72 ROC364 Instruction Manual 3.7.8 Slow Pulse Input Modules—Source and Isolated Slow Pulse Input Source Module Specifications MODULE RACK TERMINALS POWER REQUIREMENTS A: Not used. Source Input: 11 to 30 V dc, 9 mA maximum from B: Input/source voltage. ROC power supply.
  • Page 73 ROC364 Instruction Manual 3.7.9 Pulse Input Module—Low Level Pulse Input Module—Low Level Specifications MODULE RACK TERMINALS VIBRATION A: Not used. 20 Gs peak or 0.06 in. double amplitude, 10 to 2,000 Hz, per MIL-STD-202 method 204 B: Positive Pulse Input.
  • Page 74 ROC364 Instruction Manual 3.7.10 Resistance Temperature Detector (RTD) Input Module Resistance Temperature Detector (RTD) Input Module Specifications FIELD WIRING TERMINALS POWER REQUIREMENT A: RTD “Red” Input. 11 to 30 V dc, 38 mA maximum, supplied by ROC power supply. B: RTD “White” Input.
  • Page 75 ROC364 Instruction Manual 3.7.11 HART Interface Module HART Interface Module Specifications FIELD WIRING TERMINALS VIBRATION A: Loop Power (+T). 20 Gs peak or 0.06 in. double amplitude, B: Channel 1 (CH1). 10 to 2,000 Hz, per MIL-STD-202 method 204 C: Channel 2 (CH2).

  • Page 76: Section 4 - Communications Cards

    The communications cards provide communications between the ROC and a host system or external devices. The ROC364 provide room for two communications cards. The communications cards install directly onto the Master Controller Unit (MCU) board and activate communications ports (COM1 and COM2) when installed.
  • Page 77 ROC364 Instruction Manual 4.2.1 EIA-232 (RS-232) Serial Communications Card The EIA-232 (RS-232) communications cards meet all EIA-232 (RS-232) specifications for single- ended, asynchronous data transmission over distances of up to 15.24 meters (50 feet). The EIA-232 (RS- 232) communications cards provide transmit, receive, and modem control signals. Normally, not all of the control signals are used for any single application.
  • Page 78 ROC364 Instruction Manual Table 4-1. Communications Card LED Indicators Status and Activity The RXD receive data LED blinks when data is being received. The LED is on for a space and off for a mark. The TXD transmit data LED blinks when data is being transmitted. The LED is on for a space and off for a mark.
  • Page 79 ROC364 Instruction Manual 4.2.2 EIA-422/485 (RS-422/485) Serial Communications Card The EIA-422/485 (RS-422/485) communication cards meet all EIA-422/485 (RS-422/485) specifications for differential, asynchronous transmission of data over distances of up to 1220 meters (4000 feet). The EIA-422 (RS-422) drivers are designed for party-line applications where one driver is connected to, and transmits on, a bus with up to ten receivers.
  • Page 80 ROC364 Instruction Manual 4.2.3 Radio Modem Communications Card The Radio Modem Communications Card sends and receives full-duplex or half-duplex, asynchronous Frequency Shift Keyed (FSK) signals to the audio circuit of a two-way radio. The modem incorporates a solid-state push-to-talk (PTT) switch for keying the radio transmitter. Refer to Figure 4-3.
  • Page 81 ROC364 Instruction Manual 4.2.4 Leased-Line Modem Communications Card The Leased-Line Modem Communications Card is a 202T modem that is FCC part 68 tested for use with leased-line or private-line telephone networks. Refer to Figure 4-4. Two- or four-wire, half- or full- duplex asynchronous operation is supported at a software selectable 300, 600, and 1200 baud to Bell and CCITT standards.
  • Page 82 ROC364 Instruction Manual 4.2.5 Dial-Up Modem Communications Card The Dial-up Modem Communications Card supports V.22 bis / 2400 baud communications with auto- answer/auto-dial features. The modem card is FCC part 68 approved for use with public-switched telephone networks (PSTNs). The FCC label on the card provides the FCC registration number and the ringer equivalent.

  • Page 83: Installing Communications Cards

    ROC364 Instruction Manual LED Indicators COM PORTS DOC0245A Figure 4-6. Dial-up Modem Communications Card – Old 4.3 Installing Communications Cards The following procedures assume the first-time installation of a communications card in a ROC that is currently not in service. For units currently in service, refer to the procedures in Section 4.5, Troubleshooting and Repair, on page 4-19.
  • Page 84 ROC364 Instruction Manual Remove the plastic plug on the right-hand side of the ROC chassis and install the phone jack in the hole. Figure 4-7 shows the jack location. Connect the jack cable to the P2 connector on the communications card. You may discard the square shim that accompanies the installation kit.
  • Page 85 ROC364 Instruction Manual COM 2 RAD/PL COM 1 RAD/PL 2ND DECAL 1ST DECAL DOC0118A Figure 4-8. Location of LED Identification Decal 4.3.1 Setting Modem Card Jumpers The Leased-Line and Radio Modem Communications Cards make use of jumpers to select certain operational modes.
  • Page 86 ROC364 Instruction Manual 4.3.2 Setting Modem Card Attenuation Levels The output attenuation of the Leased-Line and Radio Modem Communications Cards is set by default to 0 dB (no attenuation). This level can be reduced, as necessary, to better match the modem output to the line or radio.

  • Page 87: Connecting Communications Cards To Wiring

    ROC364 Instruction Manual 4.4 Connecting Communications Cards to Wiring Signal wiring connections to the communications cards are made through the communications port connector and through TELCO (RJ11) connectors supplied with certain modem cards. These connections are summarized in Table 4-4 and detailed in Sections 4.4.1 to 4.4.5.
  • Page 88 ROC364 Instruction Manual 4.4.1 EIA-232 (RS-232) Communications Card Wiring Figure 4-10 shows the relationship between the EIA-232 (RS-232) signals and pin numbers for the communications port 9-pin connector. Figure 4-10. EIA-232 (RS-232) Wiring Schematic 4-13 Communications Cards Rev Jun/05...
  • Page 89 ROC364 Instruction Manual 4.4.2 EIA-422/485 (RS-422 / 485) Communications Card Wiring Figure 4-11 shows the signals and pin numbers for the communications port 9-pin connector. Wiring should be twisted pair cable, one pair for transmitting and one pair for receiving. Jumper P4 controls the RTS transmit functions in the EIA-422 (RS-422) mode.
  • Page 90 ROC364 Instruction Manual 4.4.3 Radio Modem Communications Card Wiring The following signal lines are used with most radios: Comm Port Signal Line Description Receive data Transmit data ROC power supply ground PTT+ Push-to-talk switch Push-to-talk return PTT– (may be grounded) The radio modem uses jumper P6 to determine the use of the PTT return line.
  • Page 91 ROC364 Instruction Manual The following signals, used only for monitoring or connecting to an analyzer, are available at connector P7 located at the bottom edge of the card. These signals are normally not active. To activate the signals, SHUTDOWN (pin 8) must be grounded by connecting a jumper between pin 8 and pin 2. All unused signals can be left un-terminated.
  • Page 92 ROC364 Instruction Manual Figure 4-14. Leased-Line Modem Wiring Schematic The 9-pin COM1 and COM2 connectors can be used to connect the modem to a private line. This connector is not FCC approved and cannot be used for leased-line operation. Present signals are:...
  • Page 93 ROC364 Instruction Manual 4.4.5 Dial-Up Modem Communications Card Wiring The Dial-Up Modem Card interfaces to a PSTN line through the RJ11 jack with two wires. The following signals, used only for monitoring or connecting to an analyzer to COM1 or COM2. These signals are normally not active.

  • Page 94: Troubleshooting And Repair

    ROC364 Instruction Manual The following signal lines (output only) are available at the COMM port for wiring to an analyzer or monitor: COMM Port Signal Line Description Speaker Receive data Transmit data Data terminal ready Common Ring indicator SHUTDOWN Disable signal lines...
  • Page 95 ROC364 Instruction Manual If the 6-pin header connector is still in socket J9 on the main board (just below the bottom edge of the communications card), remove it. If the communications card is a Dial-up or Leased-Line Modem Card, unplug the phone jack cable from board connector P2.

  • Page 96: Communication Card Specifications

    ROC364 Instruction Manual 4.6 Communication Card Specifications The following tables list the specifications for each type of communications card. Serial Communication Cards Specifications EIA-232D (RS-232) CARD LED INDICATORS Meets EIA-232 (RS-232) standard for single-ended Individual LEDs for RXD, TXD, DTR, DCD, CTS,...
  • Page 97 ROC364 Instruction Manual Leased-Line Modem Specifications OPERATION OPERATION (CONTINUED) Certification: FCC Part 68 tested. Mode: Full or half-duplex on 2-wire or 4-wire private channel (compatible with Bell 202T). Connector: RJ11 type. Data Rate: Up to 1200 baud asynchronous POWER REQUIREMENTS (software selectable).
  • Page 98 ROC364 Instruction Manual Dial-Up Modem Specifications OPERATION POWER REQUIREMENTS Mode: Full-duplex 2-wire for Dial-up PSTN (Bell 4.5 to 5.5 V dc, 0.4 W maximum (supplied by 212 compatible). ROC). Data Rate: Up to 14.4K bps asynchronous ENVIRONMENTAL (software selectable). Operating Temperature: –40 to 75ºC Parity: None, odd, or even (software selectable).

  • Page 99: Section 5 - I/O Converter Card

    ROC364 Instruction Manual SECTION 5 – I/O CONVERTER CARD 5.1 Scope This section describes the I/O Power Converter Card optionally available for the ROC364 Remote Operations Controller. Topics covered include: Section Page 5.2 Product Description 5.3 Initial Installation and Setup 5.4 Troubleshooting and Repair...
  • Page 100 ROC364 Instruction Manual Table 5-1. I/O Converter Card Requirements MCU Input Are 4 to 20 MA Is a Converter Voltage (V dc) Loops Used? Needed? 5.3 Initial Installation and Setup The following procedure assumes a first-time installation. For units currently in service, certain precautions must be taken to assure that data is not lost and equipment is not damaged.
  • Page 101 ROC364 Instruction Manual 5.4 Troubleshooting and Repair The troubleshooting and repair procedures are designed to help identify and replace faulty cards. Faulty I/O Converter Cards should be returned to your local sales representative for repair or replacement. First indications of possible I/O Converter Card failure are when: ♦...

  • Page 102: I/O Converter Card Specification

    5.5 I/O Converter Card Specification I/O Converter Card Specifications INPUT ENVIRONMENTAL 11 to 16 V dc, 15 mA with no load or shorted Same as the ROC364 unit. See the specifications in output. Section 2.6. OUTPUT DIMENSIONS 22 to 24 V dc, up to 0.6 A for transmitter power.

  • Page 103: Appendix A - Lightning Protection Module

    ROC364 Instruction Manual APPENDIX A – LIGHTNING PROTECTION MODULE This appendix describes the Lightning Protection Module (LPM) used with the Remote Operations Controller. This section contains the following information: Section Page A.1 Product Description A.2 Connecting the LPM to Wiring A.3 Troubleshooting and Repair...

  • Page 104: A.2 Connecting The Lpm To Wiring

    ROC364 Instruction Manual A.2 Connecting the LPM to Wiring There is a one-to-one correspondence between the LPM terminals and the terminals of the I/O channel being protected. If you are connecting field wiring to the LPM, refer to the I/O wiring information in this instruction manual.

  • Page 105: A.4 Lightning Protection Module Specifications

    ROC364 Instruction Manual A.4 Lightning Protection Module Specifications Lightning Protection Module Specifications ELECTRICAL CASE Material: ABS polycarbonate thermoplastic. Series Resistance: 10 Ω from input to output, each terminal. Dimensions: 17 mm H by 21 mm W by 40 mm D DC Clamping Voltage: 72 to 108 V dc.

  • Page 106: Appendix B - Local Display Panel

    ROC364 Instruction Manual APPENDIX B – LOCAL DISPLAY PANEL This appendix describes the Local Display Panel used with the ROC300-Series Remote Operations Controller (ROC). This section contains the following information: Section Page B.1 Product Description B.2 Installation B.3 Operation B.4 Troubleshooting and Repair B-22 B.5 Local Display Panel Specifications...

  • Page 107: B.2 Installation

    ROC364 Instruction Manual B.2 Installation A kit is available for field installations of the Local Display Panel (LDP) in a ROC enclosure that contains cutouts for the LDP in the door. The Local Display Panel kits come in three colors: ♦...
  • Page 108 ROC364 Instruction Manual Use the following steps to install the Local Display Panel. Inspect the kit and verify that there are no missing parts. Remove the cutout cover from the enclosure door. Place two small drops of Room Temperature Vulcanizing (RTV) sealant on the LCD sub- assembly to hold the window in place while installing the panel.

  • Page 109: B.3 Operation

    ROC364 Instruction Manual INSIDE VIEW HOLES OF DOOR LCD SUB-ASSEMBLY WITH WINDOW Figure B-5. LCD RTV Installation Position the LCD sub-assembly over the door studs and press into place. Fasten the LCD sub-assembly with the hex nuts provided in the kit.
  • Page 110 ROC364 Instruction Manual Table B-1. Function Key Labels and Descriptions Label Description Moves the cursor up one line at a time. “>” indicates the current selection. Press and hold for 5 to 10 seconds on ROC power-up, to perform a Cold Start.
  • Page 111 ROC364 Instruction Manual To return to the previous menu, press MENU. To return to the Main Menu, press MENU until the Main Menu displays. B.3.3 Main Menu Display The Main Menu provides eight menu selections. Table B-2 describes the menu items. The subsequent subsections provide detail for the various Main Menu selections.
  • Page 112 ROC364 Instruction Manual Table B-3. I/O Menu Point Types Parameter Description Provides a point display for each configured Discrete Input. Provides a point display for each configured Discrete Output. Provides a point display for each configured Analog Input. Provides a point display for each configured Analog Output.
  • Page 113 ROC364 Instruction Manual B.3.4.2 Discrete Output Point Display Each selected Discrete Output returns a display similar to the one in Figure B-9. Press HOLD to stop the display from automatically scrolling between points. Press SCAN to begin automatically scanning. To return to the I/O menu display, press MENU.
  • Page 114 ROC364 Instruction Manual Table B-6. Analog Input Point Display Parameters Parameter Description AI Tag 10-character identifier Tag for the Analog Input. Units 10-character unit of measurement identifier for the EU Value assigned to the Analog Input. Value in engineering units (EU).
  • Page 115 ROC364 Instruction Manual B.3.4.4 Analog Output Point Display Each selected Analog Output returns a display similar to the one in Figure B-12. Press HOLD to stop the display from automatically scrolling between points. Press SCAN to begin automatically scanning. To return to the I/O menu display, press MENU.
  • Page 116 ROC364 Instruction Manual B.3.4.5 Pulse Input Point Display The display shown in Figure B-14 is a typical display for each Pulse Input point. Press HOLD to stop the display from automatically scrolling between points. Press SCAN to begin automatically scanning.
  • Page 117 Description Version Name Part number of the firmware in the ROC. Version of the firmware in the ROC. Emerson as creator of the firmware and the type of ROC. Time Created Time and date that the firmware was created. B-12...
  • Page 118 ROC364 Instruction Manual B.3.5.3 SYS Parameter Display 3 Figure B-18 shows a typical SYS Parameter Display 3. This display informs you which input/output types are in manual mode (Scanning Disabled). MANUAL MODE AT: MANUAL MODE AT: ALL CLEAR AIS AOS DIS DOS PIS...
  • Page 119 ROC364 Instruction Manual B.3.6 DB Menu Display Selecting DB from the Main Menu returns a display similar to the one in Figure B-20. The Local Display Panel function keys NEXT and PREV provide access to historical database points for the base RAM area.
  • Page 120 ROC364 Instruction Manual >VIEW Plate Change DOWN ENTER MENU Figure B-22. AGA Menu Display B.3.7.1 AGA Point Display 1 – View Figure B-23 shows a typical View AGA Point Display 1. Table B-14 describes the parameters shown on an AGA Point Display 1.
  • Page 121 ROC364 Instruction Manual B.3.7.2 AGA Point Display 2 – View Figure B-25 shows a typical View AGA Point Display 2. The AGA Point Display 2 shows the parameters listed in Table B-15. AGA2 CUR TTL 622.07 Y’DAY TTL 988.24 SCAN...
  • Page 122 ROC364 Instruction Manual B.3.7.4 Entering Plate Change Information Select Plate Change from the AGA Menu Display to change the orifice plate size. After selecting, Plate Change, the Enter Password display appears. B.3.7.4.1 Entering a Password Certain requests return the Password display shown in Figure B-27. The Password prompt appears as four asterisks (*).
  • Page 123 ROC364 Instruction Manual Upon selecting an AGA point, a display appears (Figure B-29) showing the amount of time allowed before the LDP reverts to a view-only mode. Time Out (Minutes) EDIT ENTER Figure B-29. Time Out Display To edit the Time Out value, press EDIT.
  • Page 124 ROC364 Instruction Manual B.3.8 PID Point Displays The display shown in Figure B-33 is a typical display for each PID (Proportional, Integral, and Derivative) point. Press HOLD to stop the display from automatically scrolling between displays. Press SCAN to place the display in HOLD. To return to the Main Menu display, press MENU. The PID point display shows the parameters listed in Table B-17.
  • Page 125 ROC364 Instruction Manual B.3.10 MSG Point Displays Each selected FST message point returns a display similar to the one in Figure B-35. Press HOLD to stop the display from automatically scrolling between displays. Press SCAN to place the display in HOLD.
  • Page 126 ROC364 Instruction Manual B.3.11.1 Viewing LCD Parameter Values Each LCD Point Display consists of three lines, with a 10-character text field and the value of a point parameter. There are eight LCD Point Displays. Refer to Figure B-37. If the ROC has the LCD program loaded, select VIEW from the LCD Menu Display. Press HOLD to stop the display from automatically scrolling between displays.

  • Page 127: B.4 Troubleshooting And Repair

    ROC364 Instruction Manual Press NEXT to continue editing the value. Press INC (increase) until the correct number appears and press NEXT to move right. Continue this procedure for each number. Press ENTER to change the value. Select Yes or NO to save to EEPROM (permanent Internal Config Flash memory). If you press YES, an entry is generated in the Event Log and LCD menu displays.

  • Page 128: B.5 Local Display Panel Specifications

    ROC364 Instruction Manual B.5 Local Display Panel Specifications Local Display Panel Specifications DISPLAY ENVIRONMENTAL 4-line by 20-character LCD. Display size 25.4 mm Meets the Environmental specifications of the by 76.2 mm (1 in. by 3 in.). Temperature ROC, in which the module is installed, including compensated for constant contrast.

  • Page 129: Appendix C - I/O Simulation

    ROC364 Instruction Manual APPENDIX C – I/O SIMULATION This appendix describes how to simulate inputs and outputs to verify the proper operation of the ROC. The simulations make use of the various types of I/O modules available for the ROC.

  • Page 130: Analog Outputs To Ammeter Or Voltmeter

    ROC364 Instruction Manual The Analog Output Source module simulates a transmitter feeding a 0 to 5 volts dc signal to an Analog Input Differential module. Figure C-3 shows wiring connections. R1=OPEN R1=0 AO SRC AI DIFF 200K 200K LEVEL DOC0177A Figure C-3.

  • Page 131: Discrete Outputs To Discrete Inputs

    ROC364 Instruction Manual C.3 Discrete Outputs to Discrete Inputs Figure C-6 shows how to use a Discrete Output Source module to simulate a device transmitting a discrete voltage level to a Discrete Input Isolated module. Figure C-6. DO Source Module to DI Isolated Module Figure C-7 shows how to use a Discrete Output Isolated module to simulate relay contacts to a Discrete Input Source module.

  • Page 132: Potentiometer To Analog Inputs

    ROC364 Instruction Manual Figure C-9 shows how to use a Discrete Output Isolated module simulate a relay contact to a Pulse Input Source module. 1 Amp R1=10 DO ISO PI SRC 2.2K – CONTROL DOC0184A Figure C-9. DO Isolated Module to PI Source Module C.5 Potentiometer to Analog Inputs...

  • Page 133: Switch To Discrete Inputs

    ROC364 Instruction Manual C.6 Switch to Discrete Inputs Figure C-12 shows how to use a switch and power source to simulate a device transmitting a discrete voltage level to a Discrete Input Isolated module. R1=10 DI ISO SWITCH 3.3K AUX PWR OUT 1 –...
  • Page 134 ROC364 Instruction Manual Figure C-15 shows how to use a switch and power supply to simulate a device transmitting discrete pulses (turbine meter) to a Pulse Input Isolated module. R1=10 PI SRC 2.2K SWITCH DOC0189A Figure C-15. Switch to PI Isolated Module...

  • Page 135: Glossary

    “on-board” I/O. CMOS – Complementary Metal Oxide Semiconductor. Type of microprocessor used by the ROC. COM1 / COM2 – Port on the ROC364 that may be used for host communications, depending on the installed communications card. Configuration – Typically, the software setup of a device, such as a ROC, that can often be defined and changed by the user.
  • Page 136 FSK – Frequency Shift Keyed. FST – Function Sequence Table, a type of program that can be written by the user in a high-level language designed by Emerson Process Management. GFA – Ground fault analysis. GND – Electrical ground, such as used by the ROC power supply.
  • Page 137 ROC364 Instruction Manual I, J I/O – Input/Output. I/O Module – Module that plugs into an I/O slot on a ROC to provide an I/O channel. IEC – Industrial Electrical Code. Kbytes – Kilobytes. kHz – Kilohertz. LCD – Liquid Crystal Display. Display only device used for reading data.
  • Page 138 ROC364 Instruction Manual Ohms – Units of electrical resistance. On-line – Accomplished while connected (by a communications link) to the target device. For example, on-line configuration is configuring a ROC while connected to it, so that current parameter values are viewed and new values can be loaded immediately.
  • Page 139 ROC364 Instruction Manual RI – Ring Indicator modem communications signal. ROC – Remote Operations Controller, Emerson Process Management’s microprocessor-based unit that provides remote monitoring and control. ROCLINK and ROCLINK 800 – Configuration software used to configure ROC units to gather data, as well as most other functions.

  • Page 140: Index

    ROC364 Instruction Manual INDEX Backplate ..............2-6 Dimensions .............. 2-6 Numerics Installation ............... 2-6 12-volt power..............1-5 Mounting the I/O Module Rack....... 2-8 24-volt power..............1-5 Mounting the MCU to a Backplate......2-7 Backup Procedure RAM ..............2-13 Battery AGA ................B-6 Replacing ...............
  • Page 141 DC Power Source ............2-10 DC PWR IN +/– ............2-10 FCC Information ............1-2 DCD................4-3 Figure 1-1. ROC364 Controller Components Mounted on DEC ................B-5 Backplate ..............1-3 Diagnostic Inputs ............2-4 Figure 2-1. Master Controller Unit ......2-2 Dial-up Modem Communications Cards ......
  • Page 142 ROC364 Instruction Manual Figure 3-23. RTD Input Module Field Wiring for Three- Figure B-29. Time Out Display .........B-18 Wire RTDs ..............3-19 Figure B-30. Time Remaining Display......B-18 Figure 3-24. RTD Input Module Field Wiring for Four- Figure B-31. Plate Size Editing Displays ....B-18 Wire RTD With Compensation Loop......
  • Page 143 ROC364 Instruction Manual Groups A, B, C, D............1-5 P7 ..............4-16, 4-17 HART Interface Module ..........3-4 LCD ................B-6 Troubleshooting ............. 3-27 Point Displays............B-20 Wiring ..............3-20 Leased-Line Modem Communications Card ....4-6 Hazardous Location Approval ........1-5 Attenuation Levels..........4-11 Highway Addressable Remote Transducer - HART ..
  • Page 144 Potentiometer Input to AI Differential Module.....C-4 ROC364 Potentiometer Input to AI Loop Module.......C-4 Product Overview ............ 1-2 Power ROC364 Specifications ..........2-20 Installation Requirements ........1-5 ROCLINK 800 Configuration Software User Manual LED................ 2-13 (Form A6121) ............. 1-1 Power Consumption Calculations......1-7 ROCLINK for Windows Configuration Software User Radio Requirements..........
  • Page 145 Lightning Protection Module........A-2 Low-Level Pulse Input........... 3-26 Performing a Cold Start ......... 2-16 Performing a Reset ..........2-16 Table 1-1. Power Consumption of the ROC364 and Pulse Inputs............3-25 Powered Devices............1-8 Removing and Replacing the MCU Assembly ..2-19 Table 1-2.
  • Page 146 ROC364 Instruction Manual Dial-up Modem Communications Cards ....4-18 Discrete Input Isolated ..........3-11 Verifying RAM ............2-15 Discrete Input Source ..........3-10 Verifying the ROC can Communicate with the PC..2-15 Discrete Output Isolated ........3-12 Version ................B-12 Discrete Output Relay..........3-13 Version Name .............B-12...

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