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Symphony Plus S+ Control: NTDI01 Digital I/O Termination Unit User Manual Symphony Plus

Symphony Plus

S+ Control: NTDI01 Digital I/O Termination Unit User Manual

Symphony Plus

Symphony Plus S+ Control: NTDI01 Digital I/O Termination Unit User Manual Symphony Plus

NOTICE

This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that may be generally relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document support all of the features of the described or referenced standard. In order to determine the specific features supported by a particular ABB product, the reader should consult the product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB products described in this document.

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product has been designed to meet the requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC. See the Spec- ifications section in this manual for status of agency certifications

TRADEMARKS

All rights to copyrights, registered trademarks, and trademarks reside with their respective owners. Copyright © 2011-2012 ABB. All rights reserved.

Release:

May 2012

Document number:

2VAA001693

Preface

The NTDI01 Digital I/O Termination Unit is a Harmony rack I/O device that is part of the Symphony Enterprise Management and Control System. It provides a signal path between 16 I/O signals and the following I/O modules:

• Analog output module (ASO11)

• Digital input modules (DSI12, DSI13, DSI14, and DSI15)

• Pulse input module (DSM04)

• Digital output modules (DSO14 and DSO15)

• Frequency counter module (FCS01)

• Hydraulic servo module (HSS03/HSS05)

This user manual explains the NTDI01 termination unit specifications and operation. It details the procedures necessary to complete setup, installation, maintenance, repair, and replacement of the termination unit.

NOTE: The NTDI01 termination unit is fully compatible with existing INFI 90 OPEN Strategic Enterprise Management Systems, as well as Symphony Plus Rack-based systems.

Support Services

ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals. Parts without a description must be ordered from the nearest sales or service office. Recommended spare parts lists, including prices are available through the nearest sales or service office.

ABB has modern training facilities available for training your personnel. On-site training is also available. Contact your nearest ABB sales office for specific information and scheduling.

Additional copies of this instruction, or other instructions, can be obtained from the nearest ABB sales office at a reasonable charge.

Trademarks and Registrations

Registrations and trademarks used in this document include:

INFI 90®

Registered trademark of ABB.

Symphony™ Plus

Trademark of ABB S.p.A.

TABLE OF CONTENTS

TABLE OF CONTENTS

Safety Summary

1

About This Book

3

Document Conventions

3

Information and Tip Icons

3

1. Introduction

1-1

1.1 Overview

1-1

1.2 Description

1-1

1.3 Mounting Hardware

1-2

1.4 Intended User

1-2

1.5 User Manual Content

1-2

1.6 How to Use this Manual

1-2

1.7 Document

Conventions

1-3

1.8 Reference

Documents

1-3

1.9 Related Nomenclature

1-3

1.10 Specifications

1-3

2. Installation

2-1

2.1 Introduction

 

2-1

2.2 Special Handling

2-1

2.3 Unpacking and Inspection

2-1

2.4 Setup/Physical

Installation

2-1

2.4.1 Fuse Installation

2-1

2.4.2 Dipshunt Configuration

2-1

2.5 Connector P1 Signal Paths

2-3

2.6 Termination Unit Installation

2-4

2.6.1 Mounting

 

2-4

2.6.2 Cable Connection

2-5

2.6.3 Power Wiring

2-5

2.6.4 Terminal Block Wiring

2-6

2.7

Installation

Complete

2-6

3. Maintenance

3-1

3.1 Introduction

3-1

3.2 Preventive Maintenance Schedule

3-1

3.3 Equipment and Tools Required

3-1

3.4 Preventive Maintenance Procedures

3-1

3.4.1

Printed Circuit Board Cleaning

3-2

TABLE OF CONTENTS

3.4.2 Checking Connections

4. Repair and Replacement

3-2

4-1

4.1 Introduction

4-1

4.2 Fuse Replacement

4-1

4.3 Termination Unit Replacement

4-1

LIST OF TABLES

LIST OF TABLES

Table 1-1

Reference Documents

1-3

Table 1-2

Related

Nomenclature

1-3

Table 1-3

NTDI01 Termination Unit Specifications

1-4

Table 2-1

Fuse Ratings

2-2

Table 2-2

Connector P1 Signal Paths

2-3

Table 2-3

Cable Connections for I/O Signals

2-4

Table 3-1

Preventive Maintenance Schedule

3-1

Table 4-1

Parts List

4-1

LIST OF TABLES

LIST OF FIGURES

LIST OF FIGURES

Figure 1-1

Harmony Rack I/O Architecture

1-1

Figure 1-2

Mounting Hardware

1-2

Figure 2-1 Termination Unit Layout

2-2

Figure 2-2

Point Configuration Circuit

2-2

Figure 2-3 Termination Unit Configuration Circuit

2-3

Figure 2-4

Termination Unit Installation

2-5

Figure 2-5

Cable Connection

2-5

LIST OF FIGURES

Safety Summary

The following table categorizes the various safety precautions to be followed when using the NTDI01 digital I/O termination unit:

Safety Precaution

Description

 

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precautions as described in section 2- Installation

Devices labeled with this symbol require special handling precautions as described in section 2- Installation of this user manual.

GENERAL WARNINGS

Equipment Environment All components, whether in transportation, operation or storage, must be in a non-corrosive environment.

Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing

SPECIFIC WARNINGS

Verify the main power, field power, and power entry panel circuit breakers/switches are turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, retrofit, upgrade, or wiring procedures are complete. (Refer to sub-section 2.6.3- Power Wiring of this user manual, where this specific warning statement is applicable)

Never clean electrical parts or components with live power present. Doing so exposes you to an electrical shock hazard. (Refer to sub-section 3.4.1- Printed Circuit Board Cleaning of this user manual, where this specific warning statement is applicable)

Wear eye protection whenever working with cleaning solvents.When removing solvents from printed circuit boards using compressed air, injury to the eyes could result from splashing solvent as it is removed from the printed circuit board. (Refer to sub-section 3.4.1- Printed Circuit Board Cleaning of this user manual, where this specific warning statement is applicable)

There are exposed AC and DC connections inside the cabinet. These exposed electrical connections present a shock hazard that can cause injury or death. (Refer to sub-section 3.4.2- Checking Connections of this user manual, where this specific warning statement is applicable)

If input or output circuits are a shock hazard after disconnecting system power at the power entry panel, then the door of the cabinet containing these externally powered circuits must be marked with a warning stating that multiple power sources exist. (Refer to sub- section 3.4.2- Checking Connections of this user manual, where this specific warning statement is applicable)

Safety Precaution

Description

SPECIFIC CAUTIONS

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module. Refer to sub- sections 2.6.2- Cable Connection and 4.3- Termination Unit Replacement of this user manual, where this specific caution statement is applicable).

About This Book

About This Book

Document Conventions

Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key sequences, prompts, messages, menu items, screen elements, etc.

Information and Tip Icons

This publication includes Information and Notes where appropriate to point out important information or useful hints to the reader. The corresponding sections should be interpreted as follows:

Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a
Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a
Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a

Information alerts the reader to pertinent facts and conditions

Warning indicates the presence of a hazard which could result in a plant shutdown.:

Caution indicates the presence of a hazard which could result in personal or hardware module damage.

NOTE

Note indicates advice on, for example, how to design your project or how to use a certain function

About This Book

1. Introduction

1.

Introduction

1.1 Overview

Overview

The NTDI01 Digital I/O Termination Unit is a Harmony rack I/O device that is part of the Symphony Enterprise Management and Control System. It provides a signal path for 16 input signals to the following I/O modules. The inputs are used by the controller to monitor and control a process.

• Analog output module (ASO11).

• Digital input module (DSI12, DSI13, DSI14, and DSI15).

• Pulse input module (DSM04).

• Digital output module (DSO14 and DSO15).

• Frequency counter module (FCS01).

• Hydraulic servo module (HSS03/HSS05).

The following figure (Figure 1-1) shows the Harmony rack I/O architecture. A Harmony area controller and the Harmony rack controllers can use the rack I/O module and termination units for I/O interface.

rack I/O module and termination units for I/O interface. Figure 1-1 Harmony Rack I/O Architecture 1.2

Figure 1-1 Harmony Rack I/O Architecture

1.2 Description

The NTDI01 termination unit is a seven-by-seven inch square printed circuit board. The board contains:

• Two fuses.

• 17 dipshunts.

• Four terminal strips.

• One cable socket.

• Two power source Faston connectors.

• One system common Faston connector.

Mounting Hardware

1.3 Mounting Hardware

1. Introduction

Harmony termination units mount in standard ABB Automation enclosures (CAB-01, CAB-04, CAB-12). An NFTP01 Field Termination Panel is used for termination unit mounting (Figure 1-2). The panel attaches to the side rails in standard 438- millimeter (19-inch) enclosures.

side rails in standard 438- millimeter (19-inch) enclosures. Figure 1-2 Mounting Hardware 1.4 Intended User Personnel

Figure 1-2 Mounting Hardware

1.4 Intended User

Personnel installing, operating, or maintaining the NTDI01 termination unit should read this user manaul before performing any installation, operation, or maintenance procedures. Installation requires an engineer or technician with experience in handling electronic circuitry. Personnel working with the NTDI01 termination unit should have experience working on it and know the precautions to take around AC/DC power. Knowledge of the Symphony system and electronic principles is also mandatory.

1.5 User Manual Content

The user manual consists of the following sections:

Introduction:

This section provides an overview of the NTDI01 termination unit.

Installation:

This section explains the physical installation, wiring and cable requirements, fuse requirements, dipshunt settings, and handling of the termination unit.

Maintenance:

This section describes how to maintain the termination unit.

Repair and Replacement:

This section explains how to replace the termination unit.

1.6 How to Use this Manual

Make sure to read this user manual in sequence. It is important to become familiar with the entire contents of the user manual before using the termination unit.

This user manual is organized to enable quick information retrieval:

1. Perform the steps in the Installation section.

2. Refer to the Maintenance section for scheduled maintenance requirements.

3. Refer to the Repair and Replacement section to replace a termination unit.

1. Introduction

1.7 Document Conventions

Document Conventions

The ? in the nomenclature or in a part number indicates a variable for that position (e.g., IMMFP1?).

1.8 Reference Documents

The following table (Table 1-1) lists ABB Automation instructions for equipment that is referenced in this user manual.

Table 1-1 Reference Documents

Number

Document

WBPEEUI200502??

Module Mounting Unit (IEMMU11, IEMMU12, IEMMU21, and IEMMU22)

WBPEEUI200505??

Site Planning Guidelines

2VAA001623

Digital output module (SPDSO14)

2VAA001595

Digital output module (SPDSO15)

2VAA001643

Analog output module (SPASO11)

WBPEEUI240770??

Frequency counter module (IMFCS01)

WBPEEUI240771??

Hydraulic servo module (IMHSS03)

2VAA001654

Pulse input module (SPDSM04)

2VAA001638

S+ Control: SPDSI13, SPDSI14 & SPDSI22 - Digital Input Modules User Manual

1.9 Related Nomenclature

The following table (Table 1-2) lists the nomenclature related to the NTDI01 termination unit.

Table 1-2 Related Nomenclature

Nomenclature

Description

IEMMU11, IEMMU12, IEMMU21, IEMMU22

Module mounting unit

ASO11

Analog output module

DSI12/DSI13/DSI14/DSI15/DSI22

Digital input module

DSM04

Pulse input module

DSO14, DSO15

Digital output module

FCS01

Frequency counter module

HSS03/HSS05

Hydraulic servo module

NFTP01

Field termination panel

NKTU01

Termination cable (PVC)

NKTU11

Termination cable (non-PVC)

1.10 Specifications

The following table (Table 1-3) details the NTDI01 termination unit specifications:

Specifications

1. Introduction

Table 1-3 NTDI01 Termination Unit Specifications

Property

 

Characteristic/Value

Wire size

 

Maximum

12

AWG

Minimum

22

AWG

Mounting

Mounts on the field termination panel.

Environmental

 

Ambient temperature

0° to 70°C (32° to 158°F)

Relative humidity

5% to 95% up to 55°C (131°F) (noncondensing) 5% to 45% at 70°C (158°F) (noncondensing) Pollution degree: I

Altitude

Sea level to 3 km (1.86 mi)

Air quality

Noncorrosive

Cooling requirements

No cooling is required when used in ABB Automation cabinets and operated within environmental limits.

Certifications

 

Canadian Standards Association (CSA)

Certified for use as process control equipment in an ordinary (nonhazardous) location.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

2. Installation

Introduction

2.

Installation

2.1

Introduction

This section explains NTDI01 termination unit installation. Do not proceed with operation until the steps are read, understood, and performed in the order in which they appear.

2.2

Special Handling

Observe these steps when handling electronic circuitry:

1. Use Static Shielding Bag: Keep an assembly in its static shielding bag until ready to install it in the system. Save the bag for future use.

2. Ground Bags before Opening: Before opening a bag containing an assembly with static sensitive devices, touch it to the equipment housing or ground to equalize charges.

3. Avoid Touching Circuitry: Handle assemblies by the edges; avoid touching the circuitry.

4. Avoid Partial Connection of Semiconductors: Verify that all devices connected to the module are properly grounded before using them.

5. Ground Test Equipment.

6. Use an Antistatic Field Service Vacuum: Remove dust from assemblies if necessary.

7. Use a Grounded Wrist Strap: Use the ABB Automation field static kit (part number 1948385A1 - consisting of two wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with modules. The kit grounds a technician and the static dissipative work surface to the same ground point to prevent damage to the circuitry by electrostatic discharge. Connect the wrist strap to the appropriate grounding plug on the power supply or to an unpainted portion of the enclosure with the alligator clip. The wrist strap must be effectively connected to the earth grounding electrode system through the AC safety ground.

8. Do Not Use Lead Pencils to Set Switches: To avoid contamination of switch contacts that can result in unnecessary circuit board malfunction, do not use a lead pencil to set a switch.

2.3

Unpacking and Inspection

To unpack and inspect the termination unit:

1. Examine the hardware immediately to verify it has not been damaged in transit.

2. Notify the nearest ABB sales office of any such damage.

3. File a claim for any damage with the transportation company that handled the shipment.

4. Use the original packing material and container to store the hardware.

5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes.

2.4

Setup/Physical Installation

Install the fuses and configure the dipshunts before installing or operating the NTDI01 termination unit. Figure Table 2-1 shows the layout of the termination unit.

2.4.1

Fuse Installation

The two fuses on the termination unit. Fuse F1 protects the E1 power supply and fuse F2 protects the E2 power supply. Determine the voltage required and refer to Table 2-1 to select the correct fuse.

2.4.2

Dipshunt Configuration

There are 17 dipshunts on the termination unit. Dipshunts XU1 through XU16 are for point (I/O) configuration of the 16 available I/O signals. Dipshunt XU17 is used to configure signal routing for some applications. The actual configuration of

Dipshunt Configuration

2. Installation

these dipshunts depends on the I/O module being used. Refer to the I/O module instruction for the required dipshunt configurations. Figure 2-2 shows a point configuration circuit. Figure 2-3 shows a termination unit configuration circuit.

Figure 2-3 shows a termination unit configuration circuit. Figure 2-1 Termination Unit Layout Table 2-1 Fuse

Figure 2-1 Termination Unit Layout

Table 2-1 Fuse Ratings

Voltage Required

Part Number

Description

24 VDC

194776?13001

3 A

125 VDC or 120 VAC

194776?12500

0.25 A

3 A 125 VDC or 120 VAC 194776?12500 0.25 A Figure 2-2 Point Configuration Circuit 2-2

Figure 2-2 Point Configuration Circuit

2. Installation

Connector P1 Signal Paths

2. Installation Connector P1 Signal Paths Figure 2-3 Termination Unit Configuration Circuit Configure a dipshunt by

Figure 2-3 Termination Unit Configuration Circuit

Configure a dipshunt by either cutting straps or leaving straps uncut in certain sequences. Cut the dipshunt straps using a standard shunt cutting tool. Always cut straps completely. Install the configured dipshunt into the desired socket on the termination unit. To install a dipshunt, align the end of the dips hunt identified with the silver dot to the end of the socket having an identification mark and push the dipshunt into the socket. Be careful not to bend any pins during insertion.

2.5 Connector P1 Signal Paths

Figure 2-2 shows the signal paths from connector P1 to the configuration sockets XU1 through XU4, XU7, XU8, and XU11 through XU16. For these sockets, all even numbered connector P1 pins in Table 2-2 attach to socket pins 1 through 4. All odd numbered connector P1 pins attach to socket pins 5 and 6.

Table 2-2 Connector P1 Signal Paths

Pin

Socket

I/O

Pin

Socket

I/O

Pin

Socket

I/O

1

XU13

1A

13

XU9

5A

25

XU2

2B

2

XU13

1A

14

E3

COM

26

XU2

2B

3

XU14

2A

15

NC

27

XU3

3B

4

XU14

2A

16

XU9

5A

28

XU3

3B

5

XU15

3A

17

XU10

6A

29

XU4

4B

6

XU15

3A

18

XU17

6A

30

XU4

4B

7

XU16

4A

19

XU11

7A

31

XU5

5B

8

XU16

4A

20

XU11/XU12

7A/8A

32

XU5

5B

9

NC

 

21

XU8

8B

33

XU6

6B

10

NC

22

XU12

8A

34

XU17

6B

11

NC

23

XU1

1B

35

XU7

7B

12

NC

24

XU1

1B

36

XU7/XU8

7B/8B

NOTE: A = Group A; B = Group B; NC = Not Connected

Termination Unit Installation

2. Installation

Figure 2-3 shows the signal paths from connector P1 to configuration sockets XU5, XU6, XU9, XU10, and XU17. Table 2-3 shows the cable pin connections from connector P3 of the I/O module to connector P1 of the termination unit.

Table 2-3 Cable Connections for I/O Signals

 

NKTU01

 

NKTU11

 

P3 1

 

P1 2

P3 1

 

P1 2

1

-

-

- -

- -

- - - -

- -

- -

- 1

J

- -

- - - - - - - - - - - - - 22

A

- -

 

- -

- -

- - -

- - - - - - 2

9 - - - - - - - - - - - - - - - 23

2

-

-

- -

- -

- -

- -

- - - - - 3

K

-

- - - - - - - - - - - - - - 24

B

- -

 

- -

- - - -

- - - - - - - 4

10

- -

- - - - - - - - - - - - - 25

3

-

-

- -

- -

- - - -

- - - - - 5

L

- -

- - - - - - - - - - - - - 26

C

- -

-

- -

- -

- -

- - - - - - 6

11

-

- - - - - - - - - - - - - - 27

4

-

-

- -

- -

- - - -

- - - - - 7

M

- -

- - - - - - - - - - - - - 28

D

- -

-

- -

- -

- -

- - - - - - 8

12

- -

- - - - - - - - - - - - - 29

5

- -

- -

- - - - - - - - - - - 13

N

-

- - - - - - - - - - - - - - 30

E

-

- -

 

- - - - - - - - - - - - 16

13

- -

- -

- -

- - - -

- - - - - 31

6

- -

- -

- - - - - - - - - - - 17

P

-

- - - - - - - - - - - - - - 32

F

- -

-

- -

- -

- -

- - - -

- - 18

14

- -

- - - -

- - - - - - - - - 33

7

- -

- -

- - - - - - - - - - - 19

R

-

- - - - - - - - - - - - - - 34

H

-

- - - - - - - - - - - - - - 20

15

- -

- - - - - - - - - - - - - 35

8

- -

- -

- - - - - - - - - - - 21

S

-

- - - - - - - - - - - - - - 36

NOTES:

1. P3 on I/O module.

2. P1 on termination unit.

2.6 Termination Unit Installation

The termination unit is ready for installation when the fuses are installed and dipshunts are properly configured. The termination unit mounts on a standard NFTP01 panel as shown in Figure 1-2.

2.6.1

Mounting

Follow the given steps to mount the NTDI01 termination unit to the field termination panel:

1. Remove the safety shield.

2. Installation

Cable Connection

2. Insert the tabs of the circuit board into the proper slots of the termination panel standoff as shown in Figure 2-4 and slide the circuit board into position.

in Figure 2-4 and slide the circuit board into position. Figure 2-4 Termination Unit Installation 3.

Figure 2-4 Termination Unit Installation

3. Secure the termination unit circuit board to the field termination panel with two No. 10 thread-forming screws.

2.6.2 Cable Connection

After mounting the termination unit to the field termination panel, install the NKTU01 or NKTU11 termination cable.

The following figure (Figure 2-5) shows a diagram of cable connections to the I/O module and termination unit.

of cable connections to the I/O module and termination unit. Figure 2-5 Cable Connection To install

Figure 2-5 Cable Connection

To install the termination unit cable:

2-5 Cable Connection To install the termination unit cable: Remove a module from its assigned slot

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module

1. Install the J1 connector of the NKTU01 or NKTU11 termination unit cable in the module mounting unit backplane slot assigned to the I/O module.

2. Insert the J2 connector of the cable into P1 of the termination unit.

2.6.3 Power Wiring

There are three terminals that provide power and ground connections. Refer to Figure 2-1 for terminal locations. System power connects to the termination unit through Faston connectors E1 and E2 and it is distributed to the configuration sockets (XU1 - XU17) through fuses. Any combination of power can be connected to these connectors depending on the

Terminal Block Wiring

2. Installation

application. However, this requires careful system analysis to ensure circuit board trace amperage capacity is not exceeded. A single trace can handle a continuous two amperes. System ground connects through Faston connector E3.

To connect the power wiring:

through Faston connector E3. To connect the power wiring: Verify the main power, field power, and

Verify the main power, field power, and power entry panel circuit breakers/switches are turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, retrofit, upgrade, or wiring procedures are complete.

1. Attach a 14 AWG wire from the power distribution source (24 VDC, 125 VDC, or 120 VAC) to the E1 terminal on the termination unit, if required.

2. Attach a 14 AWG wire from the power distribution source (24 VDC, 125 VDC, or 120 VAC) to the E2 terminal of the termination unit, if required.

3. Attach a 14 AWG wire from the system ground to the E3 terminal of the termination unit, if required

2.6.4

Terminal Block Wiring

Refer to Figure 2-1 for terminal block assignments and terminal polarity. Field wiring requirements will depend on the application. Refer to the Site Planning Guidelines instruction for specific information on field wiring installation requirements (i.e., spacing, isolation, etc.). Connect the wiring from the input devices to the terminals.

2.7

Installation Complete

The termination unit is ready for operation when:

• The fuses are installed.

• The dipshunts are installed.

• The termination unit is installed on the field termination panel.

• The cables are connected.

• Power wiring is connected and applied to the termination unit.

• Terminal block wiring is connected to the termination unit and field device.

• The safety shield is installed.

3. Maintenance

3.

Maintenance

3.1 Introduction

Introduction

The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB Automation recommends that all equipment receive preventive maintenance to keep the equipment operating at an optimum level.

This section presents procedures that the customer should be able to perform on site. These preventive maintenance procedures should be used as a guideline to assist in establishing good preventive maintenance practices.

Personnel performing preventive maintenance should meet the following qualifications:

• Should be qualified electrical technicians or engineers that know the proper use of test equipment.

• Should be familiar with the module mounting unit and field termination panel

• Have experience working with process control systems

• Know what precautions to take when working on live AC and/or DC systems.

3.2 Preventive Maintenance Schedule

The following table (Table 3-1) details the preventive maintenance schedule for the NTDI01 termination unit. The table lists the preventive maintenance tasks in groups according to their specified maintenance interval. Tasks that require further explanation are covered under sub-section 3.4- Preventive Maintenance Procedures of this user manual.

NOTE: The preventive maintenance schedule is for general purposes only. Your application may require special attention.

Table 3-1 Preventive Maintenance Schedule

Task

Frequency

Check cabinet air filters. Clean or replace them as necessary. Check the air filter more frequently in excessively dirty environments.

3 months

Check cabinet and termination unit for dust. Clean using an antistatic vacuum.

Check all termination unit signal, power and ground connections within the cabinet. Verify that they are secure. Refer to procedure.

Check termination unit circuit board, giving special attention to power contacts and edge connectors. Clean as necessary. Refer to procedure.

12 months

Complete all tasks in this table.

Shutdown

3.3 Equipment and Tools Required

Tools and equipment required for maintenance procedures:

• Antistatic vacuum.

• Screwdriver (medium length).

• Isopropyl alcohol (99.5 percent electronic grade).

• Distilled water.

• Compressed air.

• Foam-tipped swabs.

• Lint-free cloths.

• Nonabrasive eraser.

3.4 Preventive Maintenance Procedures

Tasks from Table 3-1 that require specific instructions or further explanation:

• Cleaning printed circuit boards and edge connectors.

• Checking signal, power and ground connections.

Printed Circuit Board Cleaning

3. Maintenance

3.4.1

Printed Circuit Board Cleaning

Never clean electrical parts or components with live power present. Doing so exposes you to

Never clean electrical parts or components with live power present. Doing so exposes you to an electrical shock hazard.

 

Wear eye protection whenever working with cleaning solvents. When removing solvents from printed circuit boards using compressed air, injury to the eyes could result from splashing solvent as it is removed from the printed circuit board.

 

There are several circuit board cleaning procedures in this section. These procedures cover circuit board cleaning and washing, cleaning edge connectors and circuit board laminate between edge connectors. Use the procedures that meet the needs of each circuit board. Remove all dust, dirt, oil, corrosion or any other contaminant from the circuit board. Perform all cleaning and handling of the printed circuit boards at static safe work stations. Always observe the steps under sub-section 2.2- Special Handling of this user manual when handling printed circuit boards.

3.4.1.1

General Cleaning and Washing

If the printed circuit board needs minor cleaning, remove dust and residue from the printed circuit board surface using clean, dry, filtered compressed air or an antistatic field service vacuum cleaner.

To wash the printed circuit board:

 

1. Clean the printed circuit board by spraying or wiping it with isopropyl alcohol (99.5% electronic grade).

2. Wipe the circuit board with a foam-tipped swab to wipe.

3. Remove excess solvent by using compressed air to blow it free of the circuit board.

3.4.1.2

Edge Connector Cleaning

To clean the edge connector:

 

1. Use a solvent mixture of 80% isopropyl alcohol (99.5% electronic grade) and 20% distilled water.

2. Soak a lint-free cloth with the solvent mixture.

3. Work the cloth back and forth parallel to the edge connector contacts.

4. Repeat with a clean cloth that is soaked with the solvent mixture.

5. Dry the edge connector contact area by wiping with a clean lint-free cloth.

 

To clean tarnished or deeply stained edge connector contacts:

 

1. Use a nonabrasive eraser or equivalent to remove tarnish or stains.

NOTE: Fiberglass or nylon burnishing brushes may also be used.

2. Minimize electrostatic discharge by using the 80/20 isopropyl alcohol/water solution during burnishing.

NOTE: Do not use excessive force while burnishing. Use only enough force to shine the contact surface.

3. Inspect the edge connector after cleaning to assure no loss of contact surface.

4. Wipe clean with a lint-free cloth.

3.4.2

Checking Connections

NOTE: Power to the cabinet should be off while performing this preventive maintenance task.

There are exposed AC and DC connections inside the cabinet. These exposed electrical connections present a shock hazard that can cause injury or death.be off while performing this preventive maintenance task. If input or output circuits are a shock

If input or output circuits are a shock hazard after disconnecting system power at the power entry panel, then the door of the cabinet containing these externally powered circuits must be marked with a warning stating that multiple power sources exist.

Check all signal wiring, power and ground connections within the cabinet to verify their integrity. When checking connections, always turn a screw, nut or other fastening device in the direction to tighten only. If the connection is loose, it will be tightened. If the connection is tight, the tightening action will verify that it is secure. There must not be any motion done to loosen the connection.

Precautionary steps to follow:

• Verify that all power connections within the cabinet are secure.

• Verify that all wiring connections to the termination unit are secure.

4. Repair and Replacement

4. Repair and Replacement

4.1 Introduction

Introduction

This section explains the repair and replacement procedures for an NTDI01 termination unit.

The following table (Table 4-1) details the replacement and spare parts list.

Table 4-1 Parts List

Part Number

Description

1946715?8

Dipshunt

194776?12500

Fuse, 0.25 A

194776?13001

Fuse, 3 A

NFWAB17010

0.19-16 (no.10) x 5/8 in. Phillips-head thread forming screw

4.2 Fuse Replacement

If a fuse opens, replace it with a fuse having an equivalent rating.

Follow the given steps to replace a fuse:

1. Turn off power to the cabinet.

2. Remove the safety shield.

3. Remove the blown fuse from its holder.

4. Replace the blown fuse with an equivalent fuse.

5. Install the safety shield.

6. Turn on power to the cabinet.

4.3 Termination Unit Replacement

If it is determined that the termination unit is faulty, replace it with a new one. Do not try to repair the unit; replacing components may affect the unit performance and certification. When replacing a termination unit, observe the special handling guidelines listed in sub-section 2.2- Special Handling of this user manual.

NOTE: Turn off power to the field devices before removing the cables from the termination unit.

before removing the cables from the termination unit. Remove a module from its assigned slot before

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module

Follow the given steps to replace the termination unit.

1. Turn off power to the cabinet and remove the safety shield.

2. Disconnect the power source and ground wiring from the E1, E2, and E3 Faston connectors of the termination unit.

3. Mark the wires according to their terminal assignment as they are removed.

4. Pull the I/O module out of its cable connection on the module mounting unit backplane, if the termination unit is connected to an I/O module.

5. Disconnect the termination cable from the P1 connector on the termination unit, if it is connected.

6. Turn off power to the field devices.

7. Disconnect I/O wiring from the terminal blocks.

8. Mark the wires according to their terminal assignment.

9. Remove the two mounting screws and remove the termination unit from the field termination panel, when all cables and wires are removed from the termination unit.

10. Verify the proper fuses are installed in fuse holders F1 and F2 of the replacement termination unit.

11. Verify that the dipshunt settings on the replacement termination unit are the same as the dipshunt settings on the faulty termination unit.

Termination Unit Replacement

4. Repair and Replacement

12. Secure the replacement termination unit circuit board to the field termination panel with the two mounting screws.

13. Connect the termination unit cables to their assigned connector on the termination unit.

14. Connect the I/O wiring to the terminal strips.

15. Connect the power source and ground wiring to the E1, E2, and E3 Faston connectors of the termination unit.

16. Push on the faceplate of the I/O module to fully insert it into its module mounting unit slot.

NOTE: The I/O modules should be seated in the termination unit cable at the rear of the module mounting unit when fully inserted.

17. Install the safety shield and return power to the field devices, after all cables and wiring are replaced.

18. Return power to the cabinet.

A

Analog output module 1

C

Checking connections 2 Cleaning Edge connectors 2 Printed circuit boards 2 Conventions, documents 3 Cooling requirements 4

D

Digital I/O 1 Digital input module 1 Digital output module 1 Dipshunt Configuration 1

E

Edge Connector Cleaning 2

F

Field static kit 1 Frequency counter module 1 Fuse Installation 1 Replacement 1 Fuse Replacement 1

H

Harmony rack I/O device 1 How to use this instruction 2 Hydraulic servo module 1

I

I/O wiring 6 input signals 1 Installation 1 Cables 5 Fuse 1 I/O wiring 6 Power wiring 5 Termination unit 4

M

Maintenance 1 Schedule 1 Tools required 1 Maintenance Schedule 1 Mounting Hardware 2 Mounting hardware 2

N

Nomenclature 3

NTDI01 1

O

Overview 1

P

Parts list 1 PCB cleaning 2 Power Wiring 5 Power wiring 5 Preventive maintenance Checking connections 2 Schedule 1 Tools and equipment 1 Printed Circuit Board Cleaning 2 Pulse input module 1

R

Replacing fuses 1

INDEX

S

Setup/physical installation 1 Special handling 1 Symphony Enterprise Management and Control System

1

T

Termination Unit 1 Termination unit Cables 5 Dipshunt configuration 1 Installation 4 Mounting 4 Replacement 1 Termination Unit Replacement 1

U

Unpacking and inspection 1 User qualifications 2

INDEX

Document Number: 2VAA001693

ABB Ltd. Business Unit Power Generation P.O. BOX 8131 8050 Zürich SWITZERLAND Phone: +41 (0) 43 317-5380 Fax: +41 (0) 43 317-5382 www.abb.com/powergeneration

Notice The information in this document is subject to change without notice and should not be construed as a com- mitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, spe- cial, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be repro- duced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive

2006/95/EC.

Copyright © 2011-2012 by ABB. All rights reserved. Release: May 2012