505 Digital Control

I/O Overview

Industrial Turbomachinery Systems

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 I/O Introduction

• Summary:
 Calibration/Forcing and Troubleshooting of I/O Channels
► Discrete Inputs (Contact Inputs)
► Analog Inputs
► Speed Inputs
► Discrete Outputs (Relays)
► Analog Outputs
 Covers the following:
► I/O Screens
► Channel Calibration
► Channel Forcing
► Terminal Block Connection Diagram

 Note: This presentation assumes basic familiarity with screen and

component navigation and User Levels/Modes.

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 Contact Input Example

• Contact Input/Discrete Input

 Discrete Input 01 = External Trip Input 1
► DI 01 is hard coded, other DI functions are user configurable.
► Note: DI 01 is “Fail Safe”
► TRUE or Contact CLOSED (24 V) = Healthy
► FALSE or Contact OPEN (0 V) = Trip
► Status of other equipment in the plant, not the 505
“Trip loop”
External to 505
 Many Discrete Input functions are not trips or alarms
► Discrete trips on Trip Event screen.
► Discrete alarm functions on Alarm Event screen.
► Discrete commands/statuses on operation screens.

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 View Trip Event

LED

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 Go to “Contact Inputs” Screen

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 Contact Input Summary

• Find Function
• Note the status
 FALSE
 OPEN
 Not Energized
 = Trip
• I/O Tags
 Customizable, for
example:
► ESD-0001

• More channels
via soft keys
• View Contact 01
Channel Screen
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 Contact Input Channel Screen

• Other I/O type

screens will have
more information
 Invert Logic
► Not available for
Contact Input 01
“Emergency
Shutdown”

• Device Tag
 Entered here in
Service Mode.
• Invert Logic
 Configured here in
Configure Mode.

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 Contact Input Hardware

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 Analog Input Example

• Analog Input
 Analog Input 1 = Remote Speed Setpoint

 Example:
► Minimum Governor to Maximum Governor is 3500 to 3800 RPM.
► Expected Remote Speed Setpoint range is 3600 to 3780 RPM.

 Problem:
► Enabling Remote Speed only sets/lowers Speed Setpoint to 3500 RPM.
► No alarm/fault indicated for Remote Speed Setpoint.
► Confirmed on the DCS that it is sending 12 mA (50% demand) to 505.
► Expected to drive a 505 Speed Setpoint of 3690 RPM.

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 Go to “Analog Inputs” Screen

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 Analog Input Summary

• Find Function
• Fault condition:
 < 2 mA
 > 22 mA
 LED off = Healthy
• Value
 In Engineering Units
• I/O Tags and
Units
 Customizable
• View Contact 01
Channel Screen

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 Analog Input Channel Screen

• Signal in mA
• Scaled Value
 Ex. 100 RPM not
3690 RPM
• 4-20 mA Range
 0-200 RPM
 Config incorrect
• Loop Powered
 Configured here in
Configure Mode.
► No jumpers.
• Device Tag/Units
 Entered here when
in Service Mode.
• Modbus Multiplier
• Decimals
Displayed
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 Analog Input Hardware

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 Speed Input Example

• Speed Input
 Speed Input 1
 Speed Input 2 (optional)
• New settings for input 1 and 2 in new 505’s:
 MPU/Active Probe
► No jumpers, physical wiring difference (see hardware).
 Number of Gear Teeth
► New for input 2.
 Gear Ratio
► New for input 2.
 Maximum Speed Level
► New for input 1 and 2.
 Failed Speed Level (Input 1 and 2)

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 Go to “Analog Inputs” Screen (Speed Signal)

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 Analog Input Summary (Speed Signal)

• Use soft keys

• View Speed
Signal 1 Channel
Screen

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 Speed Input Channel Screen

• Probe Type
 Configured here in
Configure Mode.
• Device Tag/Units
 Entered here when
in Service Mode.
• Number of Teeth
• Gear Ratio
• Maximum Speed
 > Overspeed Test
Limit
• Failed Speed
 > Max Speed / 50
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 Speed Input Hardware

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 Discrete Output (Relay) Example

• 2 Discrete Output Types

• Status Indication:
 Discrete Output 2 = Summary Alarm
 Invert logic option
• Level Switch:
 Discrete Output 3 = Actual Speed
 Invert logic option
 Hysteresis
► Level ON
► Level OFF
► Not limited (hysteresis can be positive or negative in new 505)

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 Go to “Relays” Screen

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 Relay Output Summary

• Find Function
• Status:
 LED ON =
Energized
• I/O Tags
 Customizable
• View Relay
Channel Screen

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 Relay Output Channel Screen

• Signal in mA
• Scaled Value
 Ex. 100 RPM
• 4-20 mA Range
 0-200 RPM
• Loop Powered
 Configured here in
Configure Mode.
► No jumpers.

• Device Tag/Units
 Entered here when
in Service Mode.
• Modbus Multiplier
• Decimals
Displayed
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 Relay Hardware

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 Relay Output Forcing

• Go to the MODE
screen by
pressing the
MODE key

• Enter Calibration
Mode
 Shutdown
 No Speed
 User Level
► Service
► Configure

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 I/O Forcing

• “Force Ouput”
soft key

• “Enable” soft key

 Enables forcing for
this channel

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 Relay Output Forcing

• Press “Energize”
or “De-Energize”
to toggle the relay
output status.

• “Disable” soft key

 Returns output to
state driven by the
function logic.

• Exit Calibration
Mode via MODE
screen.
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 Analog Output (Readout) Example

• Analog Output
 Analog Output 1 = Actual Shaft Speed

 Example:
► Speed readout to DCS or gauge.

 Problem:
► No reading from AO1 on DCS or gauge (0mA).

 Old 505 models, no AO/Readout alarms

► Use Service Mode to troubleshoot mA output.

 New 505 models, configurable “Enable Readback Fault”

► Fault detection/alarming for output current loop.

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 Go to “Analog Outputs” Screen

x2
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 Analog Output Summary

• Find Function
• Fault condition:
 < 2 mA
 5mA demand
mismatch
 LED off = Healthy
• Value
 In Engineering Units
• I/O Tags and
Units
 Customizable
• View Contact 01
Channel Screen

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 Analog Output Channel Screen

• Signal in mA
 Note 0 mA
 Open circuit?
• Scaled Value
 Engineering Units
• 4-20 mA Range
• Input Function
 Configure Mode.
• Device Tag
 Service Mode.
• Enable Readback
Fault
 Optional Alarm.
 Configure Mode.

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 Analog Output Hardware

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 Analog Output Forcing/Calibration

• Enter Calibration
Mode
• “Enable” on
Analog Output
Channel screen

• “Enable Forcing”
soft key

• Check LED status

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 Analog Output Forcing/Calibration

• Adjust value
 Manual
 Entered “Go to”
 Rate
• Calibration
 Gain
 Offset
• Save Settings!
 Calibration values
• “Disable” soft key
 Returns output to
state driven by the
function logic.
• Exit Calibration
Mode

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