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IM300/H Series 3 Plus Hardware Referencemanual

Series 3 Plus

Hardware Reference

Publication IM300/H (6.2.4)

April 2010
http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/http://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/products.asphttp://www.cccglobal.com/http://www.cccglobal.com/

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1987-2001, Compressor Controls Corporation. All rights reserved.

This manual is for the use of Compressor Controls Corporation and is

not to be reproduced without written permission.

Air Miser, Guardian, Recycle Trip, Reliant, Safety On, SureLink, TTC,

Total Train Control, TrainTools, TrainView, TrainWare, Vanguard,

Vantage, WOIS, and the TTC and impeller logos are registered trade-

marks; and COMMAND, TrainPanel, and the Series 3

++

and Series 5logos are trademarks of Compressor Controls Corporation. Other

company and product names used in this manual are trademarks or

registered trademarks of their respective holders.

The control methods and products discussed in this manual may be

covered by one or more of the following patents, which have been

granted to Compressor Controls Corporation by the United States

Patent and Trademark Office:

4,949,276 5,347,467 5,508,943 5,609,465

5,622,042 5,699,267 5,743,715 5,752,378

5,879,133 5,908,462 5,951,240 5,967,742

6,116,258 6,217,288 6,317,655 6,332,336

6,494,672 6,503,048

Many of these methods have also been patented in other countries,

and additional patent applications are pending.

The purpose of this manual is only to describe the configuration and

use of the described products. It is not sufficiently detailed to enable

outside parties to duplicate or simulate their operation.

The completeness and accuracy of this document is not guaranteed,

and nothing herein should be construed as a warranty or guarantee,

expressed or implied, regarding the use or applicability of the

described products. CCC reserves the right to alter the designs

or specifications of its products at any time and without notice.

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Series 3 Plus Hardware Reference

3

April 2010 IM300/H (6.2.4)

Document Scope

This manual provides the information you will need to physically install and maintain

Series 3 Plus Controllers:

Chapter 1 describes the controller and its major components, and discusses

basic maintenance strategies and spare parts stocking.

Chapter 2 tells how to mount, replace, disassemble, reassemble, and convertcontrollers, and discusses general troubleshooting.

Chapter 3 describes the parameter memory and tells how to view or alterparameter values or run tests from the engineering panel.

Chapter 4 provides installation and troubleshooting instructions for the serialcommunication circuits.

Chapter 5 provides installation and troubleshooting instructions for the discreteinput and output circuits.

Chapter 6 provides installation, calibration, and troubleshooting instructions forthe Analog PCBs analog input and output circuits.

Chapter 7 describes and tells how to install, calibrate, and troubleshoot thehigh-current output and speed and position inputs.

Chapter 8 describes the fault indicators and redundant controller set up.

Appendix A describes each configuration or tuning parameter discussed in thebody of this manual.

Appendix B describes the controller test procedures that can be executed fromthe Engineering Panel of a Series 3 Plus Controller.

Additional information can be found in the following supporting documents, which

are included at the back of this manual:

DS300/P lists the replaceable components of the Series 3 Plus Controller.

DS300/H specifies the physical and electrical characteristics of Series 3 PlusCompressor Controllers.

DS307/H specifies the physical and electrical characteristics of Series 3 PlusTurbine Controllers.

DS300/T specifies the physical and electrical characteristics of Series 3 Plus

Compressor Controller Field Termination Assemblies.DS307/T specifies the physical and electrical characteristics of Series 3 Plus

Turbine Controller Field Termination Assemblies.

DS300/R describes the Series 3 Plus Redundant Control Selector.

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4

Contents

April 2010 IM300/H (6.2.4)

The document title appears in the header of each odd-numberedpage, while the chapter or appendix title appears in the header ofeven-numbered pages. Odd-page footers list the document number

and revision level [IM300/H (6.2.4)], while even-page footers providethe publication date (April 2010).

Acronyms are defined in the sections of this manual that discuss thecorresponding subjects, by placing them in parentheses followingthe spelled-out terms they represent. As an example, a three-letteracronym (TLA) is a way to represent a three-word subject by com-bining and capitalizing the initial letters of those three words. Mostare also listed under Symbols and Acronymson page 10.

Cross-references to other documents specify a section and chapter,while cross-references between chapters of this document specify apage number. References that do not specify a location are internalto the chapter in which they appear. In computerized versions of thismanual, all such references are hot-linked to their target locationsand appear in green. Entries in the tables of contents, illustrationand table lists, and index are also hot-linked but are not green.

Attention may be drawn to information of special importance byusing this text stylingor one of the following structures:

Note:

Notes contain important information that needs to be emphasized.

Caution:

Cautions contain instructions that, if not followed, could lead to irre-

versible damage to equipment or loss of data.

Warning!

Warnings contain instructions that, if not followed, could leadto personal injury.

The appearance of this electrical hazard warning symbol on CCCequipment or the word Warningappearing in this manual indicatesdangerously-high voltages are present inside its enclosure. Toreduce the risk of fire

or electrical shock, do not open the enclo-sure or attempt to access areas where you are not instructed to do

so. Refer all servicing to qualified service personnel.The appearance of this user caution symbol on CCC equipment orthe word Caution appearing in this manual indicates damage to theequipment or injury to the operator could occur if operational proce-dures are not followed. To reduce such risks, follow all proceduresor steps as instructed.

Document Conventions

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April 2010 IM300/H (6.2.4)

Table of Contents

Document Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Symbols and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 1 Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Components and Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Mounting Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14CPU PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Serial Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Discrete Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Discrete Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Auxiliary PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Frequency Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19High-Current Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Discrete Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Engineering Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Back Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Field Termination Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Power Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Return Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Support Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 2 Installation and Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Controller Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Input Power Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Internal Component Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Testing and Adjusting Internal Components . . . . . . . . . . . . . . . . . 37

Model Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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General Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Blank Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Visible Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Power Supply Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Chapter 3 Configuration and Testing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Parameter Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Alternate Parameter Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Parameter Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Configuration Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Data Groups and Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Key Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Key Sequence Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Viewing and Changing Parameter Values . . . . . . . . . . . . . . . . . . . .46Key Sequence Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Enabling Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47List Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Numeric Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Parameter Memory Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . .56Diagnostic Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Bad CRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Com# POF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57CS= XXXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Error! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57No Store. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Chapter 4 Serial Ports

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Isolated Port Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59Configuring Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Surge Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Port 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Port 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Ports 3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

RS-232 Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Modbus TCP Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Serial Port Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Termination Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Serial Port Activity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Serial Communication Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

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Chapter 5 Discrete Inputs and Outputs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Discrete Output Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Factory Testing Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Basic I/O Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Compressor Controllers with FIOM . . . . . . . . . . . . . . . . . . . . . . . . 71

24 Vdc Power Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Discrete Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Discrete Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Extended I/O Turbine Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . 7224 Vdc Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Discrete Input Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Discrete Output Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Discrete Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Discrete Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Chapter 6 Analog PCB I/O

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Analog Input Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Early-Model Analog PCB Replacement . . . . . . . . . . . . . . . . . . . 77Compression-Terminal Back Connections . . . . . . . . . . . . . . . . . 78Field Input-Output Module Connections. . . . . . . . . . . . . . . . . . . 79Field Input Module Connections. . . . . . . . . . . . . . . . . . . . . . . . . 80

Analog Output Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Output Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Analog Input Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Analog Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Current Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Voltage Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Analog Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Analog Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Chapter 7 Extended I/O Circuits

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89High-Current Analog Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Position Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Speed Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Inductive Load Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Maximum Output Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Daughter Board Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Miscellaneous Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

High-Current Output Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 94Speed Input Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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Position Input Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Output Circuit Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97Loopback Circuit Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101High-Current Output Troubleshooting . . . . . . . . . . . . . . . . . . . . . .101

Speed Input Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101Position Input Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Chapter 8 Fault Detection and Redundancy

. . . . . . . . . . . . . . . . . . . . . . .103

Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103Power Supply Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Redundant Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Switching Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106Output Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Tracking Input Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Serial Port Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Redundant Control Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108RCS Power Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Appendix A Configuration Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Appendix B Controller Test Sequences

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Glossary/Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

List of Figures

Figure 1-1 Series 3 Plus Controllers share a common hardware platform . . . . . .13Figure 1-2 Major components of Series 3 Plus Controller . . . . . . . . . . . . . . . . . .15Figure 1-3 CPU PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Figure 1-4 Auxiliary PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Figure 1-5 Analog PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Figure 1-6 Performance and Speed Controller Front Panels . . . . . . . . . . . . . . . .21Figure 1-7 The Engineering Panel mounts behind the Front Panel . . . . . . . . . . .22Figure 1-8 Basic compressor and turbine controller backs. . . . . . . . . . . . . . . . . .23Figure 1-9 CPC backs for extended I/O controllers . . . . . . . . . . . . . . . . . . . . . . .24

Figure 1-10 Field Input Module (FIM) for turbine controllers. . . . . . . . . . . . . . . . . .25

Figure 1-11 Field Output Module (FOM) for turbine controllers . . . . . . . . . . . . . . .25Figure 1-12 Field Input Output Module (FIOM) for compressor controllers . . . . . .25Figure 1-13 AC Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Figure 1-14 Using a PC to Configure Series 3 Plus Controllers . . . . . . . . . . . . . . .30

Figure 2-1 Mounting a Series 3 Plus Controller . . . . . . . . . . . . . . . . . . . . . . . . . .31Figure 2-2 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Figure 2-3 Power Cable connector configurations . . . . . . . . . . . . . . . . . . . . . . . .33Figure 2-4 Panel-mounted controller with extender board installed . . . . . . . . . . .37Figure 2-5 Voltage test points on Analog PCB . . . . . . . . . . . . . . . . . . . . . . . . . . .40
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Figure 3-1 Alternate parameter set memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Figure 3-2 Series 3 Plus Engineering Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 4-1 Serial port terminals on standard Back Panels . . . . . . . . . . . . . . . . . 59Figure 4-2 FTA Serial port features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Figure 4-3 Wiring diagrams for Ports 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Figure 4-4 Connecting to an RS-422/485 host port. . . . . . . . . . . . . . . . . . . . . . . 62Figure 4-5 Connecting to an RS-232 host port . . . . . . . . . . . . . . . . . . . . . . . . . . 63Figure 4-6 Terminating resistor DIP switch on the CPU PCB . . . . . . . . . . . . . . . 64

Figure 5-1 Discrete I/O terminals on basic controller back panels . . . . . . . . . . . 67Figure 5-2 Discrete I/O features of Field Termination Assemblies . . . . . . . . . . . 68Figure 5-3 CPU PCB Discrete output jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . 69Figure 5-4 Basic compressor controller discrete input wiring . . . . . . . . . . . . . . . 70Figure 5-5 Basic compressor controller discrete output wiring . . . . . . . . . . . . . . 70

Figure 6-1 Analog I/O features of Field Termination Assemblies . . . . . . . . . . . . 75Figure 6-2 Analog I/O terminals on basic controller back panels . . . . . . . . . . . . 76Figure 6-3 Early Analog PCB Assembly input configuration resistors. . . . . . . . . 77Figure 6-4 Analog I/O connections for basic compressor controller . . . . . . . . . . 78Figure 6-5 Analog output jumpers on inside of Back Panel. . . . . . . . . . . . . . . . . 81Figure 6-6 Analog PCB Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Figure 6-7 Calibration connections for basic compressor controllers . . . . . . . . . 84

Figure 7-1 Operation of bipolar output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Figure 7-2 Back panel speed input and high-current output terminals . . . . . . . . 91Figure 7-3 Field Termination Assembly extended I/O terminals . . . . . . . . . . . . . 92Figure 7-4 Jumper locations on the Auxiliary PCB . . . . . . . . . . . . . . . . . . . . . . . 93Figure 7-5 Daughter card configuration jumper. . . . . . . . . . . . . . . . . . . . . . . . . . 93Figure 7-6 High-current output functional diagram . . . . . . . . . . . . . . . . . . . . . . . 95

Figure 8-1 Fault and Tracking LED locations . . . . . . . . . . . . . . . . . . . . . . . . . . 103Figure 8-2 Series 3 Plus dual-redundant fault tolerance . . . . . . . . . . . . . . . . . . 105Figure 8-3 Typical redundant switching relay circuit . . . . . . . . . . . . . . . . . . . . . 106Figure 8-4 Switched I/O signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Figure 8-5 Typical Redundant Control Selector connections . . . . . . . . . . . . . . 108

List of Tables

Table 2-1 Power supply voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Table 3-1 Data groups and pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table 7-1 Expected output readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Table 7-2 Expected output readings for commonly used actuators . . . . . . . . . . 96

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Symbols and Acronyms

ohm (electrical resistance measurement)

% percent (parts or divisions per hundred)

# generic symbol for any number or numeric key

AC Alternating Current

AD1 to AD8 Analog-to-Digital variables

ADC Analog-to-Digital Converter

ALT ALTernate readout

AUX AUXiliary readout

BCC Basic (I/O) Compressor Controller

BTC Basic (I/O) Turbine Controller

C# Capacitor (for example, C9)

CCC Compressor Controls Corporation

CH1 to CH8 analog input CHannels

COND signal CONDitioning

CPC Circular Plastic Connector

CPU Central Processing Unit

CRC Cyclic Redundancy Checksum

CR1 to CR5 Control Relays (discrete outputs)

DC Direct Current

DCS Distributed Control System

D1 to D7 compressor controller Discrete Input

DEV DEViation readout

DI01 to DI16 turbine controller Discrete Input

DIP Dual Inline Package

DO1 to DO9 Discrete Outputs (control relays)

ECC Extended (I/O) Compressor ControllerETC Extended (I/O) Turbine Controller

EPROM Erasable Programmable Read-Only Memory

EEPROM Electrically-Erasable Programmable Read-Only Memory

F# Fuse (for example, F1)

FIM Field Input Module

FIOM Field Input/Output Module

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FOM Field Output Module

FREQ1 to FREQ6 Frequency input (speed measurement)

FTA Field Termination Assembly

GRD electrical ground terminal

H electrical hot terminalHDIC High-Density Interconnect Cable

Hz Hertz (frequency in cycles per second)

I1 to I3 analog current-loop output

I/H Current-to-Hydraulic signal converter

I/O Input and Output (circuits or signals)

IP Internet Protocol

I/P Current-to-Pneumatic signal converter

IVP Intended Valve Position

J# Jumper (for example, J3)

JB# Jumper Block (for example, JB10)

k or k- kilo (symbol or prefix for one thousand)

kW kilo-Watt

LED Light Emitting Diode

LVDT Linear Variable Differential Transformer (position input)

m or m- milli (symbol or prefix for one-thousandth)

M or M- mega (prefix for one million)

mA milli-Ampere

MPU Magnetic PickUp

N electrical neutral terminal

NEMA National Equipment Manufacturers Association

NO/NC Normally-Open or Normally-Closed

OUT OUTput display

OUT1 to OUT3 analog OUTputsPC (IBM-PC compatible) Personal Computer

PCB Printed Circuit Board

PI Proportional-Integral control

PID Proportional-Integral-Derivative control

PIO Programmable Input/Output computer chip

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PLC Programmable Logic Controller

PV Process Variable readout

R# Resistor (for example, R33)

RAM Random Access Memory

RCS Redundant Control SelectorRMA Returned Material Authorization

RTU Remote Terminal Unit

RVDT Rotary Variable Differential Transformer (position input)

RX serial port reception channel (for example, RX3)

S Solenoid

SCADA Supervisory Control And Data Acquisition

SP Set Point readout

SPEC SPECial response

SV1 to SV8 Signal Variables

TB Terminal Block

TCP Transmission Control Protocol

TTC Total Train Control

TX serial port transmission channel (for example, TX3)

V Voltage

Vac alternating-current Voltage

Vdc direct-current Voltage

V1 to V2 analog Voltage output

W Watt (electrical power measurement)

Xmtr transmitter

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Chapter 1 Description

This chapter describes the controller and its major components, anddiscusses basic maintenance strategies and spare parts stocking.

Figure 1-1 Series 3 Plus Controllers share a common hardware platform

Componentsand

Configu ations

All Series 3 Plus Controllers use a common hardware platform con-sisting of the following major components:

The CPU PCB Assemblyprovides the controllers primary com-putational, serial communication, and discrete I/O capabilities.

TheAnalog PCB Assemblyprovides most (if not all) of the con-trollers analog input and output circuits.

TheAuxiliary PCB Assemblyprovides the added I/O and com-putational capabilities needed for turbine control applications.

The Front Panel Assemblyprovides the controllers operator

display and input functions.

The Engineering Panel Assemblyprovides the controllers con-figuration and tuning functions.

The Power Supply Assemblyconverts the input power to thevoltages required by the controllers internal circuitry.

The Back Panel Assembliesand optional Field TerminationAssemblies(FTAs) provide wiring terminals for the controllersinput and output circuits.

OUTSP

Series 3 Plus ControllerAUX

COMP

CONTROLS

CORPORATION

AUTOMAN

Gas TurbineFuel and Nozzle

Controllers

Dual-Loop

and Air Miser

Controllers

Steam Turbine

Speed and Extraction

Controllers

Compressor Perfor-

mance and Antisurge

Controllers

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Chapter 1: Description

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MountingConfigu ation

With the exception of the externally-mounted FTAs, all of the con-trollers components are usually housed in an extruded aluminumcase for mounting in a control panel cutout (see Figure 1-2). This isreferred to as the panel-mounted configuration.

In this configuration, the Back Panel (which will cause few mainte-nance or repair problems) can usually be treated as part of the case.The remaining components can be replaced from the front of thecase without removing it from the panel.

Alternately, the components of one or more controllers can behoused in a NEMA rated enclosure. This is referred to as the enclo-sure-mounted configuration, an option most frequently used inAirMiserapplications. Most enclosure-mounted controllers use FTAs.

In this configuration, the Front and Engineering Panels are mountedin the door of the enclosure and connect to the CPU PCB via a rib-bon cable. The CPU and Analog PCBs, Power Supply, and BackPanel Assemblies are mounted as one unit within the enclosure,along with any FTAs, to which they connect using High-DensityInterconnect Cables (HDICs).

ComponentConfigu ation

Series 3 Plus Controllers can be divided into four basic componentconfigurations, depending on whether or not they are equipped withan Auxiliary PCB Assembly and whether or not the Back Panel fea-tures compression terminals or circular plastic connectors (CPCs).

Compressor control applications rarely require the Auxiliary PCB,while turbine applications usually do. Thus, component combina-tions that do not include it are referred to as compressor controller

configurations and those that do are referred to as turbine controllerconfigurations. However, Antisurge and Performance Controllerscan use a turbine controller configuration when the applicationrequires Auxiliary PCB features. Similarly, a compressor controllerconfiguration can be used for Extraction Controller applications thatdo not require features provided by the Auxiliary PCB Assembly.

Because the I/O capabilities of turbine controller FTAs exceed thoseof the compression-terminal Back Panel for the same controllers,controllers that include CPC-style Back Panels are referred to asextended I/O configurations and those with compression terminal

backs are referred to as basic I/O configurations. However, both thebasic and extended I/O compressor controller configuration offer anessentially identical combination of inputs and outputs.

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Figure 1-2 Major components of Series 3 Plus Controller

In summary, the four basic component configurations can bereferred to as:

The Basic Compressor Controller(BCC), which has neither anAuxiliary PCB nor a CPC-style Back Panel Assembly.

The Extended Compressor Controller(ECC), which has a CPCBack Panel Assembly but no Auxiliary PCB.

The Basic Turbine Controller(BTC), which has an Auxiliary PCBbut not a CPC-style Back Panel Assembly.

The Extended Turbine Controller(ETC), which has both a CPCBack Panel and an Auxiliary PCB Assembly.

Each component configuration can use either an AC or DC powersupply (which require different Back Panels) and can be provided ineither the panel- or enclosure-mounted configuration.

Rear Panel Assembly

Auxiliary PCB Assembly

Power Supply Assembly

Slide AdjusterMounting SlideCaseFront Panel Assembly

Engineering Panel Assembly

Analog PCB Assembly

CPU PCB Assembly

Auxiliary PCB Daughter Card

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Figure 1-3 CPU PCB Assembly

CPU PCBAssembly

The CPU PCB provides the controllers central processor, memory,serial communication, and discrete I/O capabilities. The major com-ponents of this assembly (see Figure 1-3) are:

a Zilog Z80 CPU chip (central processing unit);

a RAM chip (random access memory) in which the results ofinternal calculations are stored (that is, the working memory);

two EEPROM chips (electrically-erasable programmable read-only memories) that store the control program and parameters;

two I/O chips that provide four serial ports, eight discrete inputs,

and communication between the main CPU and the micropro-cessors on the Engineering Panel and optional Auxiliary PCB;

a super-capacitor that powers the RAM during power outages,thus preserving the working memory;

eight electro-mechanical relays (discrete outputs), with jumpersthat set their normally-open / normally-closed configurations;

isolating power supplies for the serial ports;

terminating resistors for the serial communication networks, anda set of DIP switches for including them in those circuits; and

a speaker for audible feedback.Storing configuration parameters in EEPROMs protects them frombeing lost or corrupted during power failures (see page 41), whilestill allowing them to be easily changed from either the EngineeringPanel keyboard or via serial communication from a computer work-station running controller support software.

Similarly, storing the control program in the EEPROMs means it canalso be updated from a computer running our Download software.

DO2 Jumper

Power Supply Connector

Factory-Test Jumpers

Engineering Panel ConnectorSpeaker Termination Resistor DIP Switch

Analog Board Connectors

RAM

CPU

E

EPROM

I/O Chip

Auxiliary Board Connector

NO/NC Jumpers

Discrete Output Relays

E

EPROM

I/O Chip

Back Panel Connector

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In panel-mount controllers, the CPU PCB slides into grooves in thecase. For enclosure-mount applications, it is mounted on the back ofthe enclosure. Either way, the Analog PCB, Auxiliary PCB (whenpresent), and Power Supply are bolted to the CPU PCB and com-municate with it via connectors mounted between them.

The CPU PCB communicates with the Back Panel via a 120-pinconnector along its trailing edge, and with the Engineering Panel viaa 20-pin connector along its leading edge. In enclosure-mountedcontrollers, the CPU PCB and Engineering Panel Assemblies areconnected by a ribbon cable.

Serial Ports The CPU boards two I/O chips provide four serial ports (Ports 1 to4) that are compatible with the EIA RS-485 standard.

Ports 1 and 2 are used for communications with other Series 3 PlusControllers, while Ports 3 and 4 are used for communication withhost computers or control systems using the Modbus protocol. Port

5 is not used.

Discrete Inputs The CPU boards I/O chips provide eight discrete inputs that arereferred to as D- or DI-1 through 8:

Compressor controllers have terminals for and thus support onlyseven of these inputs.

Turbine controllers support all eight.

Consult the configuration manual for each specific controller todetermine the functions of these inputs.

Discrete Outputs The CPU board provides eight electro-mechanical relays that can

be used to control external alarms or as inputs to other control ormonitoring systems. These are referred to as DO- or CR-1 to 8:

All compressor controllers have terminals for and thus supportonly the first five of these relays.

Basic turbine controllers support seven relays, while extendedI/O turbine controllers support all eight. All turbine controllersalso support the Auxiliary PCBs fault relay (DO/CR9).

The function of each relay can be independently selected by settingits Relay Assigned Function

[MODE:D RA #]parameter. Consult the

configuration manual for your controller to determine what controlrelay functions it provides.

CR1 is of particular interest, because it is normally energized andthus fails off. This provides an automatic indication of hardware fail-ure or power loss. In models equipped with Revision B or later CPUPCBs, CR2 can also be configured as a fault relay.

Note:

Some compressor controller CPU PCBs have only five relays, whichare generally too few to support turbine control applications.

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Figure 1-4 Auxiliary PCB Assembly

Auxiliary PCBAssembly

The Auxiliary PCB provides the additional computational and I/Ocapacity needed for speed control and valve positioning. All turbinecontrollers except the Extraction Controller require this board. It canalso be installed in Compressor Controllers that require its valvepositioning loop, speed inputs, or high-current output circuit.

The major components of this assembly (see Figure 1-4) are:

the Motorola 68332 central processing unit (CPU);

two random access memory (RAM) chips, in which the results ofinternal calculations are stored (the boards working memory);

the EPROM chip (erasable programmable read-only memory)that stores the control program for this board;

a super-capacitor that powers the RAM when the controller isunplugged and during power outages;

an analog output that can provide a bipolar current-modulatedsignal of up to 200 mA, and the jumpers to configure it;

a programmable input/output (PIO) chip that provides eightadditional discrete inputs;

one electro-mechanical relay (discrete output) and a jumper toconfigure it as normally open or closed, used for fault detection

on the Auxiliary PCB; and a daughter board that provides the speed and position inputs.

The only currently-available Daughter Board provides:

three frequency inputs for use as rotational speed inputs;

one LVDT and one 4 to 20 mA position inputs; and

a demodulation circuit for the frequency feedback signal of aRosemont 3311 pneumatic transducer.

Speaker

EPROM

CPU

RAM

I/OChip

Analog Board ConnectionDaughter Board

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The Auxiliary PCB Assembly is mounted to and above the AnalogPCB Assembly, which it completely covers (see Figure 1-2).

Frequency Inputs The Daughter Board provides three inputs for reading the rotationalspeed signals from a steam or gas turbines magnetic pickups:

Basic turbine controllers have back-panel terminals for onlythree of these inputs (FREQ 1 to 3).

Extended I/O controllers have FOM terminals for all three inputs(MPUs 1 through 3).

High-Current Output The Auxiliary board includes an analog output circuit that can pro-vide virtually any current-modulated signal (up to 200 mA) that mightbe required for control valve positioning. Thus, this circuit is usually

called the High-Current Output. Its wiring terminals are located onthe basic turbine controller back panel (OUT 1) or Field Output Mod-ule (Current Output 1).

This output can be jumper-configured for a maximum current of 20,60, or 200 mA. The control program can then be configured to mapits output signal to any portion of the selected current range.

Position Inputs The only currently-available Daughter Board provides one LVDT(Linear Variable Differential Transformer) and one 4 to 20 mA ana-log input for measuring the position of control valves or inlet guidevanes. These are supported only by extended I/O turbine control-

lers. Terminals for these inputs (Position In 1 and the Auxiliary Input)are located on the Field Input Module (FIM).

The Daughter Board also includes circuitry to decode a frequencysignal that has been modulated onto the High-Current Output. Forexample, it could recover the pressure feedback signal of a Rose-mont 3311 pneumatic transducer. This feature is available in boththe basic and extended I/O configurations.

Discrete Inputs andOutputs

The Auxiliary PCB provides eight discrete inputs (in addition to theeight provided by the CPU PCB):

Basic turbine controller configurations support only one of theseinputs (D9).

Extended I/O configurations support all eight (DI-9 through -16).

As described in the individual controller manuals, each input can beconfigured to trigger specific responses when the input is active.

The Auxiliary PCB also has a single discrete output (DO/CR9) thatsignals Auxiliary board faults in the same way that DO/CR1 indi-cates a CPU board failure or power loss.

Note:

Early models of the Auxiliary PCB that do not include the daughtercard provide two LVDT inputs but support only three MPUs.

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Figure 1-5 Analog PCB Assembly

Analog PCBAssembly

The Analog PCB Assembly (see Figure 1-5) provides eight analog

inputs and two analog outputs. It is mounted on and toward the frontof the CPU PCB (see Figure 1-2).

Analog Inputs The Analog boards inputs are referred to as either Analog Inputs 1to 8 or CH1 through CH8:

Basic turbine controller configurations support only four of theseinputs (CH1 to 4).

All other controller configurations support all eight analog inputs.

All eight of these circuits must be configured as either current orvoltage inputs by placing all of the boards configuration jumpers in

either the C (20 mA) or V (5 Vdc) positions.

Analog Outputs For compressor controllers, the Analog PCB outputs are calledOUT1 and OUT2. They are factory-set as either 20 mA or 5 Vdc cir-cuits by setting a jumper on the inside of the Back Panel Assembly.When set up for current-loop modulation, they are sometimes calledI-1 and I-2. When set up for voltage-modulation, they are also

referred to as V-1 and V-2.For turbine controllers, these outputs are referred to as OUT2 andOUT3 (OUT 1 is the High-Current Output provided by the AuxiliaryPCB). The compression terminal back panel has a jumper (similar tothat of the basic compressor controller) that configures them aseither current (I2 and I3) or voltage (V2 and V3) outputs. In contrast,the FOM provides terminals for both the current- and voltage-modu-lated forms of these outputs. However, only one form of each outputcan be used at any given time.

Calibration Potentiometers

Configuration Jumpers

Note: Early models of the Analog PCB were factory configured for all 5Vdc or all 20 mA inputs and did not include configuration jumpers.

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Figure 1-6 Performance and Speed Controller Front Panels

Front PanelAssembly

The Front Panel Assembly provides the primary operator interfacefor the Series 3 Plus Controller. It is attached to the EngineeringPanel by a swing-out hinge and communicates with it via an eight

conductor ribbon cable.

Regardless of which model you purchase, the general features ofthis panel are always the same. As shown in Figure 1-6, each has:

two five-digit numeric readouts that usually display the con-trolled variable and its set point,

a three-digit numeric readout that displays the value of the con-trollers output signal (in percent)

a twelve-character alphanumeric readout for displaying processor controller variables,

fourteen LEDs for indicating status conditions, and eight control keys.

Each model does have a unique overlay that identifies the type ofcontroller you have, the function of each control key, and the mean-ing of each status LED that it utilizes. The configuration manuals(IM3##) provide detailed information about each controllers front-panel and operator interface.

COMPRESSORCONTROLSCORPORATION

SCROLLMENU

AUTO

MANManual

Auto

Local

Tracking

Fault

TranFail

Fallback

ComErr

PV

OUTSP

Performance ControllerAUX

DISPLAY

Remote

Limit

REMOTE

LOCAL

LOOP2DISPLAYLOOP3

COMPRESSORCONTROLSCORPORATION

SCROLLMENU

AUTO

MANManual

Auto

Local

Stop

Run

Fault

ShutDn

Limit

ComErr

RPM

OUTSP

Speed ControllerAUX

SETPOINTMODE

RESET

ENTER

Remote

Idle

Tracking

AlarmCascade

OPER-ATINGMODE

KW= 2122 Speed/Remote

50.4 50.190.0 3620

90.0 3620

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Figure 1-7 The Engineering Panel mounts behind the Front Panel

EngineeringPanel Assembly

The chief feature of the Engineering Panel is the Engineering Key-board (see Figure 3-2), which can be used to enter and change theconfiguration and tuning parameters that adapt each controller to itsspecific application.

In Series 3 Plus Controllers, the Engineering Panel is equipped withan embedded microprocessor that controls both the EngineeringKeyboard and the Front Panel. Off-loading these functions from themain CPU allows the controller to run more demanding control algo-rithms while still providing a responsive user interface.

The Engineering Panel is mounted on the front of the controller,immediately behind the Front Panel (see Figure 1-7). It is accessedby loosening the screw at the bottom of the Front Panel, pulling itsleft side forward about an inch, and then swinging the entire assem-bly forward and to the left.

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Figure 1-8 Basic compressor and turbine controller backs

Back Panel

Assemblies

All I/O wiring and the input power cable connect to the controllers

Back Panel Assembly. Each controller is equipped with one of fourbasic versions of this panel:

the basic compressor controller Back Panel,

the extended I/O compressor controller Back Panel,

the basic turbine controller Back Panel, or

the extended I/O turbine controller Back Panel.

Each of these assemblies is available for either AC or DC powersupply configurations and either panel or enclosure mounting.

The I/O terminals for the basic controller configurations are mounted

directly on the Back Panel (see Figure 1-8). In order to facilitatereplacement of these controllers, two-piece terminals are used.

After permanently attaching each wire to the removable half of itsconnector, you can unplug each group of wires by detaching thathalf of the connector from the controller.

The two extended I/O versions of the Back Panel are designed to beused with separately-mounted Field Termination Assemblies(FTAs), to which they are connected using High-Density Intercon-nect Cables (HDICs) with circular plastic connectors (CPCs).

PORT 5

+RX5TX5

21

43

NOT

D

+

+

CH 1

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

+

CH 2

+

CH 3

+

CH 4 OUT 1

+

PORT 2

+ + +

24VDC

DISCRETE

+ D6 D7

PORT 1TX/RX RX2TX2

CR3 CR4 CR5 DISCRETE IN

D1 D2 D3 D4 D5

PORT 4

+ + RX4TX4

PORT 3

+ + RX3TX3

+

OUT 2

+

1 2 1 2 1 2

CH 5

35 W max

CH 6 CH 7 CH 8 CR1 CR21 2 1 2+ + +

USED

21

43

DISCRETE

D

+

+

CH1

N GRD H

96-264 VAC

MADE IN USA

21-32 VDC

+

CH2

+

CH3

+

CH4

OUT1

+

PORT 2

+ + +

24VDC

DISCRETE

+ D6 D7

PORT 1TX/RX RX2TX2

CR6 CR7 CR9 DISCRETE IN

D1 D2 D3 D4 D5

PORT 4

+ + RX4TX4

PORT 3

+ + RX3TX3

+ FREQ1

+

OUT2

+

1 2 1 2 1 2

OUT 3

D8 D9

+ FREQ2 FREQ3

35 W max

CR1 CR2 CR3 CR4 CR51 2 1 21 21 21 2

Compressor Turbine

Port 5 - Not Used

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Figure 1-9 CPC backs for extended I/O controllers

Extended I/O compressor controllers use a Back Panel with oneCPC connector, while the Back Panel for extended I/O turbine con-

trollers have two (see Figure 1-9).

For panel-mounted controllers, the Back Panel Assembly is boltedto the back of the case. In enclosure-mounted applications, theBack Panel is mounted on the back of the enclosure using anglebrackets. In either case, the optional FTAs snap onto standardinstrument mounting rails.

Extended I/O Controllers can be purchased without FTAs. We thensupply pigtail I/O cables with CPC connectors on the controller endsonly. The Series 3 Plus Compressor Controllers Field Termination

Assembly

data sheet [DS300/T]and Series 3 Plus Turbine Control-

lers Hardware Specifications

[DS307/H]list the I/O signals assignedto the color coded wires on the unterminated ends.

G

96-264 VAC

21-32 VDC

HN

MADE IN USA

35 W max

1 4

60 63

INPUTS

1 4

60 63

(J1)

OUTPUTS(J2)

Compressor Turbine

G

96-264 VAC

21-32 VDC

HN

MADE IN USA

35 W max

1 4

60 63

INPUTS/

(J1)OUTPUTS

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Figure 1-10 Field Input Module (FIM) for turbine controllers

Figure 1-11 Field Output Module (FOM) for turbine controllers

Figure 1-12 Field Input Output Module (FIOM) for compressor controllers

Analog Input Fuses andConfig. Blocks

24 Vdc Fusesand Config. Block

Terminals forDiscrete Inputs

Terminal Block forValve Position Inputs

Terminals forFrequency Inputs

Discrete Input Fuses andConfig. Blocks

Terminal Blocksfor Analog Inputs

CPC Connector forController Data Cable

Terminal Blocks forSerial Ports 1 to 4

Terminal Block for

Terminal Block for 24 Vdc

CPC Connector forDiscrete Output Fuses and Config. Blocks

Terminal Blocks for

Controller Data Cable

Analog Outputs Discrete & Misc. Outputs(Port 5 is not used)

Discrete OutputCfg. Blocks

HDICConnector

DB-9 Connectors forModbus Ports

Analog InputCfg. Blocks

24 VDCCfg. Block

DiscreteI/O Fuses

Fuses forAnalog Inputs

Terminal Blocks forAnalog I/O Circuits

Terminal Block forDiscrete Outputs

Terminal Block forDiscrete Inputs

Fuses for 24 VDCPower Circuits

Terminal Block forSerial Ports 1 to 4 (P5 is not used)

Terminal Block for 24 VDCand Instrument Ground

Serial PortCfg. Blocks

Ribbon Cable Connectorsfor Serial Port Bus

DISCONTINUED

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Field TerminationAssemblies

Because there is simply too little room on the Back Panel to provideterminals for all of their CPU, Analog, and Auxiliary PCB I/O circuits,extended I/O turbine controllers are provided with remotely-mountedField Termination Assemblies (FTAs):

The Field Input Module (or FIM, see Figure 1-10) has terminalsfor all input signals.

The Field Output Module (or FOM, see Figure 1-11) handles alloutput and serial communication connections.

The Series 3 Plus Turbine Controllers Field Termination Assembly

data sheet [DS307/T]lists the specifications for these FTAs.

In addition to supporting additional I/O circuits, the use of FTAs canreduce panel design and wiring costs. They also include fusing anddropping resistor options that would otherwise be quite difficult toinstall. Other FTA design features facilitate connecting the control-lers I/O signals to a DCS or other supervisory control system, and

simplify wiring of the serial communication networks used to coordi-nate the actions of multiple controller systems.

Because the FTAs have no active components, they should neverfail or need replacement. In the remote event one does, the terminalblocks can be disconnected and reinstalled on a replacement FTAwithout disturbing the field wiring.

Note:

The Field Input/Output Module (FIOM), shown in Figure 1-12andspecifed inSeries 3 Plus Turbine Controllers Field Termination

Assembly

data sheet [DS307/T]is a discontinued part and is nolonger available.

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Figure 1-13 AC Power Supply Assembly

Power SupplyAssembly

All Series 3 Plus Controllers are equipped with either an AC or a DCpower supply that automatically adapts to a wide range of input volt-ages (Figure 1-13illustrates the AC Power Supply):

the AC power supply accepts any voltage from 96 to 264 Vac,50 to 60 Hz, while

the DC power supply accepts any voltage from 21 to 32 Vdc.

The Back Panel of each controller is clearly labeled to indicatewhich power supply it is equipped with. Either provides regulated+5, +15, 15, and +24 Vdc output voltages, and either galvanicallyisolates the controllers internal circuitry from the power source.

The ground conductor of the power cable should be connected to asuitable earth ground. This grounds the case (for electrical safety),provides the reference potential for internal power supply voltagesand analog outputs, and serves as a sink for any high-frequencycomponents of the analog input signals.

The 24 Vdc output, which is connected to the 24 VDC terminals on

the Back Panel or FTA, can be used to power your field transmitters.This transmitter power output is isolated so that a faulty transmitterwill not affect the controllers internal voltages.

The Power Supply Assembly is mounted on and toward the rear ofthe CPU PCB Assembly (see Figure 1-2), to which it connects viaan 18-pin connector with 15 individual conductors.

5 Vdc Potentiometer (R33)

Fuse

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MaintenanceStrategies

The simplest approach to maintaining Series 3 Plus Controllers is toreplace suspect units with identical spares. The faulty unit can besent to Compressor Controls Corporation for diagnosis and repair.

Because Back Panel problems are extremely rare, you can usuallyemploy the considerably easier remedy of replacing only those com-ponents that can be removed from the front of the controller.

It is often possible to determine which component is malfunctioning(for example, the Analog PCB Assembly), in which case you canreplace just that component and return it for repair or replacement(we advise against attempting board-level repairs). Due to thealmost complete interchangeability of parts across the entire Series3 Plus line, this approach can significantly reduce your requiredspare parts inventory.

Most models of the Series 3 Plus Controller can be converted intoany other by changing the Front Panel and loading the appropriatecontrol program. You might also have to add or remove the AuxiliaryPCB Assembly, and make sure the CPU PCB has enough controlrelays (turbine controllers generally require eight, while some com-pressor controllers have only five). If the controllers are equippedwith different Back Panels, you might also have to change the RearPanel Assembly or reuse the Case and Rear Panel from the control-ler you are replacing.

Spare Parts If your chosen maintenance strategy is to replace malfunctioningunits, one identical Series 3 Plus Controller should be stocked forevery five in use. If the cost or consequences of downtime are

unusually severe, a higher ratio of spares might be in order.On the other hand, if you choose to do board-level troubleshootingand replacement, you should stock spare assemblies at the sameone-to-five level. One or more complete, spare controllers shouldalso be stocked for use while troubleshooting suspect units.

The Series 3 Plus Controller Spare Parts List[DS300/P]lists the

major assemblies used in Series 3 Plus Controllers. Your spareparts inventory should be based on the total number of installedcontrollers using each assembly.

To avoid complicating maintenance and spare parts procedures, wewill normally try to configure all of your controllers to use identical

Analog and Auxiliary PCBs. However, if this is impossible or youinstall controllers on different turbomachinery trains at different

Warning!To prevent damage from static-electric discharges, all sparecircuit boards should be stored and transported in static-resis-tant pouches.

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times, you may have multiple versions of these assemblies. Appro-priate care must then be taken when ordering and replacing them.

Return Procedure To return a controller or assembly for repair, call CCC at 515-270-0857 and ask to talk to the Return Goods Coordinator. You will beasked to identify your controller model (for example, a Series 3 PlusPerformance Controller), provide its serial number, and describe theproblem you are experiencing. He or she will then schedule yourrepair and assign a Return Material Authorization (RMA) number.

Package the items carefully (if needed, the Return Goods Coordina-tor will send you appropriate packing materials) and ship themprepaid and insured to:

Compressor Controls CorporationATTN: Service Department4725 121st StreetDes Moines, IA 50323 U.S.A.

The RMA number should be clearly displayed on all shipping car-tons and noted in all correspondence. Your equipment will usuallybe repaired and shipped back within five days of their arrival at thefactory.

Note:If you have both compressor and turbine controllers, all of your CPUPCBs should have eight discrete output relays. If you have any withonly five, contact CCC for information on replacing them.

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Figure 1-14 Using a PC to Configure Series 3 Plus Controllers

SupportSoftware

Since the Series 3 Plus Controllers were first brought to market,CCC has offered different software packages for monitoring andmaintaining them using IBM-PC compatible computers. Eachincluded utility programs that can can read, edit, and replace aSeries 3 Plus Controllers configuration parameter set and update itscontrol program via one of its Modbus RTU serial ports (seePorts 3and 4on page 63):

The Toolbox Softwarepackage was a set of Series 3 Plus sup-port programs for the MS-DOS operating system, including:

a Configuratorprogram that could read, modify, store, com-pare, and write configuration parameter sets, and

a Downloadprogram that could replace the control program(application software) of a Series 3 Plus Controller.

The Workstation Operator Interface Software(WOIS) was agroup of Series 4 and 3 Plus software packages developed for

16-bit Windows 95/98/ME operating systems. The WOISSeries3 Plus Configuratorutility could read and replace controllerparameter sets and update their control programs.

The current TrainTools Software Packagesare collectionsof programs developed for the 32-bit Windows 2000 and XPProfessional operating systems. In particular, the Platform Engi-neering Utilitiespackage includes the WOIS Series 3 PlusConfigurator program, which can reprogram and reconfigurecontrollers via the TrainTools Series 3 OPC Serverprogram.Instructions for doing so can be found in the Series 3 Engineer-ing Utilitiesuser manual [UM5513].

OUTALT

AntisurgeControllerAUX

AUTO

MAN

DISPLAY

SCROLLMENU

SURGECOUNT

RESETSAFETYON

DEV

DISPLAYLIMIT

OUTALT

AntisurgeControllerAUX

AUTO

MAN

DISPLAY

SCROLLMENU

SURGECOUNT

RESETSAFETYON

DEV

DISPLAYLIMIT

OUTSP

PerformanceControllerAUX

AUTO

MAN

DISPLAY

SCROLLMENU

SURGECOUNT

RESETSAFETYON

PV

DISPLAYLIMIT
http://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://../TrainTools/UM5513.pdfhttp://im300h/S3Config.pdf

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Chapter 2 Installation and MaintenanceThis chapter tells how to mount, replace, disassemble, reassemble,and convert controllers, and discusses general troubleshooting.

Figure 2-1 Mounting a Series 3 Plus Controller

ControllerMounting

Refer to the Series 3 Plus Compressor Controllers Hardware Speci-fications[DS300/H]or Series 3 Plus Turbine Controllers HardwareSpecifications[DS307/H]for panel cutout dimensions and Figure2-1for an illustration of the slide clamps (these are located on thetop and bottom of the controller case). If your controller has FieldTermination Assemblies (FTAs), refer to theSeries 3 Plus Compres-sor Controllers Field Termination Assembly[DS300/T]or Series 3

Plus Turbine Controllers Field Termination Assembly[DS307/T]data sheet for information on mounting rails and data cables.

Use the following procedure to mount your controller in a properlysized cutout:

Step 1: Loosen the slide clamp pressure screws, then remove theclamps from the case.

1

2 3

Mounting Slide

PressureSlide ClampScrew

Note: Panel cutouts must have specified dimensions after painting.

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Step 2: Remove the slides from the case by sliding them to theback.

Step 3: Slide the controller case back into the panel cutout until theflanges contact the panel.

Step 4: Reinstall the slides and slide clamps from behind the panel.

Step 5: Tighten the pressure screws until the slides are tight againstthe panel.

Step 6: If using locally-mounted FTAs (in the same cabinet as thecontroller), snap them onto mounting rails, connect them to thecontroller with high-density interconnect cables (HDIC), andground both of each HDICs shield pigtails.

If using remotely-mounted FTAs, only the controller ends of theHDICs should be grounded (grounding both ends can create anelectric shock hazard if the ground potentials differ).

In order to safely comply with CE electromagnetic requirements,

connect both ends of each HDIC to equal-potential grounds.

Step 7: Connect your field wiring to the appropriate terminal blockson the Back Panel or FTAs.

Step 8: Configure and connect the power cable to the controller andan appropriate power supply (observe the caution on page 33).

Step 9: Use the Program Version[MODE TEST 2]and ProgramChecksum[MODE TEST 8]tests to determine the software revi-sion and CRC, then record them on a configuration form.

Step 10: If the controller was not preconfigured, enter appropriatevalues for all configuration and tuning parameters, as describedin the controllers instruction manual. Be sure to keep a recordof these values and the resulting parameter checksum.

If your controller was preconfigured, verify that the Parameter

Checksum[MODE LOCK 4]matches that recorded on the sup-plied configuration form. If not, identify and correct any changedparameters.

Caution: Grounding both ends of a long HDIC can create a hazardous groundloop.

Warning!When mounting a Turbine Controller, make sure you connectthe FOM to the Back Panel Outputs socket and the FIM to theInputs socket.

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Figure 2-2 Power Cable

Power Cable As shown in Figure 2-2, each pair of panel-mounted controllers iscurrently supplied with a 14-foot (4.3 meter) power cable, both endsof which are fitted with connectors that plug into the Back Panelpower receptacle. This cable can be cut at any point to provide max-imum flexibility in choosing the length of the two resulting cables.

The configuration of the power cable connectors depends on whichpower supply (AC or DC) is installed, as shown in Figure 2-3.

Figure 2-3 Power Cable connector configurations

Input Power Filter Series 3 Plus Controllers meet CE-specified electromagnetic com-patibility requirements only if each controller is equipped with adedicated input power filter that is an exact electrical equivalent ofthe Corcom model 3VB3 filter.

If the controller is mounted in an enclosure or cabinet, this filter mustbe installed within the same enclosure. Otherwise, it must beinstalled within twelve inches (30 cm) of the controller.

M630

Caution:Because the power cable connector is not designed to assure theground conductor is the first connection made and the last broken,there is a risk of electric shock while connecting or disconnecting thecable to the controller.

Line (Black)

Neutral (White)

Ground (Green)

Cable Controller

AC Cable

+ (Red)

(Black)

Ground (White)

DC Cable

Cable Controller

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ControllerReplacement

Use the following procedure to replace a malfunctioning controller:

Step 1: Obtain a spare unit from your company stores. If needed,convert it to the correct model by replacing the Front Panel.When converting between compressor and turbine controllers,you might also have to change the Back Panel and install orremove the Auxiliary PCB. Chapter 1describes the potentialhardware differences between controller models.

Step 2: Transfer control of your process to an alternate device.

Step 3: Unplug the power cable from the Back Panel of the malfunc-tioning controller. For FTA-equipped controllers, also disconnectthe data cable(s). For those without FTAs, unplug the BackPanel terminal strips (rather than disconnecting the individualwires from the terminal blocks).

Step 4: Loosen and remove the slide clamps from the case, removethe slides and pull the controller forward from the panel cutout.

Step 5: Verify that all of the replacement units internal switches andjumpers are set the same as in the controller being replaced.

Step 6: Temporarily connect a spare power cable to the Back Panelof the replacement controller.

Step 7: Connect a PC running one of our Series 3 Plus Controllersupport software packages (see Support Softwareon page 30)to a controller Modbus port (see Ports 3 and 4on page 63).

Step 8: Power up the new controller, computer, and converter, andconfigure them to communicate with each other.

Step 9: Use the Program Version[MODE TEST 2]test to verify that

the replacement contains the desired control program. If not,load that software using the Download or Configurator utility.

Step 10: If the replacement was not preconfigured, use the Configu-rator program to load the correct parameter set.

If the replacement has been preconfigured, use the ParameterChecksum[MODE LOCK 4]test to verify that its parameter set-tings match those of the original. If not, use the Configuratorutility to determine which parameters differ and correct them.

Step 11: Use the Engineering Panel MODE COMM 0key sequenceto set the replacements Controller and Computer ID Numbers

to match those of the original controller.Step 12: Disconnect the temporary power cable and install the

replacement controller into your panel by following steps 1 to 5of the previously described Controller Mountinginstructions.

Step 13: Reconnect the FTA data cable(s) or Back-Panel terminalstrips and power cable.

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InternalComponent

Access

With the exception of the Back Panel, any internal component of apanel-mounted controller can be removed from the front of thepanel. The components of an enclosure-mounted unit are readilyaccessible by opening the enclosure door.

Disassembly Use the following procedure to disassemble a panel-mountedSeries 3 Plus Controller (if installed, it is not necessary to removethe controller from the panel):


Step 2: Disconnect the power cable from the rear of the controller.

Step 3: Loosen the screw at the bottom of the Front Panel, pull itsleft side forward about an inch, then swing it out and to the left.

Step 4: To separate the Front and Engineering Panels (optionalunless replacing only one of these components), unplug thecable connecting them, then squeeze the top and bottom of the

wire hinge until you can pull it away from the Engineering Panel.Step 5: Remove the Engineering Panel Assembly (and Front Panel,

if still attached) from the case by removing the four galvanizedscrews at its corners and pulling the entire assembly forward todisengage it from the CPU PCB.

Step 6: Remove the CPU PCB, Analog PCB, Power Supply, andAuxiliary PCB (if present) as a unit by pulling them forward andout of the case. Considerable force may be required to disen-gage the CPU PCB from the connector on the Back Panel.

Step 7: To separate the Auxiliary PCB (if present), remove the four

machine screws that attach it to the standoffs on the AnalogPCB, then disengage the pins on its rear side from their connec-tor on the CPU PCB.

Step 8: To separate the Analog PCB, remove the four screws orstandoffs that attach it to the standoffs on the CPU PCB, thendisengage the connector joining those circuits boards.

Step 9: To separate the Power Supply, disengage the connectornear its trailing edge and remove the four machine screws thatattach it to the standoffs on the CPU PCB.

Caution:Disconnect the power cable before disassembling the controller ordisconnecting any internal component. Failure to do so is dangerousand can severely damage the controller.

Warning!

Never disassemble a Series 3 Plus Controller or handle any ofits circuit boards without taking steps to prevent static dis-charge. Spare parts must be stored in static-protective bags.Failure to follow these precautions can result in severe damageto the controllers internal components.

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Reassembly To reassemble the controller, you basically reverse the disassemblyprocedure:

Step 1:Align the Power Supplys mounting holes with the corre-sponding standoffs on the CPU PCB, reinstall the four machinescrews that attach it to those standoffs, and re-engage thepower supply connector to the pins protruding from the top sideof its trailing edge.

Step 2:Align the pins on the Analog PCBs rear side with the con-nectors on the CPU PCB, then reinstall the machine screws orstandoffs that attach it to the standoffs on the CPU board.

Step 3: If the controller includes an Auxiliary PCB, align the pins onits rear side with the corresponding connectors on the CPUPCB, then reinstall the four machine screws that attach it to thestandoffs on the Analog board.

Step 4: Slide the CPU PCB, Analog PCB, Power Supply, and Auxil-iary PCB (if so equipped) into the case as a unit. The CPU PCBfits into the left-most set of grooves in the top and bottom of thecase. Press fairly hard until you feel the CPU PCB pop backinto the connector on the front of the Back Panel.

Step 5:Align the tabs on the sides of the Engineering Panelsmounting brackets with the grooves in the sides of the case,then slide it back until the front of those brackets is flush with thefront of the mounting flange. Secure this assembly by reinstall-ing the four screws at its corners.

Step 6: Install the Engineering Keyboard (if necessary) by aligningits mounting holes with the standoffs on the circuit board behind

it (this should align the eight pins protruding from its lower rearside with the connector on the circuit board). Then reinstall thefour black screws that hold this assembly together.

Step 7: To reinstall the Front Panel (if necessary), insert either endof the wire hinge into its hole in the Engineering Panels mount-ing bracket, then squeeze the top and bottom of the hingetogether until you can insert the other tang into its hole. Thenplug the ribbon cable from the Engineering Panel into the con-nector on the back of the Front Panel.

Step 8: Swing the Front Panel back and to the right until it contacts

the front of the case. Pull its left edge forward about an inch,until you can engage the tab on its right rear side into the slot inthe right side of the case. Push the left side back until the panelis parallel to the front of the case, then secure it by tighteningthe retaining screw at the bottom of the panel.

Step 9: Reconnect the power cable to the controller.

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Figure 2-4 Panel-mounted controller with extender board installed

Testing andAdjusting Internal

Components

Because the internal components of a panel-mounted controller canbe accessed only by disassembling it, you can test or calibrate suchcontrollers only by using a test bench or Extender Board.

A test bench can be constructed from a spare Back Panel, which theCPU PCB, Analog PCB, and Power Supply Assemblies can beplugged into as a unit. Ideally, it should also include Engineeringand Front Panel Assemblies and a ribbon cable (like that used inenclosure-mounted units) for connecting them to the CPU boardsyou will be testing. This approach provides full access to both the

Analog PCB and the Power Supply Assemblies.

In contrast, using the Series 3 Plus Extender Board provides accessonly to the Analog PCB, but does allow you to work on the controllerin place. Use the following procedure to install one of these boards:


Step 2: Disconnect the power cable from the rear of the controller.

Step 3: Loosen the screw at the bottom of the Front Panel, pull its

left side forward about an inch, then swing it out and to the left.Step 4: Remove the Engineering Panel Assembly (and attached

Front Panel) by removing the four screws at its corners and pull-ing the assembly forward to disengage it from the CPU PCB.

Step 5: Remove the CPU PCB, Analog PCB, Power Supply, andAuxiliary PCB (if present) as a unit by pulling them forward andout of the case. Considerable force may be required to disen-gage the CPU PCB from the connector on the Back Panel.

Caution:Care should be taken to minimize the unavoidable risk of electric

shock while testing a powered controller.

Warning!

Your test bench and work area must be fully protected against

the possibility of static discharge. Failure to provide adequategrounding for both your equipment and personnel can result insevere damage to the controllers internal components.

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Step 6: Slide the Extender Board into the left-most set of grooves inthe top and bottom of the case (you can determine the properorientation by comparison with the CPU PCB). Press fairly harduntil you feel the CPU PCB pop back into its Back-Panelconnector.

Step 7: Reinstall the CPU PCB, Analog PCB, and Power Supply into

the case as a unit, (the CPU PCB fits into the left-most groovesin the top and bottom of the case). Press hard enough to seatthe CPU PCB into its connector on the front of the ExtenderBoard.

Step 8: If desired, reinstall the Engineering Panel (and connectedFront Panel) by plugging it into the front of the CPU PCB.

Step 9: Reconnect the power cable to the Back Panel of thecontroller.

When you are through testing or calibrating the unit, the ExtenderBoard can be removed by simply reversing these steps.

ModelConversion

Although any model Series 3 Plus Controller can be converted intoany other, it is easiest to interconvert those with the same Compo-nent Configuration(see page 14)so you only need to replace theFront Panel and load the desired software and parameters:

Step 1: Loosen the screw at the bottom of the Front Panel, pull itsleft side forward about an inch, then swing it out and to the left.

Step 2: Unplug the cable connecting the Front and EngineeringPanels.

Step 3: Squeeze the top and bottom of the wire hinge together untilyou can pull it away from the Engineering Panel.

Step 4: Reverse steps 1 to 3 to install the new panel.

New software can then be installed using the Download module ofour optional Toolbox support software. If you have that program, itsConfigurator module is the best tool for loading the new parameters.

To convert a controller into a model having a different componentconfiguration, you might also have to add or remove the AuxiliaryPCB Assembly and make sure the CPU PCB has enough controlrelays (turbine controllers generally require eight, while some com-pressor controllers have only five). If the controllers have differentBack Panels, you might also have to change it or reuse the Caseand Rear Panel from the controller you are replacing.

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GeneralTroubleshooting

This section contains information you will need to troubleshootgeneral problems with the controller. Because it is not practical tofully discuss control system troubleshooting in this manual, we areincluding only basic information that should be helpful to a reason-ably experienced troubleshooter.

Detailed troubleshooting information concerning each type of inputor output is included in the appropriate chapter. For example, Chap-ter 4includes information on troubleshooting serial communication.In addition, each controller provides several diagnostic tests thatcan be performed from the Engineering Keyboard. A general discus-sion of them can be found inChapter 3, whileAppendix Bdescribesthem in detail.

If a controller malfunction is suspected, transfer control of your pro-cess to a backup device. Then try to determine whether the problemis in this controller, another controller with which it communicates, orelsewhere in your control system (for example, a failed transmitter).

If the problem is in a controller, verify that it is not due to incorrectengineering parameters. If you have an up-to-date configurationworksheet, the Parameter Checksum[MODE LOCK 4]procedureprovides a quick check for changed parameters.

Additional information or assistance can be obtained by contactingthe Technical Service Department at Compressor Controls.

Blank Front Panel If a controller is inadequately protected (see Surge Suppressiononpage 61and Output Isolationon page 84), excessive Port 3, Port 4,or analog output voltages can cause the Front Panel to light its FaultLED and blank all other LEDs and readouts. Normal functioning canthen be restored by temporarily unplugging the controller.

Visible Damage With the controller disconnected from its power supply, examine theFront and Back Panels and all interior components for physicaldamage, signs of overheated components, broken wires, and such.If obvious physical damage is detected, try to identify and correctany external causes before replacing the damaged assemblies otherwise you risk damaging the replacement parts as well.

Controller Faults Every Series 3 Plus Controller has a front-panel Fault LED and oneor more fault relays that indicate various internal failures (see FaultIndicatorson page 105).

Caution:Always transfer your process to a backup control device beforepowering down or trouble-shooting a Series 3 Plus Controller. Inmost cases, the process signals should also be disconnected whiletesting the controller.

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Figure 2-5 Voltage test points on Analog PCB

Power Supply

Voltages

The voltages produced by the power supply must be within theranges shown in Table 2-1.

All voltages should be measured across the indicated capacitors onthe Analog PCB Assembly (see Figure 2-5). This means panel-mounted controllers must be tested using either a test stand or anExtender Board. If any voltage is outside its indicated range, mea-sure the voltage of the input power. Other possible causes include afaulty power supply or malfunctioning internal components. Over-loading by field transmitters or transducers can reduce the transmit-ter power supply voltage but will not affect the internal voltages.

If all the output voltages measure at or near zero and there is powerat the input voltage terminals, the fuse on either the Power Supply(see Figure 1-13) or the CPU PCB (see Figure 1-3) may be blown.

The 5 Vdc signal can be adjusted by setting potentiometer R33 (seeFigure 1-13). Replace the power supply if any other voltage is out-side its indicated range for reasons other than improper loading.

Table 2-1 Power supply voltages.

C7 (15 Vdc)C9 (5 Vdc) C5 (+15 Vdc)

C16 (24 Vdc)

Caution: While testing the controllers internal voltages, care should be takento minimize the unavoidable risk of electric shock.

Power Supply Output+5 Vdc4.75 to 5.25 Vdc15 Vdc14.4 to 15.6 Vdc+15 Vdc14.4 to 15.6 Vdc+24 Vdc19.0 to 34.5 Vdc

Transmitter Power Supply24 Vdc +22.8 to 25.2 Vdc

Input Power SourceAC:96 to 264 VacDC:21 to 32 Vdc

1 Make all electrical measurements with a 20 kW/V or higher imped-ance multimeter of 0.1% or better accuracy.

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Chapter 3 Configu ation and TestingEach Series 3 Plus Controller is adapted to its specific applicationby setting the configuration and tuning parameters that govern itsoperation. These can be viewed or changed from the Engineering

Panel or from a computer running our Series 3 Plus Configuratorutility (see Support Softwareon page 30). Each controller modelalso offers several diagnostic tests that can be run from the Engi-neering Panel.

This chapter describes the parameter memory and tells how to viewor alter parameter values or run tests from the engineering panel.Detailed test procedure descriptions can be found

Documents

IM300H