CCC Vanguard Series 5 maintenance presentation

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Vanguard Duplex Vanguard Duplex MaintenanceMaintenance

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Vanguard System ComponentsVanguard System Components

• Duplex ChassisMain Processor Unit (MPU) and Transitional module (TMPU)Universal Power Supply Module (PSMU350)

• Local I/OInput/Output Cards (IOC) and Transitional Modules (TIOC)Duplex Analog Field Termination Assemblies (FTA)Duplex Discrete Field Termination Assemblies (FTA)FTA cables Power Supply (PSMU24)

• Remote I/O Subsystem (Sure Link)Remote Carrier Cards (RCC) and Transition Modules (TRCC)Remote Slaves (RSL)Remote Field Termination Assemblies (RFTA)Remote I/O power Supplies

• Ethernet ComponentsTwisted-Pair Hub and cablesFiber Optic HubFiber optic Termination Enclosure

• PC Work Station

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System OverviewSystem Overview

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System Hardware OverviewSystem Hardware Overview

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System Hardware Overview System Hardware Overview

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System Software OverviewSystem Software Overview

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HMI OverviewHMI Overview

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Modbus

OPC

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Project Engineering OverviewProject Engineering Overview

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HMI OverwiewHMI Overwiew

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Controller Components

• Vanguard System Components• Serial Communication Network• Software Architecture• Hardware Architecture

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Vanguard System Components• Duplex Chassis• Main Processor Units (MPUs) and Transitional

modules (TMPUs)• Universal Power Supply (PSMU-350)• Duplex Local IO subsystems• Duplex Input/Output Cards (IOC) and transition

modules (TIOCs)• Duplex Analog and Discrete Field Termination

Assemblies (FTAs)• FTA Cables

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System ProcessorM PUE-750

A


B

LocalI /OA

L ocalI/OB

Analo g

cPCI bus A

cPCI bus B

Dup lexFTA

AnalogDuple x

FTA

DiscreteDuplex

FTA

DiscreteDuplex

FTA

LocalI /OA

L ocalI/O

Analo gDup lex

FTADuplex

FTA

AnalogDuple x

FTA

MPU-750 A

Power Supplies

MPU-750 B

Duplex Vanguard Chassis

Controller OverviewController Overview

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A


B

LocalI /OA

L ocalI/OB

Analo g

cPCI bus A

cPCI bus B

Dup lexFTA

AnalogDuple x

FTA

DiscreteDuplex

FTA

DiscreteDuplex

FTA

LocalI /OA

L ocalI/O

Analo gDup lex

FTADuplex

FTA

AnalogDuple x

FTA

IOC-555-D A

IOC-555-D B

Local Input/Output Cards


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Duplex Analog Field Termination

Assembly

• Dual Power Inputs with Fuse Detection• Uses CCC Conditioning Modules• 11 Analog Inputs / 3 Analog Outputs


A


B

LocalI /OA

L ocalI/OB

Analo g

cPCI bus A

cPCI bus B

Dup lexFTA

AnalogDuple x

FTA

DiscreteDuplex

FTA

DiscreteDuplex

FTA

LocalI /OA

L ocalI/O

Analo gDup lex

FTADuplex

FTA

AnalogDuple x

FTA


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Duplex Digital Field Termination Assembly

• Dual Power Inputs with Fuse Detection• Discrete Input Power from External Source • Uses CCC Conditioning Modules• 8 Discrete Inputs / 7 Discrete Outputs / 3 Frequency Inputs


A


B

LocalI /OA

L ocalI/OB

Analo g

cPCI bus A

cPCI bus B

Dup lexFTA

AnalogDuple x

FTA

DiscreteDuplex

FTA

DiscreteDuplex

FTA

LocalI /OA

L ocalI/O

Analo gDup lex

FTADuplex

FTA

AnalogDuple x

FTA


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FTA POWER CONNECTIONSFTA POWER CONNECTIONS

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FTA POWER CONNECTIONFTA POWER CONNECTION

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Local Analog Conditioning

Modules

• Analog Inputs– 0.1 % accuracy – Failure Detection High and Low– 15 bit resolution– Two reference channels for converter verification– Voltage,Current, millivolt,RTD, Thermocouple

• Analog Outputs– 0.1 % accuracy– Failure Detection -

including open wire– 12 bit resolution– 4 - 20 mA output


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Local Discrete Conditioning

Modules

• Digital Inputs– 110/220 V AC or DC– 24 V AC or DC– Isolated Modules– Status LED

• Digital Outputs– Mechanical Relay

• 250 VAC 5 Amps• 250 VA up to 200 Watts

– Solid State Relay• 260 VDC 1 Amp

– Status LED– Fused Output


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Local Frequency Conditioning

Modules

• Speed Inputs– 0.01% Accuracy– Active or Passive– 5 Hz to 40K Hz


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Local Analog Conditioning

Modules

• Analog Inputs– 0.1 % accuracy – Failure Detection High and Low– 15 bit resolution– Two reference channels for converter verification– Voltage,Current, millivolt,RTD, Thermocouple

• Analog Outputs– 0.1 % accuracy– Failure Detection -

including open wire– 12 bit resolution– 4 - 20 mA output

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Serial Communication Network

• Ethernet Components• Twisted- Pair Hub and Cables• Fiber Optic Hub and cables• Fiber Optic Termination Enclosure

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Vanguard HardwareVanguard Hardware

HUB-C-4-1 • Ethernet 10Base-T Hub– Four 10 Base-T ports

with RJ45 shielded connectors

– DIN1 or 3 Railmount– LED Status Indication– Fault Relay– Redundant 24Vdc

Power inputs– Class 1 Div. 2

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S5 Ethernet ConnectionsS5 Ethernet Connections

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Software Architecture

• Real-Time Operating System• Control Application Software• Input and Output Data Flows

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• Real-Time Operating System (RTOS)• Field I/O processing• Peer Communication• System Diagnostics• Interface between hardware and control applications

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Software Architecture• Control Application Software• Steam Turbine Control • Antisurge Controller• Pressure Controller• Logic Controller• Gas Turbine• Extraction• Power Generator

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• Input and Output Data Flows

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• Functional Description– cPCI (Compact PCI) Bus used for communications

from the MPU-750 to the IOC-555-S and RCC-PBM– Input “Images” are sent to MPU-750 from the I/O

devices– Signal Selection Logic selects input to be used by

the control application.– Control applications determine output “Images” to

be sent to the I/O devices.

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Menu

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Hardware Architecture

• Hot Swap Concept• Healthy States• Critical Analog Output Failure Mode• Redundant Output Switching

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Hardware Architecture – Hot Swap• The duplex system uses an active

“Hot Backup” architecture where there aretwo control devices, one is the preferreddevice and the other is the hot backupdevice.

• The preferred device will be referred to asthe device A (primary) and is in control ofthe process whenever it is healthy.

• The hot backup device will be referred to asthe device B (secondary) and is in virtual control of the process along with the A device when the A device is healthy.

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Hardware Architecture - Hot Swap• Both system processors can communicate

with each of the two Local Input Output Cards (LIOCs) over the two cPCI busses(A and B), however each device may onlyoutput to its corresponding LIOC.

• Both LIOC’s can communicate with theduplex Field Termination Assemblies (FTAs) which support redundant outputs.

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Hardware Architecture - Hot Swap

• Two blue hot-swap LED indicators (PCI A and PCI B) are controlled by MPU A bus PCI A and MPU B bus PCI B.

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Hardware Architecture Hot Swap

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• MPU Healthy • An MPU processor is considered to be in a HEALTHY

state when there are no fatal errors conditions and processor is not forcing the card not Healthy.

• Project is running (loaded)• IOC soft heartbeat is present and IOC is installed

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Critical Faults• IOC/MPU communication failure• MPU not running • Communication time out• IOC power supply failure (greater then 15 %

from nominal)• Critical Analog output failure• FTA failure or not configured• Force fault by MPU• IOC watchdog timer not working• Corrupted Data

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IOC HEALTHY• IOC/MPU communication working• Calibration data is valid • Communication time • IOC power supply failure (greater then 15 %

from nominal)• IOC watchdog timer working

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Menu

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Healthy States

Menu

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Healthy States and Fault Relays• Each Duplex FTA contains a set of system fault relays controlled

by the following :– FT_RELAY

• Watchdog Timer is being reset• The MPUE-750 processor card is healthy• The IOC-555-D processor is acknowledging the

healthy MPUE-750 card

– FT_SWITCH• No software reset is present• No hardware reset is present• No power reset is present• The IOC-555 processor card is healthy

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Healthy States and Fault Relay• FTA’s will Feedback

– IOC connection (A and B) information– FTA is healthy indication– Fault tolerant peer healthy indication

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Healthy comes from IOCHealthy FB : is FTA relay healthy and is cable inA not B are cables correct a to a and b to bHealthy peer: is B card healthyIf IOC is healthy and one MPU processor energizes The Health Relay then these signals will be low. If the IOC is Healthy and these signals are high then IOC processor can determine that the MPU processor has not enable the Healthy Relay or the FT-Switch or the FT-relay circuitry is not operating properly.

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System Diagnostics System Diagnostics

• Self-Diagnostics of Inputs and Outputs– Analog Output (verified to controller output)– Digital Output (verified to controller output)

• Integrity Monitoring Discrete input can be used to verify a critical loop additionally

– Analog Inputs (verified to be within a configurable range)

– Frequency Inputs (verified to be above a configurable low limit)

– Discrete inputs (not verified)• Integrity Monitoring Discrete input can be used to

verify a critical loop if needed

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Typical analog input connectionTypical analog input connection

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Redundant Output Switching• An analog output loopback error will not cause

controller output switch unles that output is configured to be critical

• Setting a duplex analog output to be critical output affects both IOB A and IOB B.

• They can be set same or different on each card

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Duplex analog output connectionDuplex analog output connection

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Duplex Digital OutputDuplex Digital Output

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Duplex Digital Output MonitoringDuplex Digital Output Monitoring

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Discrete Input integrity monitoring (EXT)

Discrete Input integrity monitoring (EXT)

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Discrete Input integrity monitoring (INT)

Discrete Input integrity monitoring (INT)

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Typical RTD 3 wire inputTypical RTD 3 wire input

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Typical analog input with Cold Junction compensation

Typical analog input with Cold Junction compensation

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Frequency input passive MPUFrequency input passive MPU

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Duplex Digital Output driving Solonoid

Duplex Digital Output driving Solonoid

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S5 Fiber Optic ConnectionsS5 Fiber Optic Connections

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HUB-C-4-1 • Ethernet 10Base-T Hub– Four 10 Base-T ports

with RJ45 shielded connectors

– DIN1 or 3 Railmount– LED Status Indication– Fault Relay– Redundant 24Vdc

Power inputs– Class 1 Div. 2

Vanguard Controller OverviewVanguard Controller Overview

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Local Discrete Conditioning

Modules

• Digital Inputs– 110/220 V AC or DC– 24 V AC or DC– Isolated Modules– Status LED

• Digital Outputs– Mechanical Relay

• 250 VAC 5 Amps• 250 VA up to 200 Watts

– Solid State Relay• 260 VDC 1 Amp

– Status LED– Fused Output

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Local Frequency Conditioning

Modules

• Speed Inputs– 0.01% Accuracy– Active or Passive– 5 Hz to 40K Hz

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HubsHubs

• Hub types:» 10Base-T Hub (HUB-C-4-1)» Fiber-Optic Hub (HUB-F-2-1)

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Local Fault IndicatorsLocal Fault Indicators

• Fan Failed Indicator

• Power Supplies LED indicators

• MPU Processor LED

• IOC Card LED

• TMPU LED

• TIOC LED

• HUB LED

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Duplex Vanguard Chassis CPCI-10-D

LED INDICATORSLED INDICATORS

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• Fan Tray Indicator– Fan Fail light is located at the front and center of the fan tray.

Verify that the Fans are operating and the FAN FAIL indicator isOFF.

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Input OKFault

PSMU-350-1

CompactPCI®AC/DC InputPower Supply

Input OKFault

PSMU-350-1

CompactPCI®AC/DC InputPower Supply

LL®

COMPRESSOR

CONTROLS

CORPORATION

®

COMPRESSOR

CONTROLS

CORPORATION

v v

Input OKFault

PSMU-350

.

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MPU-750

10/10

0 BA

SE

TUSB 1

CPI

ABT

BFL

RST

CPU

PCI M

EZZA

NIN

E C

ARD

COM 1

CPCI

USB 0

CPI

BFL CPU

CPCI

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IOC-555-D

IOC-555-D

HEALTH

ALARM

POWER

CNTRL

IND 1

IND 2Tx Rx Tx Rx

P2P1

I OC-5 55-D

H E A LT H

AL A RM

PO WE R

C NTRL

IN D 1

IN D 2

TxRx Tx Rx

P2P1

P1

P2

RS–485

RS–4

85

HOT SWAP

PCI A

PCI B

HOT SWAP

PCI A

PCI B

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IOC STATESIOC STATES

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TMPU-750

PORT 1

POR

T 2PO

RT 3

PORT 4

Tx Rx Tx Rx

P1 P2

Tx Rx Tx Rx

P3 P4

E1

E2

Tx Rx Tx Rx

P3 P4

TMPU-750-2

F2F1

PORT

1POR

T 2PO

RT 3

PORT 4

Tx Rx Tx Rx

P1 P2

Tx Rx Tx Rx

P3 P4

Tx Rx Tx Rx

P1 P2

Lk Rx Lk Rx

F1 F2

Lk Rx Lk Rx

F1 F2

Rx

Tx

Rx

Tx


TMPU-750

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TIOC-555

TIOC-555HEALTHY1 4

FTA 1

FTA 2

FTA

3FTA

4RS–4

85

TIOC-555Healthy1 4The local FTA must be connected and

power applied to the FTA before the Healthy indicator shows a healthy status.

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PSMU-24

LED Status Indicator StatesPoweron Green: Power and Fuse Goodflashing Green: No Loadoff Green: Fault or No Input Power

Description

LED

1 2 3 1 2 3 4 5

Power

SureLinkRemote I/O System

LCOMPRESSORCONTROLSCORPORATION 24 Volt DC Power Supply PSMU-24-1

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FTA-544

PowerLED s

A

Healthy AL EDs

Healthy BLED s

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FTA-554

A

PowerLEDs

Healthy ALEDs

Healthy BLEDs Internal Power

LED

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HUB-C-4-1

Port 1 Port 2

Port 3 Port 4

P1 P2

1 2

3 4

DA/STAT

RH1-TPRheinmetall Elektronik

Hirschmann

Indicators

P1 P2 Ports 1 to 4on – – Green: L1 Power Good (Main)– on – Green: L2 Power Good (Backup)

on Green: Receiving Link Test Pulseson Yellow: Receiving Data

– – flashing Green: Auto Partioned (Receive Disabled)

LED Status Indicator StatesDescription

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Duplex Component ReplacementDuplex Component Replacement

Replacement Preparation Checklist

• Replacement Preparation Checklist identifies items youwill need, and preparation tasks you must complete before starting the replacement procedures, see Table 6-1.

• This preparation checklist should be done each timethe system is changed and archived for use during the replacement process.

• Replacement Preparation Checklist must be completed

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Preparation ListPreparation List

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Preparation ListPreparation List

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Configurator ViewConfigurator View

Menu

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MPU 750 ReplacementMPU 750 Replacement

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IOC 555 ReplacementIOC 555 Replacement

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Recovery procedureRecovery procedure

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Fan Maintenance Fan Maintenance

The fan tray slides in from the front of the chassis.Two locking screws hold the tray to the chassis.The locking screws are used as a handle to pull the tray from the chassis.

FRONTFan Tray

FanLockingScrew

FanLockingScrew

Fan FailIndicator

FAN FAIL

P2P1

P1

P2

RS–485

RS–485

I np ut OK

F au lt

PSMU-350-1

C omp ac tP C I ®

A C / D C I np utPo w er S up pl y

v

10 9 7 6 5 4 3 2 18

L ®

C om pre ss orC on t rol sC orp o rat i on

I n pu t OK

F au l t

PSMU-350-1

C om pa ct P C I ®

AC / D C I np utP ow e r S u pp ly

v

L ®

C o mp res so rC o nt ro l sC o rpo rat i o n

In pu t OK

Fa ul t

PSMU-350-1

C o mpa ct P C I ®

A C / D C I n pu tP ow e r Su pp ly

v

L ®

C o mp res so rC o nt ro l sC o rpo ra t io n

I np ut OK

Fa ul t

PSMU-350-1

Co mp ac tP C I ®

A C / D C In pu tPo w er S up pl y

v

L ®

C o mp re ss orC o n t rol sC o rp ora t i on

10/100 BASE T

USB 1

C P I

A B T

B FL

R S T

C P U

PCI MEZZANINE CARD

COM 1

C P C I

USB 0

10/100 BASE T

USB 1

C P I

A B T

B FL

R S T

C P U

PCI MEZZANINE CARD

COM 1

C P C I

USB 0

P2P1

P1

P2

RS–485

RS–485

P2P1

P1

P2

RS–485

RS–485

P2P1

P1

P2

RS–485

RS–485

4321

IOC-555-D IOC-555-D IOC-555-D IOC-555-D

HOT SWAPHOT SWAP HOT SWAPHOT SWAP

TxRxTxRxTxRxTxRx TxRxTxRxTxRxTxRx

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Fan MaintenanceFan Maintenance

The fan tray assembly provides multiple fans for cooling the cards and power supplies.The tray assembly can be removed under power for no longer than one minute

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Fan Maintenance Fan Maintenance

• Follow these steps to inspect the fans. – Inspect the fans by turning the fan impeller

with your finger. The fans should turn freely without dragging.

– Check the impeller for no up-and-down movement which would indicate a bad bearing.

– Use a soft brush or cloth to remove any buildup dust from the fans.

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Fan MaintenanceFan Maintenance

• Follow these steps to re-install the old fan tray or install a new fan tray when necessary.– Place the fan tray back in the chassis and push in

the tray until the connector is fully connected (stops moving).

– Listen for the fans to start and verify that the Fan Fail indicator is green. If the indicator is off, replace the fan tray.

– Turn both locking screws clockwise until they are tight (fully connect).

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Duplex Power Supply Replacement


CPCI-10-D2 Chassis Power Supply Module

Figure 6-24 Front View CPCI-10-D2

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Replacing a CPCI-10-D2 Chassis Power Supply Module

• CPCI-10-D2 duplex chassis support four PSMU-350 power supply modules. The first PSMis installed in the left position, closest to the MPU. Thethree remaining PSMs are installed in the adjacent positions.

• Specifications on the power supply (PSMU-350) used inthe CPCI-10-D and CPCI-10-D2 duplex chassis are locatedin Vanguard Power Supply Module [DS5112].

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• If any of the power supplies fail (any voltage output) or if a power supply is not fully inserted, a power fault (red LED) is reported and the fault relay will de-energize.The Power Fault relay is provided with Normally Open (NO) and Normally Closed (NC) contacts .

• Note: A power fault may or may not be reported when a functioning power supply is removed from a redundant group or when input power is removedfrom one of the supplies in a redundant group.Clear this alarm if it should occur.

Replacing a CPCI-10-D2 Chassis Power Supply Module

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Loosen the locking screws to disengage the power supply from the chassis. Unlatch the top and bottom ejector handles and pull the card out in one motion from the chassis.

Remove old PSMU-350 power supply

Observe LED indicators on the replacement power supply for Input OK (green) and no Fault (OFF).

Verify supply operation

Slide the replacement power supply module into the card guide and in one motion, insert the power supply module into the backplane connects, then latch the top and bottom ejector handles.Tighten the locking screws to secure the power supply module into the chassis.

Install replacement PSMU-350 power supply

Do not mix power supply part numbers in the same chassis.

CAUTION

START HERE and move down the table completing each task before moving to the next task.

NOTE

ActionTask

Replace AssemblyReplace Assembly

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Use Alarm Monitor to acknowledge any alarms caused by the power supply failure; they should turn yellow.You should be able to understand and resolve any remaining alarms.

Acknowledge all power supply failure alarms

ActionTask

Clear AlarmsClear Alarms

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Alarms and Error CodesAlarms and Error Codes

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• Controller status Flags

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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• I/O Error codes

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Documents

CCC Vanguard Series 5 maintenance presentation