Alan Bradley Control
Abbreviations:
CAN control
area network . interface on ECU
COS change
of state
CNBR control
net bridge redundant
NUT network
update time
RES reset
RIUP remove
(insert) under power
RPI request
package inbound
RJ45 Network
style connector
STI Selectable
time interrupt (used to communicate with the core, usually 5ms)
Rack
Modules can be removed when under power
·
Any module
can be placed in any slot.
·
Modules
are not polled (a request for information is sent from the processor to the
modules in turn, the modules respond by returning their current state)
·
Modules
put data to the backplane such that all modules on the backplane can read it.
Processor
The part number: 1756-1551A
·
The first
part indicates, 1756 indicates the rack style, all modules on the rack have
this number.
·
The suffix
–1551A indicates the amount of memory installed:- 3.5Mbit
The current firmware version (June 2003) is
8.03
RS232 link
The 9 pin RS232 link can be used to connect
the laptop to interrogate the processor.
This is not the preferred method as the link is very slow! See Ethernet connection
Battery
The battery for backup purposes is non
re-chargeable, so it is advisable to change the battery when the power is onto
the rack.
941948-01 rev B
0022 PROMARK
Key modes
Run:
Processor running; the inputs are read in,
the logic operations completed and the outputs set, i.e. scanning.
Rem (remote):
Possible to change from run to prog from a
remote, or outside position, usually the control room via the laptop.
Prog (program)
Sets the outputs to a pre-defined, safe
state. This usually leads to an
uncontrolled shut down i.e. no VGV movement to control stall and no starting of
the AC lube oil pump.
Test
Inputs are read and the logic is scanned
but the outputs are not set.
Processor Indicator lamps
·
Run lamp
on: Normal running condition
·
I/O lamp
constant green: I/O card transmitting data
·
I/O lamp
flashing green: At least one I/O card is not responding. For example the Flex I/O card failure,
coaxial cable failure.
·
I/O lamp
off: Usually no project loaded.
·
I/O lamp
flashing red: Chassis failure; usually requires replacement of chassis.
·
Force lamp on steady yellow: At least one input or output is electrically
forced to a required valve. Often used
to test systems.
·
RS232 lamp
flashing: Indicates communication by the RS232 cable.
·
Battery
lamp on steady red: Less than 10% of the battery life available. (note the battery light off may indicate
there is no power to the backplate)
·
OK light
off: no power
·
OK light
flashing red: recoverable fault. Usually
caused by a fault set as a major fault, this leads to an engine shutdown. Recoverable refers to the ability to locate
and rectify the fault then reload the program and normal running will proceed.
If the I/O to a major card (e.g. fire &
gas, fuel supply) the following will occur
1.
Stop the
scan
2.
Output to
the safe state
·
OK light
steady red: non-recoverable error, usually requires firmware update or
replacement.
The processor deals with all processes
except:
·
Govern
·
Temperature
monitoring
SAM or OCX module[1]
Specialist processor to deal with the
Governing and temperature monitoring.
The SAM module is essentially a PC (266 MHz Pentium) that fits the Alan
Bradley rack.
Changes to the governor parameters are only
accessible via the SAM module
The SAM module outputs signals to the
backplane where they are seen as inputs by the processor, which will then act
on the information.
SAM Indicator lamps
OK lamp constant on: SAM module running
OK lamp constant on red: fault e.g.
watchdog timed out
INIT lamp constant on: SAM module booting
up.
USR lamp constant on: user configurable
(not used)
Ensure the jumper is set to 16 bit at the top of the module.
DC input module
Serial number
I = input
16 = 16 bit
·
Closed
contact ⇒ light on
·
Usually
used for internal signals
DC output module
Controls such as:
·
DC pump
·
Fire &
gas
Controller tags for output points are
indicated as follows:
Local3:O:Data:0 to: Local3:O:Data:31
Local3:O:Data:0 3
indicates the slot number in the rack, note start from slot 0
Local3:O:Data:0 O indicates output
Local3:O:Data:0 0 indicates bit zero on the data word of 32 bits
Flex I/O
The field I/O is linked to the Flex I/O
Control net (CNBR‡)
Using a screwdriver, the network address is
set using the slotted indicators . The
left-hand indicator represents tens, and the right indicator units. The screen indicates the network address as
follows:
A#01 where 01 indicates the network
address.
If it is necessary to change the Control
net card set the new card as the old card.
The local wiring goes from the
transmitters, switches etc. into the Flex I/O module. The Flex I/O module outputs via a co-axial
cable to the backplane which transmits the information to the processor.
1.
The
maximum number of nodes is 99
2.
The
maximum nodes per segment is 48
Control net Indicator lamps
Steady green: control net good
Flashing green: searching the network
Steady red: network fault
Ethernet card
·
Ethernet
cards transfer information at a high rate i.e. 10 Mbit/s
·
The IP
address is stored electronically on the Ethernet card
Device Net
Run at 230 kbit/s (far slower than Ethernet
at 10 Mbit/s) to talk to the ECU
The designers are attempting to put the
device net services onto the Ethernet to eliminate the Device net.
RS Logix 5000
Software programming tool
Current version = 8.02
A higher version on the laptop will upgrade
a lower version on the rack. This can
cause problems if one turbine is upgraded this means it will not be standard
amongst a customers fleet.
·
Tags, programs and tasks must be created off line
Tags
Control tags are global i.e. All modules
have access to them.
Program tags are local to the program they
are defined in.
When saving a project, only save with
tags if the engine is cold. If the
engine is hot and the tag values are saved it is unknown what will happen if
the engine is started with information about a hot
Forcing output
Only the following can be forced, otherwise
the force mask box in Controller tags will be greyed out.
·
Aliased
output and input values, digital or analogue
·
Output and
input values, digital or analogue. E.g.
Local3:O.Data.23
The force mask in column three of the
controller tags can be used to force outputs. E.g.
·
To set a
force for Local3:O.Data.0 place a 1 in the output mask box. See Figure 2
·
To enable
the forces From the Forces drop down box and press the Enable All Forces box
see Figure
5
Figure 5
Tasks
Tasks with the following icon: indicate the task is continuously running. And
interrupts the processor at the indicated time i.e. 5ms in this instance.
·
Each
program contains one main task and up to 31 other tasks.
·
Tasks can
be assigned priority from 1 to 15 where 1 is high priority.
RS Linx
Communication software; Sets the
communication device to communicate via serial or Ethernet cable.
Current version 2.4
A flat battery will result in a Minor
recoverable fault being displayed.
RS Networks
Software to configure networks
Control net = 3.22
Device net = 3.21
SP (software protection)
Software used to view protected files
Current version = 8.02
Data types
BOOL 1
bit 21 0 or 1 e.g.
SOL25
SINT 8
bit 28 +127,-128 e.g. MCV101
swash plat for starter motor 0 to 100 %
INT 16
bit 216 +32767,-32768 e.g. SD1 speed probe 0
to 20,000 RPM
DINT 32
bit 232 +2.147 ×109,-
2.147 × 109 e.g. kWH
output power 0 to 20,000,000 W, 20 MW
REAL 32
bit floating point values e.g. PT6 0 to 7 bar
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