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ROC809 Instruction Manual

1. V 2 LED f V3 LED POWER INPUT I Lo z lt OSI AUX AUX x DUCO439A Figure 3 2 24 Volt DC Power Input Module 3 3 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 3 24 Volts DC Power Input Terminal Block Connections Terminal Blocks Volts DC and Accepts 24 volts dc nominal from an AC DC converter or 18 to 30 volts dc other 24 volts dc supply AUX and AUX Supplies reverse polarity protected source voltage to 12 volts dc minus external devices 0 7 volts dc Table 3 4 24 Volts DC Power Input LED Indicators Sigma ED Green LED on when voltage is provided to backplane Green LED on when voltage is provided to CPU 3 1 3 Auxiliary Output AUX and AUX AUX and AUX terminals can be used to supply reverse polarity protected source voltage to external devices such as a radio or solenoid All module terminal blocks accept 12 AWG or smaller wiring Refer to Figure 3 3 and Figure 3 4 For the 12 volt Power Input Module the auxiliary output follows the voltage located at BAT minus 0 7 Volts DC which is the protection diode voltage drop For example if the BAT voltage is 13 volts dc then AUX is 12 3 volts dc For the 12 volt Power Input Module AUX AUX is always on and is current limited by a fast acting glass 2 5 Amp x 20 mm fuse In the event that the fuse blows CSA requires that the 2 5 Amp fast acting
2. CURRENT LOOP CONTROL CURRENT LOOP CONTROL a a SL p E 1 5 VOLT CONTROL DEVICE Bl DOC0505A Figure 4 7 Analog Output Module Field Wiring NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying module commons together Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 5 Discrete Input Modules The eight channel Discrete Input DI modules monitor the status of relays open collector open drain type solid state switches and other two state devices Discrete Inputs come from relays switches and other devices which generate an on off open close or high low signal The DI module provides a source voltage for dry relay contacts or for an open collector solid state switch The DI module s LEDs light when each input is active Each DI channel can be software configured to function as a momentary or latched DI A latched DI remains in the active state until reset Other parameters can invert the field signal and gather statistical information on the number of transitions and the time accumulated in the on or off state The Discrete Input module operates with non powered discrete devices such as dry relay contacts or isolated solid state switches Use of the DI module with powered devices may cause improper operation or damage The DI module senses the current flow which signals the ROC800 series unit electronics tha
3. 5 6 Table 5 6 Ethernet Signalinicsisnian 5 7 Table 5 7 Built in EIA 232 RS 232 Signal Routing COT serene le eet eda et a 5 9 Table 5 8 EIA 232 RS 232 Communication Module Signal Routing Comm3 Comm4 and Comm 5 9 Table 5 9 EIA 422 RS 422 Signal Routing Comm3 Conim4 and COMMS aaneren aer Na 5 10 Table 6 1 Analog Input Module Typical Configuration Vae S oneen E N E 6 4 l 4 Index TEMP EE De E E E eres ee 3 3 Temperature Detector See J and K Type Thermocouple Inputs 4 16 Termination EIA 422 485 RS 422 485 Communications 5 10 MV Sra E AE 5 13 Tests AWOMA C s a tan eneesramwe eases 1 8 Thermocouple See J and K Type Thermocouple Inputs 4 16 FO Caran er oR A SP 1 6 TrOUDIESHOOUNE e Meganenn dees 6 1 Anado INDUS e a ues 6 4 Anador OQUPI Sea a eens 6 5 Diseret PU reene a Nea ieees 6 6 Discrete Outp t Relay masnisermire ninsori ns 6 7 Directe OMMI acarne E EER 6 7 J and K Type Thermocouple Inputs 0 6 9 Pulse PU S ep EEE 6 7 RED EDU oirin 6 8 System Analog Inputs ccccccccccecccceceeeeeeeseeeeees 1 4 U O H EE EE E EEEE E rer cn ee nee erent er nee emer 5 7 V V OFF LED aenn EEA 3 3 Vok EE Dreper en EEA EVO TE 3 3 VOIAS Ersan E 3 1 V ovER CE Doerr r an EEEE 3 3 W Watchdog Software and Hardware s sssseeeeeeeeeeeeeeeeaees 1 8 Wire channel COVEIS ctericlice ie eerie acest as 2 4 Wire G 2 10 Duchenne eee ee ee re
4. 5 11 Communications Rev Feb 05 ROC809 Instruction Manual The dial up modem provides communications with speeds up to 14 4K bps with V 42 bis and V 42 MNP2 4 and MNP 10 error correction The dial up modem module is FCC Part 68 approved for use with PSTNs The FCC label on the module provides the FCC registration number and the ringer equivalent The dial up modem module supports data compression error correction and nonvolatile RAM for permanent storage of the modem configuration The dial up modem module interfaces to two wire full duplex telephone lines using asynchronous operation The module interfaces to a PSTN through an RJ 11 jack The dial up modem can be controlled using industry standard AT command software A 40 character command line is provided for the AT command set which is compatible with EIA document TR302 2 88 08006 The dial up modem automatically hangs up after a configured period of communications inactivity The dial up modem provides automated dial up alarm reporting capabilities Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 Table 5 13 RJ 11 Field Connections LED indicators on the module show the status of the Receive RX Transmit TX Ring RI and Carrier Detect CD control lines Table 5 14 displays connector signals and their functions Table 5 14 Modem Signal Routing Comm3 Comm4 and Comm5 Signal Function Terminal Lit when module Comms Comm4 or
5. a namiele T Sensor Supply Current 85 mA at nominal 12 Type Single ended voltage sense 12 bit or 24 V dc resolution uses 16 bit A D converter Voltage 0 5 V dc 1 22 mV count Impedance 10 Megohms typical without scaling ISOLATION Field to Logic 2500 V dc 1 minute minimum resistor Field to Power 2500 V dc 1 minute minimum Maximum Overload Voltage 24V continuous Module to Module 2500 V dc 1 minute minimum Absolute Accuracy at 25 C 77 F 0 10 WEIGHT nu Accuracy Over Operating Temp 56 7 g 2 0 02 0 15 ENVIRONMENTAL Same as the ROC800 Series unit in which it is installed DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 29 in H by 2 96 in D Minimum Scan Period 50 msec for all channels APPROVALS Same as the ROC800 Series unit in which it is installed 1 Absolute Accuracy Includes Linearity Hysteresis Repeatability Stability Gain and Offset error 4 22 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 2 Analog Output Module Analog Output Module Specifications FIELD WIRING TERMINALS CO 6 COM 8 COM _ Analog Output Return 9 NA A OUTPUT Quantity 4 channels Type Single ended current control 16 bit resolution Maximum Input Overload Voltage 24 V dc continuous Output Load at 12 Volts DC 300 ohms maximum Output Load at 24 Volts DC 750 ohms maximum Absolute Accuracy at 25 C
6. Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Slide the CPU module into the slot 2 Press the CPU firmly into the slot ensuring the ejector clips are lying on the module rail guides The connectors at the back of the CPU module fit securely into the connectors on the backplane Place the CPU faceplate on the CPU Tighten the two screws on the faceplate of the CPU module firmly Refer to Figure 2 5 Replace the wire channel cover Return power to the ROC809 unit ee ae e Refer to Section 2 8 5 After Removing Power from the ROC809 on page 2 38 and perform the restore procedure 2 10 Installation and Use Rev Feb 05 ROC809 Instruction Manual 2 7 License Keys License Keys with valid license codes grant access to applications Examples of licensed applications include DS800 Development Suite Software meter run calculations and various user programs These applications can then be configured using the ROCLINK 800 configuration software and the DS800 Development Suite Software The term License Key refers to the p
7. terminal should have a similar fuse to the 12 volts dc Power Input Module See Figure 3 5 25 Amp Fuse 12 Volt DC Battery Bank AC to 12 Volt DC Power Supply 24 Volt DC 12 Volt DC Power Converter Other 12 Volt DC Nominal Source BATWIRE DSF Figure 3 5 12 VDC Power Supply and BAT BAT Wiring 7 Screw each wire into the terminal block 8 Plug the terminal block connector back into the socket 3 17 Power Connections Rev Feb 05 ROC809 Instruction Manual 9 If you are monitoring an external charge voltage 12 volts dc Power Input Module only wire the CHG and CHG terminal block connector Refer to Figure 3 6 Solar a Panel Solar Regulator Batteries Power Supply Terminal Block CHG BAT III 5 Amp Fuse 809CHG DSF Figure 3 6 12 VDC Power Supply and CHG CHG Wiring 10 Replace all other power sources if necessary to the ROC800 Series unit 11 Refer to Section 2 8 5 After Removing Power from the ROC800 Series unit on page 2 38 and perform the restore procedure NOTE Refer to Table 3 2 concerning LEDs 3 5 2 How to Wire the External Batteries External batteries can be used as the main source of power for the ROC800 Series unit with the 12 volts dc Power Input Module The maximum voltage that can be applied to the BAT BAT terminals is 16 volts dc before damage may occur The recommended
8. Duty Cycle Active time Active time Inactive time For example if a Discrete Output is active for 15 seconds out of every 60 seconds Duty Cycle 15 seconds 15 seconds 45 seconds 15 seconds 60 seconds 0 25 3 11 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 10 Power Consumption of the Discrete Output Relay Modules I O Module ROWER CONSUMPL ONLNE Quantity Duty Sub Total or er eee Discrete Relay Output 6 8 mA 12 volts dc 1800 mW ee mA for 10 msec msec 1800 mW 150 mA for 10 msec pnanners during transition ee msec 1800 mW 150 mA for 10 msec Channel 3 during transition for 10 msec 1800 mW Channel 4 150 mA for 10 Mose for 10 during transition msec 1800 mW 150 mA for 10 msec Channel 5 during transition for 10 msec 1800 mW Maximum 5 msec The Duty Cycle is Number of Transitions in some time period 0 01 sec Seconds in the period Duty Cycle For example if a DOR channel is changing state 80 time per hour 80 Number of transitions Hour is the time period There are 3600 seconds in an hour Duty Cycle 80 0 01 3600 0 0002 3 12 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 11 Power Consumption of the High and Low Speed Pulse Input Modules I O Module eee ee ee mW Quantity Duty Sub Total oe Lee eee High and Low Speed Pulse Input 21mA 12 volts dc Channel 1 sssemw Channel 2 88 8 mW E Per Active
9. In addition you will be advised of your right to file a complaint with the FCC if you believe it necessary The telephone company may make changes to its facilities equipment operations or procedures that could affect the operation of the equipment If this happens the telephone company will provide advance notice so you can make the necessary modifications to maintain uninterrupted service If trouble is experienced with this equipment dial up modem for repair or warranty information please contact Emerson Process Management Flow Computer Division 641 754 3923 If the equipment is causing harm to the telephone network the telephone company may request that you disconnect the equipment until the problem is resolved 1 3 Firmware The firmware that resides in Flash Read Only Memory ROM contains the operating system ROC Plus communications protocol and application software The CPU module provides battery backed SRAM Static Random Access Memory for saving configurations storing events alarms and the historical logs The ROC800 Series Operating System Firmware provides a complete operating system for the ROC809 Remote Operations Controller The firmware in the ROC809 is field upgradeable using a 1 5 General Information Rev Feb 05 ROC809 Instruction Manual serial connection or LOI For more information refer to the ROCLINK 800 Configuration Software User Manual Form A6121 The firmware supports Input Output Data
10. ROC809 Instruction Manual Table 3 2 12 Volts DC Power Input LED Indicators Green LED on when voltage is in tolerance on BAT and BAT Fault Red LED on when the AUXsw output are disabled by the CPU control line Fault Red LED on when AUXgw is disabled due to excess voltage on BAT TEMP Fault Red LED on when AUXsw output are disabled due to the excess temperature of the power input module 3 1 2 24 Volts DC Power Input Module The ROC800 Series unit can accept 24 volts dc nominal input power from an AC DC converter or other 24 volts dc supply connected to the and terminals Input power can be connected to either or both of the and channels The 24 V dc power module does not have CHG terminals for monitoring a charging voltage This module does not monitor the input voltage for alarming sleep mode or other monitoring purposes The module does have two LEDs that indicate voltage is received at the backplane and the CPU The base system CPU power input and backplane requires less than 70 mA The power input module economizes power consumption using 3 3 volts dc switching power that provides power to the ROC800 Series modules via the backplane When this module is installed the ROC800 Series unit requires 20 to 30 volts dc for proper operation The AUX AUX terminals can be used to supply reverse polarity protected source voltage to external devices such as a radio or solenoid PM 24 V127
11. This section describes the built in communications and the optional communication modules used with the ROC800 Series Remote Operations Controllers Section Page 5 1 Communications Ports and Modules Overview 5 1 3 2 How to Install a Communication Module 5 3 53 How to Remove a Communications Module 5 4 5 4 How to Wire Communications 5 4 S3 Local Operator Interface LOT 5 5 5 6 Ethernet Communications 5 7 S EIA 232 RS 232 Serial Communications 5 8 5 8 EIA 422 485 RS 422 485 Serial Communications Module 5 9 5 9 Dial up Modem Communications Module 5 11 5 10 Mult Variable Sensor MVS Interface Module 5 12 5 11 Communications Specifications 5 15 5 1 Communication Ports and Modules Overview The built in communications and the optional communication modules provide communications between the ROC800 Series unit and a host system or external devices The ROC800 Series unit allows up to six communication ports Three communication ports are built in on the CPU and up to three additional ports may be added with communication modules Table 5 1 displays the types of communications available for the ROC800 Series Table 5 1 Built in Communications and Optional Communication Modules EIA 232 RS 232D Local Operator Interface LOI ooo Ethernet use with DS800 Configuration Software i Ct Comms to Comms Comms to Comms The communication modules consist of a communications module card a communications port wiring terminal block LEDs
12. 12 V dc Module Maximum Voltage Range 11 25 to 16 V dc 24 V dc Module Operating Input Range 20 to 30 V dc BATTERY BACKUP User replaceable Type Sanyo 3 V CR2430 lithium Normal use life 10 years while power is applied to unit Backup life 1 year minimum while jumper is disengaged and no power is applied to unit Shelf life 10 years VOLTAGE MONITOR ACCURACY 0 75 typical 1 maximum TIME FUNCTIONS Clock Type 32 KHz crystal oscillator with regulated supply battery backed Year Month Day and Hour Minute Second with Daylight Savings Time control Clock Accuracy 0 01 Watchdog Timer Hardware monitor expires after 3 seconds and resets the processor MATERIALS Case Acrylonitrile Butadiene Styrene ABS Plastic Wire Channel Covers Polypropylene Plastic Modules Thermoplastic Polyester solvent resistant WIRING Size 12 AWG or smaller for terminal blocks DIN RAILS Size 35 DIMENSIONS 241 mm H by 244 mm W by 174 mm D 9 5 in H by 9 6 in W by 6 85 in D allow an additional 19 mm 75 in for cables Rev Feb 05 ROC809 Instruction Manual ROC809 Remote Operations Controller Specifications Continued WEIGHT 1 65 kg 3 65 Ib for housing backplane and CPU I O Modules Vary from 49 60 g 1 76 2 1 oz Modem Module 113 4 g 4 02 EIA 232 RS 232 Module 47 6 g 1 68 02 EIA 422 485 RS 422 485 Module 49 9 g 1 76 OZ MVS Module 61 2 g 2 16 oz 12 VDC Power Input Modul
13. 2 11 Installation and Use Rev Feb 05 ROC809 Instruction Manual ae id ram Ge N LS qe E bE TE U c lt U U U Incorrect Correct PEOR Figure 2 7 License Key Installation NOTE When using a single License Key it must be installed in slot P4 7 Press the License Key into the terminal until it is firmly seated Refer to Figure 2 7 Replace the CPU faceplate 9 Replace the screws on the CPU faceplate 10 11 12 Replace the wire channel cover Restore power to the ROC809 Refer to Section 2 8 5 After Removing Power from the ROC809 on page 2 38 and perform the restore procedure 2 7 2 How to Remove a License Key To remove a License Key Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 D n PF WN N Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure Remove power from the ROC809 Remove the wir
14. 6 Power Consumption of the Analog Input INIOGUICS xcidssonsscnSecmastes mr aneascnnccarsenceeseuahansareecumiases anne 3 8 Table 3 7 Power Consumption of the Analog Output INTO GUC sssaaa ann aeasusabarscu smear S 3 9 Table 3 8 Power Consumption of the Discrete Input IVIOGUBICS aeieis ese ni ce cer ates secon Mer ceuee aaa eaadaceiacede 3 10 Table 3 9 Power Consumption of the Discrete Output INIOGUICS sarsan 3 11 Table 4 1 RTD Signal Routing ee 4 14 Table 4 2 RTD Wiring cccccccccceeceeeeeeeeeeeeeeees 4 15 Table 5 1 Built in Communications and Optional Communication Modules cccsssssessessseeeeeeeeeeeees 5 1 Table 5 10 EIA 485 RS 485 Signal Routing Comm3 Comm4 and Comm cece eee eece eee 5 10 Table 5 11 EIA 422 RS 422 Module 0 5 11 Table 5 12 EIA 485 RS 485 Module 5 11 Table 5 13 RJ 11 Field Connections 0 5 12 Table 5 14 Modem Signal Routing Comm3 Comm4 and Co OMI a a E 5 12 Table 5 15 MVS Termination cccceeeseeeeeeees 5 13 Table 5 16 MVS Signal Routing Comm3 Comm4 GNC ONA ee eo E a 5 14 Table 5 2 Communication LED Indicator Definitions5 2 Table 5 3 Built in LOI EIA 232 Signal Routing 5 5 Table 5 4 RJ 45 to EIA 232 RS 232 Null modem Cable Signal Routing sss cece celta Getn ts 5 6 Table 5 5 Using Cable Warehouse 0378 2 D Sub to Modular Converter 9 Pin to RJ 45 Black
15. 6 1 How to Remove the CPU Module To remove the CPU module 2 9 Installation and Use Rev Feb 05 ROC809 Instruction Manual CAUTION Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure Remove power from the ROC809 unit Remove the wire channel cover Unscrew the two small screws on the front of the CPU module and remove the faceplate a a eS N Place a small screwdriver under the ejector clip at the top or bottom of the CPU module and lightly pry the CPU module out of its socket You may find it easiest to carefully pry on the top ejector clip a little then carefully pry the bottom ejector Refer to Figure 25 You will feel and hear the CPU as it detaches from the backplane 6 Remove the CPU module carefully Do not scrape either side of the module against the ROC809 unit Make sure not to pull on any cables attached to the CPU module 2 6 2 Howto Install the CPU Module To install the CPU module CAUTION
16. 7 1 Central Processor Unit P d EEE T E A 1 3 CHO termina iini i 3 2 Cold Junction Compensation CIC ick catia acdsee E E 4 16 COM ea a e a 5 1 COM nea e eva taeneniamate 5 1 COMIN enn Ran aeatrenieeevaataenamgtes 5 1 COTA ean a 5 1 l 1 COMIS ao e n O 5 1 Communications Bunt en EE 5 1 Common Specifications cccccceeeeeeeeeeeeeseeeeees 5 15 Diakup WI OGEI xcs setae aaa ea nee eee 5 11 FIA 2 322 CR S223 2 escaee sc pesios es Saleen aae i Iaceltiaitanes 5 8 EJA 422 485 RS 422 485 Modules c066 5 9 PUG TING ber A oars tenes ae tacos ae aate 5 7 Installins Modules iis 2 incs ich ox eel oats 5 3 Local Portoon aeons oe aeeeebrseeoees 5 5 Module Sauni a 5 1 Port Locations ceneo neen E 5 1 Removing Modules cccccccccceeeeeeeeeeeeeeeeeeeeees 5 4 SPECIE CAU ONS niea a EAT 5 15 W DS resone E R 5 4 CPU ico atecvoretecene 2 7 2 9 2 10 2 11 2 12 D Diagnostic JER DAEL ESEA E A E edinicecont ars suca nec ecea ties casccaerecas 1 4 Dial up Modem Communications Module cccccceeeeeeeeeeeeeens 5 11 LEDien T 5 12 SPee eao Sn a a a aa 5 17 M a abst a a a stent 5 12 DIN aea a ages ain aaea teens 2 5 2 6 2 7 Diseret TIDUS ee reap Aeanct tana ahaenees 4 9 EED site ete a rrr oie tectn tere none ORC aot 4 9 SPE CILMCAIIONS uch cache aia TER 4 24 Troubleshooter e 6 6 Discrete Output Relay sirincvireniainaii a 4 11 LED eonen E E EE 4 11 Specie ONS arein a a E 4 26 AP TOUDICS MO OLMO eeinetan 6
17. 77 F with full load Loop Power set for 12 V dc 0 045 Loop Power set for 24 V dc 0 200 Absolute Accuracy Over Operating Temp with full load Loop Power set for 12 V dc 0 25 Loop Power set for 24 V dc 0 35 Reset Action User selectable between outputs going to software configured value or to last value on power up on restart Minimum Scan Period 50 msec on all channels POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 V dc 100 mA maximum over operating temperature range Additional loading that may apply Output 12V 1 25 multiplied by Measured Current Draw per channel output Output 24V 2 5 multiplied by Measured Current Draw per channel output WIRING 12 AWG or smaller at the removable terminal block LOOP POWER Sensor Supply Voltage Jumper selectable between 12 V de and 24 V dc Sensor Supply Current 0 20 83 mA per channel ISOLATION Field to Logic 2500 V dc 1 minute minimum Field to Power 2500 V dc 1 minute minimum Module to Module 2500 V dc 1 minute minimum WEIGHT 54 4 g 1 92 02 ENVIRONMENTAL Same as the ROC800 Series unit in which it is installed DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 25 in H by 2 96 in D APPROVALS Same as the ROC800 Series unit in which it is installed 4 23 1 AO modules W38199 with front labels that read AO 16 are an earlier version that control the low side AO modu
18. DCE to setup a connection DTE is running and ready to communicate Ground Reference ground between a DTE and a DCE and has a Common value 0 volts dc Data received by the DTE Data sent by the DTE Request to Send Originated by the DTE to initiate transmission by the DCE Top Front Figure 5 2 RJ 45 Pin Out The LOI terminal requires a D Sub 9 pin F to RJ 45 modular converter installed between the ROC800 Series and personal computer PC Refer to Table 5 4 5 5 Communications Rev Feb 05 ROC809 Instruction Manual Table 5 4 RJ 45 to EIA 232 RS 232 Null modem Cable Signal Routing E1A 232 RJ 45 Pins RS 232 ROC80O n Series ROC800 Series s RJ 45 Pins Wire on ROC800 Color Series 5 5 1 1 How to Use the LOI Plug the LOI cable into the LOI RJ 45 connector of the ROC800 Series Connect the LOI cable to the D Sub 9 pin F to RJ 45 modular converter Plug the modular converter into the COM Port of the personal computer Launch ROCLINK 800 software Click Direct Connect Configure communications for the other built in and modular communications I O modules AGA meter parameters and other configuration parameters S O P oe 2 D m 5 6 Communications Rev Feb 05 ROC809 Instruction Manual 5 6 Ethernet Communications The Ethernet communications port in the ROC800 Series allows TCP IP protocol communications using the IEEE 802 3 10Base T standard
19. INPUT PARAMETERS Configurable Point tag units name rate period scan period conversion alarming enable alarm limits alarm deadband RBX enable value in EUs accumulated pulses and EU options Read Only Point number alarm state current rate and yesterday s total Frequency Range High Speed Input 0 12 KHz Low Speed Input 0 125 Hz RTD INPUT PARAMETERS Configurable Point tag units name value scan period units scanning enable filter value raw A D input alarm limits low high low low high high rate RTD alpha alarm deadband RBX enable averaging enable and clipping enable Read Only Point number and alarm state Minimum Scan Period 64 msec THERMOCOUPLE INPUT PARAMETERS Configurable Point tag J or K type units value scan period scanning enable filter value averaging enable alarming enable alarm limits alarm deadband and RBX enable Read Only Point number alarm state current rate and yesterday s total Minimum Scan Period 150 msec HART INPUT OUTPUT PARAMETERS Per Channel Configurable Low and high reading EU analog scanning communications mode output mode output values value on reset pass through and failsafe value Per Device Configurable Poll mode dynamic variables slot variables tag descriptor and message Read Only Version comm status EU value A D values actual scan period current of range status poll address device ID pv damping valu
20. K Type Thermocouple Input Modules The five channel J and K Type Thermocouple input module monitors either J or K Type Thermocouple T C J and K refer to the type of material used to make a bimetallic junction Type J Iron Constantan and Type K Chromel Alumel These dissimilar junctions in the thermocouple junction generate different millivolt levels as a function of the heat to which they are exposed The J and K Type Thermocouple module measures the voltage of the thermocouple to which it is connected The T C voltage is measured and a Cold Junction Compensation CJC correction factor 1s applied to compensate for errors due to any voltage inducted at the wiring terminals by the junction between the different metal of the T C wiring and the T C module s terminal blocks NOTE The use of dissimilar metals is not supported It will not provide the correct results as CJC is applied at module level Thermocouples are self powered and require no excitation current The thermocouple modules use integrated short circuit protected isolated power supplies and completely isolates the field wiring side of the module from the backplane If using the Type J above 750 C 1382 F abrupt magnetic transformation causes permanent de calibration of the T C wires De calibration can occur in thermocouple wires De calibration is the process of unintentionally altering the makeup of the thermocouple usually caused by the diffusion of atmospher
21. LED 1 25 M Jumper set to T 12 C i i Sana T volts dc urrent Draw at Terminal Jumper set to T 24 2 5 Measured Current volts dc Draw at T Terminal aa The Duty Cycle is the time on divided by the total time The Duty Cycle is essentially the percent of time that the I O channel is active maximum power consumption Duty Cycle Active Time Signals Duty Cycle Total Time Period For example if a Pulse Input is receiving signal for 6 hours over a 24 hour time period and the signal s wave form consist of an on time of 1 3 of the signal s period Duty Cycle 6 hours 1 3 24 hours 0 0825 3 13 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 12 Power Consumption of the MVS Modules cia anh ci wis todas a a mew FT Per Active LED Maximum2 15mA_ t8mw f 1 25 M Power provided by the 5 veasure module for the MVS sensors urrent Draw at Terminal Total s_ i For an MVS sensor the typical mW per MVS will be about 300 mW The Duty Cycle is the time on divided by the total time For an MVS the sensor is always drawing power so the Duty Cycle should be entered as a 1 for the MVS power calculations The LEDs can also have a Duty Cycle associated with them The Duty Cycle for the LEDs are essentially the percent of time that the LEDs are active Duty Cycle Active time Active time Inactive time For example if the LEDs are on approxi
22. Modules Rev Feb 05 ROC809 Instruction Manual 4 2 Installation Each I O module installs in the ROC800 series controller in the same manner Any I O module can be installed into any module socket whether empty or in place of another module Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When installing units in a hazardous area make sure all installation components selected are labeled for use in such areas Installation and maintenance must be performed only when the area is known to be non hazardous Installation in a hazardous area could result in personal injury or property damage The I O modules may be inserted or removed while power is connected to the ROC800 series controller If power is connected to the ROC800 series controller exercise caution while performing the following steps to install a module 4 2 1 4 3 NOTE After installing a new I O module or replacing an existing I O module it may be necessary to reconfigure the ROC800 series controller To change configuration parameters use ROCLINK 800 software to make changes to the new module Any added modules new I O points start up with default configurations Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 How to Install an I O Module Remove the wire channel cover To in
23. One application of this communications port is for downloading programs from DS800 Development Suite Configuration Software The Ethernet communications port uses a L OBASE T Ethernet interface with an RJ 45 connector Each Ethernet equipped unit is called a station and operates independently of all other stations on the network without a central controller All attached stations connect to a shared media system Signals are broadcast over the medium to every attached station To send an Ethernet packet a station listens to the medium Carrier Sense and when the medium 1s idle the station transmits the data Each station has an equal chance to transmit Multiple Access Access to the shared medium is determined by the Medium Access Control MAC mechanism embedded in each station interface The MAC mechanism is based on Carrier Sense Multiple Access with Collision Detection CSMA CD If two stations begin to transmit a packet at the same instant the stations stop transmitting Collision Detection Transmission is rescheduled at a random time interval to avoid the collision Link Ethernet networks together to form extended networks using bridges and routers Table 5 6 Ethernet Signal LEDs it when currently receiving it when currently transmitting it when Ethernet Packet Collision detected it when Ethernet has linked Use a rugged industrial temperature HUB when connecting Ethernet wiring in an environment that requires it
24. RS 232C OVER VOLTAGE PROTECTION 25 volts dc continuous on any terminal 5 15 Communications Rev Feb 05 ROC809 Instruction Manual EIA 422 485 RS 422 485 Communications Module Specifications FIELD WIRING TERMINALS EIA 422 RS 422 OVER VOLTAGE PROTECTION Label 14 volts dc continuous on any terminal POWER CONSUMPTION 2 B Receve Main power supply loading at the Battery Terminals panini Typical 112 mA ion 12 AWG or smaller at the removable terminal FIELD WIRING TERMINALS EIA 485 RS 485 block ED INDIGATORS Receive Transmit A On when currently receiving 2 B_ Receive Transmit o Y On when transmitting No Connect No Connect ISOLATION Floating EIA 485 Common Field to Logic 1500 volts dc 1 minute Field to Power 1500 volts dc 1 minute COMMUNICATIONS Module to Module 1500 volts dc 1 minute Type Single Comm Port per module Comm3 to WEIGHT CommB5 49 9 g 1 76 oz Meets EIA 422 485 and RS 422 485 Standards Bd N1902 57 6K bps maximum data rate 5 16 Communications Rev Feb 05 ROC809 Instruction Manual Dial Up Modem Module Specifications FIELD WIRING TERMINALS Connector RJ 11 type OPERATION Type Single Comm Port per module Comms to Commb 14 4 K bps with V 42 bis Providing up to 57 6K bps throughput Mode 2 wire for dial up PSTN Bell 212A and 103 compatible Data Rate Up to 57 6K bps asynchronous Error Correction
25. RTD on the RTD module The ROC800 series controller provides terminations for a four wire 100 ohm platinum RTD with a DIN 43760 curve The RTD has an alpha equal to 0 00385 or 0 00392Q Q C A two wire or three wire RTD probe can be used instead of a four wire probe however they may produce measurement errors due to signal loss on the wiring Wiring between the RTD probe and the ROC800 series controller must be shielded wire with the shield grounded only at one end to prevent ground loops Ground loops cause RTD input signal errors Table 4 1 RTD Signal Routing CH 1 REF CH 1 CH 1 te CH 1 RET Not Connected N A CH 2 REF CH 2 CH 2 CH2 RET 9 Constant Current Not Connected NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying commons together 4 14 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 Wire RTD 3 Wire RTD 2 Wire RTD Note The wire color may be different DOC0349A Figure 4 14 RTD Sensor Wiring Terminal Connections Figure 4 14 and Table 4 2 display the connections at the RTD terminals for the various RTD probes Table 4 2 RTD Wiring 4 Wire RTD 3 Wire RTD 2 Wire RTD rer Red dumpertos Jumper tor n Rda Red Jumper to REF Red Jumper to REF NOTE The wire colors for the RTD being used may differ 4 15 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 10 J and
26. Rev Feb 05 ROC809 Instruction Manual 1 3 5 Low Power Modes The ROC809 uses low power operation under predetermined conditions Two low power modes are supported Standby and Sleep Standby This mode is used during periods of inactivity When the operating system cannot find a task to run the ROC809 enters Standby mode This mode keeps all peripherals running and is transparent to the user Wake up from Standby occurs when the ROC809 needs to perform a task Sleep This mode is used if a low battery voltage is detected This mode only applies to ROC800 Series units with the 12 V dc power input module The battery voltage is measured by System AI Battery Point Number 1 and is compared to the LoLo Alarm limit associated with this point The default value for the LoLo Alarm limit is 10 6 volts dc When in Sleep mode AUXgy is turned off For information on configuring alarms and System AI points refer to ROCLINK 800 Configuration Software User Manual Form A6121 1 3 6 PID The PID Control applications firmware provides Proportional Integral and Derivative PID gain control for the ROC809 and enables the stable operation of 16 feedback control loops that employ a regulating device such as a control valve The firmware sets up an independent PID algorithm loop in the ROC809 The PID loop has its own user defined input output and override capability The typical use for PID control is to maintain a process variable at a s
27. TD Pin 3 RD Pin 3 RD Pin 6 RD Pin 6 RD Figure 5 3 IOBASE T Crossover Cable 5 7 ElA 232 RS 232 Serial Communications The built in EIA 232 RS 232 the LOI and the communication modules meet all EIA 232 RS 232 specifications for single ended asynchronous data transmission over distances of up to 15 meters 50 feet EITA 232 RS 232 communication provides transmit receive and modem control signals The LOI port also meets EIA 232D RS 232D specifications The EIA 232 RS 232 communications have the following communication port designations in ROCLINK 800 LOI Local Port EIA 232 RS 232D Refer to Section 5 5 Local Operator Interface LOD on page 5 5 Built in Comm 2 EIA 232 RS 232C Module Comm3 to Comm5 EIA 232 RS 232C 5 8 Communications Rev Feb 05 ROC809 Instruction Manual EJA 232 RS 232 uses point to point asynchronous serial communications and is commonly used to provide the physical interface for connecting serial devices such as gas chromatographs and radios to the ROC800 Series The EIA 232 RS 232 communication provides essential hand shaking lines required for radio communications such as DTR and RTS The EJA 232 RS 232 communications includes LED indicators that display the status of the Receive RX Transmit TX Data Terminal Ready DTR and Ready To Send RTS control lines Table 5 7 defines the built in EIA 232 RS 232 terminals at the Comm2 port and their function
28. The IEEE 802 3 1OBASE T standard requires that 1OBASE T transceivers be able to transmit over a link using voice grade twisted pair telephone wiring that meets EIA TIA Category four wire specifications Generally links up to 100 meter 328 feet long are achievable for unshielded twisted pair cable For each connector or patch panel in the link subtract 12 meters 39 4 feet from the 100 meter limit This allows for links of up to 88 meters 288 feet using standard 24 AWG UTP Unshielded Twisted Pair wire and two patch panels within the link Higher quality low attenuation cables may be required when using links greater than 88 meters The maximum insertion loss allowed for a LOBASE T link is 11 5 dB at all frequencies between 5 0 and 10 0 MHz This includes the attenuation of the cables connectors patch panels and reflection losses due to impedance mismatches to the link segment Intersymbol interference and reflections can cause jitter in the bit cell timing resulting in data errors A JOBASE T link must not generate more than 5 0 nanoseconds of jitter If your cable meets the impedance requirements for a 10BASE T link jitter should not be a concern The maximum propagation delay of a IOBASE T link segment must not exceed 1000 nanoseconds 5 7 Communications Rev Feb 05 ROC809 Instruction Manual Crosstalk 1s caused by signal coupling between the different cable pairs contained within a multi pair cable bundle 1OBASE T transceive
29. arguments The FST Editor provides a workspace that accepts the entry of up to 500 functions in each of the six FSTs up to 3000 lines total 1 9 General Information Rev Feb 05 ROC809 Instruction Manual 1 4 ROCLINK 800 Configuration Software The ROCLINK 800 Configuration Software a Windows based program provides the capability to monitor configure and calibrate ROC800 Series Remote Operations Controllers The ROCLINK 800 software has a standard easy to use Windows interface Tree based navigation makes accessing features quick and easy Many of the configuration screens such as stations meters I O and PIDs are available while ROCLINK 800 software is off line Configuration can be made while on line or off line with the ROCS809 The Local Operator Interface LOI port provides a direct link between the ROC809 unit and a personal computer PC The LOI port uses an RJ 45 connector with standard EIA 232 RS 232D pinout With the computer running ROCLINK 800 Configuration Software you can locally configure the ROC809 extract data and monitor its operation Configuration can be made remotely from a host computer using a serial or dial up modem communications line Configurations can be duplicated and saved to a disk In addition to creating a backup this feature is useful when multiple ROC809 units requiring similar configurations are being configured for the first time or when configuration changes need to be made off lin
30. cause a junction To increase the length of the leads from the thermocouple use the correct type of thermocouple extension wire Any connector must be made of the correct thermocouple material and correct polarity must be observed If the reading is off 1 The type J or K thermocouples are selected on a per channel basis on the thermocouple module Verify each channel on the ROC809 and make sure it is set for the type of thermocouple that you are using Ensure any plugs sockets or terminal blocks used to connect the extension wire are made from the same metals as the thermocouples and correct polarity is observed 3 Verify all connections are tight Verify the thermocouples have the correct construction ungrounded and are NOT grounded by other means Verify you are using the correct thermocouple wire all the way from the thermocouple to the ROC809 with minimal connections 6 Verify the wiring run is adequately protected from noise 6 10 Test the thermocouple reading from the thermocouple to a meter and then generate a signal into the ROC809 as described previously Finally connect a thermocouple of the same type directly to the ROC809 If it reads correctly the problem is likely to be in the wiring to the field or may be related to a ground loop Troubleshooting Rev Feb 05 ROC809 Instruction Manual SECTION 7 CALIBRATION This section provides information about calibration procedures for the Analog Inputs HAR
31. data and the Real Time Clock when the main power is not connected The battery has a one year minimum backup life while the battery is installed and no power is applied to the ROC809 The battery has a ten year backup life while the backup battery is installed and power is applied to ROC809 unit or when the battery is removed from the ROC809 1 1 General Information Rev Feb 05 ROC809 Instruction Manual The ROC809 supports of a variety of communication protocols ROC Plus Modbus Modbus TCP IP Modbus encapsulated in TCP IP and Modbus with Electronic Flow Measurement EFM extensions Figure 1 1 shows the housing typical I O modules and communication modules installed into a ROC809 The ABS Acrylonitrile Butadiene Styrene plastic housing has wire covers to protect the wiring terminals The housing includes DIN rail mounts for mounting on a panel or in a user supplied enclosure Comms to Comm5 or I O Modules I O Modules DIN Mount Power Supply Module Pry Hole LOI Local Port ElA 232 RS 232D Wire Channel Cover Built in Ethernet Comm1 Built in EIA 232 RS 232C Module Cover Comm2 Figure 1 1 ROC809 Module Rack The CPU Central Processing Unit contains the microprocessor the firmware a connector to the backplane the three built in communication ports a LED low power wakeup button a RESET button the application License Key connectors a STATUS LED indicating system integrity diagnostic Light Emitting
32. incorporated into the circuitry for monitoring system integrity Use ROCLINK 800 software to access the System Analog Inputs Refer to Table 1 1 Table 1 1 System Analog Inputs System Al Battery Input Voltage 11 25 to 16 volts dc Charge in Voltage 0 to 18 volts dc Not Used Not Used On Board Temperature 40 to 85 C 40 to 185 F 11 00 to 14 50 volts do 1 1 5 Options The ROC809 unit allows you to choose from a wide variety of options to suit many applications Optional communication modules include EIA 232 RS 232 serial communications EIA 422 485 RS 422 485 serial communications Multi Variable Sensor MVS and Dial up modem communications Refer to Section 4 Communications The ROC809 unit can handle up to two MVS interface modules This permits communications with up to 12 sensors per ROC809 unit and providing power to 10 sensors per ROC809 unit Refer to Section 4 Communications 1 4 General Information Rev Feb 05 ROC809 Instruction Manual Optional I O modules include Analog Inputs Analog Outputs Discrete Inputs Discrete Outputs Pulse Inputs RTD Inputs and Thermocouple Inputs Refer to Section 3 Input Output Modules The optional application License Keys provide extended functionality such as the use of the IEC 61131 3 compliant DS800 Development Suite Software user programs and meter runs In order to perform AGA calculations a License Key with the proper license is required Refer to Section
33. line fusing when using batteries to avoid damaging the unit To make battery connections 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure 2 Remove the BAT BAT terminal block connector from the socket 3 Install a fuse at the input power source 4 Insert each bared wire end into the clamp beneath the BAT BAT termination screws Refer to Figure 3 5 5 Screw each wire into the terminal block 6 Plug the terminal block connector back into the socket 7 Refer to Section 2 8 5 After Removing Power from the ROC800 Series unit on page 2 38 and perform the restore procedure NOTE Refer to Table 3 2 concerning LEDs 3 5 3 How to Replace the Internal Battery The internal Sanyo 3 volt CR2430 lithium backup battery provides backup of the data and the Real Time Clock when the main power is not connected The battery has a one year minimum backup life while the battery is installed and no power is applied to the ROC800 Series unit The battery has a ten year backup life while the backup battery is installed and power is applied to ROC800 Series unit or when the battery is removed from the ROC800 Series unit Refer to Figure 2 5 NOTE Remove the internal backup battery if you intend to store the ROC800 Series unit for an extended period When working on units located in a hazardous area where explosive gases may be present make sure the area is in
34. on both wires but rejection is not perfect so minimize noise where possible Take care to properly shield thermocouple wiring from noise by separating the thermocouple wiring runs from signals that are switching loads and AC signals Route wires away from noisy areas and twist the two insulated leads of the thermocouple cable together to help ensure both wires pickup the same noise When operating in an extremely noisy environment use a shielded extension cable 4 17 Input Output Modules Rev Feb 05 ROC809 Instruction Manual ate l l TypeJus dsf TypeKus dsf Figure 4 16 Type J Thermocouple Shielded Figure 4 17 Type K Thermocouple Shielded Wiring United States Color Coding Wiring United States Color Coding United States color coding for the Type J Thermocouple shielded wiring is black sheathing the positive lead is white and the negative lead is red United States color coding for the Type K Thermocouple shielded wiring is yellow sheathing the positive lead is yellow and the negative lead is red Shielded wiring is recommended Ground shields only on one end preferably at the end device unless you have an excellent ground system installed at the ROC800 series controller Do not tie the thermocouple module to ground NOTE It is highly recommended that you use shielded wiring Sheathed thermocouple probes are available with one of three junction types grounded ungrounded or exposed d Figu
35. port on the ROC or FloBoss through which local communications are established typically for configuration software running on a PC LRC Longitudinal Redundancy Checking error checking m Meter mA Milliamp s one thousandth of an ampere MAU Medium Attachment Unit Modbus A popular device communications protocol developed by Gould Modicon mm Millimeter MMBTU Million British Thermal Units msec millisecond MVS Multi Variable Sensor The MVS provides differential pressure static pressure and temperature inputs to the ROC809 for orifice flow calculation mV Millivolts or 0 001 volt mW Milliwatts or 0 001 watt N NEC National Electrical Code NEMA National Electrical Manufacturer s Association O OH Off Hook modem communications signal Off line Accomplished while the target device is not connected by a communications link For example off line configuration is configuring a ROC in a electronic file that is later loaded into the ROC unit G 3 Glossary Rev Feb 05 ROC809 Instruction Manual Ohms Units of electrical resistance On line Accomplished while connected by a communications link to the target device For example on line configuration is configuring a ROC809 while connected to it so that current parameter values are viewed and new values can be loaded immediately OP Operator Port see LOI Opcode Type of message protocol
36. power input module 3 1 3 2 How to Install the Auxiliary Output Fuse To re install the auxiliary output fuse replace the fuse located at F1 on the power input module Then perform the procedure in Section 2 5 4 to re install the power input module 3 1 4 Switched Auxiliary Output AUXSW and AUXSW The AUXSW and AUXSW terminals on the 12 volts dc Power Input Module provide switched power for external devices such as radios AUXSW is current limited for protection of the power input and the external device via a 0 5 Amp nominal Positive Temperature Coefficient PTC The AUXSW and AUXSW terminals provides voltages from 0 to 14 25 volts dc AUXsw is turned off when a software configurable voltage LoLo Alarm is detected at the BAT and BAT terminals All module terminal blocks accept 12 AWG or smaller wiring Refer to Figure 3 3 If the source voltage falls to a level below which reliable operation cannot be ensured the hardware circuitry on the power input module automatically disables the AUXSW outputs This occurs at approximately 8 85 volts dc This is based on the LoLo Alarm limit set for the System Battery Analog Input Point Number 1 The low input voltage detect circuit includes approximately 0 75 volts dc of hysteresis between turn off and turn on levels Because the linear regulator can be damaged by the presence of high input voltage if the dc input voltage at BAT exceeds 16 volts the over voltage detect circuit automatica
37. pulse generator having sufficient output to drive the module to terminals L or H and COM The pulse generator must synthesize a square wave signal of 50 for every cycle Connect a frequency counter across terminals L or H and COM Set the pulse generator to a value equal to or less than 10 KHz Set the frequency counter to count pulses oO ue Verify the count read by the counter and the count read by the ROC809 unit are the same using the ROCLINK 800 software 10 Remove the test equipment and reconnect the field device 6 3 9 Troubleshooting RTD Input Modules The RTD module is similar in operation to an RTD module and uses the same troubleshooting and repair procedures Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 1 Disconnect the field wiring at the RTD module terminations Connect to the ROCLINK 800 software Select Configuration gt I O gt RTD Point Select the correct RTD Point Number If any of the input wires are broken or not connected the ROCLINK 800 software indicates the Raw A D Input value is either at minimum less than 47974 or maximum greater than or equal to 61958 as follows oe oy An open at terminal gives a maximum reading An open at terminal gives a minimum re
38. that can be electrically re programmed It is a form of permanent memory requires no backup power Also called Flash memory Force Write an ON OFF True False or 1 0 value to a coil FPV Compressibility Factor FST Function Sequence Table a type of program that can be written by the user in a high level language Ft Foot or feet G GFA Ground Fault Analysis GND Electrical ground such as used by the ROC power supply GP Gauge Pressure H Holding Register Analog output number value to be read Hw Differential pressure Hz Hertz G 2 Glossary Rev Feb 05 ROC809 Instruction Manual J ID Identification IEC Industrial Electrical Code IEEE Institute of Electrical and Electronic Engineers The Open System Interconnection OSI reference model and an international standard for the organization of local area networks LANs established by the International Standards Organization ISO and the IEEE IMV Integral Multiplier Value Input Digital input a bit to be read Input Register Input numeric value to be read T O Input Output I O Module Module that plugs into an I O slot on a ROC to provide an I O channel IRQ Interrupt Request Hardware address oriented IV Integral Value K KB Kilobytes KHz KiloHertz L LED Light emitting diode LNK Ethernet has linked LOI Local Operator Interface Refers to the serial EAJ 232 RS 232
39. the feature if so equipped You may require an optional T C adaptor to use the multimeter To test a thermocouple do not parallel the voltage meter on a thermocouple that is connected to a ROC809 as it will distort the signal Do not try to verify a thermocouple that is connected and actively being monitored by a ROC809 by measuring the voltage at the ROC809 terminal blocks It is suggested that you independently verify the process temperature by using a certified thermometer in an adjacent thermowell and then compare it to what the ROC809 is reading To test the thermocouple module 1 Disconnect the thermocouple from the thermocouple module 2 Generate the correct J or K signal using a multimeter and connect the wiring from the multimeter to the T C module in the ROC809 3 Verify the ROC is reading the generated temperature form the multimeter 4 Remove the test equipment and reconnect the field device To test the thermocouple 1 Disconnect the thermocouple from the ROC809 2 Connect the thermocouple directly to the multimeter and verify the reading is correct as compared to a certified temperature measurement device connected to the process temperature the T C is measuring 3 Remove the test equipment and reconnect the field device 6 9 Troubleshooting Rev Feb 05 ROC809 Instruction Manual Unintentional thermocouple junctions cause many measurement errors Remember that any junction of two different metals will
40. the switch or applying power Representative Field Wiring Internal Circuit FISHER ROSEMOUNT DVC 6000 SERIES 3051 SERIES DOC0523B Figure 4 21 HART Interface Module Field Wiring 4 20 Input Output Modules Rev Feb 05 ROC809 Instruction Manual CH3 0 Switch CH1 I O Switch s onthe Figure 4 22 HART Channels I and 3 On back side of board CH2 I O Switch CH4 I O Switch Ch2_Ch4a Figure 4 23 HART Channels 2 and 4 On front side of board 4 21 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 1 0 Module Specifications This section details the specifications for the various I O modules 4 12 1 Analog Input Modules Analog Input Module Specifications FIELD WIRING TERMINALS POWER CONSUMPTION Definition Main power supply loading at the Battery Terminals Termina ee at 12 0 volts dc 84mA typical Positive Analog Input COM Common Analog Input Additional loading that may apply O 2 Positive Analog Input T 12V 1 25 multiplied by Measured COM Common Analog Input Current Draw at T Terminal Be Positive Analog Input T 24V 2 5 multiplied by Measured COM Common Analog Input Current Draw at T Terminal 4 Positive Analog Input WIRING COM Common Analog Input 12 AWG or smaller at the removable terminal T Loop Power block T loopPower iooprBoWER T Sensor Supply Voltage Jumper selectable INPUT Al 12 MODULE between 12 V dc and 24 V dc
41. you have a second MVS module installed points 7 through 12 are available Points are assigned based on which module 1s in the first slot For example if an MVS module is in slot three it automatically assigns the points 1 through 6 If you then install an MVS module into slot one the points are re assigned so that slot one holds through 6 and slot three holds 7 through 12 The ROC800 Series allows six MVS devices to be connected on its communications bus in a multi drop connection scheme The address of each MVS must be set prior to final wiring of multiple MVS devices For proper operation of multiple MVS devices each MVS device must have a unique address and none of the addresses can be 240 For details on MVS configuration refer to the ROCLINK 800 Configuration Software User Manual Form A6121 Once a unique address is set for each MVS connect the MVS units in a multi drop arrangement The only requirement for wiring multi drop devices is that all like terminals be tied together This means all the A terminals on the devices are electrically connected to the ROC800 Series A terminal and so on The wiring can be done by wiring in parallel daisy chaining through each remote MVS Terminations are required on the two MVS modules located at the extremities of the circuit That is to say the two outside modules require terminations in order to complete the communications circuit The MVS termination jumper is located at J4 on the
42. 00 400 500 protocol For more information contact your local sales representative The ROC800 Series firmware also supports Modbus protocol as Master or Slave device using RTU or ASCII modes This allows the unit to be easily integrated into other systems Extensions to the Modbus protocol are provided that allow the retrieval of history event and alarm data in Electronic Flow Metering EFM Measurement applications The ROCLINK 800 software provides for access to the ROC809 unit A maximum of 16 case sensitive user identifiers User IDs may be stored In order for the ROC809 unit to communicate a case sensitive log on ID supplied to the ROCLINK 800 software must match one of the IDs stored in the ROC809 The operating system firmware supports the application specific firmware supplied in the Flash ROM The application firmware includes Proportional Integral and Derivative PID Control FSTs Spontaneous Report By Exception SRBX Communications Enhancement optional American Gas Association AGA Flow calculations with station support and optional IEC 61131 3 language programs utilizing DS800 Development Suite software Applications are resident in the firmware The user is not required to re build and download the firmware for changes in calculation method 1 3 1 Historical Database and Event Log The historical database provides archiving of measured and calculated values for on demand viewing or saving to a file It provides an audit
43. 04 in W by Minimum Scan Period 150 mSec for all channels 5 25 in H by 2 96 in D 1 O O n O 1 Absolute Accuracy at 25 C 77 F 1 C typical ENVIRONMENTAL 1 O O 0 O 1 1p Absolute Accuracy at 25 C 77 F 2 C maximum Meets the same environmental specifications as the Absolute Accuracy Over Operating Temp 6 C ROC800 Series unit in which it is installed maximum APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed 1 Absolute Accuracy Includes Linearity Hysteresis Repeatability Stability Gain and Offset error 4 29 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 9 HART Interface Module HART Interface Module Specifications FIELD WIRING TERMINALS Signal Positive COM Common T Transmitter Power CHANNELS Four channels per module which communicate via Analog Digital signals Mode Half duplex Data Rate 1200 bps Parity Odd Modulation Phase coherent Frequency Shift Keyed FSK per Bell 202 Carrier Frequencies Mark 1200 Hz Space 2200 Hz 0 1 SUPPORTED HART COMMANDS Universal Commands Read unique identifier read primary variable read primary variable and current read dynamic variable and current write polling addresses read unique identifier associated with tag read message read tag descriptor and date read primary variable sensor information read device information write message write tag descriptor an
44. 09 Flags and calibration values Click OK 3 Select ROC menu gt Collect Data Select all check boxes and click OK This saves event logs alarm logs report data hourly logs and daily logs you can specify your own file name and path if desired Select File gt Save Configuration The Save As dialog box appears Type the desired File name of the backup file Select the Directory where you desire to store the configuration file Click Save o gt pi a 6 3 2 How to Restart the ROC809 After removing power to the ROC809 and installing components perform the following steps to start your ROC809 and reconfigure your data The procedure assumes you are using ROCLINK 800 software Ensure all input devices output devices and processes remain in a safe state upon restoring power An unsafe state could result in property damage 6 3 Troubleshooting Rev Feb 05 ROC809 Instruction Manual When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage Reconnect power to the ROC809 unit Wait 30 seconds Launch ROCLINK 800 software log in and connect to the ROC809 oe Ne Verify that the configuration is correct If major portions or the entire configuration needs to be reloaded perform the remaining steps Select
45. 1 2 g 2 16 oz POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 volts dc Typical 112 mA Additional loading that may apply Per Active LED 1 5 mA 12V 1 25 Measured Current Draw at Terminal LED INDICATORS A On when currently receiving None On when transmitting ISOLATION Field to Logic 1500 volts dc 1 minute Field to Power 1500 volts dc 1 minute Module to Module 1500 volts dc 1 minute Rev Feb 05 ROC809 Instruction Manual SECTION 6 TROUBLESHOOTING This section provides generalized guidelines for troubleshooting of the ROC809 The procedures in this chapter should be performed before removing power for any reason after restoring power and if the unit 1s disassembled The following tools are required for troubleshooting e IBM compatible personal computer e ROCLINK 800 software e Flat head size 1 10 inch and Philips size 0 screwdrivers Section Page 6 1 Troubleshooting Guidelines 6 1 6 2 Troubleshooting Checklists 6 1 6 3 Procedures 6 3 6 1 Troubleshooting Guidelines When you are attempting to diagnose a problem with the ROC809 e Remember to write down what steps you have taken e Note the order in which you remove components e Note the orientation of the components before you alter or remove them e Save the configuration and log data see Section 6 3 1 e Read and follow all Cautions in this manual When you are done troubleshooting per
46. 1 5 DS800 Development Suite Software on page 1 11 The Local Operator Interface LOI communications terminal requires an LOI cable to be installed between the ROC809 unit and PC The LOI port uses an RJ 45 connector with standard EIA 232 RS 232D pin out 1 2 FCC Information This equipment complies with Part 68 of the FCC rules Etched on the modem assembly is among other information the FCC certification number and Ringer Equivalence Number REN for this equipment If requested this information must be provided to the telephone company A FCC compliant telephone modular plug is provided with this module The module is designed to be connected to the telephone network or premises wiring using a compatible modular jack that is Part 68 compliant The REN is used to determine the quantity of devices that may be connected to the telephone line Excessive RENSs on the telephone line may result in the devices not ringing in response to an incoming call Typically the sum of the RENs should not exceed five 5 0 To be certain of the number of devices that may be connected to a line as determined by the total RENs contact the local telephone company If this equipment dial up modem causes harm to the telephone network the telephone company will notify you in advance that temporary discontinuance of service may be required However if advance notice is not practical the telephone company will notify the customer as soon as possible
47. 2 allows long distance point to point communications and the drivers are designed for true multi point applications with up to 32 drivers and 32 receivers on a single bus The default values for the EIA 422 485 RS 422 485 communications are 19200 Baud Rate 8 Data Bits 1 Stop Bit and No Parity The maximum rate is 57 6K bps ETA 422 485 RS 422 485 communication modules include LED indicators that display the status of receive and transmit activity Refer to Table 5 9 and Table 5 10 5 9 Communications Rev Feb 05 ROC809 Instruction Manual Table 5 9 EIA 422 RS 422 Signal Routing Comm3 Comm4 and Comm5 Function Terminal Lit when module Comm3 Comm4 or Comms is currently receiving B _AX __ None None Lit when module Comm3 Comm4 or Comm5 is currently transmitting o 3 oZ TX None d A i i COM Common Ground O 5 Table 5 10 EIA 485 RS 485 Signal Routing Comm3 Comm4 and Comm5 Signal RS 485 Function Terminal RX TX Lit when module Comm3 Comm4 or Comms is currently receiving B RX TX Lit when module Comm3 Comm4 or Comm is currently transmitting NOTE The EIA 422 485 RS 422 485 modules are isolated on the field side Be aware that you can induce ground loops by tying commons together ETA 422 485 RS 422 485 communications provides EIA 422 485 RS 422 485 signals on the Comm3 Comm4 or Comm5 port depending on where the module is installed Wiring should be twisted pair c
48. 5 RS 422 485 Communications 5 10 MVS Ji oeenn NEN 5 13 PulSe Inputs JAn kee 4 12 L LED AUX F And AUX S a ave EEEE N 3 3 COMMUNIC AUIONS araa E EE NARE 5 2 Dialup M de mM sania E 5 12 Discrete Ipute T 4 9 Discrete Output Relays Ea 4 11 IDISCTE Le Om PUTS ca A 4 10 EIA 232 RS 232 Communications 0606 5 9 EIA 422 485 RS 422 485 Communications 5 9 Multi Variable Sensor cccccceesseseeeeceeeeeaeeees 5 14 Power input Module cccccccceeeeeeeeeeeeeees 3 3 3 4 Pulse TAPUS seentest aie e 4 12 SEPATU re E I 2 9 LICEM E E Vorena e e 2 11 2 12 Local Operator Interface BOM bocal POL arae 5 5 Ee Atl Onenn N 2 2 Low Power Modes ccccccccccccceessseecceeeeaeeesseeeeeeeeas 1 9 M MEMOR 4 cass caine whaacenensssuapsedmadodssaasneneasaresdenanteaponeuadewiaaeatel 1 4 INIOCUIIS COVEL Parron eA E 2 5 Modules COMMUNIC AUONS 5 mscosseiaduseossuastentuteaneeupsesnncostooneees 5 1 VOe anna aaasestioanatesaienntesceretatianions 4 1 IMIOMILOUINIG essas E Ea 1 4 IMO UPUINS visccersscsests lasses e Ea 2 5 Multi Variable Sensor JUICE Aen 5 13 By B S eee TA EEE Men E N E T ay TERRE E TE 5 14 ES E E PA EE EE E E EE E T 5 12 SPE CIMCALIONS eec nare r a a er Ra SS 5 18 Termination soena anien ar EAE KEN EE ENA 5 13 WINDS aae EE 5 14 O 0 01s 021416 earn ener enn ene ner nny eer went tut aeee mr ane te wt tr 2 13 Operator Interface POrt cc ccccccssssssesesseeeeeeeeeeees 5 5 OPO
49. 6 in D 0 00392 software selectable ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed 4 28 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 8 J and K Type Thermocouple Input Module J and K Type Thermocouple Input Module Specifications FIELD WIRING TERMINALS COLD JUNCTION COMPENSATION re Cold junction is measured and corrected on a per oo CH1 Positive CH1 Negative OPEN CIRCUIT DETECTION CH2 Positive On detection of no thermocouple present the CH2 Negative reading is forced above 1500 C 2732 F ee PoSItiIve POWER CONSUMPTION CH4 Positive at 12 0 Volts DC CH3 Negative Main power supply loading at the Battery Terminals CH4 Negative Typical 84 mA CH5 Positive CH5 Negative WIRING 12 AWG at the removable terminal block INPUT ISOLATION Quantity 5 channels Field to Logic 2500 Volts DC 1 minute minimum Type J amp K Type ungrounded Thermocouple Field to Power 2500 Volts DC 1 minute minimum athe Software selectable on a per channel Module to Module 2500 Volts DC 1 minute minimum Input Temperature Range J Type 200 to 1200 C 328 to 2192 F WEIGHT K Type 100 to 1372 C 121 to 2500 F 59 0 g 2 08 oz Maximum Overload Input to Input 6 Volts DIMENSIONS DC continuous 26 mm W by 133 mm H by 75 mm D 1
50. 7 Discrete Outputs ssexs ceccsiesseeee aati ce Neate diaetae ete 4 10 LED iareret ae tereeee ever errr ental cor eee ete nner ee rer ree 4 10 SPECINICALIONS ernn ones ad seretinauen 4 25 Troubleshooting 5 ciciiscisssestteneieiaeoiesdisdeinestoveasie 6 7 Dry Relay Contacts esensi 4 9 DS800 Development Suite Software eee 1 11 DUY y Cle eieacicet castes case stats ieenont tet ccomaseaaes 3 6 3 8 E EIA 232 RS 232 Communications ceeecceees 5 8 B ltin COMM ccc ss0eeersctenamermameintese ra 5 8 LEDE enorer a E 5 9 Local POR iss ore tnr AE E 5 5 Module Comm3 to Comm cccccccccssssseeeeeeeeees 5 8 Specificatii ONS sannara snn n Sra 5 16 EIA 422 485 RS 422 485 Communications Jumpers and Termination Resistors 00006 5 10 EED aee we are nT ene SemEREET MC Renn ee nT Tee 5 9 Rev Feb 05 ROC809 Instruction Manual Modules erene soe eeo he eee Ouran setae 5 9 Selecting 422 or 485 Mode 2 0 ccceesseeeeeeeees 5 10 SP CCTM CAMONS si ua netestastvareiscninoneddaas 5 16 PC PIMIN ATION au iaae a tienen cee eamemwede 5 10 ENClOS UIC catia a eee oie Ee cteawtieee 2 1 End CADS ssctscaaotaccntaeseaiance te tesedieguemere meuneodeanee teenies 2 4 Environment 2ciic ecscuse iiss ieee etiiay eau ea aes 2 1 Ethernet SPecCA ONS ienen a e 5 15 Ethernet Communications eseese 5 7 Ethe met WII S measarra Ea EE 5 7 EUS onen E EAE A 6 5 F FCC Iniormmationcus turasi eee 1 5 Figure 1 1 ROC809 Module Ra
51. 9 DIN Rail Mount HHY Re T7 T DIN Rail Mount Ae e T 809back dsf Figure 2 3 Back of the ROCS09 2 4 1 How to Install the DIN Rail To install the ROC809 housing using the 35 x 7 5 mm DIN rails 1 Mount the lower DIN rail onto the enclosure panel Refer to Figure 2 3 2 Snap the second DIN rail into the ROC809 upper DIN rail mounting blocks 2 6 Installation and Use Rev Feb 05 ROC809 Instruction Manual 3 Place the ROC809 onto the lower rail that is mounted to the plane and ensure that the ROC809 with the second strip of DIN rail still in its upper mounting blocks is seated against the panel 4 Fasten the top strip of DIN rail to the panel By following this procedure which uses the ROC809 to provide the correct DIN rail spacing the ROC809 will be held securely in place 2 4 2 How to Remove the ROC809 from the DIN Rail To remove the ROC809 housing from DIN rails release the two DIN rail catches located on the top the housing 2 5 Backplane The backplane has connectors for the CPU the power input module and all the I O and communication modules When a module is completely inserted into the module slot the connector on the module fits into one of the connectors on the backplane The backplane does not require any wiring and there are no jumpers associated with the backplane Removing the backplane from the housing is not recommended as there are no field serviceable parts If the backplane requir
52. Association Report No 7 Measurement of Gas by Turbine Meters and use the AGA 8 method for determining the compressibility factor A gt gt A The AGA 8 method calculates the compressibility factor based on the physical chemistry of the component gasses at specified temperatures and pressures Liquid calculation methods ISO 5167 and API 12 are supported API 12 correction factors must be supplied through an FST or user program 1 3 4 Automatic Self Tests The operating system firmware supports diagnostic tests on the ROC809 hardware such as RAM integrity Real Time Clock operation input power voltage board temperature and watchdog timer The ROC809 performs the following self tests on a periodic basis Voltage tests battery low and battery high ensure the ROC809 has enough power to run while not allowing the battery to be overcharged The ROC809 operates with 12 volts dc nominal power The LEDs become active when input power with the proper polarity and startup voltage 9 00 11 25 volts dc is applied to the BAT BAT connectors Refer to Table 1 1 The software watchdog is controlled by the CPU This watchdog checks the software for validity every 2 7 seconds If necessary the processor automatically resets The ROC809 monitors Multi Variable Sensor s if applicable for accurate and continuous operation Amemory validity self test is performed to ensure the integrity of memory 1 8 General Information
53. CUIILY orraa 1 7 5 5 Setup VO Mod le Sreser r delcieseasse teow 4 3 S AE A OEE E EA EE ade cates caueieaae eee 2 2 Sleep Mode eere E e ra eee a 1 9 Software Watchdog sr e a a E 1 8 Standby MOdE ceesre er er aap E seit 1 9 SET a se A E EE EEE EN TEPO ONE O ee a 2 13 SLATS LED eeann a A 2 9 Storage B eaaa a a 3 16 SEMANO PS aa a a 1 4 T Table 1 1 System Analog Inputs cccccecceeees 1 4 Table 2 1 CPU Connector Locations eee 2 9 Table 2 2 STATUS LED Function 0 2 9 Table 3 1 12 Volts DC Power Input Terminal Block Connec Uoi nasra a a a a 3 2 Table 3 10 Power Consumption of the Discrete Output Relay NMOGUICS as 3 12 Table 3 11 Power Consumption of the High and Low Speed Pulse Input Modules cccccsseeeeeeeeeeees 3 13 Rev Feb 05 ROC809 Instruction Manual Table 3 12 Power Consumption of the MVS Modules 3 14 Table 3 13 Power Consumption of the RTD Modules 3 14 Table 3 14 Power Consumption of the Thermocouple Mod l arn aaweten shone cteanceetoraceamaeanel 3 14 Table 3 15 Power Consumption of the HART Modules EEEE ETE A E E E E E 3 15 Table 3 16 Power Consumption of Other Devices 3 15 Table 3 2 12 Volts DC Power Input LED Indicators 3 3 Table 3 3 24 Volts DC Power Input Terminal Block CONNEC HON Serpien ra RE Re 3 4 Table 3 4 24 Volts DC Power Input LED Indicators 3 4 Table 3 5 Power Consumption ccccccccsssssseeeeeees 3 7 Table 3
54. Comms is currently receiving Lit when module Comm3 Comm4 or Comm5 on ring Ring Lit when module Comm3 Comm4 or Comm5 on carrier detect Lit when module Comm3 Comm4 or Comm5 is currently transmitting Tip RL NOTE If you are installing a modem module it is recommended that you install a surge protector between the RJ 11 jack and the outside line L2 NOTE The dial up modem is not hot swappable or hot pluggable 5 10 Multi Variable Sensor MVS Interface Modules The Multi Variable Sensor MVS provides differential pressure static pressure and temperature inputs to the ROC800 Series unit for orifice flow calculation The MVS module consists of interface electronics that provide the communications link between the ROC800 Series and the MVS The interface electronics controls communications with the sensor 5 12 Communications Rev Feb 05 ROC809 Instruction Manual module provides scaling of process variables aids calibration stores operating parameters performs protocol conversion and responds to requests from the ROC800 Series unit The ROC800 Series unit can handle up to two MVS interface modules Each MVS module provides the communications interface for up to six sensora and the isolated short circuit current limited power required to connect up to five MVS sensors The MVS modules create six points automatically for each of the six MVS channels possible The points include 1 through 6 and if
55. Diodes LEDs for two of the communications ports and the main processor A maximum of nine Input Output I O modules can be added to satisfy a wide variety of field I O requirements Refer to Section 3 Input Output Modules I O modules include e Analog Inputs AD Analog Outputs AQ Discrete Inputs DI Discrete Outputs DO Digital Relay Outputs DOR HART Inputs Outputs Pulse Inputs PI High Low Speed RTD Inputs RTD J and K Type Thermocouple T C Inputs A gt gt gt gt gt 1 2 General Information Rev Feb 05 ROC809 Instruction Manual The ROC809 unit allows up to six communication ports Refer to Section 4 Communications Three communication ports are built in Local Operator Interface LOD Local Port EIA 232 RS 232D Ethernet Comm Port for use with the DS800 Development Suite Software EIA 232 RS 232C Comm Port for point to point asynchronous serial communications Communication modules provide additional ports for communicating with a host computer or other devices Installed in Comm3 to Comm5S and include ETA 232 RS 232C used for point to point asynchronous serial communications include Data Terminal Ready DTR support Ready To Send RTS support and radio power control EIA 422 EIA 485 RS 422 RS 485 used for point to point EIA 422 or multiple point EITA 485 asynchronous serial communications Multi Variable Sensor MVS int
56. EDURES Error n E A 6 3 Sechon CDr a O ceiccccesececcicaddscaceaiecdsecadssacueceedaddecestsseencccdduceeesbeusassaceasceaseeceaceveenece 7 1 7 1 CALIBRATION arunce aaan EE E E O E teieeaiees 7 1 ee HOW TO PREPARE FOR A GALIBRA TION tiatescecsinaiide Aane O TA 7 1 OOS SIV aa A E E ture G 1 WING OX isere RE senate stousxsecuassaccutsseususdauseccscesveceessstecesdeesacuoeds I 1 iV 0 Rev Feb 05 ROC809 Instruction Manual SECTION 1 GENERAL INFORMATION This manual focuses on the hardware aspects of the ROC809 Remote Operations Controller For information about the software refer to the ROCLINK 800 Configuration Software User Manual Form A6121 This manual contains the following sections Section 1 General Information provides an overview of the ROC809 hardware and specifications Section 2 Installation and Use provides information on installation tools wiring mounting the ROC809 and other essential elements of the ROC809 unit Section 3 Power Connections provides information and specifications for the power input modules available for the ROC809 Section 4 Input Output I O Modules provides information and specifications for the Input Output I O modules available for the ROC809 Section 5 Communications provides information and specifications for the built in communications and the optional communication modules available for the ROC809 Section 6 Troubleshooting provides information on diagnosin
57. File gt Download Select the backup configuration file with file extension 800 from the Open dialog box Select the portions of the configuration you desire to download restore Click Download to restore the configuration oe aw se gn Configure other required parameters 6 3 3 Troubleshooting Analog Input Modules Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations To determine if an Analog Input module is operating properly its configuration must first be known Table 6 1 shows typical configuration values for an Analog Input Table 6 1 Analog Input Module Typical Configuration Values Value Read Adjusted A D 0 1 volt dc across the and the COM terminal by a multimeter Adjusted A D 100 4095 5 volts dc across the and the COM terminal by a multimeter Low Reading EU 0 0000 EU value with 1 volt dc High Reading EU 100 0 EU value with 5 volts dc Value read by Al module 1 Connect a multimeter across the scaling resistor connected to the and COM terminals of the module and set the multimeter to measure voltage Connect to ROCLINK 800 software Select Configuration gt I O gt AI Points 4 Select the correct Analog Input Point Number 6 4 Troubleshooting Rev Feb 05 ROC809 Instruction Manual 5 V
58. Form A6116 Part Number D3801154X012 February 2005 ROC809 Remote Operations Controller Instruction Manual N Flow Computer Division EMERSON Website www emersonprocess com flow ROC809 Instruction Manual Revision Tracking Sheet February 2005 This manual is revised periodically to incorporate new or updated information The revision level of each page is indicated at the bottom of the page opposite the page number A major change in the content of the manual also changes the date of the manual that appears on the front cover Listed below is the revision level of each page Page Revision All Pages Feb 05 All pages 08 03 All pages 09 02 ROCLINK is a mark of one of the Emerson Process Management companies The Emerson logo is a trademark and service mark of Emerson Electric Co All other marks are the property of their respective owners This product may be covered under patents pending Fisher Controls International LLC 2002 2005 All rights reserved Printed in the U S A While this information is presented in good faith and believed to be accurate Fisher Controls does not guarantee satisfactory results from reliance upon such information Nothing contained herein is to be construed as a warranty or guarantee express or implied regarding the performance merchantability fitness or any other matter with respect to the products nor as a recommendation to use any product or process in conflict with any patent Fisher Cont
59. Input Discrete Input or output that is non continuous typically representing two levels such as on off DO Discrete Output DP Differential Pressure DSR Data Set Ready modem communications signal DTE Data Terminal Equipment DTR Data Terminal Ready modem communications signal Duty Cycle Proportion of time during a cycle that a device is activated A short duty cycle conserves power for I O channels radios and such EFM Electronic Flow Metering or Measurement EIA 232 RS 232 Serial Communications Protocol using three or more signal lines intended for short distances Concerning RS232D and RS232C the letters C or D refer to the physical connector type D specifies the RJ 11 connector where a C specifies a DB25 stype connector EIA 422 RS 422 Serial Communications Protocol using four signal lines EIA 485 RS 485 Serial Communications Protocol requiring only two signal lines Can allow up to 32 devices to be connected together in a daisy chained fashion EMF Electro motive force EMI Electro magnetic interference ESD Electrostatic Discharge EU Engineering Units Units of measure such as MCF DAY Firmware Internal software that is factory loaded into a form of ROM In the ROC809 the firmware supplies the software used for gathering input data converting raw input data values storing values and providing control signals Flash ROM A type of read only memory
60. N oara 1 4 P Paramete onsi E 1 6 PID CONTO brsama e 1 9 POD Earn e e 1 6 Pomt NUMD CE riesene r a E en nes 1 6 Pomt FyPe reiese a n EE E EEE 1 6 POAT o tcc asc E EEEE 1 8 TONG tet ate A 2 3 3 16 Low NIOGES wissdvcntunsisavesisevsnnsabusidelvartuneesevsvebentieden Wee 1 9 ODP STATING osre ran E EEEN riS 1 8 l 3 Index Sleep Mode waits eerestcsierincecneaenaseie E N 1 9 Standby M Odeonin ara 1 9 POW EP consump o peoa 3 5 Power input module ce 3 1 3 3 3 15 3 16 Power TeQU items oes 3 6 POWER WATS a naan ee eae 3 16 Processor and Memory scchine sn ee 1 4 Public Switched Telephone Networks PSTN ieena aaa i 5 11 Pube PUS ar E 4 12 12 and 24 volts dC vee cissscesseseversercercavecnaaradsacendens 4 12 JA AUT PCT s csnswisdeaticnnecuke ddan anctancseoiencemesienaunsesondceads 4 12 LED 2 cteasseniebonseuiwansenbsatondadanaseunnestandedesariaunexiandads 4 12 SEC MICAUIONG airinn E EER A 4 27 TroOUDIESNOONN O Ssicins ccasiscndeverwiutharranacveansrebeaionduiects 6 7 R Removing Communications Module cccccceeeeeeeeeeeeeeees 5 4 VO Mod llerinin aa 4 4 RED Eee T nantnen tan duatatsonuisehens 6 1 Resistance Temperature Detector RTD Input 4 13 ROCLINK 800 Configuration Software 1 10 RTD VY Mielec cana sehen eta eah aco uiniansiatecuuinsaaeta ech ccesiniete 4 14 RTD Input SPCCINCAL ONS stats ce si eeeahie AE 4 28 RIDI eonna a es cemsmmacedeatetaees 4 13 TROUDIESHOO ENG arera 6 8 IVINS es uesce hs ET 4 14 S DE
61. R TINTERE ACE MODULES arire a T sate da ee E T id Ka 4 19 dtl VO MODULE SPECIFICA ION aree E A wad T EE EEEE 4 22 Section 5 Communications eccseseeccsececccsececccseceocesscecccseceoccsescoccseceoccseseecessscoceseseoses 5 1 5 1 COMMUNICATION PORTS AND MODULES OVERVIEW ssssccccccceeseeececeeeeseeeceeeeeeeseceseeaaeeeeeeeeas 5 1 5 2 HOW TO INSTALL COMMUNICATION MODULES ccccccccsssseeccceceessecccceeaesecceesauenseceessaeeeeeeeesaas 5 3 5 3 HOW TO REMOVE A COMMUNICATIONS MODULE ccccccssssseecceeeeeeecccceeaessecceeeaueesceeeeaaeeeeeeesaas 5 4 5 4 HOW TO WIRETHE COMMUNICATIONS onesies ieii ENEA pret sie A N A aes 5 4 59 LOCAL OPERATOR INTERFACE LO a ee ee 5 5 5 6 ETHERNET COMMUNICATIONS raraosan ce site asec aca cteiaga saa senda ave ols aaa eaten ame ti 5 7 5 7 ELA 32 CR S 232 SERIAL COMMUNICATIONS Scada a a E N obeseitesteadina 5 8 5 8 EIA 422 485 RS 422 485 SERIAL COMMUNICATIONS MODULE ccccceccsecceescessceesseensseueees 5 9 5 9 DIAL UP MODEM COMMUNICATIONS MODULE ccccccssssccccesecccceeseccecaesecceeeueccseauseceeeaueeees 5 11 5 10 MULTI VARIABLE SENSOR MVS INTERFACE MODULES ccccceccceeccecccssccesccessceesseessseeeees 5 12 5 11 COMMUNICATIONS SPECIFICATIONS 295 waiase ete sti anic n ee a E a a 5 15 Section 6 I roubleshootihe siacsissirtinseasssronn einna a a 6 1 6 1 TROUBLESHOOTING GUIDELINE Suorien a e E 6 1 6 2 TROUBLESHOOTING CHECKLIST Seiren a E EE 6 1 6 3 PROC
62. Series are supported Refer to COMMUNICATIONS PARAMETERS Specifications Sheet 4 1 DS800 Configurable Port tag baud rate stop bits data bits parity kKey on delay key off delay port owner TCP IP and diagnostic counters 1 Refer to the ROC Plus Protocol User Manual Form A6127 for a complete list of parameters 1 16 General Information Rev Feb 05 ROC809 Instruction Manual SECTION 2 INSTALLATION AND USE This section describes the housing case the backplane electronic connection board at the back of the housing and the CPU Central Processing Unit This section provides a description and specifications of these hardware items and explains installation and startup of the ROC809 Section Page 2 Installation Requirements 2 1 2 2 Required Tools 2 4 23 Housing 2 4 2 4 How to Mount the ROC809 Unit on a DIN Rail 2 5 2 5 Backplane 2 7 2 6 Central Processor Unit CPU 2 7 2 4 License Keys 2 11 2 8 Startup and Operation 2 13 2 1 Installation Requirements The design of the ROC unit makes it highly adaptable to a wide variety of installations therefore not all possibilities can be covered in this manual If information is required concerning a specific installation not contained in this manual contact your local sales representative Planning is essential to a good installation Because installation requirements depend on many factors such as the application location ground conditions climate and accessibili
63. T Inputs RTD Inputs and Multi Variable Sensor Inputs For the full calibration procedure refer to the ROCLINK 800 Configuration Software User Manual Form A6121 This section contains the following information Section Page 7 1 Calibration 7 1 7 2 How to Prepare for a Calibration 7 1 7 1 Calibration Use ROCLINK 800 software to perform initial calibration or re calibration of the inputs on the AI HART RTD and MVS modules Re calibration would occur for example after a change in an orifice plate in the meter run handled by the ROC809 unit Calibration can be performed on sensor inputs from either orifice meter runs or turbine meter runs The AI RTD and MVS calibration routines support five point calibration with the three mid points calibrated in any order The low end or zero reading 1s calibrated first followed by the high end or full scale reading The three mid points can be calibrated next if desired The HART calibration routine supports two point calibration The low end or zero reading 1s calibrated first followed by the high end or full scale reading The diagnostic System Analog Inputs are not designed to be calibrated 7 2 How to Prepare for a Calibration Before calibrating the inputs from a sensor HART device or other device you should prepare the ROC809 unit Verify the inputs are correctly wired For information on wiring the inputs refer to Sections 4 and 5 If calibrating a pressure sensor inp
64. TDO Time Duration Output Tf Flowing temperature TLP Type of point Logical or point number and Parameter number TX or TXD Transmitted data communications signal V Z V Volts G 5 Glossary Rev Feb 05 ROC809 Instruction Manual INDEX 12 volts dc Anaoa Input a a a a 4 6 Pulse PPU ogen ints Getrceeenndahaieaai 4 12 24 volts dc Aallon NPDU osont a 4 6 PUSE DU o E auieatudtoeaaeas 4 12 PE r o a a 4 6 A After Installing Components ccccceeeeeeeeeeeees 6 3 PATIOS TPO rinna ncinadas ant anteenessudsotaidantelnntaccans 4 6 12 and 24 volts dC 0 0 ecccccccccccccceeeeeeessssseseees 4 6 SPECIMICALIONS Asie A R a 4 22 Troubleshoot Mo rarene a EEA 6 4 Anao SOUDU oeae aN AEAEE 4 7 SPCCIMCALIONS aeia 4 23 Troubleshooter EA 6 5 AC COmMaind ee e eatin ate oeataiees 5 12 Aoma SelE TESIS sron oes cueueads earectal estates 1 8 AUX Termina cic eeicket eae Jalan oon a es 3 2 3 3 3 4 AUX and AUX CED iets eal NA 3 3 Auxiliary WV AES eonan en a E 3 4 AUXSW termina oera Balen 3 2 3 5 B Back plane ag 0 telieas ea ieee eens 2 7 Backup Procedures After Installing Components ssesseeeeeeeeees 6 3 BAT temina ssicsevencesvencansatvcus ee cicoseeienateniacsaeeccawen 3 2 BATES e ea A daccan ue E NEE 3 18 3 19 Battery BackUp mennar eecen asicnredeatenvecn ees 1 1 1 4 WOITE eecatacieicaegiac ver ouster ceneeeen an Ves 3 16 Burst OS canara EE 4 19 C Calibra Onsrud e
65. V 42 MNP2 4 and MNP10 Certification FCC Part 68 approved Ring Voltage Detected 38 to 150 RMS type B ringer Ring Frequency Detected 15 3 to 68 Hz type B ringer Telephone Loop Current 20 to 100 mA when off hook Data Transmit Level 12 to 9 0 dBm 10 5 typical DTMF Transmit Level 2 5 to 0 dBm average over 3 second interval Surge Protection Conforms to FCC Part 68 5 17 Communications OVER VOLTAGE PROTECTION 14 volts dc continuous on any terminal POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 volts dc Typical 95 mA Additional loading that may apply Per Active LED 1 5 mA WIRING 12 AWG or smaller at the removable terminal block LED INDICATORS TX Transmit RX Receive RI Ring and CD Carrier Detect ISOLATION Per FCC Part 68 WEIGHT 113 4 g 4 0 02 Rev Feb 05 ROC809 Instruction Manual Multi Variable Sensor MVS Module Specifications FIELD WIRING TERMINALS 2 e m s common COMMUNICATIONS Provides communications interface for up to six MVS sensors One second updates occur for each of the three variables for each of the sensors attached POWER Provides isolated short circuit current limited power required to connect up to five MVS sensors OVER VOLTAGE PROTECTION 14 volts dc continuous on any terminal WIRING 12 AWG or smaller at the removable terminal block 5 18 Communications WEIGHT 6
66. VIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed 4 27 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 7 RTD Input Module RTD Input Module Specifications FIELD WIRING TERMINALS INPUT Terminal Minimum Scan aks 64 msec both channels REF CH1 Constant Current eee Accuracy at 25 C 77 F 0 03 of CH1 Positive RTD ae ee CH1 Negative RTD Absolute Accuracy Over Operating Temp 0 38 RET CH1 Constant Current Pin SGA N A Not Used POWER CONSUMPTION REF CH2 Constant Current Main power supply loading at 13 25 Volts DC at the CH2 Positive RTD Battery Terminals 65 mA maximum CH2 Negative RTD WIRING RET PEL ODAT CUEN 12 AWG at the removable terminal block Not Used ISOLATION INPUT Field to Logic 2500 Volts DC 1 minute minimum Quantity 2 channels Field to Power 2500 Volts DC 1 minute minimum Type 2 3 or 4 wire 100 Q platinum type RTD Module to Module 2500 Volts DC 1 minute using a 24 bit A D connector minimum Sensing Range 50 to 350 C 58 to 662 F WEIGHT Full Range Deflection DIN 43760 standard 70 g 2 47 oz Maximum Overload Input to Input 6 Volts DIMENSIONS D l C continuous 26 mm W by 133 mm H by 75 mm D 1 04 in W by Temperature Coefficient alpha of 0 00385 or 5 25 in H by 2 9
67. a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure 2 Remove all power from the ROC800 Series unit 3 Remove the two screws on the CPU faceplate 4 Remove the CPU faceplate 3 19 Power Connections Rev Feb 05 ROC809 Instruction Manual 5 Insert a plastic screwdriver behind the battery and gently push the battery out of the battery holder taking note of the orientation of the battery The negative side of the battery is placed against the CPU and the positive towards the label on the battery holder 6 Insert the new battery in the battery holder paying close attention to install the battery with the correct orientation 7 Replace the CPU faceplate 8 Replace the two screws to secure the CPU faceplate 9 Apply power to the ROC800 Series unit 10 Refer to Section 2 8 5 After Removing Power from the ROC800 Series unit on page 2 38 and perform the restore procedure 3 20 Power Connections Rev Feb 05 ROC809 Instruction Manual SECTION 4 INPUT OUTPUT MODULES This section describes the Input Output I O modules used with the ROC800 series cont
68. able one pair for transmitting and one pair for receiving The EIA 422 RS 422 module uses four wires and the EIA 485 RS 485 uses two wires for connectivity 5 8 1 EIA 422 485 RS 422 485 Jumpers and Termination Resistors Four jumpers are located on the EIA 422 485 RS 422 485 communications module J3 J4 J5 and J6 These jumpers determine in which mode the module runs RS 422 or RS 485 and if the module is terminated Terminations are required on the two EIA 422 485 RS 422 485 communication modules located at the extremities of the circuit That is to say the two outside modules require terminations in order to complete the communications circuit 5 10 Communications Rev Feb 05 ROC809 Instruction Manual Full A O u n 7 Halt je Duplex Hal Ter J5 Full Out Halt Fe 6 Duplex e 809485 dsf Figure 5 4 ETA 422 485 RS 422 485 J4 Jumper Table 5 11 EIA 422 RS 422 Module 5 9 Dial up Modem Communications Module The dial up modem module interfaces to a Public Switched Telephone Network PSTN line The dial up modem module provides for a telephone interface on the host port that is capable of both answering and originating telephone calls The dial up modem module also provides electronics that conserve power when the phone line is not in use The dial up modem module requires a telephone line connection NOTE When installing a dial up modem module you must remove power from the ROC800 Series
69. able is recommended for I O signal wiring The removable terminal blocks accept 12 AWG or smaller wire 4 5 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 3 Analog Input Modules The four Analog Input AI channels are scalable but typically measure either 4to 20 mA analog signal with the use of a precision resistor supplied 1to5 volts dc signal If required you can calibrate the low end of the analog signal to zero The AI T is module selectable as 12 or 24 volts dc via jumper J4 on the I O module The AI modules can provide isolated 12 volts dc or 24 volts dc field transmitter power on a per module basis For example one module can provide 12 volts dc for powering low power analog transmitters while another module in the same ROC800 series controller can provide 24 volts dc for powering conventional 4 20 mA transmitters Refer to Figure 4 4 4 6 Precision Resistor 1 5 VOLT DEVICE 4 EXTERNALLY POWERED OUT SIGNAL p 1 5 VOLT DEVICE EXTERNALLY POWERED CURRENT LOOP DEVICE 4 20mA ROC809 POWERED DOCO506A Figure 4 5 Analog Input Module Field Wiring Input Output Modules T 12 24Vdc Jumper Rev Feb 05 ROC809 Instruction Manual NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying commons from various modules together 4 4 Analog Output Modules The 16 bit Analog Output AO module has four cha
70. ading An open at terminal RET gives a minimum reading To verify the operation of the RTD module 1 Connect to the ROCLINK 800 software 2 Select Configuration gt I O gt RTD Point 3 Disconnect the RTD and connect a jumper between terminals and RET of the RTD module 6 8 Troubleshooting Rev Feb 05 ROC809 Instruction Manual 4 Connect either an accurate resistor or decade resistance box with a value to give a low end reading across terminals and The temperature to resistance conversion chart can determine the resistance value required for the type of RTD being used 5 Verify that the Raw A D Input value changed and reflects the Adjusted A D 0 value 6 Change the resistance to reflect a high temperature as determined by the temperature to resistance conversion chart 7 Verify that the Raw A D Input value changed and reflects the Adjusted A D 100 value 8 Remove the test equipment and reconnect the field device 6 3 10 Troubleshooting J and K Type Thermocouple Input Modules Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations Many digital multimeters can generate and measure thermocouple signals Check your documentation to see if your multimeter supports thermocouples and how to correctly use
71. age The PI modules draw power for the active circuitry from the backplane Input signals are optically isolated NOTE Do not connect wiring to both the Low and High speed selections for a given channel Unpredictable operation of the PI module will result T 12 24Vdc Jumper 809PIJ4 dsf Figure 4 11 Pulse Input J4 Jumper Set to 12 V 4 12 Input Output Modules Rev Feb 05 ROC809 Instruction Manual Representative PI Field Wiring Internal Circuit EC 12 KHz PI Filter ea Channel High External Powered amp Level Detection O H p Open Collector or Open Drain Device H Channel kow External Powered Contact Closure Device COM 125 Hz PI Filter amp Level Detection CH 2 COM T 2 CHAN PIW11059 dsf Figure 4 12 Externally Powered Pulse Input Module Field Wiring Representative Internal Circuit 12KHz PI FILTER amp OPEN oo OPEN DRAIN TYPE DEVICE ROC800 POWERED Field Wiring METER COIL DOC0511A Figure 4 13 ROC800 series Powered Pulse Input Module Field Wiring NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying commons together 4 9 RTD Input Modules The Resistance Temperature Detector RTD module monitors the temperature signal from an RTD source The module can accommodate input from a two three or four wire RTD source The act
72. and connectors to the backplane The ROC800 Series unit can hold up to three communication modules in the first three module slots Refer to Figure 5 1 5 1 Communications Rev Feb 05 ROC809 Instruction Manual y Issa Optional Comm3 to Comm5 Slot 1 7 to 1 L 4 LOI Local Port ElA 232 z oui 1 ptional Comm3 to yO F Comm5 Slot 2 Built in A Ethernet Comm1 i Optional Comm3 to Built in EIA 232 i gt o Comms Slot 3 RS 232 Comm2 S O02020 E Figure 5 1 Communication Ports Table 5 2 Communication LED Indicator Definitions Clear To Send indicates the modem is ready to send Data Carrier Detect DCD indicates a valid carrier signal tone detected Data Set Ready for ring indicator communication signal Data Terminal Ready to answer an incoming call When the DTR goes off a connection disconnects Ready To Send indicates ready to transmit Receive Data RD signal is being received Transmit Data TD signal is being transmitted 5 2 Communications Rev Feb 05 ROC809 Instruction Manual Each communications module has surge protection in accordance with the CE certification EN 61000 Each communications module is completely isolated from other modules and the backplane including power and signal isolation with the exception of the EIA 232 RS 232 module The field interface has been designed to protect the electronics in the module Filtering
73. ata in a ROC809 and is sometimes referred to as the TLP Type Logical Parameter The Input Output database contains the input and output points supported by the operating system firmware including the System Analog Inputs Multi Variable Sensor MVS inputs and Input Output I O modules The firmware automatically determines the Point Type and Point Number location of each installed I O module Each input and output is assigned a point in the database and includes user defined configuration parameters for assigning values statuses or identifiers The firmware scans each input placing the values into the respective database point These values are available for display and historical archiving Spontaneous Report by Exception SRBX communication allows the ROC809 to monitor for alarm conditions and upon detection of an alarm automatically reports the alarm to a host computer This can be performed over any kind of communications link dial up modem or serial line as long as the host is set up for receiving field initiated calls The firmware supports ROC Plus protocol Modbus master and slave protocol ROC Plus protocol can support serial communications and radio or telephone modem communications to local or remote devices such as a host computer There is also support for ROC Plus protocol over TCP IP on the 1 6 General Information Rev Feb 05 ROC809 Instruction Manual Ethernet port The ROC Plus protocol is similar to the ROC 3
74. base Historical Database Event and Alarm Log Databases Applications PID AGA FST etc Determining Task Execution 4 Measurement Station Support Real Time Clock Establishing and Managing Communications Self Test Capability The firmware makes extensive use of configuration parameters which are configured using ROCLINK 800 Configuration Software The ROC800 Series firmware uses a pre emptive multi tasking message based Real Time Operating System with hardware supported memory protection Tasks are assigned priorities and at any given time the operating system determines which task will run For instance if a lower priority task is executing and a higher priority task needs to run the operating system suspends the lower priority task allows the higher priority task to run to completion then resumes the lower priority task s execution This is more efficient than time sliced type architectures The ROC809 reads and writes to each Point in the unit A Point is a software oriented term for an I O channel or some other function such as a flow calculation Points are defined by a collection of Parameters The Point Number indicates the physical location for I O or logical instance for non I O points within the ROC809 The Point Type attributes define the database point to be one of the possible types of points available to the system These three parameters can be used to identify a specific piece of d
75. ble for voltage NOTE If these methods do not solve the problem contact your local sales representative 6 2 Troubleshooting Rev Feb 05 ROC809 Instruction Manual If you are experiencing trouble with the MVS Module If more than one MVS is connected to the ROC809 ensure that each has a unique Address as set in ROCLINK 800 Configuration Software Reset the MVS module back to factory defaults refer to the ROCLINK 800 Configuration Software User Manual Form A6121 NOTE If you believe an MVS module is damaged or faulty contact your sales representative for repair or replacement 6 3 Procedures 6 3 1 How to Preserve Configuration and Log Data Before removing power to the ROC809 for repairs troubleshooting or upgrades perform this backup procedure This procedure preserves the current ROC809 configuration and log data held in SDRAM When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a grounded wrist strap 1 Launch ROCLINK 800 software 2 Select ROC menu gt Flags gt Save Configuration This saves all configuration settings including the current states of the ROC8
76. ck eeseeeeeeees 1 2 Figure 2 1 Side View of the ROC809 00 2 6 Figure 2 2 Bottom View of the ROC809 2 6 Figure 2 3 Back of the ROC809 0 0 eeeeeeeeeees 2 6 Figure 2 4 CPU Front View cccccccccccsssssssseeeeees 2 8 Pisutre2 5 CPU Connectors aante sent stiads 2 8 Figure 2 6 License Key iccicceice in eernietetiete dees 2 11 Figure 2 7 License Key Installation 0 2 12 Figure 3 1 12 Volt DC Power Input Module 3 2 Figure 3 2 24 Volt DC Power Input Module 3 3 Figure 3 3 12 Volts DC Auxiliary Power Wiring 3 4 Figure 3 4 24 Volts DC Auxiliary Power Wiring 3 5 Figure 3 5 12 VDC Power Supply and BAT BAT NYE E eaea a a N 3 17 Figure 3 6 12 VDC Power Supply and CHG CHG NYE T e E eacsnannearuaset 3 18 Figure 4 1 Typical I O Module eeeeeeeeeees 4 Figure 4 10 Discrete Output Relay Module Field Wiring AO EE ELA EA A A E 4 11 Figure 4 11 Pulse Input J4 Jumper ee 4 12 Figure 4 12 Externally Powered Pulse Input Module Field Wt Opt stot tonite ates bes anntnana ada hereaeutunineuitadeatands 4 13 Figure 4 13 ROC800 series Powered Pulse Input Module Feld WITS oada 4 13 Figure 4 14 RTD Sensor Wiring Terminal Connections E AE E E T A E E E 4 15 Figure 4 15 Type J and K Thermocouple Wiring 4 17 Figure 4 16 Type J Thermocouple Shielded Wiring United States Color Coding ccccccees
77. cocesescoceseecooes 3 1 3 1 POWER INPUT MODULE DESCRIPTIONS cirerer iiine o n a A TENET RERET 3 1 372 HOW TO DETERMINE POWER CONSUMBPTION ssssccccesssccceesececcaneccceeseccceaeseccceeeseceseenseceeeenes 3 5 3 3 HOWTO REMOVE A POWER INPUT MODUL Esnaera a a E A GE 3 15 3 4 HOW TO INSTALL A POWER INPUT MODULE scccccccsssccecceseceeceesecceeaeecceesueecceseueeecesaueeeeeas 3 16 3 5 HOW TO CONNECT THE ROC800 SERIES UNIT TO WIRING cccccsssscccceessececeeeccceeaeeceeeueeeeeas 3 16 Section 4 Input Output Modules cccccscssssssssssssssccccccccccsssssscsssccccsssssessssees 4 1 4 1 ONER S i E E te eo eee eR Rc ee ee cee eee 4 4 2 DSA TON sciatic tae eset tuts ca ies eases ue ete ogee eee O 4 3 4 3 ANALOG INPUT MODULES sesenaseedeenssondersaniends gansatseeniainedeendaondee patton e a ea 4 6 4 4 ANALOG OUTPUT MODULES pruinis i nan a EE EAEEREN OEE AR OEE ONE 4 7 4 5 DISCRETE INPUT MODULE erorii e EE A ee E AE EA 4 9 jii 0 Rev Feb 05 ROC809 Instruction Manual 4 6 DISCRETE OUTPUT MODULES ssssesnzsansneaussusied otelnaiseaaehausenseanctmedussusied of EE AEREA EEKE ER 4 10 4 7 DISCRETE OUTPUT RELAY MODULES visicssettcccisacdeastaadicaesdadeducseedeusisandeweteadsaaastadeducneadauaseecteexse 4 11 4 8 POLS TTT MODULT Serri a A T E eee nee a ene 4 12 4 9 RIDINPUL MODULES enin T E O 4 13 4 10 J AND K TYPE THERMOCOUPLE INPUT MODULES cccccccssseccccesecccceeseccceaesececcaeececseeeeceeeaees 4 16 AN THA
78. d date Common Practice Command Read transmitter variables ACCURACY Analog Output Absolute accuracy at 25 C 77 F 0 2 Absolute accuracy over operating temperature range 1 5 Analog Input Absolute accuracy at 25 C 77 F 1 5 Absolute accuracy over operating temperature range 3 0 4 30 Input Output Modules POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 V dc 110 mA maximum over operating temperature range Additional loading that may apply for each device configured 2 5 multiplied by Measured Current Draw at T terminal LOOP POWER Total power supplied through the module for HART devices is 20 mA per channel at 24 V dc Each HART device typically uses 4 mA in multi drop mode and uses 4 20 mA in point to point mode OVER VOLTAGE PROTECTION 25 V dc continuous on any terminal ISOLATION Field to Logic 2500 V dc 1 minute minimum Field to Power 2500 V dc 1 minute minimum Module to Module 2500 V dc 1 minute minimum WIRING 12 AWG or smaller at the removable terminal block WEIGHT 76 g 2 8 OZ DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 25 in H by 2 96 in D ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed Rev Feb 05 ROC809 Instruction Manual SECTION 5 COMMUNICATIONS
79. ded as a sixth programming language With these six languages FSTs and built in functionality you can configure and program the ROC809 in an environment in which you are comfortable Programs developed in the DS800 Development Suite Software may be downloaded and implemented in the ROC809 unit in addition to or as an alternative to FST programs DS800 software has definite benefits for programmers who prefer to use the IEC 61131 3 languages who desire to multi drop units in a distributed architecture or who desire enhanced program diagnostics capabilities DS800 Development Suite Software has the additional following features Cross reference bindings between variables in separate ROC809 units Variable Dictionary Off line simulation for diagnostics and testing On line modification of programs gt gt 6M On line debugging of programs 1 11 General Information Rev Feb 05 ROC809 Instruction Manual 1 12 gt gt 6M Locking and forcing of variables User developed functions and function blocks User defined templates Creation and support of user defined libraries General Information Rev Feb 05 ROC809 Instruction Manual 1 6 Specifications ROC809 Remote Operations Controller Specifications PROCESSOR 32 bit microprocessor based on the Motorola MPC862 Quad Integrated Communications Controller PowerQUICC PowerPC processor running at 50 MHz PROCESSOR MEMORY Boot Flash 256 KB for s
80. deral codes often place restrictions on locations and dictate site requirements Examples of these restrictions are fall distance from a meter run distance from pipe flanges and hazardous area classifications Ensure that all code requirements are met Choose a location for the ROC to minimize the length of signal and power wiring ROC units equipped for radio communications should be located so the antenna has an unobstructed signal path Antennas should not be aimed into storage tanks buildings or other tall structures If possible antennas should be located at the highest point on the site Overhead clearance should be sufficient to allow the antenna to be raised to a height of at least twenty feet To minimize interference with radio communications choose a location for the ROC away from electrical noise sources such as engines large electric motors and utility line transformers Choose a location for the ROC away from heavy traffic areas to reduce the risk of being damaged by vehicles However provide adequate vehicle access to aid monitoring and maintenance The site must comply with class limits of Part 15 of the FCC rules Operation is subject to the following two conditions 1 The device may not cause harmful interference and 2 the device must accept any interference received including interference that may cause undesired Operation 2 1 3 Compliance with Hazardous Area Standards The ROC hazardous location a
81. displays and reports and defining user calculations Typically the software setup of a device that can often be defined and changed Can also mean the hardware assembly scheme CPU Central Processing Unit CRC Cyclical Redundancy Check Crosstalk The amount of signal that crosses over between the receive and transmit pairs and signal attenuation which is the amount of signal loss encountered on the Ethernet segment CSA Canadian Standards Association CSMA CD Carrier Sense Multiple Access with Collision Detection CTS Clear to Send modem communications signal D D A Digital to Analog DB Database dB Decibel A unit for expressing the ratio of the magnitudes of two electric signals on a logarithmic scale DCD Data Carrier Detect modem communications signal In addition Discrete Control Device A discrete control device energizes a set of discrete outputs for a given setpoint and matches the desired result against a set of discrete inputs DCE Data Communication Equipment G 1 Glossary Rev Feb 05 ROC809 Instruction Manual Deadband A value that is an inactive zone above the low limits and below the high limits The purpose of the deadband is to prevent a value such as an alarm from being set and cleared continuously when the input value is oscillating around the specified limit This also prevents the logs or data storage location from being over filled with data DI Discrete
82. e sensor info and pv range units and limits General Information Rev Feb 05 ROC809 Instruction Manual ROC809 Operating System Firmware Specifications Continued MVS INPUT PARAMETERS DATABASE LOGGING Configurable Sensor tag sensor address sensor Segment Database Archives more than 197 000 configuration poll mode sensor status sensor entries for example 35 days of 24 hour data on alarms DP pressure and temperature readings DP 200 points in user configured time segments and full scale and calibrate command time intervals Read Only Point number sensor voltage pressure Alarm Logs Records 450 alarms such as high and temperature full scale DP pressure and high high low low low and rate temperature minimum scale static pressure effect and manual Differential Pressure DP Absolute Pressure AP and Process Temperature PT Event Logs Records 450 events such as parameter changes and power cycling CONTROL FST Maximum of 6 up to 500 lines full math logical and control commands MODBUS PARAMETERS Master Slave RTU ASCII event log enable master start polling starting request number of requests continuous polling poll request delay float PID Maximum of up to 16 loops primary or conversions and mappable addresses Extensions override analog or discrete control action support for retrieval of history event and alarm data DS800 Development Suite Multiple resources provided per ROC800
83. e 97 5 g 3 44 oz 24 VDC Power Input Module 120 g 4 24 02 ENVIRONMENTAL Operating Temp 40 to 75 C 40 to 167 F Storage Temp 40 to 85 C 40 to 185 F Relative Humidity IEC68 2 3 5 95 non condensing Vibration IEC68 2 6 0 15 mm sec 10 150 Hz Mechanical Shock IEC68 2 27 11 ms sinusoidal 50 Gs non operating 15 Gs operating Thermal Shock EC68 2 14 Air to air from 20 to 85 C 4 to 185 F General Information APPROVALS Complies with the following European Standards EN55011 Emissions EN61000 4 2 Electrostatic Discharge Immunity EN61000 4 4 Electrical Fast Transients Immunity EN61000 4 6 Conducted Immunity EN61000 4 8 Power Frequency Magnetic Field Immunity EN61000 6 2 Radiated RF Immunity Evaluated per the following North American Standards CSA C22 2 No 142 amp No 213 CAN CSA E79 0 95 amp E79 15 95 UL 1604 3 Edition UL 508 17 Edition UL 2279 Product Markings for Hazardous Locations Class I Division 2 Groups A B C and D T4A Class Zone 2 Group IIC T4A AEx nA IIC T4A Rev Feb 05 ROC809 Instruction Manual ROC809 Operating System Firmware Specifications SYSTEM VARIABLES Configurable Device group Device address station name active PIDs active AGAs and active Samplers Read Only Firmware version time created and CPU loading ANALOG INPUT PARAMETERS Configurable Point tag units name value scan period sca
84. e Once a backup configuration file is created it can be loaded into a ROC809 by using the Download function Access to the ROC809 is restricted to authorized users with correct User ID and password You can build custom displays for the ROC809 that combines both graphic and dynamic data elements The displays can monitor the operation of the ROC809 either locally or remotely Historical values can be archived for any numeric parameter in the ROC809 For each parameter configured for historical archiving time stamped minute periodic and daily data values are kept as well as yesterday s and today s daily minimum and maximum values History values can be collected from the ROC809 via ROCLINK 800 or other third party host system You can view history directly from the ROC809 or from a previously saved disk file For each history segment the number of periodic history values archived the frequency of archiving the periodic values the number of daily values archived and the contract hour are configurable ROCLINK 800 software has the ability to create an EFM Electronic Flow Measurement report file that contains all the configuration alarms events periodic and daily history logs and other history logs associated with the stations and meter runs in the ROC809 This file then becomes the custody transfer audit trail The SRBX Spontaneous Report By Exception alarming feature is available for the host communication ports the Local and D
85. e back edge of the housing To replace the end caps 1 Align the back edge of the end cap on the housing 2 Rotate the end cap towards the housing and snap the end cap into place 2 3 2 Howto Remove and Install Wire Channel Covers Install the wire channel covers over the wiring channels once wiring of the terminal blocks is complete Wire channel covers are located on the front of the ROC809 housing Refer to Figure 1 1 To remove a wire channel cover 1 Grasp the wire channel cover at both the top and bottom 2 Start at the top or bottom and pull the wire channel cover out of the wire channel 2 4 Installation and Use Rev Feb 05 ROC809 Instruction Manual To replace a wire channel cover 1 Align the wire channel cover over the wire channel allowing unobstructed wire access 2 Press wire channel cover into place until it snaps NOTE The tabs on the left side of the wire channel cover should rest in the slots on the left edge of the channel 2 3 9 Howto Remove and Install Module Covers Before inserting an I O or communication module remove the module cover over the empty module slots in which you will be installing the modules You are not required to remove the power to the ROC809 to perform this procedure though caution is always advisable when working with a powered ROC809 unit CAUTION To avoid circuit damage when working inside the unit use appropriate electrostatic discharge precautions such as wearing a
86. e channel cover Unscrew the screws from the CPU faceplate Remove the CPU faceplate Remove the License Key from the appropriate terminal slot P4 or P6 in the CPU Refer to Figure 2 5 Replace the CPU faceplate 8 Replace the screws from the CPU faceplate 9 Replace the wire channel cover 2 12 Installation and Use Rev Feb 05 ROC809 Instruction Manual 10 Restore power to the ROC809 11 Refer to Section 2 8 5 After Removing Power from the ROC809 on page 2 38 and perform the restore procedure 2 8 Startup and Operation Before starting up the ROC809 perform the following checks to ensure the unit is properly installed Make sure the power input module is properly seated in the backplane Make sure I O and communication modules are seated in the backplane 4 Check the field wiring for proper installation Make sure the input power has the correct polarity Make sure the input power is fused at the power source Check the input power polarity before connecting power to the ROC809 Incorrect polarity can damage the ROC809 When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing procedures in a hazardous area could result in personal injury or property damage 2 8 1 Startup Apply power to the ROC809 Refer to Section 2 6 1 Wiring the DC Power Input Module on page 2 31 The powe
87. eeeeeeeeeeeees 4 18 Figure 4 17 Type K Thermocouple Shielded Wiring United States Color Coding sessessssoeooeeeeesssssssesss 4 18 Figure 4 18 Ungrounded Sheathed 4 18 Figure 4 19 Grounded sii eo i le eta 4 18 Figure 4 2 Optional I O Module Locations 4 2 Figure 4 20 Exposed Ungrounded Unsheathed 4 18 Figure 4 21 HART Interface Module Field Wiring 4 20 Figure 4 22 HART Channels and 3 On back side of DO At sescscsrinsaceanessentedatinceaauton sstnaocnmncctaecctueoeatiacsh ack 4 21 Figure 4 23 HART Channels 2 and 4 On front side of DOO annan E eatseosaseasbenee 4 21 Figure 4 3 Installing an I O Module 00 0 4 4 Figure 4 4 Analog Input Jumper J4 eee 4 6 2 Index Figure 4 5 Analog Input Module Field Wiring 4 6 Figure 4 6 Analog Output Jumper J4 Shown Set to PDN cicussaccecseatstease A statis bok soemneiesea 4 7 Figure 4 7 Analog Output Module Field Wiring 4 8 Figure 4 8 Discrete Input Module Field Wiring 4 9 Figure 4 9 Discrete Output Module Field Wiring 4 10 Figure 5 1 Communication Ports ccccceeeeeeees 5 2 Figure 5 2 RJ 45 Pin Out ceccssssseeeeeeeeeeeeeeeeaes 5 5 Figure 5 3 10BASE T Crossover Cable 5 8 Figure 5 4 EITA 422 485 RS 422 485 J4 Jumper 5 11 Figure 5 5 MVS Jumper J4 cocinncun nese 5 14 PUT WAC oo iss hc sana a a 1 5 Firmware lash C ADe 1 5 Functio
88. eld device 6 3 5 Troubleshooting Discrete Input Modules Equipment Required Jumper wire PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations oe Pl i oe a 6 6 Disconnect the field wiring at the DI module terminations Connect to ROCLINK 800 software Select Configuration gt I O gt DI Points Select the correct Discrete Input Point Number Place a Jumper across a channel input terminal 1 8 and COM The Status should change to On With no jumper on the channel terminal and COM the Status should change to Off Remove the test equipment and reconnect the field device Troubleshooting Rev Feb 05 ROC809 Instruction Manual 6 3 6 Troubleshooting Discrete Output Modules Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 1 Verify the load current requirement does not exceed the current limit value of the module 2 Verify the module is wired correctly 3 Remove all wiring from the DO module 4 Connect the multimeter set up to measure ohms to the channel that you are testing 5 Measure the resistance with the DO Status OFF It
89. erfaces with MVS Sensors up to two modules per ROC809 Dial up modem used for communications over a telephone network 14 4K V 42 bis with throughput up to 57 6K bps I O and communication modules easily install in the module slots Modules may be removed and installed while the unit is powered up hot swappable modules may be installed directly into unused module slots hot pluggable and modules are self identifying in the ROCLINK 800 Configuration Software The modules have extensive short circuit overvoltage protection and are self resetting after a fault clears 1 1 1 Central Processor Unit CPU The CPU Central Processing Unit contains the microprocessor the firmware connectors to the backplane the three built in communication ports two with Light Emitting Diodes LEDs a LED low power wakeup button a RESET button the application License Key connectors a STATUS LED indicating system integrity and the main processor The CPU components include 32 bit microprocessor based on Motorola MPC862 Quad Integrated Communications Controller PowerQUICC PowerPC processor SRAM Static Random Access Memory with battery backup Flash ROM Read Only Memory SDRAM Synchronous Dynamic Random Access Memory Diagnostic monitoring Real Time Clock Automatic self tests Power saving modes Local operator interface LOI EIA 232 RS 232D Local Port EJA 232 RS 232C serial Comm port Ethernet Comm1 por
90. erify the following readings When the Value is 25 of span as configured in Table 6 1 it is an indication of no current flow 0 mA which can result from open field wiring or a faulty field device The multimeter should show O zero volts de When the Value is in excess of 100 of span as configured in Table 6 1 it is an indication of maximum current flow which can result from shorted field wiring or a faulty field device The multimeter should show 5 volts dc When the Value is between the Low Reading EU and the High Reading EU verify the accuracy of the reading by measuring the voltage across the terminals with the multimeter 6 Convert this reading to the Value value Value V multimeter 1 4 Span Low Reading EU where Span High Reading EU Low Reading EU This calculated value should be within one tenth of one percent of the Filter value measured by the ROC809 7 Verify an accuracy Read the loop current with a multimeter set the multimeter to measure current in mAmps and connect it in series with current loop Be sure to take into account that input values can change rapidly which can cause a greater error between the measured value and the calculated value 8 Calculate the Value from the mAmp reading of the multimeter Value mMAMPmuttimeter Rscaling resistor 1 4 Span Low Reading EU where Span High Reading EU Low Reading EU and Rscaling resistor Should be 250 ohms factor
91. es I O Module oer one Penne Quantity Duty Sub Total oe Lee eee Discrete Input DiModuleBase No chamersacive 28w C canei s2ma tevotsac s4mw J C Channel s2ma t2votsac s84mw J C Chanels s2ma t2votsde ss4mw J C Channela s2ma t2votsde 384mw SS Channels 52mA t2votsdc 384mWw C Channels s2mA t2votsde 384mw C Channel s2mA t2votsde 384mw C Channels s2mA t2votsde 384mw Per Active LED 1 5 mA 18 mW Maximum 8 The Duty Cycle is the time on divided by the total time The Duty Cycle is essentially the percent of time that the I O channel is active maximum power consumption Duty Cycle Active time Active time Inactive time For example if a Discrete Input is active for 15 seconds out of every 60 seconds Duty Cycle 15 seconds 15 seconds 45 seconds 15 seconds 60 seconds 0 25 3 10 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 9 Power Consumption of the Discrete Output Modules I O Module power onsumpuon M Quantity Duty Sub Total er eee N Discrete Output 20 mA 12 volts dc pomene Recron eo C chann o sma e o oo a o e a Channl3 J isma iem TT am fmf ChannelS SMA mW J css saee ew aximum 5 EES rr O Total The Duty Cycle is the time on divided by the total time The Duty Cycle is essentially the percent of time that the I O channel is active maximum power consumption
92. es maintenance please contact your local sales representative 2 6 Central Processor Unit CPU The CPU Central Processing Unit contains the microprocessor the firmware connectors to the backplane the three built in communication ports two with LEDs a LED low power wakeup button a RESET button the application License Key connectors a STATUS LED indicating system integrity and the main processor Refer to Figure 2 4 Figure 2 5 Table 2 1 and Table 2 2 The 32 bit microprocessor is based on a Motorola MPC862 Quad Integrated Communications Controller PowerQUICC PowerPC processor running at 50 MHz The internal Sanyo 3 volt CR2430 lithium backup battery provides backup of the data and the Real Time Clock when the main power is not connected 2 7 Installation and Use Rev Feb 05 ROC809 Instruction Manual LED Button LOI EIA 232 RS 232D STATUS LED LICENSE KEYS RESET Button ETHERNET EIA 232 RS 232C DOCO488A Figure 2 4 CPU Front View Battery LED Button Boot ROM License Keys RESET Button DOC0489A Figure 2 5 CPU Connectors 2 8 Installation and Use Rev Feb 05 ROC809 Instruction Manual Table 2 1 CPU Connector Locations CPU Number 4 dNotUsed o Pe oP 6 License Key Terminal wi LED Button sw RESET Button The CPU contains a microprocessor supervisory circuit This device monitors the battery voltage resets the processor and disables the SRAM chip if the
93. es unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed Rev Feb 05 ROC809 Instruction Manual 4 12 6 Pulse Input Module Pulse Input Module Specifications FIELD WIRING TERMINALS POWER CONSUMPTION Terminal Main power supply loading at the Battery Terminals at 12 0 Volts DC 1 CH1 L CH1 Low Speed CH1 H CH 1 High Speed No Channels Active 21mA COMM CH 1 Common Additional loading that may apply COMM CH 1 Common Per Active Channel 7 4 mA one a o Speen Per Active LED 1 5mA 6 CH2H CH2High Speed _ T 12V 1 25 Measured Current Draw at a semen T Terminal 8 COMM T 24V 2 5 Measured Current Draw at LoopPower 1 Terminal WIRING INPUT 12 AWG at the removable terminal block Quantity 2 channels ISOLATION Type Optically isolated inputs common voltage Field to Logic 2500 Volts DC 1 minute minimum source and terminal selectable high low speed a hardware filter on each channel Field to Power 2500 Volts DC 1 minute minimum Filter Cutoff Frequency Module to Module 2500 Volts DC 1 minute High Speed Input 12 KHz NE Low Speed Input 125 Hz WEIGHT Input Impedance 2 K typical 56 7 g 2 0 02 Minimum On State Input Current 2 00 mA DIMENSIONS Maximum Off State Input Current 1 7 mA 26 mm W by 133 mm H by 75 mm D 1 04 in W by LEDS 5 25 in H by 2 96 in D 2 green LEDs indicate the status of the channels EN
94. etpoint If PID override control 1s configured the primary loop is normally in control of the regulating device When the change in output for the primary loop becomes less or greater user selected than the change in output calculated for the secondary override loop the override loop takes control of the regulating device When the switchover conditions are no longer met the primary loop regains control of the device Parameters are also available to force the PID into either loop or force it to stay in one loop 1 3 7 FST The Function Sequence Table FST applications firmware gives analog and discrete sequencing control capability to the ROC809 This programmable control is implemented in an FST which defines the actions to be performed by the ROC809 using a series of functions The FST is developed using the FST Editor in ROCLINK 800 Configuration Software The basic building block of an FST is the function Functions are organized in a sequence of steps to form a control algorithm Each function step can consist of a label a command and associated arguments Labels are used to identify functions and allow branching to specific steps within an FST Commands are selected from a library of mathematical logical and other command options Commands are identified by a name consisting of up to three characters or symbols Finally arguments provide access to process I O points and retrieve real time values A function may have zero one or two
95. ev Feb 05 ROC809 Instruction Manual NOTE All modules have removable terminal blocks for convenient wiring and servicing Twisted pair cable is recommended for I O signal wiring The removable terminal blocks accept 12 AWG or smaller wire 5 5 Local Operator Interface LOI The Local Operator Interface port also called the LOI port provides direct communications between the ROC800 Series and the serial port of an operator interface device such as an IBM compatible computer The interface allows you to access the ROC800 Series with a direct connection using ROCLINK 800 software for configuration and transfer of stored data Local Operator Interface uses the Local Port in ROCLINK 800 software The LOI terminal RJ 45 on the CPU provides wiring access to a built in EIA 232 RS 232 serial interface which is capable of 57 6K baud operation The RJ 45 connector pin uses the data terminal equipment DTE in the IEEE standard The LOI port supports ROC Plus and Modbus protocol communications The LOI also supports the log on security feature of the ROC800 Series if the Security on LOI is Enabled in ROCLINK 800 software Table 5 3 shows the signal routing of the CPU connections Figure 5 2 shows the RJ 45 pin out Table 5 3 Built in LOI EIA 232 Signal Routing RJ 45 Pins on 2 aa LOI Function ROC800 Description Series Originated by the ROC800 Series Data Terminal Equipment DTE to instruct the Data Communication Equipment
96. f being faulty for a short circuit between its input or output terminals If a terminal not directly connected to ground reads 0 zero when measured with an ohmmeter the module is defective and must be replaced NOTE Return faulty modules to your local sales representative for repair or replacement If you are experiencing problems with the ROC809 that appear to be software related try resetting the ROC809 e Use a Warm Start to restart without losing configuration or log data To perform a Warm Start open ROCLINK 800 software connect to the ROC809 unit and select ROC gt Flags Refer to ROCLINK 800 Configuration Software User Manual Form A6121 e Use a Cold Start to restart without a portion of the configuration log data or programming that may be the trouble To perform a Cold Start open ROCLINK 800 software connect to the ROC809 unit and select ROC gt Flags Refer to ROCLINK 800 Configuration Software User Manual Form A6121 e Use the RESET button on the CPU to restore the unit to factory defaults without connecting to ROCLINK 800 software NOTE If these methods do not solve the problem contact your local sales representative If you are experiencing trouble with powering up the ROC809 e Check the wiring connections at terminations on the Power Input Module and the wiring at the power source e Check the internal battery for voltage Refer to Section 3 e Check the external batteries if applica
97. form the restart procedure in Section 6 3 2 6 2 Troubleshooting Checklists If the LEDs do not display By default LEDs on the communication modules and I O modules enter Sleep mode after five minutes To turn the LEDs on press the LED button located on the CPU for one second NOTE This feature can be disabled via ROCLINK 800 software If disabled the LEDs always remain on If you are experiencing troubles with a serial communications connection LOI EIA 232 EIA 422 or EIA 485 6 1 Troubleshooting Rev Feb 05 ROC809 Instruction Manual e Check to make sure power is applied to the FloBoss unit Check the ON OFF jumper the wiring connections at CHG and CHG and the wiring at the power source e Check the wiring to the termination block or connector Refer to Section 4 e Check the communication port settings in ROCLINK 800 Configuration Software Refer to ROCLINK 800 Configuration Software User Manual Form A6121 If you are experiencing troubles with an I O point Analog Input Analog Output Discrete Input Discrete Output Pulse Input RTD Input or Thermocouple Input e Check to see how the channel is configured using ROCLINK 800 software e If the configuration looks correct then follow the procedure for troubleshooting that type of I O in Sections 6 3 3 through 6 3 10 e Ifa module does not function correctly determine if the problem is with the field device or the module e Check a module suspected o
98. fuse be replaced with a Little Fuse 217 025 or equivalent Refer to Section 2 5 5 1 Removing the Auxiliary Output Fuse on page 2 20 For the 24 volt Power Input Module The AUX voltage is always 12 volts dc minus 0 7 volts AUX AUX is internally current limited by a 0 5 Amp PTC If power to the radio or other device needs to be cycled to reduce the load on the power source recommended when batteries are used use a Discrete Output DO module to switch power on and off Refer to the ROCLINK 800 Configuration Software User Manual Form A6121 Power Supply Terminal Block Other Equipment 2 5 Amps Maximum S Rapp Current On Non switched VYUUYWW a 2 Amp or less Fast Acting use S q o AUXsw AUX Other Equipment 14 5 Volts DC Maximum 0 5 Amps Switched Power 809AUX DSF Figure 3 3 12 Volts DC Auxiliary Power Wiring 3 4 Power Connections Rev Feb 05 ROC809 Instruction Manual Terminai Block Other Equipment AUN 12 Volts DC Maximum 0 5 Amps ae Current Limited Always On JAJ AE 0 5 Amp or less Fast Acting Fuse 809AUX24 DSF Figure 3 4 24 Volts DC Auxiliary Power Wiring 3 1 3 1 Howto Remove the Auxiliary Output Fuse To remove the auxiliary output fuse perform the procedure in Section 2 5 3 to remove the power input module Then remove the fuse located at F1 on the
99. g and correcting problems for the ROC809 Section 7 Calibration provides information for calibrating Analog Inputs HART Inputs RTD Inputs and MVS Inputs for the ROC809 Glossary Provides definitions of acronyms and terms Index Lists alphabetically the items contained in this manual including the section and page number The ROC809 Remote Operations Controller is a microprocessor based controller that provides the functions required for a variety of field automation applications The ROC809 controller is ideal for applications requiring general logic and sequencing control historical data archiving multiple communication ports Proportional Integral and Derivative PID control and flow measurement on up to twelve meter runs 1 1 Hardware The ROC809 controller is highly innovative and versatile with a backplane to which the Central Processor Unit CPU power input module communication modules and I O modules connect The ROC809 unit has nine module slots of which three can house communication modules The ROC809 uses a power input module to convert external input power to the voltage levels required by the ROC809 unit s electronics and to monitor voltage levels to ensure proper operation Two power input modules are available for the ROC809 12 volts dc and 24 volts dc For more information on the power input modules refer to Section 2 5 The internal Sanyo 3 volt CR2430 lithium backup battery provides backup of the
100. grounded wrist strap When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage To remove a module cover 1 Remove the wire channel cover 2 Unscrew the two captive screws on the face of the cover 3 Using the tab at the left side of the removable terminal block pull the module cover straight out from the ROC809 housing NOTE If you remove a module for an extended period install a module cover plate over the empty module slot to keep dust and other matter from getting into the ROC809 unit To install a module cover 1 Place the module cover over the module slot 2 Screw the two captive screws on the module cover plate 3 Replace the wire channel cover 2 4 How to Mount the ROC809 Unit on a DIN Rail When choosing an installation site be sure to check all clearances Provide adequate clearance for wiring and service The ROC809 controller mounts on Type 35 DIN rails The ROC809 requires two strips of DIN rail Refer to Figure 2 1 Figure 2 2 and Figure 2 3 2 5 Installation and Use Rev Feb 05 ROC809 Instruction Manual 7 50 in 191 mm o ROC809SD DSF ROC809BT DSF Figure 2 1 Side View of the ROCS09 Figure 2 2 Bottom View of the ROC amp 0
101. hysical piece of hardware that can contain up to 7 different licenses Refer to Figure 2 6 Each ROC809 can have none one or two License Keys installed If a License Key is removed after an application is enabled the firmware disables the task from running This prevents unauthorized execution of protected applications in a ROC809 O p DOC0422A Figure 2 6 License Key 2 7 1 How to Install a License Key To install a License Key CAUTION Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure Remove power from the ROC809 Remove the wire channel cover Unscrew the screws from the CPU faceplate Remove the CPU faceplate D RYN Place the License Key in the appropriate terminal slot P4 or P6 in the CPU Refer to Figure 2 5
102. ial up modem ports SRBX allows the ROC809 to contact the host to report an alarm condition 1 10 General Information Rev Feb 05 ROC809 Instruction Manual Use ROCLINK 800 software to Configure and view Input Output I O points flow calculations meter runs PID control loops system parameters and power management features Retrieve save and report historical data Retrieve save and report events and alarms Perform five point calibration on Analog Inputs and Multi Variable Sensor Inputs Implement user security Create save and edit graphical displays Create save edit and debug Function Sequence Tables FSTs of up to 500 lines each gt gt gt gt OH hh OH Setup communication parameters for direct connection telephone modems and other communications methods d Configure Modbus parameters Setup radio power control Update the firmware 1 5 DS800 Development Suite Software DS800 Development Suite Software allows you to program in any one of the five IEC 61131 3 languages DS800 applications can be downloaded to a ROC809 unit over the Ethernet port independent of the ROCLINK 800 Configuration Software DS800 Development Suite Software allows programming in all five of the IEC 61131 3 languages Ladder Logic Diagrams LD Sequential Function Chart SFC Function Block Diagram FBD Structured Text ST Instruction List IL A Flow Chart language is also provi
103. ic particles into the metal at the extremes of the operating temperature range Impurities and chemicals can cause de calibration from the insulation diffusing into the thermocouple wire If operating at high temperatures check the specification of the probe insulation Itis advised to use thermocouples with insulated junctions to protect against oxidation and contamination Thermocouples use thin wire typically 32 AWG to minimize thermal shunting and increase response times Wire size used in the thermocouple depends upon the application Typically when longer life is required for the higher temperatures select the larger size wires When sensitivity is the prime concern use smaller size wiring Thin wire causes the thermocouple to have a high resistance that can cause errors due to the input impedance of the measuring instrument If thermocouples with thin leads or long cables are required keep the thermocouple leads short and use a thermocouple extension wire to run between the thermocouple and measuring instrument The thermocouple wires directly to the module s removable terminal block No special terminal or isothermal block is required 4 16 Input Output Modules Rev Feb 05 ROC809 Instruction Manual J OR K THERMOCOUPLE UNGROUNDED SHEATH DOC0512B Figure 4 15 Type J and K Thermocouple Wiring Be sure to use the correct type of thermocouple wire to connect the thermocouple to the ROC800 series controller Minimize con
104. ice and the LED Calculate the Duty Cycle for each I O module and enter the value in the Duty Cycle column of Table 3 6 through Table 3 15 Calculate Duty Cycle Duty Cycle Multiply the PTypical values times the Quantity Used times the Duty Cycle and enter the values in the Sub Total column of Table 3 6 through Table 3 15 PTypica Quantity Used Duty Cycle Sub Total 7 Total the Sub Total column for Table 3 6 through Table 3 15 3 6 Enter the Sub Totals Total from Table 3 6 through Table 3 15 into the Sub Totals column of Table 3 5 NOTE Do not forget to add the Total from the Other Devices in Table 3 16 Add the Table Totals of all values in the Sub Totals column of Table 3 5 Multiply the Table Totals by a safety factor of 1 25 to account for losses and other variables not factored into the power consumption calculations This safety factor may vary depending on external influences thus the factor may be adjusted up or down 1 25 Table Totals TOTAL mW Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 5 Power Consumption Device Quantity Sub Total Pra Used rm CPU Backplane amp Power Input 70 mA 12 voltsde 840 mW 840 00 Per Active LED Maximum 10 1 5 MA ismw EIA 232 RS 232 Module 4mA 12voltsdc 48mw Per Active LED Maximum 4 1 5mA ismw fo EIA 422 485 RS 422 485 Module 112 mA 12 volts 1344 mW Per Active LED Maximum 2 1 5 mA 18 mW Dial up Modem M
105. imited When powered by the ROC terminal T is connected in parallel to the positive terminal on all of the HART devices regardless of the channel to which they are connected Channel 1 is wired to the negative terminal of a single HART device or in parallel to the negative terminals of the devices Likewise channel 2 is wired to the negative terminal of a single HART device or in parallel to the negative terminals of a second group of HART devices When powered by an external device the positive terminal from the power source is connected in parallel to the positive terminal on all of the HART devices regardless of the channel to which they are connected Channel 1 on the HART module is wired to the positive terminal of the HART device The power source negative terminal is connected to the channel s COM terminal and to the 4 19 Input Output Modules Rev Feb 05 ROC809 Instruction Manual negative terminal of a single HART device or in parallel to the negative terminals of the HART devices Switches on the module board allow channel by channel selection as an Analog Input IN or Analog Output OUT The switches for Channel 2 and 4 are located on the front of the module while the switches for channel 1 and 3 are located on the back of the module Refer to Figure 4 22 and Figure 4 23 Use a pin to move the switches to the desired state NOTE Always set the IN or OUT switches before wiring
106. imum Field to Power 2500 Volts DC 1 minute minimum Module to Module 2500 Volts DC 1 minute minimum WEIGHT 49 9 g 1 76 oz DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 25 in H by 2 96 in D ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed Rev Feb 05 ROC809 Instruction Manual 4 12 4 Discrete Output Modules Discrete Output Module Specifications FIELD WIRING TERMINALS Terminal Definition CH2 Common 10 OUTPUT Quantity 5 channel Type Isolated solid state switch Output Voltage Range 0 to 32 Volts DC Maximum On State Current 0 2 A 32 Volts DC per output across complete operating temperature Maximum Off State Leakage 0 01 mA 32 Volts DC Over Current Protection Self resetting circuitry on each channel Minimum Channel Activation Time 4 msec 4 25 Input Output Modules POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 Volts DC No Channels Active 20mA Additional loading that may apply Per Active Channel 1 5 mA Per Active LED 1 5mA WIRING 12 AWG at the removable terminal block LEDS 5 green LEDs indicate the status of the channel ISOLATION Field to Logic 2500 Volts DC 1 minute minimum Field to Power 2500 Volts DC 1 minute minimum Module to Module 2500 Volt
107. ing Make sure the label on the front of the module is facing right side up Gently glide the module in place until it contacts properly with the connectors on the backplane Ifthe module stops and will not go any further do not force the module Remove the module and see if the pins are bent If so gently straighten the pins and re insert the module The back of the module must connect fully with the connectors on the backplane Ifthe wiring channel cover has not been removed it can prevent the module from entering the socket on the backplane NOTE Communication modules can only be installed in slot 1 2 or 3 Refer to Figure 5 1 4 Plug the module into its mating connectors on the backplane pressing gently until the connectors firmly seat 5 Install the retaining captive screws to secure the module 6 Wire the module 5 3 Communications Rev Feb 05 ROC809 Instruction Manual NOTE All modules have removable terminal blocks for convenient wiring and servicing Twisted pair cable is recommended for I O signal wiring The removable terminal blocks accept 12 AWG or smaller wire 7 For dial up modem communications connect the cable to the RJ 11 connector on the communications module NOTE If you are installing a modem module it is recommended that you install a surge protector between the RJ 11 jack and the outside line 8 Replace the wire channel cover 9 Connect to ROCLINK 800 software and logi
108. ions The following tables list the specifications for each type of communications port and module Communications Built in and Module Common Specifications DIMENSIONS APPROVALS 26 mm W by 133 mm H by 75 mm D 1 04 in W by Meets the same approvals as the ROC800 Series 5 25 in H by 2 96 in D unit in which it is installed ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed Ethernet Specifications FIELD WIRING TERMINALS LED INDICATORS r Ep RX Receive TX Transmit COL Ethernet Packet Collision and LNK Ethernet Link ee een Ethernet Packet Collision 100 m 330 ft Ethernet has linked COMMUNICATIONS Type 10BASE T twisted pair IEEE multi segment 10 MB second baseband Ethernet Comm1 EIA 232 RS 232 Communications Specifications FIELD WIRING TERMINALS POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 volts dc oan aoa Request to Send Additional loading that may apply Data Terminal Ready Per Active LED 1 5 mA WIRING COMMUNICATIONS is or smaller at the removable terminal Type Single Comm Port per module Meets EIA 232 and RS 232 Standard LED INDICATORS 57 6K bps maximum data rate RX Receive TX Transmit RTS Ready To LOI Local Port EIA 232D and RS 232D Send and DTR Data Terminal Ready Built in Comm2 EIA 232C and RS 232C WEIGHT Module Comm3 to Comm5 EIA 232C and 47 6 g 1 68 02
109. is provided on each module to reduce communication errors 5 2 How to Install Communication Modules All communication modules install into the ROC800 Series unit in the same manner You can install or remove communication modules while the ROC800 Series unit is powered up hot swappable modules may be installed directly into unused module slots 1 2 or 3 hot pluggable and modules are self identifying in the software All modules are self resetting after a fault clears NOTE The dial up modem module is not hot swappable or hot pluggable When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing procedures in a hazardous area could result in personal injury or property damage Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 1 Remove the wire channel cover 2 To install a module perform one of the following If there was previously a module in the slot unscrew the captive screws and remove that module If the slot was previously unused remove the module cover NOTE When installing a dial up modem module you must remove power from the ROC800 Series 3 Insert the new module through the module slot on the front of the ROC800 Series hous
110. ive element of an RTD probe is a precision temperature dependent resistor made from a platinum alloy The resistor has a predictable positive temperature coefficient meaning its resistance increases with temperature The RTD input module works by supplying a small consistent current to the RTD probe and measuring the voltage drop across it Based on the voltage curve of the RTD the signal is converted to temperature by the ROC800 series firmware 4 13 Input Output Modules Rev Feb 05 ROC809 Instruction Manual The RTD input module monitors the temperature signal from a resistance temperature detector RTD sensor or probe A 2 channel 16 bit RTD module is available The RTD module isolation includes the power supply connections The RTD modules draw power for the active circuitry from lines on the backplane It may be more convenient to perform calibration before connecting the field wiring However if the field wiring between the ROC800 series controller and the RTD probe is long enough to add a significant resistance then perform calibration in a manner that considers this 4 9 1 Connecting the RTD Wiring Temperature can be input through the Resistance Temperature Detector RTD probe and circuitry An RTD temperature probe mounts directly to the piping using a thermowell Protect RTD wires either by a metal sheath or by conduit connected to a liquid tight conduit fitting The RTD wires connect to the four screw terminals designated
111. l state latching relays to provide a set of normally open dry contacts capable of switching 2 A at 32 volts dc across the complete operating temperature The module can be software configured as latched toggled momentary or Timed Duration Outputs TDO You can configure the DOR either to retain the last value on reset or to use a user specified fail safe value Figure 4 10 displays the field wiring connections to the output circuit of the DO Relay module NOTE The Discrete Output Relay module operates only with discrete devices having their own power source When a request is made to change the state of a DOR the request is immediately sent to the DOR module There is no scan time associated with a DOR Under normal operating conditions the DOR channel registers the change within 12 msecs If the DOR is in momentary or toggle mode DOR channels register the change within 48 msecs The DOR modules draw power for the active circuitry from the backplane NOTE On power up or reset the DO Relay module s LEDs enter indeterminate state for a few seconds as the module self identifies The LEDs may flash stay on or stay off for a few seconds B ae Field Wiring Internal Circuit 8 oo E LATCHING RELAY NOTE S SET R RESET Mas ug ar E DOC0509A Figure 4 10 Discrete Output Relay Module Field Wiring 2 NOTE All I O modules are isolated on the field side Be aware that you can induce g
112. les W38269 with front labels that read AO are the newer version January 2005 and later that control the high side 2 Ifall channels are at 100 output and R load is lt 100 ohms on each channel then the unit s operating temperature range must be reduced by 1 degree channel when maximum battery voltage is applied to the unit 3 Absolute Accuracy Includes Linearity Hysteresis Repeatability Stability Gain and Offset error Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 12 3 Discrete Input Module Discrete Input Module Specifications FIELD WIRING TERMINALS Terminal CH1 CH1 Positive pent CH 2 Positive CH 3 Positive CH 4 Positive CH 5 Positive Definition CH 6 Positive CH 7 Positive CH 8 Positive Common Common INPUT Quantity 8 channels Type Optically isolated inputs common voltage Source Minimum Scan Period 4 msec Input Impedance 6 6 KO Maximum Input Overload Voltage 24 Volts DC continuous Minimum On state Input Current 1 1 mA Maximum Off state Input Current 0 35 mA 4 24 Input Output Modules POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 Volts DC No Channels Active 19mA Additional loading that may apply Per Active Channel 3 2 mA Per Active LED 1 5mA WIRING 12 AWG at the removable terminal block LEDS 8 green LEDs indicate the status of the channels ISOLATION Field to Logic 2500 Volts DC 1 minute min
113. lly disables the linear regulator shutting off the unit Refer to Table 2 2 concerning LEDs 3 2 How to Determine Power Consumption Table 3 5 lists the power consumption of the ROC800 Series unit and the optional devices NOTE When calculating power consumption include all device relays meters solenoids radios and other devices that receive DC power from the ROC800 Series unit excluding those connected to the I O modules Refer to Table 3 16 3 5 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 6 through Table 3 15 list the power consumption of the various I O modules In estimating total I O power requirements the Duty Cycle must also be estimated for each I O channel on each I O module To calculate the power required by the ROC800 Series unit 1 Determine how many communication modules you will be implementing and enter those numbers in the Quantity Used column of Table 3 5 Multiply the PTypical value times the Quantity Used and enter the values in the Sub Total column of Table 3 5 Perform this calculation for both the communications module and the LED Prypical Quantity Used Sub Total Determine how many I O modules you will be implementing and enter those numbers in the Quantity Used column of Table 3 6 through Table 3 15 Calculate the PTypical values and enter them in the PTypical columns of Table 3 6 through Table 3 15 Perform this calculation for both the I O module other dev
114. mately 20 minutes a day Duty Cycle 20 minutes 24 60 minutes in a day 20 1440 0 014 Table 3 13 Power Consumption of the RTD Modules O Module Power E derek ania mW Quantity Duty Sub Total one eee See RTD Module RTD Module 65 mA 13 25 voltsde J 1f Tota There is no Duty Cycle associated with a RTD The Duty Cycle is always set as 1 Table 3 14 Power Consumption of the Thermocouple Modules O Module Power Consumption mW Quantity Duty Sub Total oe eee eee Type J or K Thermocouple Module T C Module B4mA 12voitsdo 1008mw 1 f Total There is no Duty Cycle associated with a thermocouple The Duty Cycle is always set as 1 3 14 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 15 Power Consumption of the HART Modules Other Device Power Consumption mW Quantity Duty Sub Total aa A ann Other Devices HART Module Base 110 mA 12 volts dc 1320mWwW Po p Channel s mA current Each Channel draw from T 2 50 12 Table 3 16 Power Consumption of Other Devices Other Device Power _ Power Consumption mW mW Quantity Duty Sub Total GSA ee A Other Devices Although Table 3 5 and Table 3 6 through Table 3 16 take into account the power supplied by the ROC800 Series unit to its connected devices be sure to add the power consumption in mW of any other devices used with the ROC800 Series unit in the same power system but a
115. maximum voltage is 14 5 volts dc Refer to Table 3 2 concerning LEDs It is important that you use good wiring practiced when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes Use 12 American Wire Gauge AWG or smaller wire for all power wiring Batteries should be rechargeable sealed gel cell lead acid batteries Connect batteries in parallel to achieve the required capacity Refer to Figure 3 6 The amount of battery capacity required for a particular installation depends upon the power requirements of the equipment and days of reserve autonomy desired Calculate battery requirements based on power consumption of the ROC800 Series unit and all devices powered by the batteries Battery reserve is the amount of time that the batteries can provide power without discharging below 20 of their total output capacity The battery reserve should be a minimum of five days with ten days of reserve preferred Add 24 hours of reserve capacity to allow for overnight discharge Space limitations cost and output are all factors that determine the actual amount of battery capacity available 3 18 Power Connections Rev Feb 05 ROC809 Instruction Manual To determine the system capacity requirements multiply the system current load on the batteries by the amount of reserve time required The equation is as follows System Requirement Current Load in Amps Reserve Hours Amp Hours Apply in
116. module Refer to Table 5 15 Table 5 15 MVS Termination Not Terminated Jumper TER Out TER Out_ O4 xx eee eee 5 13 Communications Rev Feb 05 ROC809 Instruction Manual ea eran a J Out In TER Jee 2 ZS 809MVSJ4 dsf Figure 5 5 MVS Jumper J4 Shown Not Terminated Four wires run from the MVS module terminal block and connect to the sensor The wires should be a minimum size of 22 AWG and a maximum length of 1220 m 4000 ft NOTE Insulated shielded twisted pair wiring is required when using MVS signal lines Two of the terminal blocks provide power and the other two terminals provide a communication path The terminals are identified in Table 5 16 Table 5 16 MVS Signal Routing Comm3 Comm4 and Comms Terminal RX TX Lit green when receiving N A Lit green when transmitting N A P Common NA Pay close attention and do not reverse the power wires These connections should always be made with power removed from the ROC800 Series Double check for proper orientation before applying power If the connections are reversed and power is applied the MVS and the ROC800 Series processor board will be damaged NOTE MVS modules are isolated on the field side Be aware that you can induce ground loops by tying commons together 5 14 Communications Rev Feb 05 ROC809 Instruction Manual 5 11 Communications Specificat
117. n The modules are self identifying after re connecting to ROCLINK 800 software 5 3 How to Remove a Communications Module To remove a communications module 1 Remove the wire channel cover 2 Unscrew the two captive screws holding the module in place 3 Gently pull out the lip of the module and remove the module from the slot You may need to gently wiggle the module 4 Install anew module or install the module cover Screw the two captive screws to hold the module in place 6 Replace the wire channel cover 5 4 How to Wire the Communications Signal wiring connections to the communications are made through the communications port removable terminal bock connectors and through RJ 11 and RJ 45 connectors All modules have removable terminal blocks for convenient wiring and servicing The terminal blocks can accommodate a wide range of wire gauges 12 AWG or smaller Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations To connect the wire to the removable block compression terminals 1 Bare the end 4 inch maximum of the wire 2 Insert the bared end into the clamp beneath the termination screw 3 Tighten the screw The ROC800 Series should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain 5 4 Communications R
118. n Sequence Table FST eniinn na bead qenconcthestandelesamecentebentea 1 9 G CAO ESOL WITE cihan re E T 4 5 5 4 GrOUN d raeo AI E AE A NAR 2 3 Ground no een r E 2 3 H PLATO W ALC A E A E sons 1 1 Hardware Wate hdo aieri giene Enee aneia 1 8 HART Inter a e sel cicsccscciasacadchascabaeddideadednaaociolasboadebebic 4 19 SPCCIMC AU ONS EE E E E 4 30 Hazardous Afe aasenso rosen nE 2 2 FOUS O oee E 2 4 MO Module eimen E 4 1 ANOS MPS oiera e R 4 6 ADOS OUUDUES ueirai e a 4 7 Pirc Opu e ra 4 9 Discrete Output Relay mscctadewissccwetaap scooter iinit 4 11 Discrete QUE PU IS oinei T REENE 4 10 HART Interface seeeeeeeeeeeeeeesessssssssssssseeseseeeeses 4 19 Installation and Setup eeessesessssssoooeeeeessssssssssssse 4 3 J and K Type Thermocouple Inputs 4 16 Pulse Inputs nasa ietaaerslaaneisedsestoess 4 12 FRCIMO VAIN aara e saatea teh aueesiapodesassaaeds 4 4 RIBI a a NA 4 13 W I oae r ec Se en EAS 4 5 VO Speciation reee r 4 22 VO WIP ar 2 3 PUOH eiee e e RN 4 1 WSCA AMON ss secineacsdncceeeneselewodscsedaletbeebevennenteobeesuonsdess 2 1 2 5 Communication Modules ceeeeeeececeeeeeeeeeeees 5 3 VO M d l asihc2 condones caret e bean ven netacensmen 4 3 J J and K Type Thermocouple Inputs 4 16 SPC CIC ALON pasate cena eset s Ades sean seats 4 29 THOUBICSHO OHNO iio ences oenst ales Sesceetives dee pbedeeni oat 6 9 Jumpers Rev Feb 05 ROC809 Instruction Manual EIA 422 48
119. nections and make sure connections are tight If you use any dissimilar metals for instance using copper wire to connect a thermocouple to the ROC800 series controller you create junction of dissimilar metals that can generate millivolt signals and increase reading errors Ensure any plugs sockets or terminal blocks used to connect the extension wire are made from the same metals as the thermocouples and observe correct polarity The thermocouple probe must have sufficient length to minimize the effect of conduction of heat from the hot end of the thermocouple Unless there is insufficient immersion readings will be low Itis suggested the thermocouple be immersed for a minimum distance equivalent to four times the outside diameter of a protection tube or well Use only ungrounded thermocouple constructions Grounded thermocouples are susceptible to the creation of ground loops In turn ground loops can cause interaction between thermocouple channels on the thermocouple module NOTE Use thermocouples as individual sensing devices All modules are isolated on the field side Be aware that you can induce ground loops by tying module to module commons together Millivolt signals are very small and are very susceptible to noise Noise from stray electrical and magnetic fields can generate voltage signals higher than the millivolt levels generated from a thermocouple The T C modules can reject common mode noise signals that are the same
120. njury or property damage 2 1 4 Power installation Requirements Be sure to route power away from hazardous areas as well as sensitive monitoring and radio equipment Local and company codes generally provide guidelines for installations Adhere rigorously to all local and National Electrical Code NEC requirements The removable terminal blocks accept 12 AWG or smaller wiring Although the ROC809 can operate on 11 25 to 14 25 volts dc power it is good practice to install a low voltage cutoff device to help protect batteries and other devices not powered by the ROC 2 1 5 Grounding Installation Requirements The National Electrical Code NEC governs the ground wiring requirements When the equipment uses a DC voltage source the grounding system must terminate at the service disconnect All equipment grounding conductors must provide an uninterrupted electrical path to the service disconnect This includes wire or conduit carrying the power supply conductors The National Electrical Code Article 250 83 1993 paragraph c defines the material and installation requirements for grounding electrodes The National Electrical Code Article 250 91 1993 paragraph a defines the material requirements for grounding electrode conductors The National Electrical Code Article 250 92 1993 paragraph a provides installation requirements for grounding electrode conductors The National Electrical Code Article 250 95 1993 defines the size req
121. nnels that provide a current output for powering analog devices Analog Outputs are analog signals generated by the ROC800 series controller to regulate equipment such as control valves or any device requiring analog control Each channel on this module provides a 4 to 20 mA current signal for controlling analog current loop devices The AO module isolation includes the power supply connections NOTE AO modules Part Number W38199 with front labels that read AO 16 are an earlier version that control the low side AO modules Part Number W38269 with front labels that read AO are the newer version January 2005 and later that control the high side The AO module is selectable as 12 or 24 volts dc via jumper J4 on the I O module The AO module can provide isolated 12 volts dc or 24 volts dc field transmitter power on a per module basis For example one module can provide 12 volts dc for powering low power analog transmitters while another module in the same ROC800 series controller can provide 24 volts dc for powering conventional 4 20 mA transmitters Refer to Figure 4 6 J4 24V 112V A T 12 24 V dc Jumper 809AOJ4 dsf Figure 4 6 Analog Output Jumper J4 Shown Set to 12V 4 7 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 8 Representative Internal Circuit CURRENT LOOP CONTROL Field Wiring 9 CURRENT LOOP DEVICE 4 20mA a ROC809 POWERED CURRENT LOOP CONTROL
122. nning enable filter value adjusted Analog Digital A D 0 and 100 values low reading Engineering Units EU high reading EU alarm limits rate alarm alarm deadband RBX enable averaging enable and clipping enable Read Only Point number alarm state raw A D input and actual scan Minimum Scan Period 50 msec ANALOG OUTPUT PARAMETERS Configurable Point tag auto value manual value physical value units scanning enable adjusted D A 0 and 100 values low reading EU high reading EU value on power reset alarming enable and RBX enable Read Only Point number alarm state and raw D A output value Minimum Scan Period 50 msec DISCRETE INPUT PARAMETERS Configurable Point tag scan period status enable scanning enable DI type standard or latched input type normal or inverted filter value accumulated value on off counter alarming enable and RBX enable Read Only Point number and alarm state Minimum Scan Period 4 msec DISCRETE OUTPUT PARAMETERS Configurable Point tag time on state on off manual state on off momentary on off time on DO type scanning enable accumulated value status on power reset units name TDO cycle time 0 and 100 count low reading time high reading time low reading EU high reading EU EU value alarming enable and RBX enable Read Only Point number and alarm state Minimum Channel Activation Time 4 msec for a DO 48 msec for a DOR PULSE
123. o the DO module There is no scan time associated with a DO Under normal operating conditions the DO channel registers the change within 2 milliseconds If the DO is in momentary or toggle mode the minimum time on that can be entered is 4 milliseconds Figure 4 9 displays the field wiring connections to the output circuit of the DO module The Discrete Output module only operates with non powered discrete devices such as relay coils or solid state switch inputs Using the module with powered devices may cause improper operation or damage The DO modules draw power for the active circuitry from the backplane The DO module is fused for protection against excessive current NOTE When using the Discrete Output module to drive an inductive load such as a relay coil place a suppression diode across the input terminals to the load This protects the module from the reverse Electro Motive Force EMF spike generated when the inductive load is switched off Representative Field Wiring Internal Circuit ii DOC0508A Figure 4 9 Discrete Output Module Field Wiring NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying module to module commons together 4 10 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 7 Discrete Output Relay Modules The five channel DO Relay DOR module provides LEDs that light when each output is active DOR modules use dua
124. odule 95 mA 12 volts dc 1140 mW Per Active LED Maximum 4 1 5 mA 18 mW Al Modules Table 3 6 AO Modules Table 3 7 DI Modules Table 3 8 DO Modules Table 3 9 DOR Modules Table 3 10 PI Modules Table 3 11 MVS Modules Table 3 12 RTD Modules Table 3 13 Thermocouple Modules Table 3 14 PP HART Modules S S S Other Devices Table316 e NOTE The power drawn by field devices connected to I O modules is included in the Prypica values in Table 3 6 through Table 3 14 3 7 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 6 Power Consumption of the Analog Input Modules I O Module oer CONSUME ON MNE Quantity Duty Sub Total or me eee Analog Input Al Module Base 84 mA 12 volts dc 1oosmw DoS o Jumper set for T 12 volts dc Channel s mA current Sannen draw from T 1 25 12 Channel s mA current eNaNNEhe draw from T 1 25 12 Ch 13 Channel s mA current OAS draw from T 1 25 12 Ch A Channel s mA current en draw from T 1 25 12 Jumper set for T 24 volts dc Channel s mA current Channel 1 draw from T 2 50 12 Ch 19 Channel s mA current MANG draw from T 2 50 12 Ch 13 Channel s mA current Anne draw from T 2 50 12 Ch A Channel s mA current Ane draw from T 2 50 12 The Duty Cycle is based on the average current flow compared to the full scale current flow value Approximate the Duty Cycle by estimating the ave
125. pproval is for Class I Division 2 Groups A B C and D The Class Division and Group terms include 1 Class defines the general nature of the hazardous material in the surrounding atmosphere Class I is for locations where flammable gases or vapors may be present in the air in quantities sufficient to produce explosive or ignitable mixtures 2 Division defines the probability of hazardous material being present in an ignitable concentration in the surrounding atmosphere Division 2 locations are locations that are presumed to be hazardous only in an abnormal situation 3 Group defines the hazardous material in the surrounding atmosphere Groups A to D are as follows Group A Atmosphere containing acetylene Group B Atmosphere containing hydrogen gases or vapors of equivalent nature Group C Atmosphere containing ethylene gases or vapors of equivalent nature Group D Atmosphere containing propane gases or vapors of equivalent nature For the ROC unit to be approved for hazardous locations it must be installed in accordance with the National Electrical Code NEC guidelines or other applicable codes 2 2 Installation and Use Rev Feb 05 ROC809 Instruction Manual CAUTION When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing procedures in a hazardous area could result in personal i
126. r input BAT LED indicator should light green to indicate that the applied voltage is correct Then the STATUS indicator should light and stay lit green to indicate a valid reset sequence has been completed Refer to Table 2 2 2 8 2 Operation Once startup is successful configure the ROC809 to meet the requirements of the application Once the ROC809 is configured and the I O and MVS are calibrated it can be placed into operation When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing procedures in a hazardous area could result in personal injury or property damage 2 13 Installation and Use Rev Feb 05 ROC809 Instruction Manual SECTION 3 POWER CONNECTIONS This section describes the power input module This section provides a description and specifications and explains power input module installation and wiring for the ROC800 Series units Section Page 3 1 Power Input Module Descriptions 3 1 3 2 How to Determine Power Consumption 3 5 2 3 How to Remove a Power Input Module 3 15 3 4 How to Install a Power Input Module 3 16 3 5 How to Connect the ROC800 Series Unit to Wiring 3 16 3 1 Power Input Module Descriptions The ROC800 Series unit uses a power input module to convert external input power to the voltage levels required by the ROC800 Series unit s electronics and to monitor voltage levels to ens
127. rage current consumption in relation to its maximum range For example if an AI channel s current averages 16 mA Duty Cycle Average mA output Maximum mA Output 16 20 0 80 3 8 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 7 Power Consumption of the Analog Output Modules I O Module Owen CONSUMPLON MY Quantity Duty Sub Total or Lee eee Analog Output AO Module Base 100 mA 12 volts dc 1200MmW Jumper set for T 12 volts dc Ch 4 Channel s mA current eee draw from T 1 25 12 Ch 19 Channel s mA current one draw from T 1 25 12 Ch 13 Channel s mA current aac draw from T 1 25 12 Ch A Channel s mA current pone draw from T 1 25 12 Jumper set for T 24 volts dc Ch 4 Channel s mA current ane draw from T 2 50 12 Ch 19 Channel s mA current ANG draw from T 2 50 12 Ch 13 Channel s mA current ne draw from T 2 50 12 Ch A Channel s mA current Anne draw from T 2 50 12 The Duty Cycle is based on the average current flow compared to the full scale current flow value Approximate the Duty Cycle by estimating the average current consumption in relation to its maximum range For example if an AO channel s current averages 12 mA Duty Cycle Average mA output Maximum mA Output 12 20 0 60 3 9 Power Connections Rev Feb 05 ROC809 Instruction Manual Table 3 8 Power Consumption of the Discrete Input Modul
128. re 4 18 Ungrounded Figure 4 19 Grounded Figure 4 20 Exposed Sheathed Ungrounded Unsheathed In an ungrounded probe the thermocouple junction is detached from the probe wall Response time slows down from the grounded style but the ungrounded probe offers electrical isolation of 1 5 M at 500 volts dc in all diameters The wiring may or may not be sheathed K2 NOTE Only ungrounded probes are supported Itis highly recommended that you use sheathed probes Use an ungrounded junction for measurements in corrosive environments where it is desirable to have the thermocouple electronically isolated from and shielded by the sheath The welded wire thermocouple is physically insulated from the thermocouple sheath by MgO powder soft At the tip of a grounded junction probe the thermocouple wires physically attach to the inside of the probe wall This results in good heat transfer from the outside through the probe wall to the thermocouple junction Grounded wiring is not supported The thermocouple in the exposed junction protrudes out of the tip of the sheath and is exposed to the surrounding environment This type offers the best response time but is limited in use to non corrosive and non pressurized applications Exposed junction thermocouples are not supported NOTE Avoid subjecting the thermocouple connections and measurement instrument to sudden changes in temperature 4 18 Input Outp
129. re Se ene eet nn eee Teen err ee 4 5 5 4 Wiring COMMUMICATIONS 00cccceeeeeeeeeeeeeeeeeeeeeeeaeaeeeeenes 5 4 Dial up Modem ssi sercccsancsoasteueeceatiadaseeenerccacdeane 5 12 VOMod le S eanan nana 4 5 Multi Variable Sensor cccccccccccecceeeeessseeeeees 5 14 BD perenne tere er eet nnn ny inet E et Uren rere 4 14 REOT aa eae 4 14 Rev Feb 05 ROC809 Instruction Manual If you have comments or questions regarding this manual please direct them to your local sales representative or contact Emerson Process Management Flow Computer Division Marshalltown IA 50158 U S A Houston TX 77065 U S A Pickering North Yorkshire UK Y018 7JA Website www EmersonProcess com flow I 5 Index EMERSON Rev Feb 05
130. re not accounted for in the tables Other devices may include radios or solenoids that are powered by the ROC800 Series unit Enter that Total value in the Other Devices row of Table 3 5 NOTE mW 0 001 Watts Watts divided by 1000 3 3 How to Remove a Power Input Module To remove the power input module CAUTION Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure 3 15 Power Connections Rev Feb 05 ROC809 Instruction Manual Remove power from the ROC800 Series unit Remove the wire channel cover Unscrew the two captive screws on the front of the power input module oY ge fe oS Remove the power input module NOTE Remove the internal backup battery if you intend to store the ROC800 Series unit for an extended period 3 4 How to Install a Power Input Module To install the power input module Failure to exercise proper electrostatic discharge precautions such as wearing a grounded
131. rence RFI Radio Frequency Interference and transients Insulated shielded twisted pair wiring is required when using MVS signal lines The removable terminal blocks accept 12 AWG or smaller wire 2 2 Required Tools The following tools will be required to perform installation and maintenance procedures on the ROC unit For tools required for installation or maintenance of accessories refer to the ROC FloBoss Accessories Instruction Manual Form A4637 Philips screwdriver size 0 Flat blade screwdriver size 2 5 mm 0 1 inch Flat blade screwdriver large or other prying instrument 2 3 Housing The housing case is made of Acrylonitrile Butadiene Styrene ABS Plastic and the wire channel covers are made of Polypropylene Plastic 2 3 1 How to Remove and Replace the End Caps Normal use and maintenance of the ROC809 will not require removal of the end caps on the housing However instructions are provided in case removal is necessary Refer to Figure 1 1 To remove the end caps 1 Place the tip of a screwdriver into the top pry hole of the end cap loosen the end cap by pulling the handle of the screwdriver away from the backplane NOTE The pry holes are located on the sides of the end caps Refer to Figure 1 1 2 Place the tip of a screwdriver into the bottom pry hole of the end cap loosen the end cap by pulling the handle of the screwdriver away from the backplane 3 Pivot the front end cap away from th
132. reporting Configuration is provided for each meter run As a result redundant meter run data within a station is eliminated to enable faster data processing The meter runs can be grouped among the twelve stations maximum in any combination Meter runs belong in the same station when they have the same gas composition data and calculation methods Stations allow for Contract hours to be set differently for each station Several individual meter runs to be designated as part of a station 1 7 General Information Rev Feb 05 ROC809 Instruction Manual One to twelve meter runs to be configured for each station 1 3 3 Flow Calculations Gas and liquid calculation methods include AGA and API Chapter 21 compliant AGA linear and differential meter types AGA 3 Orifice Plates gas AGA 7 Turbine Meters ISO 9951 gas AGA 8 Compressibility Detailed ISO 12213 2 Gross I ASO 12213 3 and Gross II gas ISO 5167 Orifice Plates liquid API 12 Turbine Meters liquid Full calculations are completed every second on all configured runs up to 12 for AGA 3 AGA 7 AGA 8 ISO 5167 and ISO 9951 The AGA 3 calculations conform to methods described in American Gas Association Report No 3 Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids Based on the second and third editions the calculation method is 1992 AGA 3 The AGA 7 calculations conform to methods described in American Gas
133. riate electrostatic discharge precautions such as wearing a grounded wrist strap To connect the wire to the removable block compression terminals 3 16 Power Connections Rev Feb 05 ROC809 Instruction Manual 1 Bare the end 1 4 inch maximum of the wire 2 Insert the bared end into the clamp beneath the termination screw 3 Tighten the screw The ROC800 Series unit should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain 3 5 1 How to Wire the DC Power Input Module Use 12 American Wire Gauge AWG wire or smaller for all power wiring It is important to use good wiring practice when sizing routing and connecting power wiring All wiring must conform to state local and NEC codes Verify the hook up polarity is correct To make DC power supply connections 1 Refer to Section 2 8 2 Backup Procedure Before Removing Power on page 2 36 and perform the backup procedure Install a surge protection device at the service disconnect Remove all other power sources from the ROC800 Series unit Install a fuse at the input power source Remove the terminal block connector from the socket oF SY ee oe oN Insert each bared wire end from either the 12 volts dc source into the clamp beneath the appropriate BAT BAT termination screw Refer to Figure 2 13 the 24 volts dc source into the clamp beneath the appropriate termination screw The
134. rminals is O to 18 volts dc For example you may connect the solar panel voltage upstream of the solar regulator to monitor the output of the solar panel This allows you to compare the System AI Point Number 2 for the charging voltage CHG to the actual battery voltage BAT System AI Point Number 1 and take action as required The ROC800 Series unit has a low voltage cut off circuit built in to guard against draining down power supply batteries Refer to Section 2 4 6 Automatic Self Tests on page 2 12 The AUX AUX terminals can be used to supply reverse polarity protected source voltage to external devices such as a radio or solenoid The AUXSW and AUXSW terminals can be used to provide switched power for external devices The AUXSW is turned off when a software configurable voltage is detected at the BAT and BAT terminals Table 3 1 12 Volts DC Power Input Terminal Block Connections Terminal Blocks Volts DC BAT and BAT Accepts 12 volts dc nominal from an AC DC converter or Absolute Maximum other 12 volts dc supply 11 25 to 16 volts dc Recommended Operating Range 11 25 to 14 25 volts dc CHG and CHG Analog Input used to monitor an external charging source O to 18 volts dc AUX and AUX Supplies reverse polarity protected source voltage to BAT minus 0 7 external devices volts dc AUXsw and AUXsyw Supplies switched power for external devices O to 14 25 volts dc 3 2 Power Connections Rev Feb 05
135. roller and contains information on installation specifications wiring and removal of the I O modules Section Page 4 1 Overview 4 4 2 Installation 4 3 4 3 Analog Input Modules 4 6 4 4 Analog Output Modules 4 7 4 5 Discrete Input Modules 4 9 4 6 Discrete Output Modules 4 10 4 7 Discrete Output Relay Modules 4 1 4 8 Pulse Input Modules 4 12 4 9 RTD Input Modules 4 13 4 10 J and K Type Thermocouple Input Modules 4 16 4 11 HART Interface Modules 4 19 4 12 I O Module Specifications 4 22 4 1 Overview The I O modules consist of a terminal block for field wiring and connectors to the backplane The ROC800 series supports up to nine I O modules The ROC can accommodate a wide range of process inputs and outputs Each I O module electrically connects to field wiring by a removable terminal block Refer to Figure 4 1 and Figure 4 2 DOC0513A Front View Side View Figure 4 1 Typical I O Module 4 1 Input Output Modules Rev Feb 05 ROC809 Instruction Manual Optional Comms or I O Slot 7 I O Slot 1 I O Slot 4 Optional Comm4 or I O Slot 2 I O Slot 5 I O Slot 8 Optional Comm5 or I O Slot 9 Figure 4 2 Optional I O Module Locations I O modules for the ROC800 series Remote Operations Controllers include Analog Input AI modules that provide the ability to monitor various analog field values Discrete Input DI and Pulse Input PI modules that provide the ability to monitor various discrete and pul
136. rols reserves the right without notice to alter or improve the designs or specifications of the products described herein ji Rev Feb 05 ROC809 Instruction Manual TABLE OF CONTENTS section 1 General Information scsssceccsssceccsecceccseececosescocesesceceseececcsescecessscocessseoses 1 1 1 1 TARD W ART orea eaten acacia esd aaa eaten adnate ae eee acne eed l 1 12 FCC INFORMATION eener EA E EN ENRE 1 5 1 3 FIRMWARE a secs E E EE E EN E 1 5 1 4 ROCLINK 800 CONFIGURATION SOFTWARE lt 32 2003iitetne neni neue Re ees 1 10 1 5 DS800 DEVELOPMENT SUITE SOPT WARE ccss gcacdiaviecasasenaaediitidecweschenedeivevcasewepanededsileczesstaaedeaveeet l 11 1 6 SPECIFICATION resna e a S 1 13 Section 2 Installation and Use secersvesacessccecsesssazivesicaaeasacessdexsvesveagicessessscesseeeesessdsactaeess 2 1 pea INSTALLATION REOUIREMEN TS mirena a oie ieee 2 1 22 FRE OUMR ED WOO IS er teats setae iether iin Sieh tents E E acme eee sarah Nant saaeaee tts 2 4 2 3 USING oot cts snc et Seether cee es ce eessest ate eee cece hereto evo cls eters aera E A 2 4 2 4 How TO MOUNT THE ROC809 UNIT ON A DIN RAIL ccccccessecceceeeecceceeecceeaeeceesaeeeceeeaees 2 5 2D YN 5G 2 ANE ea ae RR eC EER Ee Re ee 2 7 2 6 CENTRAL PROCESSORS UNT CPU crc etc ctae ered E EE neonate 2 7 eN E INS FT E O AA AANO 2 11 2 8 STARTUP AND OPERA TION rerpsredr nur a e E a aa 2 13 Section 3 Power Connections sssceccssececcssececessoceccsesceccsescoccsscoceseoceccses
137. round loops by tying module to module commons together 4 11 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 8 Pulse Input Modules The Pulse Input PI module provides two channels for measuring either a low speed or high speed pulse signal The PI module processes signals from pulse generating devices and provides a calculated rate or an accumulated total over a configured period Functions supported are slow counter input slow rate input fast counter input and fast rate input The PI is most commonly used to interface to relays or open collector open drain type solid state devices The Pulse Input can be used to interface to either self powered or ROC800 series powered devices The high speed input supports signals up to 12 KHz while the low speed input is used on signals less than 125 Hz The PI module is selectable as 12 or 24 volts dc via jumper J4 on the I O module The PI modules can provide isolated 12 volts dc or 24 volts dc field transmitter power on a per module basis For example one module can provide 12 volts dc power while another module in the same ROC800 series controller can provide 24 volts dc power Refer to Figure 4 11 The PI module provides LEDs that light when each input is active The Pulse Input module only operates with non powered devices such as dry relay contacts or isolated solid state switches Use of the PI module with powered devices may cause improper operation or dam
138. rs are designed so that you do not need to be concerned about cable crosstalk provided the cable meets all other requirements Noise can be caused by crosstalk of externally induced impulses Impulse noise may cause data errors if the impulses occur at very specific times during data transmission Generally do not be concerned about noise If you suspect noise related data errors it may be necessary to either reroute the cable or eliminate the source of the impulse noise Multi pair PVC 24 AWG telephone cables have an attenuation of approximately 8 to 10 dB 100 m at 200 C 392 F The attenuation of PVC insulted cable varies significantly with temperature At temperatures greater than 400 C 752 F use plenum rated cables to ensure that cable attenuation remains within specification When connecting two twisted pair MAUs Medium Attachment Units or repeaters together over a segment wire the transmit data pins of one eight pin connector to the receive data pins of the other connector and vice versa There are two methods for accomplishing OBASE T crossover wiring Special cable Wire the 10BASE T crossover inside the hub For a single segment connecting only two devices provide the signal crossover by building a special crossover cable wire the transmit data pins of one eight pin connector to the receive data pins of the other connector and vice versa Refer to Figure 5 3 Signal Signal Pin 1 TD Pin 1 TD Pin 2 TD Pin 2
139. rs to Spontaneous RBX in which the ROC contacts the host to report an alarm condition RFI Radio Frequency Interference RI Ring Indicator modem communications signal ROC Remote Operations Controller microprocessor based unit that provides remote monitoring and control ROCLINK 800 Configuration software used to configure ROC809 units to gather data as well as most other functions ROM Read only memory Typically used to store firmware Flash memory RTC Real time clock RTD Resistance Temperature Detector RTS Ready to Send modem communications signal RTU Remote Terminal Unit RX or RXD Received data communications signal G 4 Glossary Rev Feb 05 ROC809 Instruction Manual S Script A uncompiled text file such as keystrokes for a macro that is interpreted by a program to perform certain functions Typically scripts can be easily created or edited by the end user to customize the software Soft Points A type of ROC point with generic parameters that can be configured to hold data as desired by the user SP Setpoint or Static Pressure SPI Slow Pulse Input SRAM Static Random Access Memory Stores data as long as power is applied typically backed up by a lithium battery or supercapacitor SRBX Spontaneous Report By Exception See RBX SVA Signal Value Analog SVD Signal Value Discrete T U T C Thermocouple Input TDI Time Duration Input
140. rt a maximum of 20 HART devices The number of devices per channel is limited by the static current draw of the devices A ROC800 series controller equipped with a HART module 1s considered to be a HART Host primary master interface with a Class 1 Conformance classification Most Universal and some Common Practice commands are supported For a list of the commands refer to the HART Interface Module specification table on page 4 30 The supported commands conform to HART Universal Command Specification Revision 5 1 and Common Practice Command Specification Revision 7 HCF SPEC 127 amp 151 Refer to www hartcomm org for more information on the specifications The HART module polls the channels simultaneously If more than one device is connected to a channel in a multi drop configuration the module polls one device per channel at a time The HART protocol allows one second per poll for each device so with five devices per channel the maximum poll time for the channel would be five seconds NOTE Burst mode is not supported by the ROC800 Series HART module The device should not be configured in Burst mode when connected to the ROC Ifa device is in Burst mode use a Hand Held Communicator to turn off Burst mode The indication that the device is in Burst mode is a quick flashing of the Channel s receive LCD The HART module provides loop source power T and four channels for communications 1 through 4 The T power is current l
141. s DC 1 minute minimum WEIGHT 52 2 g 1 84 oz DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 29 in H by 2 96 in D ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Series unit in which it is installed APPROVALS Meets the same approvals as the ROC800 Series unit in which it is installed Rev Feb 05 ROC809 Instruction Manual 4 12 5 Discrete Output Relay Module Discrete Output Relay Module Specifications FIELD WIRING TERMINALS 10 OUTPUT Quantity 5 channel Type Isolated dual latching relay Contact Rating 0 to 32 Volts DC Maximum Current 2 0 A 32 Volts DC per output across complete operating temperature Minimum Channel Activation Time 48 msec LEDS 5 green LEDs indicate the status of the channel 4 26 Input Output Modules POWER CONSUMPTION Main power supply loading at the Battery Terminals at 12 0 Volts DC No Channels Active 6 8 mA Additional loading that may apply During Active Transition 150 mA for 10 mSec Per Active LED 1 5mA WIRING 12 AWG at the removable terminal block ISOLATION Field to Logic 1500 Volts DC 1 minute minimum Field to Power 1500 Volts DC 1 minute minimum Module to Module 1500 Volts DC 1 minute minimum WEIGHT 59 0 g 2 08 02 DIMENSIONS 26 mm W by 133 mm H by 75 mm D 1 04 in W by 5 25 in H by 2 96 in D ENVIRONMENTAL Meets the same environmental specifications as the ROC800 Seri
142. se input field values Analog Output AO Discrete Output DO and Discrete Output Relay DOR modules that provide the ability to control various control devices The RTD Input and Thermocouple Input T C modules that provide the ability to monitor various analog temperature field values The HART interface modules that enable the ROC to communicate with HART devices using the Highway Addressable Remote Transducer HART protocol as either Analog Inputs or Analog Outputs Each module rests in a module slot at the front of the ROC800 series housing I O modules easily install into and remove from the module slots You can install and remove modules while the ROC800 series controller is powered up hot swappable Modules may be installed directly into unused module slots hot pluggable and modules are self identifying in the software All modules have removable terminal blocks to make servicing easy I O modules can be added in any module slot The I O modules acquire power from the backplane Each module has an isolated DC DC converter that provides logic control and field power as required The ROC800 series controller has eliminated the need for fuses on the I O modules through the extensive use of current limited short circuit protection and over voltage circuitry Isolation 1s provided from other modules and the backplane power and signal isolation The I O modules are self resetting after a fault clears 4 2 Input Output
143. self identifying after re connecting to ROCLINK 800 software 7 Configure the I O point 4 2 2 How to Remove an I O Module To remove an I O module 1 Remove the wire channel cover 2 Unscrew the two captive screws holding the module in place 3 Gently pull the module s lip out and remove the module from the slot You may need to gently wiggle the module 4 Install anew module or install the module cover 5 Screw the two captive screws to hold the module or cover in place 6 Replace the wire channel cover 4 4 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 2 3 How to Wire I O Modules All modules have removable terminal blocks for convenient wiring and servicing The terminal blocks can accommodate a wide range of wire gauges 12 AWG or smaller Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations To connect the wire to the removable block compression terminals 1 Bare the end 4 inch maximum of the wire 2 Insert the bared end into the clamp beneath the termination screw 3 Tighten the screw The ROC800 series controller should have a minimum of bare wire exposed to prevent short circuits Allow some slack when making connections to prevent strain NOTE All modules have removable terminal blocks for convenient wiring and servicing Twisted pair c
144. should be over 2 megohms 6 Measure the resistance with the DO Status ON It should be approximately 1 ohm 6 3 7 Troubleshooting Discrete Output Relay Modules Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 1 Connect the multimeter set up to measure ohms to the channel that you are testing 2 Set the Status to On and click Apply 3 Measure the resistance across terminals and A reading of 0 zero ohms should be obtained No continuity should be indicated 4 Measure the resistance across the terminals and The reading should indicate an open circuit 6 3 8 Troubleshooting Pulse Input Modules Equipment Required Pulse Generator Voltage Generator Frequency Counter Jumper wire PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations 6 7 Troubleshooting Rev Feb 05 ROC809 Instruction Manual To verify high speed operation 1 Disconnect the field wiring at the PI module terminations Connect to ROCLINK 800 software Select Configuration gt I O gt PI Points Select the correct Pulse Input Point Number AE E E Connect a
145. signals Table 5 7 Built in EIA 232 RS 232 Signal Routing Comm2 _Signal_ LED Function Lit when Comma is currently receiving Lit when Comm2 is currently transmitting P 2 Lit when Comm2 ready to send is not active 63 Lit when Comm2 data terminal ready is active The EJA 232 RS 232 communications module provides for EI A 232 RS 232C signals on the Comm3 Comm4 or Comm5 port depending on where the module is installed Refer to Table 5 8 Table 5 8 EIA 232 RS 232 Communication Module Signal Routing Comm3 Comm4 and Comm5 Signal_ LED Function Lit when module Comm3 Comm4 or Comms is currently receiving Lit when module Comm3 Comm4 or CommsS is currently transmitting Lit when module Comm3 Comm4 or Comm5 is ready to send is not active Lit when module Comm3 Comm4 or Comm5 data terminal ready is active Common 5 8 ElA 422 485 RS 422 485 Serial Communications Module ETA 422 485 RS 422 485 communication modules meet all EIA 422 485 RS 422 485 specifications for differential asynchronous serial communication transmissions of data over distances of up to 1220 meters 4000 feet EIA 485 RS 485 communications are commonly used to multi drop units on a serial network over long distances using inexpensive twisted pair wiring EIA 422 RS 422 drivers are designed for party line applications where one driver is connected to and transmits on a bus with up to ten receivers EJA 422 RS 42
146. stall a module perform one of the following If there was previously a module in the slot unscrew the captive screws and remove that module If the slot was previously unused remove the module cover Insert the new I O module through the module slot on the front of the ROC800 series housing Make sure the label on the front of the module is facing right side up Refer to Figure 4 3 Gently glide the module in place until it contacts properly with the connectors on the backplane If the module stops and will not go any further do not force the module Remove the module and see if the pins are bent If so gently straighten the pin and re insert the module The back of the module must connect fully with the connectors on the backplane If the wiring channel cover has not been removed it can prevent the module from entering the socket on the backplane Input Output Modules Rev Feb 05 ROC809 Instruction Manual Figure 4 3 Installing an I O Module 4 Tighten the captive screws on the front of the module 5 Replace the wire channel cover and wire the I O module Never connect the sheath surrounding shielded wiring to a signal ground terminal or to the common terminal of an I O module Doing so makes the I O module susceptible to static discharge which can permanently damage the module Connect the shielded wiring sheath to a suitable earth ground only 6 Connect to ROCLINK 800 software and login The I O modules are
147. t gt gt gt gt OH HoH FH HoH SH 1 3 General Information Rev Feb 05 ROC809 Instruction Manual 1 1 2 Processor and Memory The ROC809 uses a 32 bit microprocessor with processor bus clock frequency at 50 MHz with a watchdog timer The Motorola MPC862 Quad Integrated Communications Controller PowerQUICC PowerPC processor and the Real Time Operating System RTOS provide both hardware and software memory protection 1 1 3 Real Time Clock The Real Time Clock can be set for year month day hour minute and second The clock provides time stamping of the database values The battery backed clock firmware tracks the day of the week corrects for leap year and adjusts for daylight savings time user selectable The time chip automatically switches to backup power when the ROC809 unit loses primary input power The internal Sanyo 3 volt CR2430 lithium backup battery provides backup of the data and the Real Time Clock when the main power is not connected The battery has a one year minimum backup life while the battery is installed and no power is applied to the ROC809 The battery has a ten year backup life while the backup battery is installed and power is applied to ROC809 unit or when the battery is removed from the ROC809 If the Real Time Clock does not keep the current time when power is removed replace the lithium battery Refer to Section 3 5 3 1 1 4 Diagnostic Monitoring The ROC809 has diagnostic inputs
148. t the relay contacts have closed When the contacts open current flow interrupts and the DI module signals the ROC800 series unit electronics that the relay contacts have opened The fastest time that a DI can be read is 250 times per second In Figure 4 8 the left side of the diagram displays the internal circuitry while the right side of the diagram displays possible field wiring DRY CONTACT ROC800 POWERED OPEN COLLECTOR OR OPEN DRAIN TYPE DEVICE EXTERNALLY POWERED DOC0507A Figure 4 8 Discrete Input Module Field Wiring NOTE All I O modules are isolated on the field side Be aware that you can induce ground loops by tying module to module commons together 4 9 Input Output Modules Rev Feb 05 ROC809 Instruction Manual 4 6 Discrete Output Modules The five channel Discrete Output DO module provides two state outputs to energize solid state relays and power small electrical loads These are solid state relays A Discrete Output may be set to send a pulse to a specified device Discrete Outputs are high low outputs used to turn equipment on off DO modules can be software configured as latched toggled momentary or Timed Duration Outputs TDO The DO can be configured to either retain the last value on reset or use a user specified fail safe value The DO module provides LEDs that light when each output is active When a request is made to change the state of a DO the request is immediately sent t
149. trail per API Chapter 21 1 Each point in the historical database up to 200 points can be configured to archive values under various schemes such as averaging or accumulating as appropriate for the type of database point The historical database is maintained in 11 segments Each segment in the database can be configured to archive selected points at specified time intervals The segments can continuously archive or can be turned on and off The history database holds up to 200 points History points can be distributed among history segments 1 through 10 and the general history segment For each history segment the number of periodic history values archived the frequency of archiving the periodic values the number of daily values archived and the contract hour are configurable The number of minute values is fixed at 60 The 200 points provide a total of over 197 000 entries equal to more than 35 days of 24 hour data for 200 points The Event Log records the last 450 parameter changes power on off cycles calibration information and other system events The event is recorded along with a date time stamp The Alarm Log records the last 450 configured occurrences of alarms set and or clear The logs can be viewed saved to a disk file or printed using ROCLINK 800 Configuration Software 1 3 2 Meter Runs and Stations Similarly configured meter runs can be grouped into stations The largest benefit of using stations is in configuring and
150. ty this document only provides generalized guidelines 2 1 1 Environmental Requirements Always install the ROC unit in a user supplied enclosure as the ROC unit requires protection from direct exposure to rain snow ice blowing dust or debris and corrosive atmospheres If the ROC unit is installed outside a building it must be placed in a National Electrical Manufacturer s Association NEMA 3 or higher rated enclosure to ensure the necessary level of protection NOTE In salt spray environments it is especially important to ensure that the enclosure is sealed properly including all entry and exit points ROC units operate over a wide range of temperatures However in extreme climates it may be necessary to provide temperature controlling devices to maintain stable operating conditions In extremely hot climates a filtered ventilation system or air conditioning may be required In extremely cold climates it may be necessary to provide a thermostatically controlled heater in the same enclosure as the ROC unit To maintain a non condensing atmosphere inside the ROC enclosure in areas of high humidity it may be necessary to add heat or dehumidification 2 1 Installation and Use Rev Feb 05 ROC809 Instruction Manual 2 1 2 Site Requirements Careful consideration when locating the ROC unit on the site can help reduce future operational problems Consider the following items when choosing a location Local state and fe
151. uirements for equipment grounding conductors Proper grounding of the ROC unit helps to reduce the effects of electrical noise on the ROC unit s operation and protects against lightning Install a surge protection device at the service disconnect on DC voltage source systems to protect against lightning and power surges for the installed equipment You may also consider a telephone surge protector for the dial up modem communications module The grounding installation method for the ROC depends on whether the pipeline has cathodic protection On pipelines with cathodic protection the ROC must be electrically isolated from the pipeline All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with a ground system tester When connecting shielded cable be sure to tie the shielded cable to earth ground at the end of the cable attached to the ROC unit only Leave the other end of the shielded cable open to avoid ground loops 2 1 6 I O Wiring Requirements I O wiring requirements are site and application dependent Local state and NEC requirements determine the I O wiring installation methods Direct buried cable conduit and cable or overhead cable are options for I O wiring installations 2 3 Installation and Use Rev Feb 05 ROC809 Instruction Manual Shielded twisted pair cable is recommended for I O signal wiring The twisted pair minimizes signal errors caused by EMI Electro Magnetic Interfe
152. ure proper operation Two power input modules are available for the ROC800 Series 12 volts dc and 24 volts dc The power consumption of a ROC800 Series unit and related devices determines the current I requirements for the external power supply Refer to Section 3 2 The power input module has removable terminal blocks for convenient wiring and servicing The terminal blocks can accept wire sizes 12 AWG or smaller 3 1 1 12 Volt DC Power Input Module The ROC800 Series unit can accept 12 volts dc nominal input power from an AC DC converter or other 12 volt dc supply The input source should be fused and connected to the BAT and BAT terminals The base system CPU power input and backplane requires less than 70 mA The power input module economizes power consumption using 3 3 volts dc switching power that provides power to the ROC800 Series modules via the backplane The ROC800 Series unit requires 11 25 to 14 25 volts dc for proper operation 3 1 Power Connections Rev Feb 05 ROC809 Instruction Manual PM 12 Voka BAT BAT Vox LED m p ie CHG CHG g x lt AUX AUX 5 3 Vor LED AUXew AUXsw OFF a i 2 Vover LED TEMP LED Figure 3 1 12 Volt DC Power Input Module The CHG and CHG terminals comprise a Analog Input channel that allows you to monitor a voltage such as an external charging source The voltage that can be applied to the CHG CHG te
153. used by the ROC809 to communicate with the configuration software as well as host computers with ROC driver software P Q Parameter A property of a point that typically can be configured or set For example the Point Tag ID is a parameter of an Analog Input point Parameters are normally edited by using configuration software running on a PC Pf Flowing pressure PC Personal Computer P DP Pressure Differential Pressure PI Pulse Input PID Proportional Integral and Derivative control feedback action PIT Periodic Timer Interrupt Point Software oriented term for an I O channel or some other function such as a flow calculation Points are defined by a collection of parameters Point Number The location of an I O point as installed in the ROC system Point Type Defines the database point to be a specifice type of point available to the system The point type determines the basic functions of a point Preset Number value previously determined for an register PRI Primary PID control loop PSTN Public switched telephone network PT Process Temperature PTT Push to talk signal Pulse Transient variation of a signal whose value is normally constant PV Process variable or process value R RAM Random Access Memory In a ROC809 it is used to store history data most user programs and additional configuration data RBX Report by exception In a ROC809 it always refe
154. ut be sure to remove the sensor from the flow as directed in the calibration procedure in the ROCLINK 800 Configuration Software User Manual Form A6121 Verify that any external monitoring devices such as multimeters are connected to the ROC809 unit if they are required for the calibration 7 1 Calibration Rev Feb 05 ROC809 Instruction Manual GLOSSARY A A D Analog to Digital ABS Acrylonitrile Butadiene Styrene ADC Analog to Digital Converter AGA American Gas Association AWG American Wire Gauge AI Analog Input AO Analog Output Analog Analog data is represented by a continuous variable such as an electrical current signal AP Absolute Pressure API American Petroleum Institute ASCII American Standard Code for Information Interchange Attribute A parameter that provides information about an aspect of a database point For example the alarm attribute is an attribute that uniquely identifies the configured value of an alarm B BPS Bits Per Second BTU British Thermal Unit a measure of heat energy C COL Ethernet Packet Collision COM Communications port on the Personal Computer PC COMM Communications port on the ROC809 Configuration Refers either to the process of setting up the software for a given system or the result of performing this process The configuration activity includes editing the database building schematic
155. ut Modules Rev Feb 05 ROC809 Instruction Manual 4 11 HART Interface Modules The HART interface module allows a ROC800 series controller to communicate with HART devices using the Highway Addressable Remote Transducer HART protocol The HART module can receive signals from HART transmitters or receive and transmit signals from HART transducers LEDs provide a visual indication of the status of each HART channel Refer to Figure 4 21 The module has four analog channels When configured as an input the channel can be configured for use in point to point or multi drop mode and typically connects to some type of transmitter such as for a temperature reading When configured as an output the channel can be configured for use in point to point mode only The output supports a Digital Valve Controller DVC In point to point mode digital communications are superimposed using the Frequency Shift Keying FSK technique on the 4 to 20 milliAmp analog signal which can still measure the process variable This mode allows communications with one HART device per analog channel In multi drop mode up to five HART devices can be connected in parallel to each analog input channel As with the point to point mode digital communications are superimposed on the 4 to 20 milliAmp signal However the analog signal is used only to measure the current consumed by the multi drop loop When all four analog inputs are in the multi drop mode the ROC can suppo
156. voltage goes out of tolerance The CPU has an internal Analog to Digital Converter A D The A D monitors the supply voltage and board temperature Refer to Section 2 4 6 Automatic Self Tests on page 2 12 The CPU has two buttons Figure 2 4 LED Press to turn on the LEDs on the CPU module I O modules and communication modules when the ROC809 has timed out RESET Press to reset the ROC809 system to defaullts Refer to Section 2 8 4 1 Reset on page 2 37 The STATUS LED helps to indicate the integrity of the ROC809 Refer to Table 2 2 Table 2 2 STATUS LED Function Status LED _Color__ _ iDefinitions Solution Continually Lit ROC809 functioning normally PNA Continually Lit Low Battery Voltage alert Charge battery lll Al Point Number 1 LoLo Alarm Apply DC voltage source Flashing Update firmware Flashing p Firmware update in decompression e a restart the Flashing Green to Red Firmware update is flashing image e as restart the LEDs on the ROC809 with the exception of the LED on the power module can be enabled or disabled as a power saving feature In ROCLINK 800 software the user configures how long the LEDs remains on after the LED button on the CPU module is pressed For instance with the default setting of 5 minutes all LEDs will go off after 5 minutes If you press the LED button LEDs become active again for 5 minutes By entering a 0 zero setting they will always stay active 2
157. wrist strap may reset the processor or damage electronic components resulting in interrupted operations When working on units located in a hazardous area where explosive gases may be present make sure the area is in a non hazardous state before performing these procedures Performing these procedures in a hazardous area could result in personal injury or property damage 1 Slide the power input module into the slot 2 Press the power input firmly into the slot Make sure the connectors at the back of the power input module fit into the connectors on the backplane 3 Tighten the two captive screws on the front of the power input module firmly Refer to Figure 3 1 and Figure 3 2 4 Replace the wire channel cover 5 Return power to the ROC800 Series unit 6 Refer to Section 2 8 5 After Removing Power from the ROC800 Series unit on page 2 38 and perform the restore procedure 3 5 How to Connect the ROC800 Series Unit to Wiring The following paragraphs describe how to connect the ROC800 Series unit to power Use the recommendations and procedures described in the following paragraphs to avoid damage to equipment Use 12 American Wire Gauge AWG wire or smaller for all power wiring CAUTION Always turn off the power to the ROC800 Series unit before you attempt any type of wiring Wiring of powered equipment could result in personal injury or property damage To avoid circuit damage when working with the unit use approp
158. y installed scaling resistor value If the calculated value and the measured value are the same the AI module is operating correctly 9 Remove the test equipment 6 3 4 Troubleshooting Analog Output Modules Equipment Required Multimeter PC running ROCLINK 800 software Failure to exercise proper electrostatic discharge precautions such as wearing a grounded wrist strap may reset the processor or damage electronic components resulting in interrupted operations Calibrate the module 1 Connect a multimeter between the and channel terminals of the module and set the multimeter to measure current in milliamps 2 Connect to ROCLINK 800 software 3 Select Configuration gt I O gt AO Points 6 5 Troubleshooting Rev Feb 05 ROC809 Instruction Manual a Se a 12 13 14 Select the correct Analog Output Point Number Select Scanning Manual and click Apply Set the output to the High Reading EU value Verify a 20 mA reading on the multimeter Set the output to the Low Reading EU value and click Apply Verify a4 mA reading on the multimeter Calibrate the Low Reading EU value by increasing or decreasing the Adjusted D A 0 units value Select Scanning Enabled and click Apply Remove the test equipment and reconnect the field device If possible verify the correct operation of the AO module by setting the High Reading EU and Low Reading EU values as before Scanning Disabled and observing the fi
159. ystem initialization and diagnostics Flash 4 MB for firmware image SRAM 1 MB for Historical Data Logs and configuration Synchronous DRAM 8 MB for firmware execution and execution memory I O MODULES Analog Input 12 4 channels 12 bits of resolution Analog Output 4 channels Discrete Input 8 channels Discrete Output 5 channels Digital Relay Output 5 channels HART Input Output 4 channels each capable of communications with up to 5 HART devices when in input multi drop mode Pulse Input 2 channels high speed or low speed is user selectable per channel RTD Input 2 channels J amp K Type Thermocouple Input 5 channels type is software configurable per channel Refer to Specification Sheets 6 3 HART 6 3 IOM1 6 3 IOM2 6 3 IOM3 and 6 3 IOM4 EIA 232 RS 232 PORT ON CPU Type Single 57 600 bps Maximum Data Rate Refer to Specification Sheet 6 3 COM ETHERNET PORT ON CPU Type 10BASE T twisted pair IEEE multi segment 10 MB second baseband Ethernet Maximum Segment 100 m 330 ft LOI PORT ON CPU Type EIA 232D RS 232D Standard 57 600 bps Maximum Data Rate Refer to Specification Sheet 6 3 COM BOARD TEMPERATURE ACCURACY 1 typical 2 maximum 1 13 General Information POWER REQUIREMENTS Base system draws 70 mA typical at 12 V dc or 35 mA Typical at 24 V dc power module backplane and CPU 12 V dc Module Recommended Voltage Range 11 5 to 14 5 V dc

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