Micronet TMR Digital Control: Product Manual 26167V3 (Revision New, 10/2016)
Micronet TMR Digital Control: Product Manual 26167V3 (Revision New, 10/2016)
Read this entire manual and all other pertinent publications prior to installing,
operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
General
Precautions Failure to follow instructions can cause personal injury and/or property
damage.
This publication may have been revised or updated since this copy was
produced. To verify that you have the latest revision, check manual 26455,
Customer Publication Cross Reference and Revision Status & Distribution
Revisions Restrictions, on the publications page of the Woodward website:
www.woodward.com/publications
Revisions—A black line alongside the text highlights changes in this publication since the
previous revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by
Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward
unless otherwise expressly undertaken.
Manual 26167V3
Copyright © Woodward, Inc. 2016
All Rights Reserved
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Contents
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Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
IMPORTANT - Designates an operating tip or maintenance suggestion.
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Chapter 1.
General Information
Introduction
This manual contains obsolete boards, cards, and CPUs from the MicroNet Simplex and MicroNet Plus
Digital Controls, created to serve as a reference volume for customers who are using this equipment in
their systems. All safety and compliance information is contained in Volume 1 and Volume 2 of this
manual.
The information contained within this volume pertains to modules, which may
be active in the field, but are obsolete and no longer supported by Woodward.
These modules are not recommended for news systems or designs.
Obsolete Boards,
Cards and CPUs
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Chapter 2.
CPUs
Introduction
This chapter contains information on CPUs and each section pertains to a different CPU with all of the
data from the original manual.
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Every MicroNet TMR control contains three CPU modules, one located in the second slot of each kernel,
just to the right of the kernel power supply.
For CPU module installation and replacement instructions, see the instructions for installing the VME
module in Chapter 14, and for replacement in Chapter 15.
The CPU modules run the application program. Figure 5-7 is a block diagram of a CPU module. When
the reset switch is toggled to the Run position, the CPU modules will perform diagnostic tests, sync
together, and then run the application program.
The CPU has a PCMCIA (Personal Computer Memory Card International Association) slot on its front
panel. The PCMCIA slot is used to download application files to the CPU module.
The CPU module contains a battery to power the real time clock when power to the control is off. This
battery is not user-replaceable. During normal operation, on-board circuitry keeps the battery charged.
Once the battery is fully charged (taking a maximum of three days), the battery will continue to run the
clock for a minimum of three months without external power to the control. If power is removed from the
CPU module for longer than three months, the real time clock may need to be reset. The resolution of the
real time clock is 10 milliseconds.
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This communication port is non-isolated. Shielded cable and a Serial Port Isolator/ Converter is required
when using this port to avoid susceptibility to EMI noise and ground loops related to PC connections and
typical industrial environments. The following standard options are available:
RS-232–RS-232 Isolator and Filter
RS-232–RS-485 Isolator/Converter and Filter
RS-232–RS-422 Isolator/Converter and Filter
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2.1.3—FTM Reference
No FTM is used with this CPU. However, additional installation and application information can be found
in Chapter 12.
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If during diagnostics, a particular test fails, testing stops and a message identifying the cause of the
failure will be displayed. Also, the FAILED LED on the CPU module will periodically repeat bursts of
flashes; the number of flashes in each burst indicates the test that failed as shown in Table 2-2.
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A failure of any one of the on-line tests results in the I/O lock being asserted and display of a message as
shown in Table 2-4. The message will be displayed on the Service Panel at the time the error occurs, and
it also will go into the Fault Mode Buffer so that it can be displayed in the Fault Mode.
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MESSAGE MEANING
Checksum Error Local RAM Failed
System Error (#) Application RAM Failed (ref. Table 5-6)
EEPROM Fault FPU C0-processor Failed
Math Exception The FPU (Co-processor) has received an illegal instruction
Rate Group Slip (#) Rate group # (number) is scheduled to run and it did not complete
its previous scheduled run.
EEPROM Initialization Fault The CPU attempted to program the EEPROMs during system
initialization and failed, or the EEPROM was detected bad
(EEPROM FAULT). The system is not permitted to run because
the EEPROM data is not current.
Exception Error Vector # An error was detected by the processor. The vector number
indicates which exception the 68040 processor took. For an
explanation of exceptions, refer to page 8-5 of Motorola Manual
M 68040 UM/AD, MC68040 Enhanced 32-bit Microprocessor
User’s Manual.
When the system detects an error when starting or running an application, the CPU will flash the FAILED
LED on the CPU module with two bursts of flashes separated by a medium longer pause. The CPU will
re-start flashing the fault codes after a long pause. The number of flashes will match the display message
or it can be determined by counting the two groups of short flashes between the medium pause. The
number of flashes in each burst indicates the detected failure as shown in Table 2-7.
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The ALARMS in Tables 2-8 and 2-9 do not automatically display; they are stored by the system and to
see them, you must use the OPSYS_FAULTS Mode of the Service Panel.
MESSAGE MEANING
SIO n Configuration Fails A configuration error occurred on Port n of SIO x module.
port x n (1-…) = SIO number
x (1-4) = port number
SIO n Missing SIO n module is not installed.
n (1-…) = SIO number
SIO n Self-Test Failed SIO n module failed its self-test.
n (1-…) = SIO number
SIO n Initialization Failed SIO n module failed to initialize.
n (1-…) = SIO number
System Alarm # n A numbered system alarm has occurred. The number of the
alarm is n (see Table 20-8, Numbered System Alarms).
Divide by Zero A divide by zero operation was performed.
Real to Int Conversion An Overflow has occurred during a Real-to-integer conversion
Overflow operation.
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Chapter 3.
Communication
3.1.2—Module Specification
Parallel Interface: High-speed, differential line drivers operating at VME transmission rate
Cable Interface: 100 pin metal shell Micro-D connector (2 per module)
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3.1.3—Installation
The Main XCVR module can be installed in any slot in the Main Chassis.
No jumpers are used to configure this module.
This Transceiver module has no switches or LEDs.
3.1.4—Troubleshooting
1. If the Main XCVR module is not functioning or not functioning properly, verify cable connections.
2. If the module is still not functioning properly after verifying the cable connections, replace the cables
connecting to module.
3. If the module is still not functioning properly after replacing cables, replace the module.
The Remote XCVR module connects to the VME bus of the chassis. The bus receiver/driver of the
Remote Transceiver module interfaces with the VME bus, exchanging control, data, and address
information. The chassis decoder determines if this chassis is to be accessed, and if so, it activates the
receiver/driver of this chassis' Remote Transceiver module to receive or send information. Figure 6-8
(Chapter 6-1 in Volume 1) is a block diagram of the Remote Transceiver module.
The bus-arbitration logic determines priority of bus-access operations and controls the receiver/driver
accordingly.
Table 3-1 shows the jumpers on the Remote XCVR module used to configure the chassis ID.
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3.2.2—Module Specification
Parallel Interface:High-speed, differential line drivers operating at VME transmission rate
Cable Interface:100 pin metal shell Micro-D connector (2 per module)
3.2.3—Installation
1. The Remote XCVR module has no switches or LEDs.
2. All expansion chassis except for the last one in the chain should use the Remote XCVR module
without termination resistors. This module must be installed in Slot 1.
3. The last expansion chassis in the chain should use the Remote XCVR module with termination
resistors. This module must be installed in Slot 1.
3.2.4—Troubleshooting
1. If the Remote XCVR module is not functioning or not functioning properly, verify the cable
connections.
2. If the module is still not functioning properly after verifying the cable connections, replace the cables
connecting to module.
3. If the module is still not functioning properly after replacing cables, replace the module.
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The Ethernet module has a VME adapter board attached to allow its use in a MicroNet chassis. However,
this module is not “hot swappable” due to signal integrity issues on the VME backplane. When inserted
into a powered chassis, the module will interrupt VME bus backplane communications and cause other
Woodward modules and expansion racks to shut down.
On power-up, the Ethernet board run a series of self-tests that check the board hardware. After
successful completion of the tests, the red FAIL LED will turn OFF. The self-tests may last 10–20
seconds.
Due to addressing conflicts with the Pentium CPU, this module can be
used only with the Motorola CPU family.
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LED Annunciations
The following LEDs annunciate board failure as well as different functions related to Ethernet
communications. When continuous communications are present, the RX and TX LEDs will be ON
continuously.
10BaseT Ethernet
A 10BaseT RJ45 Ethernet connector is available for system use. This connection is used for control
configuration, data gathering, and networking of multiple controls. In addition, this port may be relied upon
for interfacing TCP/IP Distributed I/O devices into the control system.
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To ensure signal integrity and robust operation of Ethernet devices, an Ethernet Interface FTM (Field
Termination Module) is required when using this port. The FTM’s primary function is to implement EMI
shielding and cable shield termination of the Ethernet cable. Along with the Ethernet Interface FTM,
double-shielded Ethernet cables (SSTP) are required. See the Ethernet Interface FTM section below for
more details.
3.4.2—Module Specifications
Ethernet Features
Industry Standard 6U, VME-32 format
Network interface conforming to the IEEE 802.3 standard
Configured for 10BaseT communication support
Module failure/reset, Link LED, Transmit, Receive, Collision, and 10/100 Mbps LEDs
Supports Woodward communications such as Modbus, GAP Download, and Tunable
Capture/Download.
Electrical Specifications
Voltage: 5.0 Vdc, 5% tolerance
Power: 15.0 W max (13.5 W typical)
Processor: PowerPC 750, 400 MHz
Memory: 64 MB DRAM, 2 MB boot flash, 32 MB user flash
Bus Interface: 32 bit VME bus
On board I/O: RJ45 10 Mbps Ethernet port
Hardware Configuration: VME address #1 or #2 configuration for using 2 modules in a
system
3.4.3—Installation
The DIP switch (S2) is located directly behind the RJ45 Ethernet
connector.
NOT USED
NOT USED
VME1
OFF 1 2 3 4 5 6 7 8
VIS-151
*SWITCH POSITIONS SHOWN AT DEFAULTS 02-27-2001
KDW
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1 TX+
2 TX–
3 RX+
4 ---
5 ---
6 RX–
7 ---
8 ---
Shield Chassis GND
3.4.4—FTM Reference
Please see Chapter 13 for the Ethernet Interface FTM specifications and wiring information.
The Ethernet module is only for use with the Motorola x040/060 CPUs and cannot be used with the
Pentium CPU.
System wiring requires using the Ethernet Interface FTM.
System wiring requires using shielded RJ45 Ethernet cables (for part numbers, see Appendix A):
Double shielded Cat-5 Ethernet cable (SSTP), 1.5 ft. (457 mm)
Double shielded Cat-5 Ethernet cable (SSTP), 3 ft. (914 mm)
Double shielded Cat-5 Ethernet cable (SSTP), 7 ft. (2.1 m)
Double shielded Cat-5 Ethernet cable (SSTP), 10 ft. (3.0 m)
Double shielded Cat-5 Ethernet cable (SSTP), 14 ft. (4.3 m)
Double shielded Cat-5 Ethernet cable (SSTP), 25 ft. (7.6 m)
Double shielded Cat-5 Ethernet cable (SSTP), 50 ft. (15 m)
Double shielded Cat-5 Ethernet cable (SSTP), 100 ft. (30 m)
3.4.6—Troubleshooting
1. If the Ethernet module is not functioning or not functioning properly, verify the cable connections.
2. If the module is still not functioning properly after verifying the cable connections, replace the cables
connecting to module.
3. If the module is still not functioning properly after replacing cables, replace the module.
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Chapter 4.
Discrete I/O Modules
4.1.1—Physical Description
The modules slide into card guides in the control’s chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
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4.1.2—Specifications
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Contact ratings:
5.0 A @ 240 Vac, 50/60 Hz (resistive) (meets UL ratings only)
3.0 A @ 240 Vac, 50/60 Hz (inductive)·(meets UL ratings only)
10.0 A @ 120 Vac, 50/60 Hz (resistive) (meets UL ratings only)
6.0 A @ 120 Vac, 50/60 Hz (inductive) (meets UL ratings only)
600 watt @ 120 Vac, 50/60 Hz (lamp) (meets UL ratings only)
3.0 A @ 150 Vdc (resistive) (meets UL ratings only)
1.2 A @ 150 Vdc (inductive) (meets UL ratings only)
10.0 A @ 28 Vdc (resistive) (meets LVD and UL ratings)
3.0 A @ 28 Vdc (inductive) (meets LVD and UL ratings)
In a TMR system, each 24/12 TMR Discrete I/O module is connected through two high-density 62
conductor discrete cables to four FT Relay/Discrete Input modules. All of the I/O on 24/12 TMR Discrete
I/O module is accessible on the relay modules. See Figure 7-14 for an example.
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4.1.4.1—Field Wiring
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4.1.4.2—Discrete Inputs
The 24/12 TMR Discrete I/O Discrete module accepts 24 discrete inputs. Each of the control’s four FT
Relay/Discrete Input modules accepts six contact inputs. Contact wetting voltage can be supplied by the
control or from an external source. 24 Vdc contact wetting voltage is available on each relay module.
Optionally, an external 18-32 Vdc power source or an external 100–150 Vdc power source can be used to
source the voltage. Because all discrete inputs are fully isolated, a common reference point must be
established between the inputs and the contact power source. If the 24 Vdc internal power source is used
for contact wetting, jumpers are required between relay module terminals 33, 34, and 35. If an external
power source is used for contact wetting, the external source’s common must be connected to the relay
module’s discrete input commons (terminals 34 and 35).
The inputs have components, which establish a voltage threshold and a current threshold, to prevent a
closed indication due to the leakage current of most solid-state relays. The discrete inputs also have time
stamping on a change of state, with one millisecond resolution.
Figures 7-18 and 7-19 illustrate the different discrete input wiring configurations based on the input
voltage.
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Configuration Notes
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Discrete outputs can be configured to use latent fault detection to identify relay failures without affecting a
relay output’s state. Six individual relays make up one relay output. When a relay output is closed, the
contacts of all six relays are closed. Because of the series-parallel configuration of the relays, the failure
of any two individual relays will not cause the output to open. The individual relays are periodically
opened and reclosed in pairs to ensure that they are in the correct state and that they change state.
When a relay output is open, the contacts of all six relays are open. Because of the series-parallel
configuration of the relays, the failure of any one relay will not cause the output to close. The individual
relays are periodically closed and reopened one by one to ensure that they change state.
Readback circuitry allows the state of each relay contact to be detected. Any failures are annunciated,
and further testing is disabled without affecting the state of the relay output contact or control operation.
Latent fault detection is not appropriate for all applications or circuits. The control’s latent fault detection
logic can only work with circuits using voltages between 18-32 Vdc, 100–150 Vdc, or 88-132 Vac. For
latent fault detection to work, a small leakage current is passed through the circuit’s load. Depending on
the size of the load, the leakage current may be enough to cause a load to be on or active when a relay
contact is open. In this case, the individual relay’s latent fault detection logic may be disabled, eliminating
the leakage current.
With latent fault detection, when a relay contact is closed, no difference in operation is experienced; the
relay output appears as a closed contact. However, when a relay contact is open, it appears to the
interfaced circuit as a large resistor instead of an open contact. A small amount of current is leaked to the
load, resulting in a developed voltage across the load. In most cases, this has no bearing on the circuitry,
because only a small amount of voltage is developed across its load. However, when a relay output is
used with a very high resistance load (low current load), enough voltage may be developed across the
load to prevent it from de-energizing.
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Verifying That Latent Fault Detection Can Be Used With a Relay Output
1. Verify that the circuit the relay output is used with has a voltage level of 18-32 Vdc, 100–150 Vdc, or
88-132 Vac.
2. Use graph, which corresponds to the circuit’s voltage level to determine if the voltage developed
across the load (due to the leakage current) is lower than the load’s dropout voltage level.
Acquire the resistance of the load (relay, motor, solenoid, etc.) to be driven by the relay.
Acquire the load’s minimum dropout voltage.
From the bottom of the graph, follow the line corresponding to the load’s resistance up to the
point at which it intersects the circuit power line. At this point, the corresponding voltage level
(on the left of the graph) is the level of voltage that will be developed across the load due to
leakage current.
If circuit voltage is acceptable, and the developed load voltage (from the graph) is less than the load’s
dropout voltage, latent fault detection can be used with the circuit.
If the developed load voltage is greater than the load’s dropout voltage, it is recommended that latent fault
detection be disabled or that a resistor be connected in parallel (shunt) with the load. A correctly sized
resistor connected in parallel with the circuit load will decrease the developed load voltage below the
load’s dropout voltage level. Using the corresponding latent fault detection graph and the load’s minimum
dropout voltage, perform the above procedure in reverse (see Step #2) to determine an acceptable shunt
resistance. When selecting a shunt resistor, also verify that its voltage and wattage ratings meet that of
the circuit.
Using the graph below, the intersection point between the 200-ohm load resistance line and the 110 Vac
line was found. From this intersection point it was determined that the voltage developed across the load
due to leakage current when the relay is open, is approximately 7.5 Vac. This voltage level is lower than
the load’s 25 Vac dropout voltage, so latent fault detection can be used.
If, however, the load resistance were 1200 ohms, the intersection would be approximately 29.5 Vac, too
high for latent fault detection. By following the graph along the allowable dropout voltage, 25 Vac, it can
be determined that a total load resistance of 900 Ohms or less is needed. By placing a properly rated
3600 ohm resistor in shunt with the load, (1200 ohms//3600 ohms=>900 ohms) latent fault detection can
be used.
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To retain circuit integrity if an external power supply is used for relay coil power, the external power
supply must be an isolated 24 Vdc source with +5% regulation. It is recommended that a start-up routine
be utilized to remove the source during system power-up and power-down. This routine will guarantee
that no relay is inadvertently energized due to system power-up surges. (By using the relay module’s
internal relay coil power this start-up routine is automatically performed.)
Each relay output has two banks of jumpers. One jumper-bank (a set of nine jumpers) is used to match
the latent fault detection circuit with the circuit voltage to which it is being interfaced. The second jumper
bank (a set of four jumpers) is used to select which set of relay contacts (N.O. or N.C.) is tested by the
latent fault detection logic. During operation, only one set of relay contacts (normally open or normally
closed) can be tested. The set of relay contacts tested should be same set of relay contacts used by the
load. Refer to [Figure 14-12 and 14-13]. Latent fault detection circuitry can be jumper configured to be
compatible with the following circuit voltages:
18-32 Vdc circuit power
88-132 Vac circuit power
100–150 Vdc circuit power
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After all jumper-banks have been correctly positioned, mark the placement of each jumper-bank on the
FT Relay/Discrete Input module cover labels. See the figure below.
Configuration Notes
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Verify that system power is off before removing or installing any relay module jumper. Use ESD
precautions when removing and installing relay module jumper-banks.
Select internal or external relay coil power. If the control’s internal power is used, verify that the relay
module’s “Relay Coil Power Jumper” bank is in the INT. position. If external relay coil power is
supplied, move the relay module’s “Relay Coil Power Jumper” bank to the EXT. position and verify
that the external source is fully isolated. (Mark the module’s label to indicate jumper position.)
Verify that latent fault detection can be used with each relay output.
If latent fault detection cannot be used with the relay output, verify that the relay’s latent fault
detection jumper-banks are in their disabled positions. (Mark the module’s label to indicate jumper
position.) Alternatively, an external resistor can be wired in parallel with the load to allow latent fault
detection to be used with the relay output. In this case, it is the customer’s responsibility to calculate
the required resistor ratings and install the resistor.
If latent fault detection can be used with the relay output, move the relay’s latent fault detection
jumper-bank to the correct position for the circuit power. Also, select which set of relay contacts
(N.O. or N.C.) are to be tested by the latent fault detection logic. (Mark the module’s labels to
indicate jumper positions.)
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Microcontroller Faults
The system monitors a software watchdog, a hardware watchdog, and a software watchdog on the VME
bus communications. All outputs are shut down in the event of a microcontroller fault.
Discrete Inputs
If a discrete input is not functioning properly, verify the following:
Measure the input voltage on the terminal block. It should be in the range of 18-32 Vdc for the low
voltage input terminal blocks, or 100–150 Vdc for the high voltage terminal blocks.
Check the wiring. If the inputs are reading open, look for a loose connection on the terminal blocks,
disconnected or misconnected cables, or a missing jumper on the terminal block.
Check the software configuration to ensure that the input is configured properly.
If the other channels on the 24/12 TMR Discrete I/O module are also not working, check the fuse on
the 24/12 TMR Discrete I/O module. See instructions for module replacement in Chapter 15,
Installation and Service. This fuse is visible and can be changed through the bottom of the module. If
this fuse is blown, fix the wiring problem and replace the fuse with another fuse of the same type and
rating.
After verifying all of the above, remove the 24/12 TMR Discrete I/O module and exchange the J1 and J2
cables. See instructions for replacing the module in Chapter 15, Installation and Service. If the problem
moves to a different channel, replace the cable. If not, exchange the cables at the FT Relay/Discrete
Input modules so J1 is driving J2 and vice versa. If the problem moves to a different input, replace the
24/12 TMR Discrete I/O module. If the fault remains with the same input, replace the FT Relay/Discrete
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Input module. See instructions for replacing the FT Relay/Discrete Input modules in Chapter 15,
Installation and Service.
Discrete Outputs
If a discrete output is not functioning properly, verify the following:
Check the wiring for a loose connection on the terminal blocks and disconnected or misconnected
cables.
Verify that the current through the relay contact does not exceed the contact rating.
Make sure that if latent fault detection is being used, the trickle current through the relay is
insufficient to energize the relay load. See Figures 15-8 through 15-10.
If the other output channels on the 24/12 TMR Discrete I/O module are also not working, check the
fuse on the 24/12 TMR Discrete I/O module. See instructions for module replacement in Chapter 15,
Installation, and Service. This fuse is visible and can be changed through the bottom of the module.
If this fuse is blown, fix the wiring problem and replace the fuse with another fuse of the same type
and rating.
Check the software configuration to ensure that the output is configured properly.
After verifying all of the above, remove the 24/12 TMR Discrete I/O module and exchange the J1 and J2
cables. See instructions for replacing the module in Chapter 15, Installation, and Service. If the problem
moves to a different channel, replace the cable. If not, exchange the cables at the FT Relay/Discrete
Input modules so J1 is driving J2 and vice versa. See instructions for replacing the module in Chapter 15,
Installation and Service. If the problem moves to a different relay, replace the 24/12 TMR Discrete I/O
module or the relay. See instructions for replacing the FT Relay/Discrete Input modules and relays in
Chapter 15, Installation and Service. If the fault remains with the same relay, replace the relay or the FT
Relay/Discrete Input module.
Configuration 1 consists of one 48/24 Discrete FTM connected to the 48/24 Discrete Combo module via
two High Density Analog/Discrete cables. The 48/24 Discrete FTM is then connected to either two 16 Ch.
Relay Modules or one 32 Ch. Relay Module via a Low Density Discrete Cable(s).
Configuration 2 consists of two 24/12 Discrete FTMs (DIN rail mounted) connected to the 48/24 Discrete
Combo module via two High Density Analog/Discrete cables.
The discrete inputs are optically isolated and accessible through either the 48/12 Discrete FTM or the
24/12 Discrete FTM depending on the configuration. The discrete outputs are accessible through either
the 24/12 Discrete FTM or the 2 16 Ch. Relay Modules or the 1 32 Ch. Relay Module when so configured.
See Figures 7-14 and 7-19 for examples of configurations.
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4.2.2—Module Specification
For the 24/12 Discrete FTM input specifications, see Chapter 12.
For the 24/12 Discrete FTM, 16 Ch. Relay Module, and the 32 Ch. Relay Module output specifications,
see Volume 2, Chapter 12.
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4.2.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
There are two different FTM I/O configurations for the 48/12 Discrete Combo Module.
4.2.3.1. Configuration 1
Configuration 1 consists of one 24 Vdc or 125 Vdc 48/24 Discrete FTM connected to the 48/24 Discrete
Combo module via two High Density Analog/Discrete cables. The top connector on the 48/24 Discrete
Combo module, which is labeled J1, connects to J1 on the 48/24 Discrete FTM, and J2 connects to J2.
There are two versions of the FTM, one for 24 Vdc inputs, and one for 125 Vdc inputs. The LVD applies
only to the 24 Vdc version. The 24 Vdc 48/24 Discrete FTM handles 24 Vdc input signals and the 125
Vdc 48/24 Discrete FTM handles 125 Vdc input signals. Either 48/24 Discrete FTM is then connected to
either two 16 Ch. Relay Modules or one 32 Ch. Relay Module via a Low Density Discrete Cable(s) via the
third connector. See Figure 4-15 for an example of configuration.
Figure 4-15. Configuration 1, One 48/24 Discrete FTM with Relay Module(s)
All of the discrete inputs on the module are accessible on the FTM, and the channels are labeled to
correspond to their designation in the application software (discrete input 1 on the FTM will be discrete
input 1 in the application software).
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MicroNet TMR Digital Control Manual 26167V3
Discrete Inputs
Each 48/24 Discrete Combo module accepts 48 contact inputs. The 48/24 Discrete FTM may supply
contact-wetting voltage. Optionally, an external 18–32 Vdc power source or an external 100–150 Vdc
power source can be used to source the circuit wetting voltage. If the 24 Vdc internal power source is
used for contact wetting, a jumper is required between FTM terminals 98 and 99. If an external power
source is used for contact wetting, the external sources common must be connected to the FTM’s
discrete input common, terminal 49. If 125 Vdc contact inputs are needed, the High Voltage (125 Vdc)
FTM must be used. The FTM provides a common cage-clamp terminal connection for customer field
wiring. Figures 7-30 and 7-31 illustrate different discrete input wiring configurations based on the input
voltage.
Figure 4-16. Discrete Input Interface Wiring to a 24 Vdc 48/24 Discrete FTM
Figure 4-17. Discrete Input Interface Wiring to a 125 Vdc 48/24 Discrete FTM
HIGH VOLTAGE—If the high voltage FTM is being used, and there is
125 Vdc on the FTM terminal blocks, there will be 125 Vdc on the FTM
sub D connectors and on the cable when it is connected to the FTM.
For this reason, any power should be removed from the FTM terminal
blocks before installing the 48/24 Discrete Combo module or the FTM.
Configuration Notes:
Refer to Chapter 12 for Discrete Input wiring.
Each 48/24 Discrete I/O module can only accept one input voltage range, 24 Vdc (LVD and UL) or
125 Vdc (UL only).
All contact inputs accept dry contacts.
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MicroNet TMR Digital Control Manual 26167V3
24 Vdc FTM only—If the internal 24 Vdc is used, a jumper must be added to tie the internal 24 Vdc
to the bussed power terminal blocks (see Figure
6-16).
24 Vdc FTM only—If an external 24 Vdc is used, the common for the external 24 Vdc must be tied to
the discrete input common (see Figure
6-16). Power for contacts must be supplied by the control’s power supplies, or the external power
supply outputs must be rated to Class II at 30 Vdc or less and outputs must be fused with
appropriately sized fuses (a maximum current rating of 100 V, where V is the supply’s rated
voltage or 5 A, whichever is less).
High Voltage FTM only—the common for the 125 Vdc must be tied to the discrete input common
(see Figure 7-14).
Discrete Outputs
For the 48/24 Discrete Combo FTM configuration, there are three types of relay output boxes that can be
used. These consist of the 16 Ch. Relay (Phoenix) Module, 16 Ch. Relay Module, and the 32 Ch. Relay
Module (see Chapter 12 for a description of the available modules). The relay modules connect to the
48/24 Discrete FTM through individual cables and provide a common cage-clamp terminal connection for
customer field wiring. The discrete outputs on the 48/24 Discrete I/O module are non-isolated; the
isolation takes place in the relay boxes.
Discrete outputs 9, 10, 11, 12, 21, 22, 23, and 24, drive two relays per output (see Table 7-5). Internal
wiring on the 48/24 Discrete I/O FTM provides this dual relay functionality. The application software may
use these relays for outputs where extra relay contacts are needed, such as alarm or shutdown outputs.
Figures 4-20 and 4-21 illustrate examples of different discrete output wiring configurations.
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MicroNet TMR Digital Control Manual 26167V3
Configuration Notes
Verify that each set of relay contacts meets the power requirements of the circuit with which it is being
used. Interposing relays are required when the interfaced circuit demands relay contacts with a higher
power rating. If interposing relays or other inductive loads are required, it is recommended that
interposing relays with surge (inductive kickback) protection be used. Improper connection could cause
serious equipment damage.
4.2.3.2. Configuration 2
Configuration 2 consist of two 24/12 Discrete FTMs (DIN rail mounted) connected to the 48/24 Discrete
Combo module via two High Density Analog/Discrete cables. See Figure 7-40 for an example of
configuration.
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MicroNet TMR Digital Control Manual 26167V3
J1
P1
J2
P1
P2
J1
P2
J1
Both the 48 discrete inputs and 24 discrete outputs are wired to the 24/12 Discrete FTM. An external 24
Vdc source connection to the FTM is required for discrete input contact sensing and relay coil energizing.
For wiring information on the 24/12 Discrete FTM, see Volume 2, Chapter 12.
Discrete Inputs
Each 24/12 Discrete FTM accepts 24 contact inputs. The 24/12 Discrete FTM may supply contact-wetting
voltage. Optionally, an external 18–32 Vdc power source can be used to source the circuit wetting
voltage. If the 24 Vdc internal power source is used for contact wetting, a jumper is required between
FTM terminals on TB9. If an external power source is used for contact wetting, the external source’s
common must be connected to the FTM’s discrete input common, terminal 49 (see Figure 4-21).
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MicroNet TMR Digital Control Manual 26167V3
Internal External
TB6
Channel 1 1
25
Field Contacts
Channel 2 2
26
48/24
Discrete
Combo TB9
Module
A
Jumper
B (remove for
external Optional
TB8 excitation) External
Excitation
+24VDC 50 NC
24Ret 49
TB10
Cable
91 Ground to
Sheild
DIN rail
92
Configuration Notes:
Refer to Chapter 12 for Discrete Input wiring.
All contact inputs accept dry contacts.
If the internal 24 Vdc is used, a jumper must be added to tie the internal 24 Vdc to the bussed power
terminal blocks (see Figure 4-21).
If an external 24 Vdc is used, the common for the external 24 Vdc must be tied to the discrete input
common (see Figure 4-21). Power for contacts must be supplied by the control’s power supplies, or
the external power supply outputs must be rated to Class II at 30 Vdc or less and outputs must be
fused with appropriately sized fuses (a maximum current rating of 100/V, where V is the supply’s
rated voltage, or 5 A, whichever is less).
Discrete Outputs
The discrete outputs on the 48/24 Discrete I/O module are non-isolated; the isolation takes place in the
24/12 Discrete FTM. See Chapter 12 for field wiring of discrete output relays. Figure 4-22 illustrates an
example of a discrete output-wiring configuration.
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MicroNet TMR Digital Control Manual 26167V3
Configuration Note
Verify that each set of relay contacts meets the power requirements of the circuit with which it is being
used. Interposing relays are required when the interfaced circuit demands relay contacts with a higher
power rating. If interposing relays or other inductive loads are required, it is recommended that
interposing relays with surge (inductive kickback) protection be used. Improper connection could cause
serious equipment damage.
4.2.4—FTM Reference
See Chapter 12 for detailed wiring of FTMs. See Appendix A for part number Cross Reference for
modules, FTMs, and cables.
4.2.5—Troubleshooting
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MicroNet TMR Digital Control Manual 26167V3
If during normal control operation all of a chassis’ 48/24 Discrete Combo modules have Fault LEDs on,
check the chassis’ CPU module for a failure. If during normal control operation, only the 48/24 Discrete
Combo module’s Fault LED is on or flashing, insures that it is installed in the correct slot. If it is, then
replace that 48/24 Discrete Combo module. When a module fault is detected, its outputs should be
disabled or de-energized.
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MicroNet TMR Digital Control Manual 26167V3
4.3.2—Module Specification
Number of channels: 32
Update time: 5 ms
Output Type: Open drain drivers, intended for use with Woodward relay
interface modules.
Fault Detection Readback: Output channel status, relay status is not available
System Faults: Outputs are turned off if communications with the CPU is lost.
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MicroNet TMR Digital Control Manual 26167V3
For the 16 Ch. Relay Module and the 32 Ch. Relay Module output specifications, see Chapter 12.
4.3.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
This module receives digital data from the CPU and generates 32 non-isolated relay driver signals. All
discrete output modules in the system interface to one or more Woodward Relay Modules, each with 16
or 32 relays. The contacts of these relays then connect to the field wiring.
A separate 24 Vdc power source must be provided for the relays; this module does not furnish this power.
A section of a multi-output Main Power Supply can be used, or power from a single-output Main Power
Supply can be used, as long as sufficient current is available.
Each 32 Ch. DO Module is connected through one low-density discrete cable to a 32 Ch. Relay module
or a 16 Ch. Relay module daisy chained to a second 16 Ch. Relay module with another low-density cable.
See Figure 7-50 for system installation configuration.
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MicroNet TMR Digital Control Manual 26167V3
J1
P1
P2 P2
P1
P2
J2
J1
J1 J1
Figures 4-26 and 4-27 illustrate examples different discrete output wiring configurations.
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MicroNet TMR Digital Control Manual 26167V3
Configuration Notes
Verify that each set of relay contacts meets the power requirements of the circuit with which it is being
used. Interposing relays are required when the interfaced circuit demands relay contacts with a higher
power rating. If interposing relays or other inductive loads are required, it is recommended that
interposing relays with surge (inductive kickback) protection be used. Improper connection could cause
serious equipment damage.
4.3.4—FTM Reference
See Chapter 12 for detailed wiring of relay modules. See Appendix A for part number Cross Reference
for modules, FTMs, and cables.
4.3.5—Troubleshooting
Figure 4-28 is a block diagram of the 32-Channel Discrete Output module. The CPU sends the address of
this module and the address and state of the channel to be output to this module. This information is
received by the VME interface and passed to the latches. The latch associated with the channel to be
output stores the information and passes it to the drivers. The driver for that channel then energizes or
de-energizes the relay for that channel.
Each channel has a readback buffer that indicates the status of the output driver (not the relay). The CPU
compares this status to the value written to the channel and generates a fault signal if these two values
are different. The relay module power is turned off if communications with the CPU are lost or a fault is
detected.
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MicroNet TMR Digital Control Manual 26167V3
RELAY
POWER TO
ENABLE WOODWARD
RELAY
CHANNELS MODULE
1-32
LATCHES DRIVERS
VME
VME
INTER-
BUS
FACE
BUFFERS
FAULT
LED
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MicroNet TMR Digital Control Manual 26167V3
Chapter 5.
Analog I/O Modules
The TMR 24/8 Analog module comes in the following configuration: 24 channels of 4–20 mA inputs with 8
channels of 4–20 mA outputs (2-pole 10 ms filter on all input channels, except channels 23 and 24, which
have 2-pole 5 ms filter).
All 4–20 mA analog inputs may be used with two-wire ungrounded (loop powered) transducers or isolated
(self-powered) transducers. All analog inputs have 200 Vdc of common mode rejection. If interfacing to a
non-isolated device, which may have the potential of reaching over 200 Vdc with respect to the control’s
common, the use of a loop isolator is recommended to break any return current paths producing
erroneous readings.
Each board has an on-board processor for automatic calibration of the I/O channels. Each analog input
incorporates a time-stamping feature with 5 ms resolution for two low setpoints and two high setpoints.
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5.1.2—Module Specification
The maximum voltage input range may vary between 4.975 and 5.025
Volts from module to module.
The 24 channel analog inputs are divided into two banks, with
channel 1 through channel 12 data gathering at 1.8 ms after the MFT
tick and channel 13 through channel 24 data gathering at 3.7 ms after
the MFT tick.
5.1.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
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MicroNet TMR Digital Control Manual 26167V3
Three 24/8 Analog I/O modules are connected through six high density 62 conductor analog cables (two
from each module) to two 24/8 Analog I/O FTMs. Each 24/8 Analog I/O module has two sub D connectors
on the front panel. The top sub D connector contains the first half of the channels (analog input channels
1-12 and analog output channels 1-4) and the bottom sub D connector contains the second half of the I/O
channels. See Figure 8-2 for an example.
Analog Inputs
For a 4–20 mA input signal, the 24/8 Analog Module uses a 200 ohm resistor across the input located on
the 24/8 Analog Module. Each analog input channel may power its own 4–20 mA transducer. See Figure
8-3 for analog input connection. This power is protected with a 100 mA fuse on each channel to prevent
an inadvertent short from damaging the module. The 24 Vdc outputs are capable of providing 24 Vdc with
±10% regulation. The maximum current is 0.8 A. Power connections can be made through terminals
located on the 24/8 Analog FTMs. See Chapter 12 for complete field wiring information for the 24/8
Analog FTM.
When configuring the AI Combo block in GAP for 4-20mA input, set
the Conf. input field to "2" for all inputs using the TMR Analog FTM.
This will allow the block to use the module factory voltage calibration
values with a gain factor for a 200 ohm external resistor on the TMR
Analog FTM.
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MicroNet TMR Digital Control Manual 26167V3
Analog Outputs
There are eight analog output channels of 4–20 mA with a full-scale range of 0–25 mA. All Analog
Outputs can drive a maximum load of 600 ohms (load + wire resistance). See Figure 8-4 for analog
output connection. Each output monitors the output source current for fault detection. All of the analog
outputs may be individually disabled. When a channel fault or a module fault is detected, the application
program may annunciate the fault, disable the channel, and stop using data in system calculations or
control. Care should be taken to prevent ground loops and other faults when interfacing to non-isolated
devices. See Chapter 12 for complete field wiring information for the Analog High Density FTM.
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MicroNet TMR Digital Control Manual 26167V3
5.1.4—FTM Reference
See Chapter 12 for complete field wiring information for the Analog High Density FTM. See Appendix A
for part number Cross Reference for modules, FTMs, and cables.
5.1.5—Troubleshooting
Each 24/8 Analog module has a red Fault LED that is turned on when the system is reset. During
initialization of a module, which occurs after every CPU reset, the CPU turns the Fault LED on. The CPU
then tests each module using diagnostic routines built into the software. If the diagnostic test is not
passed, the LED remains on or blinks. If the test is successful, the LED goes off. If the Fault LED on a
module is illuminated after the diagnostics and initialization have been run, the module may be faulty or
may be located in the wrong slot.
Analog Input Faults: The application software may be set with a high and low latch setpoint to detect input
faults.
Analog Output Driver Faults: The module monitors the source currents and annunciates faults. The
application software determines the course of action in the event of a fault.
Microcontroller Faults: The system monitors a software watchdog, a hardware watchdog, and a software
watchdog on the VME bus communications. All outputs are shut down in the event of a microcontroller
fault.
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MicroNet TMR Digital Control Manual 26167V3
Troubleshooting Guide
If during normal control operation all of a chassis’ 24/8 Analog I/O modules have Fault LEDs on, check
the kernel’s CPU module for a failure. If during normal control operation only the 24/8 Analog I/O
module’s Fault LED is on or flashing, ensure that it is installed in the correct slot. If it is, then replace that
24/8 Analog I/O module. See instructions for replacing the module in Chapter 15, Installation and Service.
When a module fault is detected, its outputs should be disabled or de-energized.
Analog Inputs
If an analog input is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded per the section on Shields and
Grounding in Chapter 15, Installation and Service.
Measure the input voltage on the terminal block. It should be in the range of 0–5 V.
Look at the individual inputs into each kernel. Each 24/8 Analog I/O module reads the same input
from the FTM, so the application software should contain three separate numbers, one from each
24/8 Analog I/O module. The numbers should be within 0.1% of each other unless a high common
mode voltage is present.
If all of the 24/8 Analog I/O modules are reading approximately the same number, but the reading is
incorrect, go to step 1. If two of the 24/8 Analog I/O modules are reading correctly, but one is reading
incorrectly, go to step two.
Check the wiring. If the inputs are reading zero or the engineering units that correspond to zero mA,
look for a loose connection on the terminal blocks, disconnected or misconnected cables, a missing
jumper on the terminal block if the input is a loop powered current input, or a blown fuse on the 24
Vdc on the FTM. See instructions for replacing the fuse on the FTM below. If all of the inputs are
reading high, check to ensure that the 24 Vdc is not connected across the input directly. Check the
fuse on the 24/8 Analog I/O module. See instructions for replacing the module in Chapter 15,
Installation and Service. This fuse is visible and can be changed through the bottom of the module. If
this fuse is blown, fix the wiring problem and replace the fuse with a fuse of the same type and
rating. Check the application software configuration to ensure that the input is configured properly. If
the connections and application software are verified and the correct voltage is present on the
terminal block, but all of the 24/8 Analog I/O modules are reading 0 V, exchange FTM #1 with FTM
#2. See instructions for replacing the FTM in Chapter 15. If the problem follows the FTM, replace the
FTM. The FTM contains only a wire wound 3 W resistor and traces, so failure is extremely unlikely.
If one or two of the 24/8 Analog I/O modules are reading the correct number, but the other 24/8
Analog I/O module(s) is (are) incorrect, check the application software configuration of the modules
with the non-working channels, and check to ensure that the cables are connected properly. If the
other channels on the same 24/8 Analog I/O module are not working either, check the fuse on the
24/8 Analog I/O module. See instructions for replacing the module in Chapter 15, Installation and
Service. This fuse is visible and can be changed through the bottom of the module. If this fuse is
blown, fix the wiring problem and replace the fuse with a fuse of the same type and rating. If the
reading is still incorrect, but the other readings from the 24/8 Analog I/O module are correct, remove
the 24/8 Analog I/O module and exchange the J1 and J2 cables. If the problem moves to a different
channel, replace the cable. If not, replace the 24/8 Analog I/O module. If the readings are incorrect
on several channels of the 24/8 Analog I/O module, corresponding to both cables, replace the 24/8
Analog I/O module.
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MicroNet TMR Digital Control Manual 26167V3
Analog Outputs
If an analog output is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded Shields and Grounding section
in Chapter 15, Installation and Service.
Check the load resistance to ensure that it is below 600 ohms.
Check to ensure that the load wiring is isolated.
Disconnect the field wiring and connect a resistor across the output. If the output current is 0 mA, go
to step one. If the output current is correct, but some of the outputs have a fault, go to step two.
Check the wiring for a loose connection on the terminal blocks or disconnected or misconnected
cables. If none of the outputs on a given 24/8 Analog I/O module are functioning, check the 24/8
Analog I/O module fuse. See instructions for replacing the module in Chapter 15, Installation and
Service. This fuse is visible and can be changed through the bottom of the module. If the fuse is
blown, fix the wiring problem and replace the fuse with a fuse of the same type and rating. Check the
application software configuration to ensure that the output is configured properly. If the connections
and application software are verified, exchange FTM #1 with FTM #2. See instructions for replacing
the FTM in Chapter 15. If the problem follows the FTM, replace the FTM. The FTM contains only
traces and a few discrete components, so failure is extremely unlikely.
If one or two of the 24/8 Analog I/O modules have an output fault, but the other module(s) does (do)
not, check the application software, and check to ensure that the cables are connected properly. If
the other output channels on the same 24/8 Analog I/O module are also not working, check the fuse
on the 24/8 Analog I/O module. See instructions for replacing the module in Chapter 15, Installation
and Service. This fuse is visible and can be changed through the bottom of the module. If the fuse is
blown, fix the wiring problem and replace the fuse with a fuse of the same type and rating. If the
output still has a fault, but the other output channels on the 24/8 Analog I/O module are functioning
properly, remove the 24/8 Analog I/O module and exchange the J1 and J2 cables. If the problem
moves to a different channel, replace the cable. If not, replace the 24/8 Analog I/O module. If the
readings are incorrect on several channels of the 24/8 Analog I/O module, corresponding to both
cables, replace the same 24/8 Analog I/O module.
If power has not been removed from the control system, power will
be active at the module and at the FTM. Shorting of protected
circuitry could cause a control system shutdown.
2. Remove FTM cover carefully, to prevent contact with any FTM circuitry under the cover. To remove
the FTM cover, pinch the retaining barb and lift the cover.
3. Locate and replace the fuse with another fuse of the same size, type, and rating. See Figure 12-12
or Figure 12-13 for channel fuse location.
4. Replace the FTM Cover.
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MicroNet TMR Digital Control Manual 26167V3
Each analog input must be 4–20 mA, and each actuator driver may be configured as 4–20 mA or 20–160
mA.
There are three configurations of the Analog Combo Modules. One has the analog inputs configured for
4–20 mA and the other two are configured for 0–5 V. 0–5 V modules are the ones used for TMR, see
Appendix A for specific part numbers. In addition to the module, the FTM configuration determines if the
0–5 V or 4–20 mA AI’s are available. In a simplex configuration, either Analog Combo module, 4–20 mA
or 0–5 V is connected through two analog cables to one Analog Combo FTM. All of the I/O are accessible
on the FTM, and the channels are labeled to correspond to their software locations, e.g. analog input 1 on
the FTM will be analog input 1 in the application software.
This module includes no potentiometers and requires no calibration. An Analog Combo module may be
replaced with another module of the same part number without any adjustment.
5.2.2—Module Specifications
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The maximum input voltage range may vary between 4.975 and 5.025
Volts from module to module.
Isolation: 0 VRMS, -60 dB CMRR, 200 Vdc common mode rejection voltage; no
galvanic isolation
Input impedance: 200 ohms
Anti-aliasing filter: 2 poles at 10 ms
Resolution: 16 bits
Accuracy: Software calibrated to 0.1%, over 25 mA full scale
Temp drift: 275 ppm/C, maximum
Fuse: 100 mA fuse per channel
Time stamping: 5 ms resolution on low event and latch, and high event and latch
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MicroNet TMR Digital Control Manual 26167V3
5.2.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
Three TMR Analog Combo Modules (MPU and Analog I/O modules) are connected through six analog
cables (two from each module) to two FTMs. Each MPU and Analog I/O module has two sub D connectors
on the front panel. The top sub D connector contains the first half of the channels (speed sensor channels 1
and 2, actuator channel 1, analog output channels 1 and 2, and analog input channels 1-4), and the bottom
sub D connector contains the second half of the I/O channels. See Figure 8-14 for an example.
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MicroNet TMR Digital Control Manual 26167V3
The first three channels of the control accept passive magnetic pickup units (MPUs) and channel 4
accepts 12 or 24 Vdc proximity probes. (Channel 4 proximity probe is to be used for slow speed detection
only.) Each speed input channel can only accept one MPU or one proximity probe.
A proximity probe may be used to sense very low speeds. With a proximity probe, speed can be sensed
down to 0.5 Hz. When interfacing to open collector type proximity probes, a pull-up resistor is required
between the supplied proximity probe voltage and the proximity probe input to the FTM. Individually fused
12 Vdc (via 24 Vdc) and 24 Vdc sources are provided with each speed input to power system proximity
probes (100 mA fuses, located on the FTMs, are used). External pull-up resistors are required when
interfacing with an open collector type proximity probe. The proximity probe input (channel 4) is only
designed to be used as a turning gear input, but will detect signals up to 25,000 Hz. This input may not be
used for control purposes, other than to indicate the turbine is not operating and is in pre-powered mode
being turned by the turning gear.
See Figures 8-15 and 8-16 for MPU/proximity probe wiring example. Channel 1 shows an MPU
connection, channel 2 shows a 24 V proximity connection, and channel 3 is an example of a 12 V
proximity connection. Always jumper the unused MPU connection to eliminate possible noise interference
when connecting a proximity probe.
When a speed sensor input channel has been wired as either MPU or
proximity probe input, the unused MPU/Prox must be jumpered at the
FTM. When an input channel is not used, both the MPU and Prox
inputs must be jumpered. See example in Figures 8-15 and 8-16.
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MicroNet TMR Digital Control Manual 26167V3
Figure 5-7. MPU Interface Wiring to TMR Analog Combo FTM (Speed 1-3)
Figure 5-8. Prox Interface Wiring to TMR Analog Combo FTM (Speed 4)
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Analog Inputs
The TMR analog inputs must be current type due to the TMR FTM. See Appendix A for specific part
numbers. All modules use the same cable and FTMs.
All current inputs may be used with two-wire ungrounded (loop powered) transducers or isolated (self-
powered) transducers. All analog inputs have 200 Vdc of common mode rejection. If interfacing to a non-
isolated device, which may have the potential of reaching over 200 Vdc with respect to the control’s
common, the use of a loop isolator is recommended to break any return current paths that may produce
erroneous readings. All current inputs use 200-ohm resistors across their inputs.
Each current input channel may power its own 4–20 mA transducer. This power is protected with a 100
mA fuse on each channel to prevent an inadvertent short from damaging the module. The 24 Vdc outputs
are capable of providing 24 Vdc with ±10% regulation. Power connections can be made through terminals
located on the FTMs. Refer to Figure 5-9 for 4–20 mA Current Input wiring.
Only self-powered voltage transducers should be used on voltage input channels. The full-scale range
must not exceed 5 volts. Refer to Figure 5-10 for 0–5 Vdc voltage transducer input wiring.
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MicroNet TMR Digital Control Manual 26167V3
TB1
F8
24 NC
68 NC
.01uF
25 Ch. 1
J1 J1
-
9 9 69 -
Anti- Self Powered
AI_01 aliasing Voltage
+ Filter 27 27 26 + Transducer
F7
70 NC
27 NC
.01uF
71 SHLD Ch. 2
-
Anti- 7 7 28 -Input
AI_02 aliasing
+ Filter 25 25 72 +Input
F6
29 NC
73 NC
.01uF
30 SHLD Ch. 3
-
Anti- 5 5 74 -Input
AI_03 aliasing
+ Filter 23 23 31 +Input
F5
75 NC
32 NC
.01uF
76 SHLD Ch. 4
-
Anti- 2 2 33 -Input
AI_04 aliasing
+ Filter 21 21 77 +Input
F4
34 NC
78 NC
.01uF
35 SHLD Ch. 5
J2 J2
-
Anti- 9 9 79 -Input
AI_05 aliasing
+ Filter 27 27 36 +Input
F3
80 NC
37 NC
.01uF
81 SHLD Ch. 6
-
Anti- 7 7 38 -Input
AI_06 aliasing
+ Filter 25 25 82 +Input
F2
13 13 39 NC
J1 J1
13 13 83 NC
.01uF
40 SHLD Ch. 7
J2 J2
-
Anti- 5 5 84 -Input
AI_07 aliasing
+ Filter 23 23 41 +Input
F1
- 15 15 85 NC
11 11
+24VDC J1 J1 42 NC
+ 15 15 .01uF
11 11 86 SHLD Ch. 8
J2 J2
-
Anti- 2 2 43 -Input
AI_08 aliasing
+ Filter 21 21 87 +Input
J1&2 J1&2
20 20 88
Figure 5-10. Voltage Input Wiring for an Analog Combo Module FTM (Simplex)
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Analog Outputs
The analog outputs are 4–20 mA with a full-scale range of 0–25 mA. Each output monitors the output
source current for fault detection. All of the analog outputs may be individually disabled. When a channel
fault or a module fault is detected, the application program may annunciate the fault, disable the channel
or module, and stop using the data in system calculations or control.
The Analog Combo module has four 4–20 mA current output drivers. All analog outputs can drive a
maximum load of 600 ohms (load + wire resistance). Care should be taken to prevent ground loops and
other faults when interfacing to non-isolated devices. See Figure 8-19 for an example of 4–20 mA output
wiring.
Actuator Outputs
The actuator outputs may be configured for 4–20 mA or 20–160 mA. Configuration is done through the
application software; no hardware modifications in the forms of jumpers or switches are necessary. For
fault detection, each output monitors the output source current and the output return current. All of the
actuator outputs may be individually disabled. When a channel fault or a module fault is detected, the
application program may annunciate the fault, disable the channel or module, and stop using the data in
system calculations or control.
Dither may be provided in the application software for each output. Dither is a low frequency (25 Hz)
signal consisting of a 5-millisecond pulse modulated onto the DC actuator-drive current to reduce sticking
due to friction in linear type actuators. Woodward TM-type actuators typically require dither. Dither
amplitude is variable through the application software. See Figure 8-19 for an example of actuator wiring.
For a dual coil actuator, two actuator driver outputs must be used.
Configuration Notes
Maximum impedance for a 4 to 20 mA actuator output driver is 360 ohms (actuator impedance +
wire resistance).
Maximum impedance for a 20 to 160 mA actuator output is 45 ohms (actuator impedance + wire
resistance).
Each actuator driver senses its source and return current to allow overcurrent and undercurrent
alarms and shutdowns.
5.2.4—FTM Reference
See Volume 2, Chapter 12 for complete Analog Combo FTM field wiring information. See Appendix A for
proper Module, FTM, and cable part numbers.
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Figure 5-11. Analog Output and Actuator Wiring for an Analog Combo FTM
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5.2.5—Troubleshooting
Analog Input Faults. The application software may set a high and low latch setpoint to detect input faults.
Speed Sensor Input Faults. The application software may set a high and low latch setpoint to detect input
faults. The low latch setpoint must be greater than one fiftieth of the frequency range.
Analog Output Driver Faults. The module monitors the source currents and annunciates faults. The
application determines the course of action in the event of a fault.
Actuator Driver or Load Faults. The module monitors the source, returns currents, and annunciates faults.
The application determines the course of action in the event of a fault.
Micro-controller Faults. The system monitors a software watchdog, a hardware watchdog, and a software
watchdog on the VME bus communications. All outputs are shutdown in the event of a microcontroller
fault.
Troubleshooting Guide
If during normal control operation, all of a chassis’ TMR Analog Combo I/O modules have Fault LEDs on,
check the kernel’s CPU module for a failure. If during normal control operation only the MPU and Analog
I/O module’s Fault LED is on or flashing, insure that it is installed in the correct slot. If it is, then replace
that MPU and Analog I/O module. See instructions for replacing the module in Chapter 14, Installation
and Replacement Procedures. When a module fault is detected, its outputs should be disabled or de-
energized.
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Look at the individual inputs into each kernel. A and B should read an input, and C should also read this
input if the terminal block jumpers are installed. The application software should contain three separate
numbers, one from each module. The numbers should be within 0.1% of each other, except kernel C if
the jumpers are not installed.
Verify that any unused MPU/Prox inputs are jumpered per Figures 8-15 and 8-16.
The following actions may shut down the prime mover. If all of the
MPU and Analog I/O modules are reading approximately the same
number, but it is not the right reading, go to step 1. If two of the MPU
and Analog I/O modules are reading correctly, but one is reading
incorrectly, go to step 2.
Check the wiring. If the inputs are reading 0, look for a loose connection on the terminal blocks or
disconnected or misconnected cables. Check the application software configuration to ensure that
the input is configured properly. If the connections and application software are verified and the
correct voltage is present on the terminal block, but all of the MPU and Analog I/O modules are
reading 0 V (with a meter), exchange FTM #1 with FTM #2. See instructions for replacing the FTM in
Chapter 14, Installation and Replacement Procedures. If the problem follows the FTM, replace the
FTM. The FTM contains only traces and a few discrete components, so failure is extremely unlikely.
If one or two of the MPU and Analog I/O modules are reading the correct number, but the other
module(s) is (are) incorrect, check the application software configuration of the modules with the
non-working channels. Also check to ensure that the cables are connected properly. If C kernel is
not working, but A and B are, check to insure that the terminal block jumpers are installed and if the
MPU can drive three inputs. If the reading is still incorrect, but the other readings from the MPU and
Analog I/O module are correct, remove the MPU and Analog I/O module and exchange the J1 and
J2 cables. See instructions for replacing the module in Chapter 14, Installation and Replacement
Procedures. If the problem moves to a different channel, replace the cable. If not, replace the MPU
and Analog I/O module. If the readings are incorrect on several channels of the same MPU and
Analog I/O module, corresponding to both cables, replace the MPU and Analog I/O module.
Proximity Probes
If a speed sensor input is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14, Installation and Replacement Procedures.
Measure the input voltage on the terminal block. It should be in the range of 3.5 - 32 Vpeak.
Verify that the signal waveform is clean and void of double zero crossings.
Verify that no ground connection exists and that the resulting 60 Hz signal is absent.
Measure the frequency. It should be in the range of 0.5 Hz, to 25 kHz.
Verify that any unused MPU inputs are jumpered per Figure 8-15.
Check the wiring. Look for a loose connection at the terminal blocks, disconnected or misconnected
cables, a missing jumper on the terminal block, or a blown fuse on the 24 Vdc on the FTM. See
Figure 8-20 or 8-21 for FTM fuse locations.
Check the software configuration to ensure that the input is configured properly.
Check the fuse on the FTM. See the instructions and fuse locations below.
If the other channels on the MPU and Analog I/O module are also not working, check the fuse on the
MPU and Analog I/O module. This fuse is visible and can be changed through the bottom of the
module. If the fuse is blown, fix the wiring problem and replace the fuse with another fuse of the
same type and rating.
Look at the individual inputs into each kernel. Each module reads the same input from the FTM, so
the software should contain three separate numbers, one from each MPU and Analog I/O module.
The numbers should be within 0.1% of each other unless a high common mode voltage is present.
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The following actions may shut down the prime mover. If all of the
MPU and Analog I/O modules are reading approximately the same
number, but it is not the right reading, go to step 1. If two of the
modules are reading correctly, but one is reading incorrectly, go to
step 2.
Check the wiring. If the inputs are reading zero, look for a loose connection on the terminal blocks,
disconnected or misconnected cables, a missing jumper on the terminal block, or a blown fuse on
the 24 Vdc on the FTM. See instructions for replacing the fuse, below. Check the MPU and Analog
I/O module fuse. See instructions for replacing the module in Chapter 14, Installation and
Replacement Procedures. This fuse is visible and can be changed through the bottom of the module.
If the fuse is blown, fix the wiring problem, then replace the fuse with another fuse of the same type
and rating. Check the application software configuration to ensure that the input is configured
properly. If the connections and application software are verified and the correct voltage is present
on the terminal block, but all of the MPU and Analog I/O modules are reading 0 V (with a meter),
exchange FTM #1 with FTM #2. See instructions for replacing the FTM in Chapter 14, Installation
and Replacement Procedures. If the problem follows the FTM, replace the FTM. The FTM contains
only a wire wound 3 W resistor and traces, so failure is extremely unlikely.
If one or two of the MPU and Analog I/O modules are reading the correct number, but the other
module(s) is (are) incorrect, check the application software configuration of the modules with the
non-working channels, and check to ensure that the cables are connected properly. If the other
channels on the same MPU and Analog I/O module are also not working, check the fuse on the MPU
and Analog I/O module. See the instructions for replacing the module in Chapter 14, Installation and
Replacement Procedures. This fuse is visible and can be changed through the bottom of the module.
If this fuse is blown, fix the wiring problem and replace the fuse with a fuse of the same type and
rating. If the reading is still incorrect, but the other readings from the MPU and Analog I/O module
are correct, remove the MPU and Analog I/O module and exchange the J1 and J2 cables. If the
problem moves to a different channel, replace the cable. If not, replace the MPU and Analog I/O
module. If the readings are incorrect on several channels of the MPU and Analog I/O module,
corresponding to both cables, replace the MPU and Analog I/O module.
Analog Inputs
If an analog input is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14, Installation and Replacement Procedures.
Measure the input voltage on the terminal block. It should be in the range of
0–5 V.
Look at the individual inputs into each kernel. Each module reads the same input from the FTM, so
the application software should contain three separate numbers, one from each MPU and Analog I/O
module. The numbers should be within 0.1% of each other unless a high common mode voltage is
present.
Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look
for a loose connection on the terminal blocks, disconnected or misconnected cables, a missing
jumper on the terminal block if the input is a current input, or a blown fuse on the 24 Vdc on the FTM.
See Figure 8-20 or 8-21 for FTM fuse locations.
If all of the inputs are reading high, check that the 24 Vdc is not connected across the input directly.
Check the software configuration to ensure that the input is configured properly.
Check the fuse on the FTM. See the instructions and fuse locations below.
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The following actions may shut down the prime mover. If all of the
MPU and Analog I/O modules are reading approximately the same
number, but the reading is incorrect, go to step 1. If two of the MPU
and Analog I/O modules are reading correctly, but one is reading
incorrectly, go to step 2.
Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look
for a loose connection on the terminal blocks, disconnected or misconnected cables, a missing
jumper on the terminal block if the input is a loop powered current input, or a blown fuse on the 24
Vdc on the FTM. See instructions for replacing the fuses on the FTM, below. If all of the inputs are
reading high, check to ensure that the 24 Vdc is not connected across the input directly. Check the
MPU and Analog I/O module fuse. See instructions for replacing the module in Chapter 14,
Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem, then replace the fuse with another
fuse of the same type and rating. Check the application software configuration to ensure that the
input is configured properly. If the connections and application software are verified and the correct
voltage is present on the terminal block, but all of the MPU and Analog I/O modules are reading 0 V
(with a meter), exchange FTM #1 with FTM #2. See instructions for replacing the FTM in Chapter 14,
Installation and Replacement Procedures. If the problem follows the FTM, replace the FTM. The
FTM contains only a wire wound
3 W resistor and traces, so failure is extremely unlikely.
If one or two of the MPU and Analog I/O modules are reading the correct number, but the other
module(s) is (are) incorrect, check the application software configuration of the modules with the
non-working channels, and check to ensure that the cables are connected properly. If the other
channels on the same MPU and Analog I/O module are not working either, check the fuse on the
MPU and Analog I/O module. See instructions for replacing the module in Chapter 14, Installation
and Replacement Procedures. This fuse is visible and can be changed through the bottom of the
module. If this fuse is blown, fix the wiring problem and replace the fuse with a fuse of the same type
and rating. If the reading is still incorrect, but the other readings from the MPU and Analog I/O
module are correct, remove the MPU and Analog I/O module and exchange the J1 and J2 cables. If
the problem moves to a different channel, replace the cable. If not, replace the MPU and Analog I/O
module. If the readings are incorrect on several channels of the MPU and Analog I/O module,
corresponding to both cables, replace the MPU and Analog I/O module.
Analog Outputs
If an analog output is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14, Installation and Replacement Procedures.
Check the load resistance to ensure that it is below 600 ohms.
Check to ensure that the load wiring is isolated.
Check the wiring for a loose connection on the terminal blocks and disconnected or misconnected
cables.
Disconnect the field wiring and connect a resistor across the output. If the output is correct across
the resistor, there is a problem with the field wiring.
If the other output channels on the MPU and Analog I/O module are also not working, check the fuse
on the MPU and Analog I/O module. See instructions for module replacement in Chapter 14,
Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem and replace the fuse with a fuse of
the same type and rating.
Check the software configuration to ensure that the output is configured properly.
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The following actions may shut down the prime mover. Disconnect
the field wiring and connect a resistor across the output. If the output
current is 0 mA, go to step 1. If the output current is correct, but some
of the outputs have a fault, go to step 2.
Check the wiring for a loose connection on the terminal blocks or disconnected or misconnected
cables. If none of the outputs on a given MPU and Analog I/O module are functioning, check the
MPU and Analog I/O module fuse. See instructions for replacing the module in Chapter 14,
Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem, then replace the fuse with another
fuse of the same type and rating. Check the application software configuration to ensure that the
output is configured properly. If the connections and application software are verified, exchange FTM
#1 with FTM #2. See instructions for replacing the FTM in Chapter 14, Installation and Replacement
Procedures. If the problem follows the FTM, replace the FTM. The FTM contains only traces and a
few discrete components, so failure is extremely unlikely.
If one or two of the MPU and Analog I/O modules have an output fault, but the other module(s) does
(do) not, check the application software, and check to ensure that the cables are connected properly.
If the other output channels on the same MPU and Analog I/O module are also not working, check
the fuse on the MPU and Analog I/O module. See instructions for replacing the module in Chapter
14, Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem and replace the fuse with a fuse of
the same type and rating. If the output still has a fault, but the other output channels on the MPU and
Analog I/O module are functioning properly, remove the MPU and Analog I/O module and exchange
the J1 and J2 cables. If the problem moves to a different channel, replace the cable. If not, replace
the MPU and Analog I/O module. If the readings are incorrect on several channels of the MPU and
Analog I/O module, corresponding to both cables, replace the same MPU and Analog I/O module.
Actuator Outputs
If an actuator output is not functioning properly, verify the following:
Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14, Installation and Replacement Procedures.
Check the load resistance to ensure that it is below the specified limit.
Check to ensure that the load wiring is isolated.
Check the wiring for a loose connection on the terminal blocks or disconnected or misconnected
cables.
Disconnect the field wiring and connect a resistor across the output.
If the other output channels on the MPU and Analog I/O module are also not working, check the fuse
on the MPU and Analog I/O module. See instructions for module replacement in Chapter 14,
Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem, and replace the fuse with a fuse of
the same type and rating.
Check the software configuration to ensure that the output is configured properly
The following actions may shut down the prime mover. Disconnect
the field wiring and connect a resistor across the output; if the output
current is 0 mA, go to step 1. If the output current is correct, but some
of the outputs have a fault, go to step 2.
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Check the wiring for a loose connection on the terminal blocks, or disconnected or misconnected
cables. If none of the outputs on a given MPU and Analog I/O module are functioning, check the
MPU and Analog I/O module fuse. See instructions for replacing the module in Chapter 14,
Installation and Replacement Procedures. This fuse is visible and can be changed through the
bottom of the module. If the fuse is blown, fix the wiring problem, then replace the fuse with another
fuse of the same type and rating. Check the application software configuration to ensure that the
output is configured properly. If the connections and application software are verified, exchange FTM
#1 with FTM #2. See instructions for replacing the FTM in Chapter 14, Installation and Replacement
Procedures. If the problem follows the FTM, replace the FTM. The FTM contains only traces and a
few discrete components, so failure is extremely unlikely.
If one or two of the MPU and Analog I/O modules have an output fault, but the other module(s) does
(do) not, check the application software configuration, and check to ensure that the cables are
connected properly. Check the wiring for dual coil and single coil actuators, and ensure that the
wiring configuration matches the application software configuration. If the other output channels on
the same MPU and Analog I/O module are also not working, check the fuse on the MPU and Analog
I/O module. See instructions for replacing the module in Chapter 14, Installation and Replacement
Procedures. This fuse is visible and can be changed through the bottom of the module. If this fuse is
blown, fix the wiring problem and replace the fuse with a fuse of the same type and rating. If the
output still has a fault, but the other output channels on the MPU and Analog I/O module are
functioning properly, remove the MPU and Analog I/O module and exchange the J1 and J2 cables. If
the problem moves to the other channel, replace the cable. If not, replace the MPU and Analog I/O
module. If the readings are incorrect on several channels of the same MPU and Analog I/O module,
corresponding to both cables, replace the MPU and Analog I/O module.
If power has not been removed from the control system, power will be
active at the module and also at the FTM. Shorting of protected
circuitry could cause a control system shutdown.
2. Remove FTM cover carefully, to prevent contact with any FTM circuitry under the cover. To remove
the FTM cover, pinch the retaining barb and lift the cover.
3. Locate and replace the fuse with another fuse of the same size and rating. See Figure 5-12 or 5-13
for channel fuse locations.
4. Replace the FTM cover.
Figure 5-12. TMR MPU and Analog I/O Module FTM Fuse Locations
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Figure 5-13. Simplex MPU and Analog I/O Module FTM Fuse Locations
All 4–20 mA analog inputs may be used with two-wire ungrounded (loop powered) transducers or isolated
(self-powered) transducers. All analog inputs have 200 Vdc of common mode rejection. If interfacing to a
non-isolated device, which may have the potential of reaching over 200 Vdc with respect to the control’s
common, the use of a loop isolator is recommended to break any return current paths producing
erroneous readings.
Each board has an on-board processor for automatic calibration of the I/O channels. Each analog input
incorporates a time-stamping feature with 5 ms resolution for two low setpoints and two high setpoints.
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5.3.2—Module Specification
The maximum voltage input range may vary between 4.975 and 5.025
Volts from module to module.
The 24 channel analog inputs are divided into two banks, with
channel 1 through channel 12 data gathering at 1.8 ms after the MFT
tick and channel 13 through channel 24 data gathering at 3.7 ms after
the MFT tick.
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5.3.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
Each 24/8 Analog Module is connected through two High Density Analog/Discrete cables to two 24/8
Analog FTMs. All I/Os on the module are accessible on the FTM, and the channels are labeled to
correspond to their software locations (e.g., analog input 1 on the FTM will be analog input 1 in the
application software). See Figure 8-23 for an example.
J1
P1
J2
P1
P2
J1 24/8 Analog FTM
(Inputs Ch. 12-24)
(Outputs Ch. 5-8)
P2
J1 24/8 Analog FTM
(Inputs Ch. 1-12)
(Outputs Ch. 1-4)
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When configuring the AI Combo block in GAP, set Conf. input field to
1 for all inputs when used with the 24/8 Analog FTM. This will allow
the block to use the module factory calibration values for the 4–20 mA
inputs that were calibrated with 200 ohm internal resistors on the 24/8
Analog Module.
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Analog Outputs
There are eight analog output channels of 4–20 mA with a full-scale range of 0–25 mA. All Analog
Outputs can drive a maximum load of 600 ohms (load + wire resistance). See Figure 8-25 for analog
output connection. Each output monitors the output source current for fault detection. All of the analog
outputs may be individually disabled. When a channel fault or a module fault is detected, the application
program may annunciate the fault, disable the channel and stop using data in system calculations or
control. Care should be taken to prevent ground loops and other faults when interfacing to non-isolated
devices. See Chapter 12 for complete field wiring information for the Analog High Density FTM.
5.3.4—FTM Reference
See Chapter 12 for complete field wiring information for the Analog High Density FTM. See Appendix A
for part number Cross Reference for modules, FTMs, and cables.
5.3.5—Troubleshooting
Each 24/8 Analog module has a red Fault LED that is turned on when the system is reset. During
initialization of a module, which occurs after every CPU reset, the CPU turns the Fault LED on. The CPU
then tests each module using diagnostic routines built into the software. If the diagnostic test is not
passed, the LED remains on or blinks. If the test is successful, the LED goes off. If the Fault LED on a
module is illuminated after the diagnostics and initialization have been run, the module may be faulty or
may be located in the wrong slot.
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Analog Input Faults: The application software may be set with a high and low latch setpoint to detect input
faults.
Analog Output Driver Faults: The module monitors the source currents and annunciates faults. The
application software determines the course of action in the event of a fault.
Microcontroller Faults: The system monitors a software watchdog, a hardware watchdog, and a software
watchdog on the VME bus communications. All outputs are shut down in the event of a microcontroller
fault.
Troubleshooting Guide
If during normal control operation, all of the 24/8 Analog modules have Fault LEDs on, check the chassis’
CPU module for a failure. If during normal control operation only the 24/8 Analog module’s Fault LED is
on or flashing, insure that it is installed in the correct slot. If it is, then replace that module. See
instructions for replacement in Chapter 15. When a module fault is detected, its outputs will be disabled or
de-energized.
Analog Inputs
If an analog input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage on the FTM terminal block. It should be in the range of 0–5 V.
3. Verify that there are no or minimal AC components to the Analog Input signal. Improper shielding may
introduce AC noise on the input terminals.
4. Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look for
a loose connection on the terminal blocks, disconnected or misconnected cables, a missing jumper
on the terminal block if the input is a current input, or a blown fuse on the 24 Vdc on the FTM.
5. If all of the inputs are reading high, check that the 24 Vdc is not connected across the input directly.
6. Check the software configuration to ensure that the input is configured properly.
7. If all of the channels on the 24/8 Analog module are not working, check the fuse on the 24/8 Analog
module. See instructions for module replacement in Chapter 15. This fuse is visible and can be
changed through the bottom of the module. If the fuse is blown, fix the wiring problem, then replace
the fuse with another fuse of the same type and rating.
8. After verifying all of the above, exchange the J1 and J2 cables. If the problem moves to a different
channel, replace the cable. If not, replace the module.
9. If the readings are incorrect on several channels of the 24/8 Analog module, corresponding to both
cables, replace the module.
10. If replacing the module does not fix the problem, replace the FTM. The FTM contains only traces and
a few discrete components, so failure is extremely unlikely. See instructions for replacing the FTM in
Chapter 15.
Analog Outputs
If an analog output is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Check the load resistance to ensure that it is not greater than 600 ohms.
3. Check to ensure that the load wiring is isolated.
4. Check the wiring for a loose connection on the FTM terminal blocks and disconnected or
misconnected cables.
5. Disconnect the field wiring and connect a resistor across the output. If the output is correct across the
resistor, there is a problem with the field wiring.
6. If all of the channels on the 24/8 Analog module are not working, check the fuse on the 24/8 Analog
module. See instructions for module replacement in Chapter 15. This fuse is visible and can be
changed through the bottom of the module. If the fuse is blown, fix the wiring problem, then replace
the fuse with another fuse of the same type and rating.
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7. Check the software configuration to ensure that the output is configured properly.
8. After verifying all of the above, exchange the J1 and J2 cables. If the problem moves to a different
channel, replace the cable. If not, replace the module.
9. If the readings are incorrect on several channels of the module, corresponding to both cables, replace
the module.
10. If replacing the module does not fix the problem, replace the FTM. The FTM contains only traces and
a few discrete components, so failure is extremely unlikely. See instructions for replacing the FTM in
Chapter 15.
5.4.2—Specifications
To obtain overall signal input accuracy and bandwidth, the Dataforth FTM (0–5 V) module input accuracy
and the Dataforth 24/8 Analog Module must be taken into account.
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* Accuracy includes the effects of repeatability, hysteresis, and conformity. CJC sensor, thermocouple, or
RTD sensor accuracy should be added to the module accuracy to compute the overall measurement
accuracy.
** The maximum input voltage range may vary between 4.975 and 5.025 Volts from Dataforth module to
Dataforth module.
Outputs can drive a maximum load of 600 ohms (load + wire resistance).
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5.4.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
Each Dataforth module is connected through two high density analog/discrete cables to two Simplex
Dataforth FTMs. All I/Os on the module are accessible on the FTM. See Figure 5-19 for an example.
J1
P1
J2
P1
P2
J1
Simplex Dataforth FTM
(Inputs Ch. 12-24)
(Outputs Ch. 5-8)
P2
J1
Simplex Dataforth FTM
(Inputs Ch. 1-12)
(Outputs Ch. 1-4)
Linearization is achieved by creating a non-linear transfer function through the module itself. This non-
linear transfer function is configured at the factory, and is designed to be equal and opposite to the
thermocouple non-linearity.
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The cold junction compensation (CJC) is performed by using an NTC thermistor, externally mounted on
the FTM module, as shown in Figure 5-20. The thermocouple signal will fail high if an open wire is
detected.
These modules incorporate both Thompson (Bessel) and Butterworth five-pole filter to maximize both
time and frequency response. After the initial field side filtering, the input signal is chopped by a
proprietary chopper circuit and transferred across the transformer isolation barrier. The signal is then
reconstructed and filtered and scaled for 1 to 5 V for the Dataforth Module.
1
Fuse
100 mA 250 V
2
These modules incorporate both Thompson (Bessel) and Butterworth five-pole filter to maximize both
time and frequency response. After the initial field side filtering, the input signal is chopped by a
proprietary chopper circuit and transferred across the transformer isolation barrier. The signal is then
reconstructed and filtered and scaled for 1 to 5 V for the Dataforth Module.
Linearization is achieved by creating a non-linear transfer function through the module itself. This non-
linear transfer function is configured at the factory, and is designed to be equal and opposite to the
specific RTD non-linearity. Lead compensation is achieved by matching two current paths thus canceling
the effects of lead resistance.
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NTC
Thermistor * 2
+24 V 3 2 14 - In
RTD
3
+ V out 4 1 15 + In
0.01uf, 500V
- Com 5
4
16
3 5
IN * Note: The thermistor remains present on
Px 2
1 OUT
17 the FTM on all circuits, but has no effect
6 on the accuracy of the measurement .
24 RTN 18
Jumper
TB15
1
Fuse
100 mA 250 V
2
When configuring the AI Combo block in GAP, set Conf. input field to
2 for all 4–20 mA inputs when used with the current input plug-in
module. This will allow the block to use the module factory voltage
calibration values with a gain factor for a 200-ohm external resistor
on the Dataforth FTM.
Plug-in FTM
Module Term Blk
1
0 13
2
3 2 14 4/20 mA (Loop Powered)
+24 V
+ V out 4 1 3
15 + In -
Sig
3 5
IN
Px 2
1 OUT
17
6
24 RTN 18 +24 V
Jumper
TB15
1
Fuse
100 mA 250 V
2
Figure 5-22. Loop powered 4–20 mA Signal Wiring to Simplex Dataforth FTM
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4-20mA Transmitter
+ V out 4 1 3
15
+ In +
Sig
0.01uf, 500V
- Com 5 4
16
Shield
3 5
IN
Px 2
OUT
17
1
6
24 RTN 18
Jumper
TB15
1
Fuse
100 mA 250 V
2
When configuring the AI Combo block in GAP, set Conf. input field to
0 for all voltage inputs when used with the voltage input plug-in
module. This will allow the block to use the module factory voltage
calibration values with the Dataforth FTM.
3
0-5VDC Transmitter
+ V out 4 1
15
+ In +
Sig
0.01uf, 500V
Com 4
- 5 16
Shield
3 5
IN
Px 2
1 OUT
17
6
24 RTN 18
Jumper
TB15
1
Fuse
100 mA 250 V
2
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+24 V
MicroNet™ Module
I/O Lockout
Analog Output +
Dataforth® FTM
Feedback - FTM
TB1
Analog Output
- Out -
1
Output
Analog Output B + Out + Device
2
0.01uf, 500V
Shield
3
24 COM
TB15
5.4.4—FTM Reference
See Chapter 12 for complete field wiring of the Simplex Dataforth FTM. See Appendix A for part number
Cross Reference for modules, FTMs, and cables.
5.4.5—Troubleshooting
Each Dataforth 24/8 Analog Module has a red Fault LED that is turned on when the system is reset.
During initialization of a module, which occurs after every CPU reset, the CPU turns the Fault LED on.
The CPU then tests each module using diagnostic routines built into the software. If the diagnostic test is
not passed, the LED remains on or blinks. If the test is successful, the LED goes off. If the Fault LED on a
module is illuminated after the diagnostics and initialization have been run, the module may be faulty or
may be located in the wrong slot.
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Analog Input Faults: The application software may be set with a high and low latch setpoint to detect input
faults.
Analog Output Driver Faults: The module monitors the source currents and annunciates faults. The
application software determines the course of action in the event of a fault.
Microcontroller Faults: The system monitors a software watchdog, a hardware watchdog, and a software
watchdog on the VME bus communications. All outputs are shut down in the event of a microcontroller
fault.
Troubleshooting Guide
If during normal control operation, all of a chassis’ Dataforth 24/8 Analog Module has Fault LEDs on,
check the chassis’ CPU module for a failure. If during normal control operation, only the Dataforth
Module’s Fault LED is on or flashing, insure that it is installed in the correct slot. If it is, then replace that
module. See instructions for replacement in Chapter 15. When a module fault is detected, its outputs
should be disabled or de-energized.
Thermocouple Inputs
If a Thermocouple input is not functioning properly, verify the following:
1. Verify that the correct Dataforth plug-in module is installed. Swap plug-in modules on FTM. Replace
module if problem follows module.
2. Check that the cable is shielded and the shield is properly grounded per section Shields and
Grounding section in Chapter 14.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check the wiring. If the inputs are reading full scale, look for a loose connection on the terminal
blocks, disconnected or misconnected cables, a missing jumper on the terminal block, or a blown
fuse on the 24 Vdc on the FTM.
5. Check the software configuration to ensure that the input is configured properly.
6. Verify that FTM module is within operating limits of +5 to 45 degrees C.
7. If all of the thermocouple channels on the Dataforth Module are not working, check the fuse on the
Dataforth Module. See instructions for module replacement in Chapter 15. This fuse is visible and can
be changed through the bottom of the module. If the fuse is blown, fix the wiring problem, then
replace the fuse with another fuse of the same type and rating.
8. If the readings are incorrect on several channels of the Dataforth Module, after replacing both cables,
replace the module. If replacing the module does not fix the problem, replace the FTM. See
instructions for replacing the FTM in Chapter 15.
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RTD Inputs
If an RTD input is not functioning properly, verify the following:
1. Verify that the correct Dataforth plug-in module is installed. Swap plug-in modules on FTM. Replace
module if problem follows module.
2. Check that the cable is shielded and the shield is properly grounded per section Shields and
Grounding section in Chapter 14.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check the wiring. If the inputs are minimum scale or full scale, look for a loose connection on the
terminal blocks, disconnected or misconnected cables, a missing jumper on the terminal block, or a
blown fuse on the 24 Vdc on the FTM.
5. Check the software configuration to ensure that the input is configured properly.
6. If all of the RTD channels on the Dataforth Module are not working, check the fuse on the Dataforth
Module. See instructions for module replacement in Chapter 15. This fuse is visible and can be
changed through the bottom of the module. If the fuse is blown, fix the wiring problem, then replace
the fuse with another fuse of the same type and rating.
7. If the readings are incorrect on several channels of the Dataforth Module, after replacing both cables,
replace the module. If replacing the module does not fix the problem, replace the FTM. See
instructions for replacing the FTM in Chapter 15.
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7. If the readings are incorrect on several channels of the Dataforth Module, after replacing both cables,
replace the module. If replacing the module does not fix the problem, replace the FTM.
Analog Outputs
If an analog output is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded.
2. Check the load resistance to ensure that it is not greater than 600 ohms.
3. Check to ensure that the load wiring is isolated.
4. Check the wiring for a loose connection on the FTM terminal blocks and disconnected or
misconnected cables.
5. Disconnect the field wiring and connect a resistor across the output. If the output is correct across the
resistor, there is a problem with the field wiring.
6. If all of the channels on the Dataforth Module are not working, check the fuse on the Dataforth
Module. See instructions for module replacement in Chapter 15. This fuse is visible and can be
changed through the bottom of the module. If the fuse is blown, fix the wiring problem, then replace
the fuse with another fuse of the same type and rating.
7. Check the software configuration to ensure that the output is configured properly.
8. After verifying all of the above, exchange the J1 and J2 cables. If the problem moves to a different
channel, replace the cable. If not, replace the module.
9. If the readings are incorrect on several channels of the module, corresponding to both cables, replace
the module.
10. 1 If replacing the module does not fix the problem, replace the FTM. The FTM contains only traces
and a few discrete components, so failure is extremely unlikely. See instructions for replacing the
FTM in Chapter 15.
The first 12 Thermocouple/4–20 mA inputs are isolated as a group, from the other inputs, and from
control common. The second 12 Thermocouple/4–20 mA inputs are isolated as a group, from the other
inputs, and from control common. The first 4 RTD/4–20 mA inputs are isolated as a group, from the other
inputs, and from control common. The second 6 RTD/4–20 mA inputs are isolated as a group, from the
other inputs, and from control common.
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5.5.2—Module Specifications
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CJ Update time: 5 ms
CJ accuracy: ±3 C
Latency
Odd numbered channels: 1 ms
Even numbered channels: 3 ms
Failure detection: Open wire detection provided for thermocouples
Isolation: All input channels are isolated from the rest of the MicroNet platform to
500 Vdc, however they are not isolated from each other. The inputs are
differential, with a high impedance between channels.
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100 RTD (European Curve): 18.49 (–200 C/–328 F) to 390.48 (850 C/1562 F)
200 RTD (European Curve): 37.04 (–200 C/–328 F) to 533.10 (457 C/854.6 F)
100 RTD (American Curve): 59.57 (–100 C/–148 F) to 269.35 (457 C/854.6 F)
200 RTD (American Curve): 119.14 (–100 C/–148 F) to 538.70 (457 C/854.6 F)
Update time: 5 ms
I/O Latency: 1 ms
Isolation: All input channels are isolated from the rest of the MicroNet platform to 500 Vdc, however inputs
are not isolated from each other.
5.5.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a Simplex system, each 34 Ch. HDVIM module is connected through two high density 62 conductor
analog cables to two 34 Ch. HDVIM FTMs. All inputs on the module are accessible on the FTM, and the
channels are labeled to correspond to their software locations (e.g., analog input 1 on the FTM will be
analog input 1 in the application software). See Figure 8-42 for an example.
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J1
P1
J2
P1
P2
34Ch HDVIM FTM
J1 (AI/TC Ch. 1-12)
(RTD Ch. 1-4)
Loop power for the Analog inputs must be supplied by an external supply, if needed. This supply should
be wired to terminals 40 and 81 on each FTM. The FTM will fuse and distribute the power to 9 sets of
terminals on the FTM. The 4–20 mA, thermocouple, or RTD configurable inputs are selected in the GAP
block software, for each input. The GAP block configuration sets input gain via software. The maximum
wire size that the FTM can accept is one 16 AWG or two 20 AWG wires.
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The first 12 Analog inputs on each FTM are isolated as a group from control common, earth ground, and
the rest of the Analog inputs. The next 4 or 6 Analog inputs on the FTM are also isolated as a group from
control common, earth ground, and the rest of the Analog inputs. This results in 4 isolated groups of
inputs on each module.
5.5.4—FTM Reference
See Chapter 12 for complete 34 Ch. HDVIM FTM field wiring information. See Appendix A for proper
Module, FTM, and cable part numbers.
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Figure 5-31. Analog Interface Wiring to the 34 Ch. HDVIM Module Inputs
Figure 5-32. 4–20 mA Interface Wiring to 34 Ch. HDVIM Module RTD Inputs
Figure 5-33. RTD Interface Wiring to the 34 Ch. HDVIM Module RTD Inputs
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5.5.5—Troubleshooting
Each 34 Ch. HDVIM module has a red fault LED that is turned on when the system is reset. During
initialization of a board, which occurs after every CPU reset, the CPU turns the Fault LED on. The CPU
then tests the board using diagnostic routines built into the software. If the diagnostic test is not passed,
the LED remains on or blinks. If the test is successful, the LED goes off. If the fault LED on a board is
illuminated after the diagnostics and initialization have been completed, the 34 Ch. HDVIM module may
be faulty.
Analog Input Faults. The application software may set a high and low latch setpoint to detect input faults.
For thermocouple inputs, open wire detection is provided.
Micro-controller Faults. The system monitors a software watchdog, a hardware watchdog, and a software
watchdog on the VME bus communications. All outputs are shutdown in the event of a microcontroller
fault.
Troubleshooting Guide
If an Analog input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage on the terminal block. It should be in the range of 0–5 V for 4–20 mA
inputs. RTD inputs have a 2 mA current source. Thermocouple inputs should have the appropriate
millivolt signal.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding. Thermocouple inputs are extremely sensitive to signal fluctuations.
4. Check the wiring. For a 4–20 mA input if the input is reading 0 or the engineering units that
correspond to 0 mA, look for a loose connection at the terminal blocks and disconnected or
misconnected cables.
5. For RTD inputs, check for proper connection of the sense line.
6. For thermocouple inputs, check for proper cold junction location.
7. If the input is reading high, check that the power is not connected across the input directly.
8. Check the software configuration to ensure that the input is configured properly. Ensure that the
proper RTD or thermocouple type is selected, if applicable.
9. After verifying all of the above, exchange the J1 and J2 cables. If the problem moves to a different
channel, replace the cable. If not, replace the 34 Ch. HDVIM module.
10. If the readings are incorrect on several channels of the 34 Ch. HDVIM module, corresponding to both
cables, replace the 34 Ch. HDVIM module.
11. If replacing the module does not fix the problem, replace the FTM. See the instructions in Chapter 15
for replacing the FTM. The FTM contains only traces and a few discrete components, so failure is
extremely unlikely.
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There are three different 8 Ch. Current Input modules available from Woodward. These consist of the 8
Ch. Current Input (4–20 mA) module, Non-Standard 8 Ch. Current Input (4–20 mA) module, and the 8
Ch. Current/Voltage Input Module. The 8 Ch. Current/Voltage Input module was created for a special
program and is not a standard Woodward product.
5.7.1—Module Description
Each 8 Ch. Current Input (4–20 mA) Module contains circuitry for eight fully isolated double-ended current
inputs. The module is connected through one Low Density Analog cable to one Analog Input FTM for field
wiring connections. All analog inputs may be used with two-wire ungrounded (loop powered) transducers
or isolated (self-powered) transducers. The Input signal range is between 0 and 25 mA. The module has
a built-in precision voltage source. The readings from the precision-voltage reference are used for on-line
temperature compensation and automatic calibration for the module.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
5.7.2—Specification
Number of Channels: 8
Input Range: 0–25 mA
Accuracy: 0.5% of full scale
Temperature Coefficient: 12 ppm/degrees C
Anti-aliasing filter 2 poles at 12 ms (Channels 1-8)
Module interface: VMEbus
Resolution: 16 bit converter
Isolation: 1500 Vac continuous (channel input to control common)
CMRR: -90 db
Input Impedance: 249 ohms
Status Indication: RED LED - channel fault or board fault
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5.7.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8 Ch. Current Input (4–20 mA) module is connected through one Low Density
Analog cable to one Analog Input FTM. All of the I/O are accessible on the FTM. See Figure 8-49 for
configuration.
J1
P1
P2
J1
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Field Wiring
See Chapter 12 for complete wiring connections for the Analog Input FTM. See Figure 8-50 for
transducer wiring.
All analog inputs may be used with two-wire ungrounded (loop powered) transducers or isolated (self-
powered) transducers. Loop powered or self-powered 4–20 mA transducers may be connected to the
current input modules via the Analog Input FTM shown in Figure 8-50.
5.7.4—FTM Reference
See Chapter 12 for complete Analog Input FTM field wiring. See Appendix A for proper Module, FTM, and
cable part numbers.
5.7.5—Troubleshooting
The input MUX (multiplexer) permits the module to read either the value of the precision-voltage
reference for this channel, or the sensed input for this channel. The MUX receives the current input and,
under the control of the microcontroller, passes the value through the Gain amplifier to the Isolation
Amplifier. The output of the Isolation Amplifier goes to one input of the channel-selecting MUX.
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J2 J1 TB1
-15V +15V
19 19 1 +
15V1
.01uF Loop Powered
Gnd - Transducer
18 18 2
A1
+ 7.5V
Anti- 37 37 20
249
AI_01 aliasing Ohm
- Filter 36 36 21
-15V +15V
15V2 17 17 3
.01uF
Gnd
16 16 4
A2
+ 7.5V
35 35 22 +
Anti-
249 Self Powered
AI_02 aliasing Ohm Transducer
- Filter 34 34 23 -
-15V +15V
15V3 15 15 5 +15V
.01uF
Gnd
14 14 6 SHLD
7.5V
A3
Ch. 3
+
Anti- 33 33 24 +Input
249
AI_03 aliasing Ohm
- Filter 32 32 25 -Input
-15V +15V
15V4 13 13 7 +15V
.01uF
Gnd
12 12 8 SHLD
7.5V
A4
Ch. 4
+
Anti- 31 31 26 +Input
249
AI_04 aliasing Ohm
- Filter 30 30 27 -Input
-15V +15V
15V5 11 11 9 +15V
.01uF
Gnd
10 10 10 SHLD
7.5V
A5
Ch. 5
+
Anti- 29 29 28 +Input
249
AI_05 aliasing Ohm
- Filter 28 28 29 -Input
-15V +15V
15V6 9 9 11 +15V
.01uF
Gnd
8 8 12 SHLD
7.5V
A6
Ch. 6
+
Anti- 27 27 30 +Input
249
AI_06 aliasing Ohm
- Filter 26 26 31 -Input
-15V +15V
15V7 7 7 13 +15V
.01uF
Gnd
6 6 14 SHLD
7.5V
A7
Ch. 7
+
Anti- 25 25 32 +Input
249
AI_07 aliasing Ohm
- Filter 24 24 33 -Input
-15V +15V
15V8 5 5 15 +15V
.01uF
Gnd
4 4 16 SHLD
7.5V
A8
Ch. 8
+
Anti- 23 23 34 +Input
249
AI_08 aliasing Ohm
- Filter 22 22 35 -Input
3 3 17
2 2 18
1 1 19
21 21 36
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
Figure 5-36. Analog Input Wiring for an 8 Ch. Current Input (0–25 mA) Module
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This MUX, under control of the microprocessor, selects the channel to be read. The analog output of
this MUX is converted to a digital value by the A/D converter, and passed to the microcontroller. The
microcontroller makes any necessary corrections to this value and stores the result in the Dual-Port
RAM. The CPU can then access the values stored in Dual-Port RAM through the VME interface and
bus. See Figure 8-51 for block diagram of module.
Figure 5-37. 8 Ch. Current Input (0–25 mA) Module Block Diagram
During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed,
the LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
The CPU also tells this module in which rate group each channel is to run, as well as special
information. At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them
which rate groups are to be updated at that time. Through this initialization/key broadcast system, each
I/O module handles its own rate-group scheduling with minimal CPU intervention.
This module also has on-card on-line fault detection and automatic calibration/compensation. Each
input channel has its own precision voltage reference. Once per minute, while not reading inputs, the
on-board microcontroller reads this reference. The microcontroller then uses this data read from the
voltage reference for both fault detection and automatic temperature compensation/calibration.
Limits have been set for the expected readings when the on-board microcontroller reads each voltage
reference. If the reading obtained is outside these limits, the system determines that the input channel,
A/D converter, or the channel's precision-voltage reference is not functioning properly. If this happens,
the micro-controller flags that channel as having a fault condition. The CPU will then take whatever
action the application engineer has provided for in the application program.
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The readings from the precision-voltage reference are also used for on-line temperature compensation
and automatic calibration for the module. The readings of the precision-voltage reference, obtained from
the A/D converter, are used by the microcontroller to determine software scaling- and offset-constants for
each channel. These scaling-and offset-constants are respectively multiplied by and added to each
channel reading to provide corrected channel readings. The module therefore includes no potentiometers
and needs no calibration.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
Troubleshooting Guide
If a current input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage across the + and – inputs on the terminal block. It should be in the range of
0–5 V.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look for
a loose connection on the terminal blocks, disconnected or misconnected cables.
5. Check the software configuration to ensure that the input is configured properly.
6. If the other channels on the module are not working either, check the fuse on the 8 Ch. Current Input
(0–25 mA) module. This fuse is visible and can be changed through the bottom of the module. If the
fuse is blown, fix the wiring problem, then replace the fuse with another fuse of the same type and
rating.
7. If the problem remains, swap out the 8 Ch. Current Input (0–25 mA) module with another module of
the same part number. If the problem remains, replace the cable.
8. If the problem remains, replace the FTM. The FTM contains only traces and a few discrete
components, so failure is extremely unlikely. See instructions for replacing the FTM in Chapter 15.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
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5.8.2—Specification
Number of Channels: 8
Input Range: 0–25 mA
Accuracy: 0.5% of full scale
Temperature Coefficient: 12 ppm/degrees C
Anti-aliasing filter 2 poles at 12 ms (Channels 1-6)
Anti-aliasing filter 2 poles at 5 ms (Channels 7-8)
(Channel 8 is the derivative of channel 7.)
Module interface: VMEbus
Resolution: 16 bit converter
Isolation: 1500 Vac continuous (channel input to control common)
CMRR: -90 db
Input Impedance: 249 Ohms
Status Indication: RED LED - channel fault or board fault
5.8.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8 Ch. Current Input module is connected through one analog cable to one
FTM. All of the I/O are accessible on the FTM.
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J1
P1
P2
J1
Non-Standard
Analog Input FTM
Field Wiring
See Chapter 12 for complete wiring connections for the Non-standard Analog Input FTM. See Figure 8-54
for transducer wiring.
The first six analog inputs may be used with two-wire ungrounded (loop powered) transducers or isolated
(self-powered) transducers. The seventh channel can be used with a self-powered transducer only.
Channel eight should not be connected to any field wiring. Loop powered or self-powered 4–20 mA
transducers may be connected to the current input modules via the Non-Standard Analog Input FTM
shown in Figure 8-54.
5.8.4—FTM Reference
The output from channel seven is split and fed to channel seven on the Non-Standard Current Input (4–
20 mA) Module and also fed through a derivative circuit on the FTM to channel eight on the Non-Standard
Current Input (4–20 mA) Module. See Chapter 12 for complete field wiring information for the Non-
Standard Analog Input FTM. See Appendix A for proper Module, FTM, and cable part numbers.
5.8.5—Troubleshooting
The input MUX (multiplexer) permits the module to read either the value of the precision-voltage
reference for this channel, or the sensed input for this channel. The MUX receives the current input and,
under the control of the microcontroller, passes the value through the Gain amplifier to the Isolation
Amplifier. The output of the Isolation Amplifier goes to one input of the channel-selecting MUX.
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J2 J1 TB1
-15V +15V
19 19 1 +
15V1
.01uF Loop Powered
Gnd - Transducer
18 18 2
A1
+ 7.5V
Anti- 37 37 20
249
AI_01 aliasing Ohm
- Filter 36 36 21
-15V +15V
15V2 17 17 3
.01uF
Gnd
16 16 4
A2
+ 7.5V
35 35 22 +
Anti-
249 Self Powered
AI_02 aliasing Ohm Transducer
- Filter 34 34 23 -
-15V +15V
15V3 15 15 5 +15V
.01uF
Gnd
14 14 6 SHLD
7.5V
A3
Ch. 3
+
Anti- 33 33 24 +Input
249
AI_03 aliasing Ohm
- Filter 32 32 25 -Input
-15V +15V
15V4 13 13 7 +15V
.01uF
Gnd
12 12 8 SHLD
7.5V
A4
Ch. 4
+
Anti- 31 31 26 +Input
249
AI_04 aliasing Ohm
- Filter 30 30 27 -Input
-15V +15V
15V5 11 11 9 +15V
.01uF
Gnd
10 10 10 SHLD
7.5V
A5
Ch. 5
+
Anti- 29 29 28 +Input
249
AI_05 aliasing Ohm
- Filter 28 28 29 -Input
-15V +15V
15V6 9 9 11 +15V
.01uF
Gnd
8 8 12 SHLD
7.5V
A6
Ch. 6
+
Anti- 27 27 30 +Input
249
AI_06 aliasing Ohm
- Filter 26 26 31 -Input
-15V +15V
15V7 7 7 13 +15V
.01uF
Gnd
6 6 14 SHLD
7.5V
A7
Ch. 7
+ Special 25 25 32 +Input
Anti- 249
AI_07 aliasing Ohm
- 24 24 33 -Input
Filter
+15V In
Derivative
Circuit
-15V Out
-15V +15V
15V8 5 5 15 NC
.01uF
Gnd
4 4 16 NC
7.5V
A8
Ch. 8
+ Special 23 23 34 NC
Anti- 249
AI_08 aliasing Ohm
- 22 22 35 NC
Filter
3 3 17
2 2 18
1 1 19
21 21 36
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
This MUX, under control of the microprocessor, selects the channel to be read. The analog output of this
MUX is converted to a digital value by the A/D converter, and passed to the microcontroller. The
microcontroller makes any necessary corrections to this value and stores the result in the Dual-Port RAM.
The CPU can then access the values stored in Dual-Port RAM through the VME interface and bus. See
Figure 8-51 for block diagram of module.
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During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed, the
LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
The CPU also tells this module in which rate group each channel is to run, as well as special information.
At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them which rate groups
are to be updated at that time. Through this initialization/key broadcast system, each I/O module handles
its own rate-group scheduling with minimal CPU intervention.
This module also has on-card on-line fault detection and automatic calibration/compensation. Each input
channel has its own precision voltage reference. Once per minute, while not reading inputs, the on-board
microcontroller reads this reference. The microcontroller then uses this data read from the voltage
reference for both fault detection and automatic temperature compensation/calibration.
Limits have been set for the expected readings when the on-board microcontroller reads each voltage
reference. If the reading obtained is outside these limits, the system determines that the input channel,
A/D converter, or the channel's precision-voltage reference is not functioning properly. If this happens, the
micro-controller flags that channel as having a fault condition. The CPU will then take whatever action the
application engineer has provided for in the application program.
The readings from the precision-voltage reference are also used for on-line temperature compensation
and automatic calibration for the module. The readings of the precision-voltage reference, obtained from
the A/D converter, are used by the microcontroller to determine software scaling- and offset-constants for
each channel. These scaling-and offset-constants are respectively multiplied by and added to each
channel reading to provide corrected channel readings. The module therefore includes no potentiometers
and needs no calibration.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
Troubleshooting Guide
If a current input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage across the + and – inputs on the terminal block. It should be in the range of
0–5 V.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 mA, look for
a loose connection on the terminal blocks, disconnected or misconnected cables.
5. Check the software configuration to ensure that the input is configured properly.
6. If the other channels on the module are not working either, check the fuse on the Non-Standard 8 Ch.
Current Input (0–25 mA) module. This fuse is visible and can be changed through the bottom of the
module. If the fuse is blown, fix the wiring problem, then replace the fuse with another fuse of the
same type and rating.
7. If the problem remains, swap out the Non-Standard 8 Ch. Current Input (0–25 mA) module with
another module of the same part number. If the problem remains, replace the cable.
If the problem remains, replace the FTM. The FTM contains only traces and a few discrete components,
so failure is extremely unlikely. See instructions for replacing the FTM in Chapter 15
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These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
5.10.2—Specification
Number of Channels: 8
Input Range: 0–10 Volts
Accuracy: 0.5% of full scale
Temperature Coefficient: 12 ppm/degrees C
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5.10.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.In a simplex system, each 8 Ch.
Voltage Input module is connected through one analog cable to one FTM. All of the I/O are accessible on
the FTM.
J1
P1
P2
J1
Field Wiring
See Chapter 12 for complete wiring connections for the Analog Input FTM. See Figure 8-57 for
transducer wiring.
5.10.4—FTM Reference
See Chapter 12 for complete field wiring information for the Voltage Input (0–10 Vdc) FTM. See Appendix
A for part number Cross Reference for modules, FTMs, and cables.
5.10.5—Troubleshooting
The input MUX (multiplexer) permits the module to read either the value of the precision-voltage
reference for this channel, or the sensed input for this channel. The MUX receives the voltage input and,
under the control of the microcontroller, passes the value through the Gain amplifier to the Isolation
Amplifier. The output of the Isolation Amplifier goes to one input of the channel-selecting MUX.
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Figure 5-43. Voltage Input Wiring for an 8 Chnl Voltage Input Module
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This MUX, under control of the microprocessor, selects the channel to be read. The analog output of this
MUX is converted to a digital value by the A/D converter, and passed to the microcontroller. The
microcontroller makes any necessary corrections to this value and stores the result in the Dual-Port RAM.
The CPU can then access the values stored in Dual-Port RAM through the VME interface and bus. See
Figure 8-58 for block diagram of module.
Figure 5-44. 8 Ch. Voltage Input (0–10 Vdc) Module Block Diagram
During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed, the
LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
The CPU also tells this module in which rate group each channel is to run, as well as special information.
At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them which rate groups
are to be updated at that time. Through this initialization/key broadcast system, each I/O module handles
its own rate-group scheduling with minimal CPU intervention.
This module also has on-card on-line fault detection and automatic calibration/compensation. Each input
channel has its own precision voltage reference. Once per minute, while not reading inputs, the on-board
microcontroller reads this reference. The microcontroller then uses this data read from the voltage
reference for both fault detection and automatic temperature compensation/calibration.
Limits have been set for the expected readings when the on-board microcontroller reads each voltage
reference. If the reading obtained is outside these limits, the system determines that the input channel,
A/D converter, or the channel's precision-voltage reference is not functioning properly. If this happens, the
micro-controller flags that channel as having a fault condition. The CPU will then take whatever action the
application engineer has provided for in the application program.
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The readings from the precision-voltage reference are also used for on-line temperature compensation
and automatic calibration for the module. The readings of the precision-voltage reference, obtained from
the A/D converter, are used by the microcontroller to determine software scaling- and offset-constants for
each channel. These scaling-and offset-constants are respectively multiplied by and added to each
channel reading to provide corrected channel readings. The module therefore includes no potentiometers
and needs no calibration.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
Troubleshooting Guide
If a voltage input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage across the + and – inputs on the terminal block. It should be in the range of
0–5 V.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check the wiring. If the inputs are reading 0 or the engineering units that correspond to 0 V, look for a
loose connection on the terminal blocks, disconnected or misconnected cables.
5. Check the software configuration to ensure that the input is configured properly.
6. If the other channels on the module are not working either, check the fuse on the 8 Ch. Voltage
Input (0–10 Vdc) module. This fuse is visible and can be changed through the bottom of the module. If the
fuse is blown, fix the wiring problem, then replace the fuse with another fuse of the same type and rating.
7. If the problem remains, swap out the 8 Ch. Voltage Input (0–10 Vdc) module with another module
of the same part number. If the problem remains, replace the cable.
8. If the problem remains, replace the FTM. The FTM contains only traces and a few discrete
components, so failure is extremely unlikely. See instructions for replacing the FTM in Chapter 15.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
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5.12.2—Specification
Number of Channels: 8
Current range: 0–25 mA
Maximum load resistance: 600 ohms max.
Analog Channel bandwidth: 500 Hz min.
Module interface: VMEbus
Output update time: 1 ms
Resolution: 12 bit
Accuracy: 0.1% of full scale @25 degrees C
Maximum Drift: 50 ppm/degrees C
Status Indication: RED LED - channel fault or board fault
Channel faults: Output current monitored
Microcontroller faults: System monitors a software watchdog
System faults: All outputs are set to zero if MFT is lost.
Operating Temp: 0 to 70 °C
Isolation: None
5.12.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8 Ch. Current Output module is connected through one analog cable to one
FTM. All of the I/O are accessible on the FTM.
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MicroNet TMR Digital Control Manual 26167V3
J1
P1
P2
J1
There are 8 analog output channels of 4–20 mA with a full scale range of 0–25 mA. All Analog Outputs
can drive a maximum load of 600 ohms (load + wire resistance). See Figure 8-61 for analog output
connection. Each output monitors the output source current for fault detection. All of the analog outputs
may be individually disabled. When a channel fault or a module fault is detected, the application program
may annunciate the fault, disable the channel and stop using data in system calculations or control. Care
should be taken to prevent ground loops and other faults when interfacing to non-isolated devices.
5.12.4—FTM Reference
See Chapter 12 for complete field wiring information for the 8 Ch. Current Output (4–20 mA) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.12.5—Troubleshooting
The system writes output values to the Dual-Port RAM through the VME bus and interface. The
microcontroller scales the data using calibration constants stored in EEPROM, and schedules outputs to
occur at the proper time.
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MicroNet TMR Digital Control Manual 26167V3
J2 J1 TB1
19 19 1 NC
+24 .01uF
V
18 18 2 SHLD
37 37 20 +Output Ch. 1
I/O Lockout AO_01
36 36 21 -Output
Analog
+
Output 17 17 3 NC
- .01uF
Feedback
16 16 4
Analog
B +
Output 35 35 22 Ch. 2
Output
AO_02 Device
34 34 23 -
24 COM
15 15 5 NC
.01uF
14 14 6 SHLD
33 33 24 +Output Ch. 3
AO_03
32 32 25 -Output
13 13 7 NC
.01uF
12 12 8 SHLD
31 31 26 +Output Ch. 4
AO_04
30 30 27 -Output
11 11 9 NC
.01uF
10 10 10 SHLD
29 29 28 +Output Ch. 5
AO_05
28 28 29 -Output
9 9 11 NC
.01uF
8 8 12 SHLD
27 27 30 +Output Ch. 6
AO_06
26 26 31 -Output
7 7 13 NC
.01uF
6 6 14 SHLD
25 25 32 +Output Ch. 7
AO_07
24 24 33 -Output
5 5 15 NC
.01uF
4 4 16 SHLD
23 23 34 +Output Ch. 8
AO_08
22 22 35 -Output
3 3 17 NC
2 2 18 NC
1 1 19 NC
21 21 36 NC
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
Figure 5-47. Analog Output Wiring for 8 Chnl Output (4–20 mA) Module
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The microcontroller monitors the output current of each channel and alerts the system if a fault is
detected. The current-output drivers can be disabled by the system. If a fault, which prevents the entire
card from operating is detected by either the microcontroller or the system, the FAULT LED will illuminate.
See Figure 8-62 for module block diagram.
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These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
5.13.2—Specification
Number of Channels: 8
Current range: 0 – 1.25 mA
Maximum load resistance: 10 k max.
Analog Channel bandwidth: 500 Hz min.
Module interface: VMEbus
Output update time: 1 ms
Resolution: 12 bit
Accuracy: 0.1% of full scale @25 °C
Maximum Drift: 50 ppm/degrees C
Status Indication: RED LED - channel fault or board fault
Channel faults: Output current monitored
Microcontroller faults: System monitors a software watchdog
System faults: All outputs are set to zero if MFT is lost.
Operating Temp: 0 to 70 °C
Isolation: None
5.13.3—Installation
See 8 Ch. Current Output (4–20 mA) Module.
5.13.4—FTM Reference
See Chapter 12 for complete field wiring information for the 8 Ch. Current Output (0–1 mA) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.13.5—Troubleshooting
See 8 Ch. Current Output (4–20 mA) Module.
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5.15.1—Module Description
Each 8 Ch. Voltage Output (0–5 Vdc) Module has eight channels for outputting 0–5 Vdc. The module is
connected through one Low Density Analog cable to one Analog Input FTM for field wiring connections.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
5.15.2—Specification
Number of Channels: 8
Current range: 0–6.25 V
Minimum load resistance: 500 ohms
Analog Channel bandwidth: 500 Hz min.
Module interface: VMEbus
Output update time: 1 ms
Resolution: 12 bit
Accuracy: 0.1% of full scale @25 °C
Maximum Drift: 50 ppm/degrees C
Status Indication: RED LED - channel fault or board fault
Channel faults: Output current monitored
Microcontroller faults: System monitors a software watchdog
System faults: All outputs are set to zero if MFT is lost.
Operating Temp: 0 to 70 °C
Isolation: None
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MicroNet TMR Digital Control Manual 26167V3
5.15.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8 Ch. Voltage Output module is connected through one analog cable to one
FTM. All of the I/O are accessible on the FTM.
J1
P1
P2
J1
There are 8 analog output channels of 0–5 Vdc with a full scale range of
0-6.25 Vdc. All Analog Outputs can drive a minimum load of 500 ohms (load + wire resistance). See
Figure 8-66 for analog output connection. Each output monitors the output source voltage for fault
detection. All of the analog outputs may be individually disabled. When a channel fault or a module fault is
detected, the application program may annunciate the fault, disable the channel and stop using data in
system calculations or control. Care should be taken to prevent ground loops and other faults when
interfacing to non-isolated devices.
5.15.4—FTM Reference
See Chapter 12 for complete field wiring information for the 8 Ch. Voltage Output (0–5 Vdc) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.15.5—Troubleshooting
Figure 8-67 is a block diagram of the Voltage Output Module with eight 0–5 Vdc outputs.
The system writes output values to the Dual-Port RAM through the VME bus and interface. The
microcontroller scales the data using calibration constants stored in EEPROM, and schedules outputs to
occur at the proper time.
The microcontroller monitors the output voltage of each channel and alerts the system if a fault is
detected. If a fault, which prevents the entire card from operating is detected by either the microcontroller
or the system, the FAULT LED will illuminate.
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MicroNet TMR Digital Control Manual 26167V3
J2 J1 TB1
19 19 1 NC
+24 V .01uF
18 18 2 SHLD
37 37 20 +Output Ch. 1
I/O Lockout AO_01
36 36 21 -Output
Analog 17 17 3 NC
Output B
.01uF
16 16 4
35 35 22 + Ch. 2
Analog Output
+ AO_02
Output - - Device
34 34 23
Feedback
24 COM 15 15 5 NC
.01uF
14 14 6 SHLD
33 33 24 +Output Ch. 3
AO_03
32 32 25 -Output
13 13 7 NC
.01uF
12 12 8 SHLD
31 31 26 +Output Ch. 4
AO_04
30 30 27 -Output
11 11 9 NC
.01uF
10 10 10 SHLD
29 29 28 +Output Ch. 5
AO_05
28 28 29 -Output
9 9 11 NC
.01uF
8 8 12 SHLD
27 27 30 +Output Ch. 6
AO_06
26 26 31 -Output
7 7 13 NC
.01uF
6 6 14 SHLD
25 25 32 +Output Ch. 7
AO_07
24 24 33 -Output
5 5 15 NC
.01uF
4 4 16 SHLD
23 23 34 +Output Ch. 8
AO_08
22 22 35 -Output
3 3 17 NC
2 2 18 NC
1 1 19 NC
21 21 36 NC
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
Figure 5-52. Analog Output Wiring for an 8 Chnl Voltage Output Module
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MicroNet TMR Digital Control Manual 26167V3
Figure 5-53. 8 Ch. Voltage Output (0–5 Vdc) Module Block Diagram
5.16.1—Module Description
The 8 Ch. Voltage Output (0–10 Vdc) Module is the same as an 8 Ch. Voltage Output (0–5 Vdc) Module
with different feedback gain to scale the output for 0–10 Vdc on each channel.
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5.16.2—Specification
Number of Channels: 8
Current range: 0 – 12.5 V
Maximum load resistance: 500 ohms min.
Analog Channel bandwidth: 500 Hz min.
Module interface: VMEbus
Output update time: 1 ms
Resolution: 12 bit
Accuracy: 0.1% of full scale @ 25 °C
Maximum Drift: 50 ppm/degrees C
Status Indication: RED LED - channel fault or board fault
Channel faults: Output current monitored
Microcontroller faults: system monitors a software watchdog
System faults: All outputs are set to zero if MFT is lost.
Operating Temp: 0 to 70 °C
Isolation: None
5.16.3—Installation
See 8 Ch. Voltage Output (0–5 Vdc) Module.
5.16.4—FTM Reference
See Chapter 12 for complete field wiring information for the 8 Ch. Voltage Output (0–10 Vdc) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.16.5—Troubleshooting
See 8 Ch. Voltage Output (0–5 Vdc) Module.
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The board performs on-line temperature compensation and hardware diagnostics. These modules have
no potentiometers and require no calibration. A module may be replaced with another module of the
same part number without any adjustment.
5.18.2—Specification
Number Channels: 8 double ended, fully isolated, thermocouple input channels
1 cold junction channel.
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5.18.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8 Ch. TC (Fail Low) module is connected through one low Density analog
cable to one TC Input FTM. All of the I/O are accessible on the FTM.
J1
P1
P2
J1
TC Input FTM
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5.18.4—FTM Reference
See Volume 2, Chapter 12 for TC Input FTM information. See Appendix A for proper Module, FTM, and
cable part numbers.
J2 J1 TB1
19 19 1 NC
.01uF
18 18 2
+
37 37 20 +
Anti-
TC_01 aliasing
- Filter 36 36 21 -
17 17 3 NC
.01uF
16 16 4 SHLD
+
Anti- 35 35 22 +Input Ch. 2
TC_02 aliasing
- Filter 34 34 23 -Input
15 15 5 NC
.01uF
14 14 6 SHLD
+
Anti- 33 33 24 +Input Ch. 3
TC_03 aliasing
- Filter 32 32 25 -Input
13 13 7 NC
.01uF
12 12 8 SHLD
+
Anti- 31 31 26 +Input Ch. 4
TC_04 aliasing
- Filter 30 30 27 -Input
11 11 9 NC
.01uF
10 10 10 SHLD
+
Anti- 29 29 28 +Input Ch. 5
TC_05 aliasing
- Filter 28 28 29 -Input
9 9 11 NC
.01uF
8 8 12 SHLD
+
Anti- 27 27 30 +Input Ch. 6
TC_06 aliasing
- Filter 26 26 31 -Input
7 7 13 NC
.01uF
6 6 14 SHLD
+
Anti- 25 25 32 +Input Ch. 7
TC_07 aliasing
- Filter 24 24 33 -Input
5 5 15 NC
.01uF
4 4 16 SHLD
+
Anti- 23 23 34 +Input Ch. 8
TC_08 aliasing
- Filter 22 22 35 -Input
+15V 3 3 17 NC
Cold
CJ_09 2 2 AD590 18 NC
Junction
GND 1 1 19 NC
21 21 36 NC
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
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MicroNet TMR Digital Control Manual 26167V3
5.18.5—Troubleshooting
The board performs on-line temperature compensation and hardware diagnostics. To do this, once per
minute, it reads two known voltages for each channel. These values are checked against certain limits to
determine if a hardware fault has occurred. These values are also used to determine software scaling
constants used for temperature compensation. The MUX receives the thermocouple input and, under the
control of the microcontroller, passes the value through the gain amplifier to the isolation amplifier. The
output of the isolation amplifier goes to one input of the channel-selecting MUX.
This MUX, under control of the microprocessor, selects the channel to be read. The analog output of this
MUX is converted to a digital value by the A/D converter, and passed to the microcontroller. The
microcontroller uses a lookup table to linearize the thermocouple readings and stores the result in the
Dual-Port RAM. The CPU can then access the values stored in Dual-Port RAM through the VME interface
and bus. Upon detection of an open wire on the input, the channel will indicate a minimum scale reading.
See Figure 5-58 for module block diagram.
During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed, the
LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
The CPU also tells this module in which rate group each channel is to run, as well as special information.
At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them which rate groups
are to be updated at that time. Through this initialization/key broadcast system, each I/O module handles
its own rate-group scheduling with minimal CPU intervention.
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This module also has on-card on-line fault detection and automatic calibration/compensation. Each input
channel has its own precision voltage reference. Once per minute, while not reading inputs, the on-board
microcontroller reads this reference. The microcontroller then uses this data read from the voltage
reference for both fault detection and automatic temperature compensation/calibration.
Limits have been set for the expected readings when the on-board microcontroller reads each voltage
reference. If the reading obtained is outside these limits, the system determines that the input channel,
A/D converter, or the channel's precision-voltage reference is not functioning properly. If this happens, the
micro-controller flags that channel as having a fault condition. The CPU will then take whatever action the
application engineer has provided for in the application program.
The readings from the precision-voltage reference are also used for on-line temperature compensation
and automatic calibration for the module. The readings of the precision-voltage reference, obtained from
the A/D converter, are used by the microcontroller to determine software scaling- and offset-constants for
each channel. These scaling-and offset-constants are respectively multiplied by and added to each
channel reading to provide corrected channel readings. The module therefore includes no potentiometers
and needs no calibration.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
Troubleshooting Guide
If a Thermocouple input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage on the terminal block. It should be in the range of appropriate millivolt
signal.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding. Thermocouple inputs are extremely sensitive to signal fluctuations.
4. If the input is reading minimum range, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
5. If all the temperature measurements are offset by a fixed amount, check for proper cold junction
location. Replace the FTM.
6. Check the software configuration to ensure that the input is configured properly. Ensure that the
proper thermocouple type is selected.
7. After verifying all of the above, replace the 8 Ch. TC module.
.
5.19. 8Ch TC (Fail High) Module
5.19.1—Module Description
There are two types of the Thermocouple (Fail High) modules. The standard module is the same as the 8
Ch. TC (Fail Low) Module except when a failure is detected, the signal will indicate a full scale value. The
Non-standard 8 Ch. TC (Fail High) module has replaced the type “E” table with a type “N” table and also
fails high when a failure is detected.
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5.19.2—Specification
Number Channels:8 double ended, fully isolated, thermocouple input channels
One cold junction channel.
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5.19.3—Installation
See 8 Ch. TC (Fail Low) Module.
5.19.4—FTM Reference
See Volume 2, Chapter 12 for complete field wiring information for the 8 Ch. TC (Fail High) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.19.5—Troubleshooting
See 8 Ch. TC (Fail Low) Module.
T=(R*25.95)-(234.5)
The board performs on-line temperature compensation and hardware diagnostics. These modules have
no potentiometers and require no calibration. A module may be replaced with another module of the
same part number without any adjustment.
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5.21.2—Specification
Number of Channels: 8 semi-isolated, RTD channels
Input Type: 3 wire
(Must conform to 10 ohm copper RTD temperature/resistance relationship (Alpha = .00427))
5.21.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 8Ch RDT Input Module is connected through one low Density analog cable to
one Analog Input FTM. All of the I/O are accessible on the FTM.
J1
P1
P2
J1
5.21.4—FTM Reference
See Chapter 13 for complete field wiring information for the 8Ch RTD Input (10 ohm) FTM. See Appendix
A for part number Cross Reference for modules, FTMs, and cables.
5.21.5—Troubleshooting
The board performs on-line temperature compensation and hardware diagnostics. To do this, once per
minute, it reads two known voltages for each channel. These values are checked against certain limits to
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determine if a hardware fault has occurred. These values are also used to determine software scaling
constants used for temperature compensation. The MUX receives the RTD input and, under the control of
the microcontroller, passes the value through the gain amplifier to the isolation Amplifier. The gain
amplifier introduces the proper gain for the type of RTD used. The output of the isolation amplifier goes to
one input of the channel-selecting MUX.
This MUX, under control of the microprocessor, selects the channel to be read. The analog output of this
MUX is converted to a digital value by the A/D converter, and passed to the microcontroller. The
microcontroller uses a lookup table to linearize the RTD reading and stores the result in the Dual-Port
RAM. The CPU can then access the values stored in Dual-Port RAM through the VME interface and bus.
See Figure 9-56 for module block diagram.
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J2 J1 TB1
19 19 1
.01uF
18 18 2
+ +
Current
Source
37 37 20
RTD_01 RTD
- 36 36 21 -
17 17 3 Sense
.01uF
16 16 4 Shld
Ch. 2
+ Current
Source
35 35 22 +Input
RTD_02
- 34 34 23 -Input
15 15 5 Sense
.01uF
14 14 6 Shld
Ch. 3
+ Current
Source
33 33 24 +Input
RTD_03
- 32 32 25 -Input
13 13 7 Sense
.01uF
12 12 8 Shld
Ch. 4
+ Current
Source
31 31 26 +Input
RTD_04
- 30 30 27 -Input
11 11 9 Sense
.01uF
10 10 10 Shld
Ch. 5
+ Current
Source
29 29 28 +Input
RTD_05
- 28 28 29 -Input
9 9 11 Sense
.01uF
8 8 12 Shld
Ch. 6
+ Current
Source
27 27 30 +Input
RTD_06
- 26 26 31 -Input
7 7 13 Sense
.01uF
6 6 14 Shld
Ch. 7
+ Current
Source
25 25 32 +Input
RTD_07 - 24 24 33 -Input
5 5 15 Sense
.01uF
4 4 16 Shld
Ch. 8
+ Current
Source
23 23 34 +Input
RTD_08
- 22 22 35 -Input
3 3 17 NC
2 2 18 NC
1 1 19 NC
21 21 36 NC
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
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During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed, the
LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
The CPU also tells this module in which rate group each channel is to run, as well as special information.
At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them which rate groups
are to be updated at that time. Through this initialization/key broadcast system, each I/O module handles
its own rate-group scheduling with minimal CPU intervention.
This module also has on-card on-line fault detection and automatic calibration/compensation. Each input
channel has its own precision voltage reference. Once per minute, while not reading inputs, the on-board
microcontroller reads this reference. The microcontroller then uses this data read from the voltage
reference for both fault detection and automatic temperature compensation/calibration.
Limits have been set for the expected readings when the on-board microcontroller reads each voltage
reference. If the reading obtained is outside these limits, the system determines that the input channel,
A/D converter, or the channel's precision-voltage reference is not functioning properly. If this happens, the
micro-controller flags that channel as having a fault condition. The CPU will then take whatever action the
application engineer has provided for in the application program.
The readings from the precision-voltage reference are also used for on-line temperature compensation
and automatic calibration for the module. The readings of the precision-voltage reference, obtained from
the A/D converter, are used by the microcontroller to determine software scaling- and offset-constants for
each channel. These scaling-and offset-constants are respectively multiplied by and added to each
channel reading to provide corrected channel readings. The module therefore includes no potentiometers
and needs no calibration.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
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Troubleshooting Guide
If an RTD input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the shields and grounding
section in Chapter 15, installation.
2. Measure the input voltage on the terminal block (Sense to – input). It should be in the range
generated by a 4 mA current source across the RTD.
3. Verify that there are no or minimal AC components to the Analog Input signal. AC components can be
caused by improper shielding.
4. Check for proper connection of the sense line.
5. Check the software configuration to ensure that the input is configured properly. Ensure that the
proper RTD is selected. Ensure that the Lag input Tau is set to at least 0.200.
6. If replacing the module does not fix the problem, replace the FTM. See the instructions in Chapter 15,
Installation, for replacing the FTM. The FTM contains only traces and a few discrete components, so
failure is extremely unlikely.
5.22.2—Specification
Number of Channels: 8 semi-isolated, RTD channels
Input Type: 3 wire
(Must conform to (Deutsche Institut für Normung) DIN standard for 100 ohm European curve (Alpha =
.00385) or American curve 100 ohm curve (Alpha = .00392))
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Temperature ranges
Standard module: –40 to +450 °C (100 ohm platinum, American, European)
High Temp Module: –40 to +645 °C (100 ohm platinum, European)
–40 to +450 °C (100 ohm platinum, American)
Excitation: 2 mA
Module interface: VMEbus
Output: Linearized temperatures in °C
Resolution: 14 bit converter
Accuracy: 0.5% of full scale over the entire temperature range
Temperature Coefficient: 12 ppm/degree C
Isolation: 1500 Vac continuous (input channels to control common, not channel
to channel)
Input Impedance: 2.2 MΩ
CMRR: -90 db
Status Indication: RED LED - channel fault or board fault
5.22.3—Installation
See 8Ch RTD Input (10 ohm) Module.
5.22.4—FTM Reference
See Chapter 13 for complete field wiring information for the 8Ch RTD Input (100 ohm) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.22.5—Troubleshooting
See 8Ch RTD Input (10 ohm) Module.
5.23.1—Module Description
The eight channels of this module are semi-isolated. The channels are isolated from the control common
but not from each other. Each channel receives a signal from an RTD. This signal must be from a 200
Platinum RTD (European or American curve).
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5.23.2—Specification
Number of Channels: 8 semi-isolated, RTD channels
Input Type: 3 wire
(Must conform to (Deutsche Institut für Normung) DIN standard for 200 ohm European curve (Alpha =
.00385) or American curve 200 ohm curve (Alpha = .00392))
5.23.3—Installation
See 8Ch RTD Input (10 ohm) Module.
5.23.4—FTM Reference
See Chapter 13 for complete field wiring information for the 8Ch RTD Input (200 ohm) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.23.5—Troubleshooting
See 8Ch RTD Input (10 ohm) Module.
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5.24.2—Specification
Number of Channels: 8 semi-isolated, RTD channels
Input Type: 3 wire
(Must conform to (Deutsche Institut für Normung) DIN standard for 500 ohm European curve (Alpha =
.00385) or American curve 500 ohm curve (Alpha = .00392))
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5.24.4—FTM Reference
See Chapter 13 for complete field wiring information for the 8Ch RTD Input (500 ohm) FTM. See
Appendix A for part number Cross Reference for modules, FTMs, and cables.
5.24.5—Troubleshooting
See 8Ch RTD Input (10 ohm) Module.
5.24.1—Module Description
This module has four speed inputs that can be configured as either transformer isolated MPU inputs or
non-isolated proximity inputs. The configuration of MPU and proximity inputs is dependent on the part
number.
These modules have no potentiometers and require no calibration. A module may be replaced with
another module of the same part number without any adjustment.
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8.29.2—Specification
Number Channels: 4
Input Type: MPU/Proximity Detector (factory selected by part number)
Input Frequency Range: MPU: 50 Hz to 25 KHz
Prox: 0.04 Hz to 2 KHz
Input Amplitude: MPU: 1 Vrms min, 25 Vrms max, Freq > 20 Hz
Prox: 10 mA
Input Impedance: MPU: 2000 Ω
Prox: 2000 Ω
Isolation Voltage: MPU: 500 Vrms
Prox: None
Resolution: 16 bits
0.0015% of range per LSB
Speed Accuracy (max): 0.01% over temperature range
Temperature drift: 1 ppm/C
Derivative Accuracy (max): 0.10% of range (p-p)
Speed Filter: 5-10,000 ms (2 real poles)
Derivative Filter: 5-10,000 ms (1 pole + speed filter)
Acceleration Limit: 1-10,000 percent/second
Operating Temperature: –15 to +55 °C
8.29.3—Installation
The modules slide into card guides in the control's chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
In a simplex system, each 4 Ch. Speed Module is connected through one low Density analog cable to
one Analog Input FTM. All of the I/O are accessible on the FTM.
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J1
P1
P2
J1
Any of the module’s four speed channels accept passive magnetic pickup units (MPUs) or proximity
probes. The number of MPU and proximity inputs per module is determined by the position of jumpers
internal to the module. These jumpers are factor set. The part number of the module will determine the
ratio of MPU to Proximity inputs. Each speed input channel can only accept one MPU or one proximity
probe. See Appendix A for desired part number of modules.
A proximity probe may be used to sense very low speeds. With a proximity probe, speed can be sensed
down to 0.5 Hz. When interfacing to open collector type proximity probes, a pull-up resistor is required
between the supplied proximity probe voltage and the proximity probe input to the FTM. See Figure
7-62 for MPU and proximity probe wiring examples.
8.29.4—FTM Reference
See Chapter 12 for complete field wiring information for the 4 Ch. MPU/Proximity FTM. See Appendix A
for part number Cross Reference for modules, FTMs, and cables.
8.29.5—Troubleshooting
Speed ranges are selected from the GAP and the signal is pre-scaled accordingly. The pre-scaled signal
then goes to a counter where the period of the signal is measured. The Digital Signal Processor samples
the counter's values every 100 microseconds and performs a divide to generate a digital speed signal.
Every 100 microseconds a digital-filter algorithm is executed to average the speed values in order to
improve speed-sensor resolution at input frequencies greater than 200 Hz. This digital filter also provides
a derivative output.
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Once every rate time (5-200 ms typically), the latest speed and derivative information is moved to the
Dual-Port RAM for access by the CPU module.
During initialization, which occurs after every reset, the CPU turns the FAULT LEDs on. The CPU then
tests each I/O module using diagnostic routines built into software. If the diagnostic test is not passed, the
LED remains on. If the test is successful, the LED goes off.
During initialization of the module, the module's micro-controller turns the LED off after power-on self-
tests have passed and the CPU has initialized the module.
19 19 1 NC
.01uF
MPU_01 18 18 2
JPR 3
+
37 37 20
JPR 1
MPU #1
36 36 21 -
17 17 3 +24V
.01uF
16 16 4 Shld
MPU/PROX_02 Ch. 2
35 35 22 +Input
34 34 23 -Input
15 15 5 +24V
.01uF
14 14 6 Shld
MPU/PROX_03 Ch. 3
+24VDC 33 33 24 +Input
+5VDC
32 32 25 -Input
13 13 7 +24VDC
.01uF
JPR 23
PROX_04 12 12 8
+
31 31 26
PROX #4
30 30 27 -
JPR 21
11 11 9 NC
.01uF
10 10 10 NC
29 29 28 NC
28 28 29 NC
9 9 11 NC
.01uF
8 8 12 NC
27 27 30 NC
26 26 31 NC
7 7 13 NC
.01uF
6 6 14 NC
25 25 32 NC
24 24 33 NC
5 5 15 NC
.01uF
4 4 16 NC
23 23 34 NC
22 22 35 NC
3 3 17 NC
2 2 18 NC
1 1 19 NC
21 21 36 NC
20 20 37
Ground to DIN Rail
J1 Outer Shell 38
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The CPU also tells this module in which rate group each channel is to run, as well as special information.
At run time, the CPU then periodically broadcasts a "key" to all I/O cards, telling them which rate groups
are to be updated at that time. Through this initialization/key broadcast system, each I/O module handles
its own rate-group scheduling with minimal CPU intervention.
Each I/O module has a fuse on it; this fuse is visible and can be changed through a cutout in the plastic
cover of the module. If this fuse is blown, replace it with a fuse of the same type and size.
Troubleshooting Guide
MPUs. If a magnetic pickup input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage on the terminal block. It should be in the range of 1-25 VRMS.
3. Verify that the signal waveform is clean and void of double zero crossings.
4. Verify that no ground connection exists and that the resulting 60 Hz signal is absent.
5. Measure the frequency. It should be in the range of 50 Hz - 25 kHz.
6. Check the wiring. Look for a loose connection at the terminal blocks and disconnected or
misconnected cables.
7. Check the software configuration to ensure that the input is configured properly.
8. If the readings are incorrect on several channels of the module, replace the Speed module.
9. If replacing the module does not fix the problem, replace the FTM. See instructions for replacing the
FTM in Chapter 15. The FTM does not contain any active components on the MPU inputs, so
replacing it should be the last option.
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Proximity Probes
If a proximity probe input is not functioning properly, verify the following:
1. Check that the cable is shielded and the shield is properly grounded per the Shields and Grounding
section in Chapter 14.
2. Measure the input voltage on the terminal block. It should be in the range of 3.5 - 24 Vpeak.
3. Verify that the signal waveform is clean and void of double zero crossings.
4. Verify that no ground connection exists and that the resulting 60 Hz signal is absent.
5. Measure the frequency. It should be in the range of 0.5 Hz to 25 kHz.
6. Check the wiring. Look for a loose connection at the terminal blocks, disconnected or misconnected
cables.
7. Check the software configuration to ensure that the input is configured properly.
8. If the readings are incorrect on several channels of the Speed module, replace the Speed module.
9. If replacing the module does not fix the problem, replace the FTM. See instructions for replacing the
FTM in Chapter 15.
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Chapter 6.
Actuator Modules
Figure 9-5 is a block diagram of the four-channel Actuator Driver module. The system writes output
values to dual-port memory through the VME-bus interface. The microcontroller scales the values using
calibration constants stored in EEPROM, and schedules outputs to occur at the proper time.
The microcontroller monitors the output voltage and current of each channel and alerts the system of any
channel and load faults. The system can individually disable the current drivers. If a fault is detected
which prevents the module from operating, by either the microcontroller or the system, the FAULT LED
will illuminate.
This module requires no calibration; an actuator may be replaced with a like actuator without any module
or software adjustment.
6.1.2—Module Specification
Output Current Ranges: 0–25 mA, 0–200 mA
Resolution: 12 bits
Accuracy @ 25 °C: 0.1% of full scale
Drift: 150 ppm/°C
Maximum Actuator Resistance: 45 Ω @ 200 mA, 360 Ω @ 25 mA
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6.1.3—Installation
The modules slide into card guides in the control’s chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
6.1.4—FTM Reference
See Chapter 12 for complete field wiring information for the Four Channel Actuator Module FTM. See
Appendix A for part number cross reference for modules, FTMs, and cables.
6.1.5—Troubleshooting
Each I/O module has a red fault LED, which indicates the status of the module. This LED will help with
troubleshooting if the module should have a problem. A solid red LED indicates that the actuator
controller is not communicating with the CPU module. Flashing red LEDs indicate an internal problem
with the module, and module replacement is recommended.
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6.2.1—Module Description
Figure 9-12 is a block diagram of the Position Controller Module (PCM). The microcontroller executes a
position controller which receives a reference input from the CPU across the VME bus. It receives a
feedback input from a remote driver via a serial link. The controller output is sent to the remote driver
serially. Shutdown, reset, and fault signals are passed between the PCM and the remote driver using
discrete lines.
The feedback input from the remote driver is a 16 bit value from the digitized output of a resolver. This
gives the PCM the ability to control position with high accuracy and resolution. Consequently, the PCM is
used primarily with Dry Low Emissions (DLE) systems or other systems where high accuracy is required.
The PCM can be used with various remote drivers as shown by Figure 6-4. For more information on using
the position controller module with specific remote drivers, see the remote driver manual.
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Figure 6-4. Position Control Module as used with various Remote Drivers
9.5.2—Module Specification
Controller Type: model-based
Execution time: 1.67 ms
Dither: Tunable amplitude, 50% duty cycle
Frequency: 40 Hz with TM100 DFB and EM35 drivers, 25 Hz with TM100
SFB
Communications
Type: Synchronous
Interface: RS-485
Data length: 16 bits +1 bit parity
Error detection: Odd parity
PCM Detectable Faults Parity: Shutdown if parity error exist four consecutive times
Feedback: Shutdown if feedback angle > 90°
Position error: Alarm if feedback differs from demand by tunable amount for
tunable delay
Null fault: Alarm if null current moves outside settable limits
(TM100 drivers only)
Fdbk spread fault: Alarm if feedback signals differ by settable amount. Control from higher/lower
feedback selectable.
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9.5.3—Installation
The modules slide into card guides in the control’s chassis and plug into the motherboard. The modules
are held in place by two screws, one at the top and one at the bottom of the front panel. Also at the top
and bottom of the module are two handles which, when toggled (pushed outward), move the modules out
just far enough for the boards to disengage the motherboard connectors.
9.5.4—FTM Reference
See Chapter 12 for complete field wiring information for the EM/TM Position Control Module FTM. See
Appendix A for part number cross reference for modules, FTMs, and cables.
9.5.5—Troubleshooting
Following being reset, the PCM will perform a series of self-tests. The PCM will also check for run-time
errors. This includes checking for the presence of the Minor Frame Timer (MFT) signal along with insuring
that proper communications exists between itself and the CPU. If a self-test has failed or if a run-time fault
exists, the LED will blink according to the following chart:
Number
Error Type of Blinks Meaning
Self-test Errors 1 Internal register test failure
2 RAM test failure—both bytes
3 RAM test failure—high byte
4 RAM test failure—low byte
5 EPROM checksum error
6 EEPROM read/write failure
7 EEPROM checksum error
Run-time Errors 8 MFT signal absent > 200 ms
9 Invalid command received
10 Loss of communication with CPU
A fault LED that is constantly lit may indicate that the PCM did not get a proper reset or that it is unable to
execute its program.
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Chapter 7.
Field Termination Modules (FTMs)
The Service panel can be used by the system operator to communicate with a 040 CPU Module in a
stand-alone MicroNet system (see Chapter 5 for MicroNet CPU module information and Appendix A for
applicable module part number). The panel can be used to occasionally check the system, continuously
monitor a value, or tune variables, (when applicable), through a 24-key keypad with a split-screen display.
An optional mounting panel may be used to install the Service Panel in a 19 inch rack.
The Service Panel is used only with the 68040 CPU Module.
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The VFD module communicates with the CPU through a twin fiber-optic cable. The fiber optic cables
come in several different lengths. See Appendix A for part numbers and lengths.
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Additional hardware is required when an RS-232 serial port connection on either the MicroNet CPU (040)
or (Pentium) module is needed (see Appendix A for the CPU Serial Interface (RS-232–RS-232) FTM part
number). These communication ports are non-isolated. A shielded cable and Serial Port
Isolator/Converter are required when using any of these ports to avoid susceptibility to EMI noise and
ground loops related to PC connections and typical industrial environments. Depending on the CPU type,
the hardware may include the following parts:
1 Ea Filter–RS-232 Db9mf
1 Ea Cable–10 ft. Molded Db9f to Db9f Null Modem w/thumbscrews
1 Ea Converter–Isolated RS-232–RS-232, Phoenix Contact, DIN Rail
Serial Cable to
end device Isolator/ Filter Serial port
Converter
Cable
CPU
(040)
Additional hardware is required for Marine Certified applications when an RS-232 serial port connection
on either the MicroNet CPU (040) or (Pentium) module is needed (see Appendix A for the CPU Serial
Interface (RS-232–RS-232) FTM Marine Certified part number). Depending on the CPU type, the
hardware may include the following parts:
1 Ea Filter–RS-232 Db9mf
1 Ea Cable–10 ft. Molded Db9f to Db9f Null Modem w/thumbscrews
1 Ea Converter–Isolated RS-232–RS-232, KD485, DIN Rail
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Additional hardware is required when an RS-485 serial port connection on either the MicroNet CPU (040)
or (Pentium) module is needed (see Appendix A for the CPU Serial Interface (RS-232–RS-485) FTM part
number). Depending on the CPU type, the hardware may include the following parts:
1 Ea Filter–RS-232 Db9mf
1 Ea Cable–10 ft. Molded Db9f to Db9f Null Modem w/thumbscrews
1 Ea Converter–Interface (RS-232 to RS-485)
Additional hardware is required for Marine Certified applications when an RS-485 serial port connection
on either the MicroNet CPU (040) or (Pentium) module is needed (see Appendix A for the CPU Serial
Interface (RS-232–RS-485) FTM Marine Certified part number). Depending on the CPU type, the addition
hardware may include the following parts:
1 Ea Filter–RS-232 Db9mf
1 Ea Cable–10 ft. Molded Db9f to Db9f Null Modem w/thumbscrews
1 Ea Converter–Isolated RS-232–RS-422/RS-485, KD485, DIN Rail
Woodward 160
MicroNet TMR Digital Control Manual 26167V3
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Woodward 161