Jaquet FT 3000 Operating Instructions Manual

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JAQUET AG, Thannerstrasse 15, CH-4009 Basel Tel. +41 61 306 88 22 Fax +41 61 306 88 18

FT 3000 Speed measurement system

3-channel speed control and overspeed protection

System documentation FT 3000 :

• Operating instructions FT 3000

• Operating instructions sensor

• Rack 19 ¨ description

• Bloc function description

• System configuration

• Connection diagram

• IEC 61508 certificate

Operating Instructions FT 3000JAQUET AG

377E-63917 Rev 4.00 page 2 of 47

Table of contents

1 THE REDUNDANT OVER SPEED PROTECTION CONCEPT :.............................................................. 5

2 SAFETY WARNING..................................................................................................................................... 7

3 APPLICATIONS............................................................................................................................................ 7

4 CONSTRUCTION......................................................................................................................................... 7

5 FRONT PANEL DESCRIPTION....................................................................................................... ...........8

5.1 FTFU 3024............................................................................................................................................. 8

5.2 FTV 3090 ............................................................................................................................................... 8

5.3 FTK 3072...............................................................................................................................................9

5.4 FTW 3013............................................................................................................................................... 9

5.5 FTBU 3034 .......................................................................................................................................... 10

6 SPECIFICATIONS...................................................................................................................................... 11

6.1 S

TATISTICS............................................................................................................................................ 11

6.2 IEC 61508-2-3

SPECIFICATIONS :..........................................................................................................11

6.3 T

ECHNICAL DATA OSPS........................................................................................................................ 11

6.4 T

ECHNICAL DATA TCCC........................................................................................................................ 16

7 PRINCIPLE OF OPERATION.................................................................................................................... 16

7.1 M

EASURING SYSTEM.............................................................................................................................. 16

7.2 M

EASURING PRINCIPLE .......................................................................................................................... 16

7.2.1 Standardising the measured value.........................................................................................16

7.2.2 Speed monitor............................................................................................................................ 16

7.2.3 Frequency measurement (Period measurement principle) ................................................ 16

7.2.4 Acceleration measurement......................................................................................................19

7.2.5 Limit value control..................................................................................................................... 21

7.2.6 Limit value time control............................................................................................................ 21

7.3 M

ONITORING FUNCTIONS........................................................................................................................ 21

7.3.1 Supply.......................................................................................................................................... 21

7.3.2 Monitoring of internal voltages................................................................................................ 21

7.3.3 Sensor monitoring..................................................................................................................... 21

7.3.4 System monitoring....................................................................................................................22

7.3.5 Module OK message................................................................................................................. 22

7.3.6 Fault condition ........................................................................................................................... 22

7.4 D

IRECTION OF ROTATION DISCRIMINATOR............................................................................................... 22

7.5 R

ELAY CONTROL.................................................................................................................................... 22

7.6 T

EST FREQUENCY GENERATOR .............................................................................................................. 23

Operating Instructions 377E-63917

V 4.00 20.12.04

FT 3000

Operating Instructions FT 3000JAQUET AG

377E-63917 Rev 4.00 page 3 of 47

7.7 TEST...................................................................................................................................................... 23

7.8 F

REQUENCY OUTPUTS ........................................................................................................................... 23

7.9 L

AMP TEST.............................................................................................................................................24

7.10 M

ESSAGE ACKNOWLEDGEMENT............................................................................................................. 24

7.11 B

INARY INPUTS...................................................................................................................................... 24

7.12 P

ARAMETER ENTRY................................................................................................................................24

7.13 SIGNAL MONITORING.............................................................................................................................. 24

8 INSTALLATION.......................................................................................................................................... 26

8.1 G

ENERAL............................................................................................................................................... 26

8.2 IEC 61508-2-3 S

PECIFIC INSTALLATION RULES.....................................................................................26

9 SETTING PARAMETERS AND OPERATION.........................................................................................27

9.1 S

OFTWARE CONCEPT............................................................................................................................. 27

9.1.1 Process parameter list.............................................................................................................. 27

9.1.2 Configuration parameter list.................................................................................................... 27

9.1.3 Service parameter list............................................................................................................... 29

9.2 PC

COMMUNICATIONS............................................................................................................................ 29

9.2.1 PC system requirements.......................................................................................................... 29

9.2.2 PC software installation............................................................................................................ 29

9.2.3 Optimisation...............................................................................................................................30

9.2.4 Setting the display interval....................................................................................................... 30

9.2.5 Protection of configuration parameters................................................................................. 30

9.2.6 Protection of process parameters .......................................................................................... 30

9.2.7 Reading and writing parameters............................................................................................. 30

9.2.8 Parameter printout..................................................................................................................... 30

9.2.9 Display of current measured data........................................................................................... 30

9.3 S

ETTING PARAMETERS........................................................................................................................... 31

9.3.1 System settings ......................................................................................................................... 31

9.3.2 Sensor monitor .......................................................................................................................... 32

9.3.3 Analog outputs........................................................................................................................... 32

9.3.4 Limit values.................................................................................................................................32

9.3.5 Test values.................................................................................................................................. 33

9.3.6 Parameter enable....................................................................................................................... 33

9.3.7 Password .................................................................................................................................... 33

9.4 O

PERATING BEHAVIOUR......................................................................................................................... 33

9.4.1 Power up.....................................................................................................................................33

9.4.2 Measurements............................................................................................................................ 34

9.4.3 Response to sensor failure...................................................................................................... 34

9.4.4 Behaviour during system alarm..............................................................................................34

9.4.5 Response to mains failure........................................................................................................ 34

9.5 F

REQUENCY MEASUREMENT CALIBRA TION............................................................................................. 34

9.5.1 Calibration tools......................................................................................................................... 35

9.5.2 Factors influencing accuracy .................................................................................................. 35

9.5.3 Calibration rules......................................................................................................................... 35

9.6 C

ALIBRATING THE SENSOR MONITOR...................................................................................................... 36

9.6.1 Factors influencing accuracy .................................................................................................. 36

9.6.2 Calibration rules......................................................................................................................... 36

10 MECHANICAL CONSTRUCTION......................................................................................................... 37

11 CIRCUIT DESCRIPTION........................................................................................................................ 39

11.1 FTFU 3024 M

OTHERBOARD AND INPUT CA RD....................................................................................... 39

11.1.1 Frequency measurement.......................................................................................................... 39

11.1.2 Speed monitors.......................................................................................................................... 39

11.1.3 Micro controller.......................................................................................................................... 39

11.1.4 Supply.......................................................................................................................................... 39

11.1.5 Reset and non-maskable interrupt (NMI)............................................................................... 40

11.1.6 Input amplifier ............................................................................................................................ 40

11.1.7 Sensor monitoring..................................................................................................................... 40

11.1.8 Module monitoring .................................................................................................................... 41

11.1.9 Relay outputs ............................................................................................................................. 41

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377E-63917 Rev 4.00 page 4 of 47

11.1.10 LIMIT LED’s............................................................................................................................. 41

11.1.11 Frequency generator............................................................................................................. 41

11.1.12 Frequency outputs ................................................................................................................ 41

11.1.13 Binary inputs .......................................................................................................................... 41

11.1.14 Test .......................................................................................................................................... 41

11.1.15 Direction of rotation discriminator...................................................................................... 42

11.1.16 Lamp test ................................................................................................................................42

11.2 FTW 3013 - A/D

CONVERTER AUXILIARY MODULE.................................................................................42

11.2.1 Supply.......................................................................................................................................... 42

11.2.2 Analog outputs........................................................................................................................... 42

11.3 FTV 3090 R

ELAY CARD ........................................................................................................................ 42

11.3.1 Supply.......................................................................................................................................... 42

11.3.2 Relay outputs ............................................................................................................................. 42

11.4 FTK 3072 C

OMMS MODULE .................................................................................................................. 42

11.4.1 Rack bus ..................................................................................................................................... 42

11.4.2 RS 232 interface......................................................................................................................... 43

12 MAINTENANCE...................................................................................................................................... 44

12.1 P

ERIODIC TEST.......................................................................................................................................44

12.1.1 Description ................................................................................................................................. 44

12.1.2 IEC 61508-2-3 specifications.................................................................................................... 44

12.2 T

ROUBLE SHOTING :...............................................................................................................................45

12.2.1 Procedure for the OSPS ........................................................................................................... 45

12.2.2 Procedure for the TCCC :.........................................................................................................46

12.2.3 IEC 61508-2-3 specifications.................................................................................................... 46

12.3 M

ODULE EXCHANGING :......................................................................................................................... 46

12.3.1 General........................................................................................................................................46

12.3.2 IEC 61508-2-3 specifications :.................................................................................................. 47

13 STORAGE...............................................................................................................................................47

14 WARRANTY............................................................................................................................................ 47

15 DRAWINGS............................................................................................................................................. 47

Operating Instructions FT 3000JAQUET AG

377E-63917 Rev 4.00 page 5 of 47

1 The Redundant Over Speed Protection Concept :

Speed

Measurement

Speed

Measurement

Speed

Measurement

PSU 1 PSU 2

2 of 3

Module

commissio

ning

Customer specific control logic, 1/3, 2/3 …

Secure monitoring

even if modules are

exchanged during

operation

1. Measurement Protection Safety Availability

3. Measurement Protection Safety Availability

2. Measurement

Protection Safety Availability

OUTPUT CONTACTS

Secure supply via

redundant PSU’s

allowing exchange

during operation

FT 3000

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377E-63917 Rev 4.00 page 7 of 47

2 Safety Warning

During operation, parts of the FT 3000 are under dangerous voltages. The units conform to protection class 1 and require an earth connection on the corresponding module connector and/or termi nal on the 19" rack.

The units have been designed and tested in accordance with IEC 348 and have left the factory in perfect condition. These operating instructions include information and guidance on the safe operation of the equipment and installation.

Please specially note section 6. If in doubt about the condition of any part following electrical, environmental or mechanical damage, the unit should be

returned for repair.

3 Applications

FT 3000 tachometers are used to monitor and measure frequencies in the range 0 to 30000Hz eg from frequency proportional sources such as rotational speed.

The FT 3000 family comprises of the following modules:

• Monitoring module (Motherboard) FTFU 3024

with input card -E01 FTFU 3024- E01 Art. Nr. 377Z-03981 with input card -E02 FTFU 3024- E02 Art. Nr. 377Z-03982 with input card -E03 FTFU 3024- E03 Art. Nr. 377Z-03983

• Trip Chain Control card FTBU 3034 Art. Nr. 377Z-05030

• Frequency to current converter FTW 3013 Art.Nr.377Z-03984

(Auxiliary module)

• Relay card (Auxiliary module) FTV 3090 Art. Nr. 377Z-03985

• Comms module FTK 3072 Art. Nr. 377Z-03986

• PSU 116/230Vac FTZ 3061 Art. Nr. 377Z-04065

• PSU 24/48Vac FTZ 3062 Art. Nr. 377Z-04073

• PSU 14...70Vdc FTZ 3064 Art. Nr. 377Z-04074

• PSU 75...372Vdc FTZ 3065 Art. Nr. 377Z-04075

• Mains filter (2 wire) FTZ 3069 Art. Nr. 804D-35886

FT 3000 3 channel speed monitoring and over speed protection systems comprise of 3 independent channels, from speed pick ups through to limit signalling. High integrity operation is provided for in the rack through the use of 2 redundant power supplies to each module via diode decoupling. Rack module supply requirements are matched to the incoming supply by the 2 redundant power supplies.

4 Construction

The modules are plug in units in a 19" rack, with height 3 HE and with 4, 12 or 20 TE in accordance with DIN 41494.

Compatible card frames with up t o 21 l ocati ons at 4 TE are used for mounting and wiring the modules. The card frames are built by JAQUET to customer requirements. Connections for speed sensors, control and output signals along with power supplies are normally provided at the back via screw terminals or Termi-Point connections.The setting of measuring range, monitoring and relay parameters is via front panel RS 232 interface on the FTK 3072 comms module to a PC. This module controls the data flow between the PC and individual modules in the rack (RS 485 rack bus). The parameters are stored in EEPROM’s and protected against mains failure.

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5 Front Panel description

5.1 FTFU 3024

5.2 FTV 3090

PSU Monitor

PSU Monitor Green if 18V < V < 33

Self check system fault = red

No system fault (Green)

Sensor fault = red

Sensor monitor OK = green

Direction forwards = yellow

Direction backwards = yellow

Limit 1, 2, 3, 4 passed high /low = red

(dep

endent on configuration

)

Limit 1, 2, 3, 4 passed high /low = green

(dep

endent on configuration

)

For factor setting only

Sensor frequency = yellow

Test point ; Reference signal inputTest point ; Refrence signal input

Test point ; scaled trigger level 0V corresponds to 0%, 10V to 100%

Lower sensor monitor current limit 10V corresponds to 30 mA (E01)

Upper sensor monitor current limit 10V corresponds to 30 mA (E01)

Sensor current : 10 V corres

onds to 30 mA (E01

)

Relay 1 active = yelllow

Relay 2 active = yellow

Relay 3 active = yellow

Relay 4 active = yellow

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5.3 FTK 3072

5.4 FTW 3013

PSU 2 monitor Green if 18V < V < 33V

Self check system fault = red

PSU 1 monitor Green if 18V < V < 33

No system fault = green

ctive comms to PC = yellow

Active internal rack bus comms = yellow

Interface to PC

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5.5 FTBU 3034

PSU Monitor

PSU Monitor Green if 18V < V < 33

Self check system fault = red

No system fault (Green)

6 Signal monitoring channels. If red, the corresponding channel is activ e

6 signal monitoring channels. If green, the corresponding channel is not active

Combinated signal monitoring output. Yellow if no signal input active. Off, if the channel combination criteria is reached : channel 1 and channel 2 active or channel 3 and channel 4 active or channel 5 active or channel 6 active

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6 Specifications

6.1 Statistics

Mean Time Between Failure for each channel (without voting) : 188683 hours # 21.5 years Mean Time Between Failure for each OSP channel (FTFU 3024) : 230700 hours # 26,0 years Mean Time Between Failure for each signal monitoring channel (FTBU 3x34) : 1036000 hours # 118 years

PFHg according to IEC 61508-2 : 2.69e-8 fits DC % according to IEC 61508-2 : 94.23%

Life duration for the system is 20 years. During this period the data integrity of the programable devices are garanted, this time is equivalent to the MTBF of the channel. After this period the overspeed protection system must be replaced.

6.2 IEC 61508-2-3 specifications :

• System configuration for the Overspeed Protection System :

The system definition must include for reaching the IEC 61508-2-3 and SIL 3 conformity an alarm signal with following activated selfcontrols for the S + M + P Alarm output :

- System check : Watchdog, Parameter monitoring, soft ware test

- Sensor monitoring : Static and/or dynamic sensor m onitori ng activated

- Power supply check : monitoring of the supply voltage

In addition, for a safe system behaviour in the case of multiple faults, the system S +M + P Alarm must be combined with the overspeed signal. This means that multiple detected system faults generate a trip. Only 3 channel systems can fulfil the IEC 61508-2-3 requirement s.

• System configuration for the optinal additional Trip Chain Control Card.

Only a 3 channel Trip Chain Control System can fulfil the IEC 61508-2-3 requirements for SIL3. The voted or non voted TCCC signals can be combined with OSPS trip signals.

• System installation :

The installation specification must be kept for reaching the IEC 61508-2-3 conformity. These specifications must be realised by the system integrator / end user. See chapter Installation.

• System maintenance :

The maintenance specification must be kept for reaching the IEC 61508-2-3 conformity. These specifications must be realised by the system integrator / the end user. See chapter Maintenance.

6.3 Technical data OSPS

Reference conditions: Operating temperature +20ºC

Supply within defined limits Smallest measuring range: 0...1.000 Hz Largest measuring range: 0...35.00 KHz

Once the machine factor M is defined (M = Freq. In Hz/ measured value eg rpm), the input of measuri ng range and limit values is directly in the chosen physical units eg rpm. In place of the machine factor, the number of pulses per rev from the pole wheel may be entered. Moreover once the nominalspeed is defined (=100%), lim its can be given as a percentage of nominal. The measured range may be continuously exceeded up to 55KHz without affecting functionality or causing any damage to the unit.

Sensor signal inputFrequency input 1

Input card -0X for frequency input 1, plugged onto the motherboard FTFU 3024

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377E-63917 Rev 4.00 page 12 of 47

Input card E-01:

potential free, isolation 500V, 50Hz,1 Min. from electroni cs and earth ie from front panel and card frames.

for connection of electromagnetic, ferrostat or HF sensors, proximity switc hes and sensors with line amplifiers.

Input impedance: 100kohm Input voltage: 50mV...80V rms

Bandwith (-3dB) : 0,5 Hz /3.3 kHz Frequency domain for pulsed signals : 0.02Hz / 30kHz Input level for sinus signals : 50 mv rms at min trigger Input level for pulsed signals : 10Vpp at 20% tri gger level

Trigger level: adjustable between 0 and +3.5V via front panel

trimmer T. The voltage at test point T t o ground of fixed hysteresis of 50mV rms = 141mVss

Integral pull up (+12V) and pull down (0V) resistance of 820 Ohm for connecting 2 wire sensors, jumper selectable.

Sensor monitoring of 2 and 3 wire sensors, jumper selectable -If the supply current i s < I min or > I max a defect is signalled by the green LED ‘MO’ off and the red LED ‘M O’ on. I min is set via front panel trimm er ‘L’ I max is set via front panel trimm er ‘H’ A voltage at test points ‘L’ and ‘H’ to ground of 0...10V corresponds to supply current of

0...30mA. A voltage of 0...10V at test point ‘M’ corresponds to the actual supply current of ...30mA.

To adjust the trimmers the module m ust be plugged ont o an extensi on card to open the seal. Integral sensor supply of +11.5...12.5V, max 25mA, short circuit proof (max 40mA).

Input card E-02: potential free, insulation 500V, 50Hz,1 Mi n. from elect ronics and earth i e from front panel

and card frames. This input card is a special version and is only for specific applications avail able.

Configuration available only by contacting the system suppl ier. Input impedance: 100kohm

Input voltage: 0...-24V Frequency domain for pulsed signals : 0... 30kHz

Input level for pulsed signals : 0.2 ...24Vpp Trigger level: Adjustable between 0 and +3.5V via front panel trimm er T.

The voltage at test point T of 0...10V correspnds to 0...3.5V Trigger Voltage Fixed hysteresis of 50mV rms = 141mVss

Default setting : T = 2V corresponds to 660mV Trigger level

The sensor monitoring is realised by checking the sensor output signal (C ard Uin). Uin (low) must be greater then the defined minimum val ue (absolut val ues). Uin(high) must be smaler then de defined maxim um val ue (absolut val ues). Uin < Uin(min) or Uin > Uin(max) is signaled by t he green LED ‘MO’ off and t he red LED ‘MO’ on. Uin(min) is set via front panel trimm er ‘L’ Uin(max) is set via front panel trimm er ‘H’ A voltage at test points ‘L’ and ‘H’ to ground of 0...10V corresponds signal level of 0...-24V. Default setting of ‘L’ = 1V corresponds to a minimum si gnal le vel of -2.4V. Default setting of ‘H’ = 8.33 V corresponds to a maximum si gnal l evel of – 19.9V. A square wave signal of 0...10Vpp at test point ‘M’ corresponds to the actual sensor signal of

0...-24Vpp. To adjust the trimmers the module m ust be plugged ont o an extensi on card to open the seal.

Integral sensor supply of –24V +/- 4%

Frequency inputs 2 and 3 Motherboard FTFU 3024

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377E-63917 Rev 4.00 page 13 of 47

For average/max values and direction

2 inputs with common reference voltage -

-V of supply

+24 level U low: 0...+3V or open

U high: +10...+33V, I source = max 3mA.

Limit values 1 - 4

Motherboard FTFU 3024 with optional relay card FTV 3090

Up to 4 limits for speed or frequency functions Hysteresis Upper and lower set points are freely programmable for each limit Relay function Monostable function, individually definable as ‘Norm a l’ energized i n when upper set point

exceeded ‘Inverse’ energized in when speed below lower set point Relay outputs 1, 2 and 3 on

FTFU 3024 motherboard

1 potential free change over contact

AC Umax 250V, Imax 5A, Pmax 1250VA

DC Umax 30V, Imax 5A, Pmax 150W

Initial breakdown voltage : 1000Vrms 1min. from neighbouring output, electronics and

earth, ie from front panel and card frames Relay outputs 1 - 4 on

FTV 3090 relay card

1 potential free change over contact

AC Umax 250V, Imax 2A, Pmax 125VA

DC Umax 220V, Imax 2A, Pmax 60W

Initial breakdown voltage : 1000Vrms 1min. from neighbouring output, electronics and

earth, ie from front panel and card frames Accuracy 0.1% of the set point Temperature error max +/- 50ppm with reference to the set point Reaction time of speed

monitor

Reaction time of comporaters

Where the limit is assigned to one of the three speed monitors on the motherboard, the

minimum measuring ti m e is 1 peri od of the correspondi ng set point frequency.

The reaction time of the corresponding relay output is Max 1 peri od of the i nput frequency

+ 9ms.

Where the limit is assigned to one of the 4 comparators on the motherboard, the minimum

measuring time may be set as the Fixed Tim e. Where the period of the input frequency is

shorter than the Fixed Time the relay output reaction time is -

Max twice Fixed Time + max input freq. period + 12ms

Typically = Fixed Time + 1 input period + 12ms

Where the input period is longer than the Fixed Time the reaction time of the relay output is -

Max max input period + 12ms

Analog outputs 1, 2 and 3

Auxiliary module FTW 3013

Each of the 3 analog outputs can be used for speed or frequency functions each having

independent ranges. The outputs are potential free and isolated to 500V, 50Hz, 1 Min. from

each other, the main electronics and earth (neighbouring o/p, front panel and card frame). Standard configuration 0...20mA or 4...20mA,

programmable for rising or falling characteristi c M ax load 500 Ohm (10V) Optional version S3 0...5mA or 1...5mA

programmable for rising or falling characteristi c Ma x load 2000 Ohm (10V) Option U, voltage output 0...10V or 2...10V

programmable for rising or falling characteristi c Ma x load 7 KOhm (1.4m A) Max output voltage 30 V Resolution 12 Bit. 1: 4096 Max linearity error 0.1%

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377E-63917 Rev 4.00 page 14 of 47

Accuracy 0.2% of the range Temperature drift typically +/- 150ppm/ºK, m a x +/- 300ppm / ºK

Reaction time (step change) The minimum measuring time may be entered. Where the input period is shorter than the

Fixed Time, the reaction time is -

Max twice Fixed Time + m ax i nput period + 7.5ms

Typically Fixed Time + 1 input period + 7.5ms

Where the input period is longer than than the Fixed Time, the reaction times is

Max input period + 7.5ms

Each of the analog outputs can be allocated a software defined low pass filter, whose time

constant T can be configured in the range 0.0 to 9.9 seconds. The sample rate is T/10.

Binary inputs 1 - 6

Motherboard FTFU 3024

For programmable control functions such as

- failure memory reset

- max memory reset

- initiate lamp test

- set direction of rotation

- initiate test

2 binary inputs (B1 and B2) having common reference -

-V of the supply 4 potential free binary inputs

(B3...B6) with common floating reference voltage

+ 5 V level with pull up resistor

V low = active 0...+1V, Isink = max 1mA

V high + 3,5...+33V or open

Isolation 500V, 50Hz, 1 Min. from electronics and earth

+24V level

V low 0...+5V or open V high = active +10...+33V Isource = max 4mA

Frequency outputs 1 and 2

Motherboard FTFU 3024 Frequency output 1

having common 0V with supply

Square wave, amplitude +10V, output impedance 100 Ohm

Output current +/-50mA continuous

+/- 100mA for 10% of operating time

Frequency output 2 potential free

Square wave, amplitude +15Vpp, output impedance 100 Ohm

Output current +/-50mA continuous

+/- 100mA for 10% of operating time

Isolation 500V, 50Hz, 1 Min. from electronics and earth

Frequency generator Motherboard FTFU 3024

Frequency range 0.002Hz / 30KHz. Signal only accessible internally = F4

Data I/O

Comms module FTK 3072 Having potential free

floating reference

Serial RS 232 interface via front panel D9 connector

Supply PSU in the rack for all modules excluding supply modules

18...33Vdc

Power consumption Typically Max

Motherboard FTFU 3024/E01 4.5W 5.5W

Converter FTW 3013 2.6W 2.8W

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377E-63917 Rev 4.00 page 15 of 47

Relay card FTV 3090 4.0W 4.2W

Comms module FTK 3072 2.0W 2.5W

Power on surge is limited as follows

Motherboard FTFU 3024/E01 7A

Input cards E01, E02, E03 3.3A

Converter FTW 3013 0.1A

Relay card FTV 3090 0.1A

Comms module FTK 3072 7A

Power Supply

To FTZ 306X

Output 24VDC-2A (1.5A for FTZ3061/62, 4A for FTZ3066)

Isolation 500V, 50Hz, 1min from earth

Isolation 2000V, 50Hz, 1min from input Model FTZ 3061 FTZ 3062 FTZ 3064 FTZ 3065 FTZ 3066 FTZ 3069

Voltage max power consumption surge

115/230Vac, -20, +15% 63VA 10A

24/48Vac, -20, +15% 63VA 50A

14...70Vdc 60W 500A

88...372Vdc 60W 55A

14 … 70Vdc 120W 500A

Mains filter - required if modules

supplied direct with 18...33Vdc 66A

Environment

KUE to DIN 40 040

Operating temp 0...+60ºC, +70ºC for max 2 hours Storage temp -25...+85ºC

rH 75% yearly average, max 90% over 30 days, condensation to be avoided.

Electromagnetic immunity

Conforms to current european standards

Card frames and modules

Mounting to DIN 41494

Material anodised aluminium

Rack space 84 TE - 21 slots each 4 TE

Height 3 HE

Depth approx 220mm

Connectors 2 or 3 row type F to DIN 41612, wire wrap connections as standard to rear

screw terminals.

Optional Termi Point terminals for direct connection. Dimensional drawings Card frames Dwg nr. 3-110.544/4

Modules Dwg nr. 3-110.544/2 Rear screw terminals Sprung terminals for 2.5mm sq. cable or 1.5m m sq. wire Protection class to DIN 40050 Card frames IP 10

Plugged modules IP 20

Terminals IP 20 Block diagram Dwg nr. 4-110.505 Module layout in rack Dwg nr. 4-110.545 Rack terminal layout/wiring Dwg nr. 3-110.536 Module connections Motherboard FTFU 3024 Converter FTW 3013 Relay card FTV 3090 Comms module FTK 3072

Dwg nr. 4-110.531/23

Dwg nr. 4-110.531/24

Dwg nr. 4-110.531/25

Dwg nr. 4-110.531/26

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6.4 Technical data TCCC

TCCC = Trip Chain Control Card, FTBU 3x34

INPUT : IN1 – IN6 6 potential free inputs. Input voltage for IN1- IN6 20 – 50 V, active level is 0V. IN1 – IN6 Sink current Min 10 mA, Max 15 mA Logical channel combination The output OUT is active when the following logical combination occurs :

IN1.IN2 + IN3.IN4 + IN5 + IN6, where Ini means channel i is active (low level).

INPUT : TEST The TEST input simulates the logical combination whic h activates t he OUT output. Thi s

signal is used for performing periodic FTBU testing. Input voltage for TEST 5 – 48V, input active level is high. No test mode is at TEST = 0V TEST Sink current < 15 mA for the whole voltage range.

OUTPUT : K1 – K6 These relays are the output stage associated with each signal channel. The Relay Ki is

energized when INi is high. Relay K1 – K6 Potential free change over contact

AC Umax 250V Imax 5A Pmax 1250 VA DC Umax 30 V Imax 5A Pmax 150 VA

Initial breakdown voltage : 1000Vrms 1min. from neighbouring output, electronics and earth,

ie from front panel and card frames Reaction time INi to Ki < 8 ms

OUTPUT : OUT This relay is the combined output of the 6 signal channels. The Relay OUT is energized when

the logical combination of IN1 – IN6 is not true. Relay OUT 2 potential free change over contacts

AC Umax 250V Imax 2A Pmax 125VA

DC Umax 220V Imax 2A Pmax 60W

Initial breakdown voltage : 1000Vrms 1min. from neighbouring output, electronics and

earth, ie from front panel and card frames Reaction time Ini to OUT < 8 ms

OUTPUT : ALARM The alarm relay is the out put stage of t he on board self-dia gnostic funct ion. The suppl y

voltage and the logical correlation between input levels and output level s are m onit ored. The

relay is energized when the current card status is no-alarm. Relay ALARM Potential free change over contact,

AC Umax 250V Imax 5A Pmax 1250 VA DC Umax 30 V Imax 5A Pmax 150 VA

Initial breakdown voltage : 1000Vrms 1min. from neighbouring output, electronics and earth,

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377E-63917 Rev 4.00 page 17 of 47

ie from front panel and card frames

Power Supply The card FTBU 3x34 can be used with standard FT3000 redundant power supply units. Both

voltages are combined on the card and the supply voltages are monitored. Supply voltage 18 ... 33V Supply current Typ : 160 mA Max 250 mA at 24V Power on surges Limited at 1 A

7 Principle of operation

7.1 Measuring system

The measuring system on the FTU 3024 motherboard processes four frequencies, F1, F2, F3, F4. Input F1 is derived from the amplified sensor signal from the i nput card EOX. Inputs F2 and F3 are deri ved from the outputs of additional FTFU 3024’s present in a 3 channel system. Input F4 i s derived from t he test frequency generator.

7.2 Measuring principle

7.2.1 Standardising the measured value

Following input of the machine factor M = f/n, where f = sensor frequency in Hz for a known speed and

n = machine speed in rpm

or input of the number of pulses per rev (nr. of pole wheel teeth), the frequency relay lim it values and the converter measuring ranges can be directly entered in rpm.

The relationship between the sensor signal frequency f and the speed n of a pole wheel to be sensed is f = n * p/60 where f = sensor frequency in Hz

n = pole wheel speed in rpm p = nr. of pole wheel teeth

For rotational speed measurements the machine factor M = p/60. In place of speed n in the formulae above, any other frequency proportional physical unit may be used. If the limit values and measuring ranges are to be entered in percent of nominal, the above calculations are still required.

7.2.2 Speed monitor

The max 3 speed monitors are based on hardware re-triggerable One Shot circuits that are set with every positive edge of the input frequency. The timebases are derived from 3 down counters that are set wit h the set point frequency and clocked down using a 2.5MHz reference signal. If the counter reaches zero before the arrival of the next positive edge, this indicates that the input frequency is lower than the set point. These functions for one li mi t value are perform ed in an ASIC (Appli ca t i o n Sp ec i f i c IC ) . T he pr es e t val ues for the down counter are com put ed by a m i croprocessor for the required set point and loaded into the ASIC.

The 3 speed monitors continuously collect speed frequency data without interrupt ion. Each speed monitor is supplied with 1 of 5 possible input signal s, defined by software confi guration (None, F1, F2, F3, F4)

7.2.3 Frequency measurement (Period measurement principle)

FT 3000 tachometers work on the continuous period measurement principl e. The measuri ng chains for 3 frequency measurements are implemented i n hardware using ASIC’s. Each of the 3 ASIC’s contai n a counter to m easure the period duration of up to 3 frequencies. The mpu reads the counter’s status with each positive edge of the input frequency. The difference between the status of 2 counters is a measure of the period of the input signal. The frequency

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data is continuously collected from all 3 measuri ng chains wit hout pause. The num ber of periods m easured is determined by the Fixed Time and the magni tude of the input frequency .

The measured value (rotational speed) is then computed by the mpu. There are then 3 floati ng point values available - <AbsolutA>, <AbsolutB> and <AbsolutC>.

Each measuring chain is supplied with 1 of 5 possible input signal s, defined by soft ware configuration (None, F1, F2, F3, F4).

7.2.3.1 Measurement functions

Based on the measured values <AbsolutA>, <AbsolutB> and <AbsolutC>, t he following functi ons can be realised: <FunctionOutput>

• Majority value of A, B and C: From the 3 values 2 are selected that display the smallest difference

and used to generate an average value.

• Max value of A, B and C: The max value is selected from the 3

• Min value of A, B and C: The min value is selected from the 3

• Average of A+B+C

• Average of A+B

• Average of B+C

• Average of C+A

• Difference A-B

• Difference B-C

• Difference C-A

• Ratio A/B

• Acceleration 1 (Accel. 1) :

Accel

= (speed2 – speed1) / (time2 – time1) (RPM/s)

• Acceleration 2 (Accel. 2) :

Accel

= Accel1 / speed1 (RPM/s)

Accel

units could also be %/s, this means that we are speaking here of a rate of change from the nominal

speed. The function is defined by software configuration.

7.2.3.2 Max value memory

The max value memory <MaxMem> registers the m axim um value of a measurem ent (Drag pointer function) The max value memory can only be reset via an intent ional entry ResetMaxMem in the CommandByte or through tot al power failure. Which measured value is stored is defined by the software configuration -

• <AbsolutA>

• <AbsolutB>

• <AbsolutC>

• <FunctionOutput>

Always remember to reset the Max value memory following testing with internal generators. Speed measurement and over speed trip monitors are separate functions wit hin the FT 3000.

In operation, there are 2 main reasons why the recorded Max value may not correspond to t he limit setting:

- the trip point is reached but the machine runs on until the shutdown valve has closed. The maximum speed the machine reached prior to shutdown is therefore recorded.

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- gear machining inaccuracies, coupled with a low number of pulses configured for the trip setting may result in the over speed monitor activating the trip relay at a speed apparently lower than the limit set. The solution to this is to increase the number of pulses used to say 20% of the number of teeth on the gear

7.2.3.3 Comparators

Each of the 4 comparators can be allocated one value from the following list by soft ware configuration -

• <AbsolutA>

• <AbsolutB>

• <AbsolutC>

• <FunctionOutput>

• <MaxMem>

A comparator compares the actual measured value with the predefined set point and establishes limit status (upper/lower limit reached)

7.2.3.4 Analog outputs

Each of the 3 analog outputs from the FTW 3013 can be allocated one measured value via software. The start and end values for each range can be independently defined. Rising and falling characteristics are permissible. Each analog output may include a low pass filter with software configurable time constant.

7.2.4 Acceleration measurement

The acceleration is measured with the speed measurement unit implemented in hardware (FPGA). The m easurement of the speed is made every 10 ms (for speeds greater than 100 RPM). The precision of this measurement is determined by the clock of the „time counter“, which is 2.5 Mhz. Here we consider that this clock has no jitter, what is true due to the integration of the jitter during the measurement

The relative measurement accuracy of the acceleration is defined by :

)/(

)(

*8.0(%)

sRPMonaccelerati

RPMspeed

onaccelerati

For example : Speed = 3000 RPM Acceleration = 1200 RPM (rate of change of 40% per second) The reachable accuracy is +/- 2% for the acceleration.

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FT3000 acceleration measurement error

0.01

0.1

100

0.1 1 10 100

nom inal speed (RPM ) / acceleration (RPM /s)

measurement error (%)

3000 RP M / 1200 RPM /s

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7.2.5 Limit value control

There are 4 limit values available. There are independent upper and lower set points for each so that almost any hysteresis is possible. Limit1, Limit2 and Limit3 m ay be assigned to either speed m onitor 1, speed m onit or 2, speed moni tor 3, comparat or 1, comparator 2 or comparator 3 via software configuration.

Limit4 is permanently assigned to comparator 4. Limit status is displayed on the FTFU 3024 front panel via 4 green and 4 red LED’s. The act ive lim it col our can be defined by software configuration. The operation of the limit can be defined by software configuration t o be normal or inverse. One relay from the FTFU 3024 and the FTV 3090 can be assigned to a limit value. The status of the relay in failure mode (energized, deenergized) can be defined by software configuration (table)

7.2.6 Limit value time control

Time control for the first 3 limit values can be defined by software configuration.

7.3 Monitoring functions

7.3.1 Supply

The FTFU 3024 and the comms module FTK 3072 are supplied with +24Vdc from 2 redundant PSU’s, PS1 and PS2. The 2 supplies are separately fused and diode decoupled. The microprocessor’s A/D converter monitors the supply tolerance after t he fuse. Both front panel green LED’s only light when their corresponding supplies are within tolerance of 18...33V. The internal messages PS1OK and PS2OK are set (=1) in the status byte when the supplies are within tolerance, reset (=0) when not. PSOK is an AND function of PS1OK and PS2OK and is available for relay control. The constituents of t he AND function can be masked by software configuration. When not otherwise specified, relay K1 on the FTFU 3024 signals PSOK.

7.3.2 Monitoring of internal voltages

The voltages before and after the +5V regulator are monitored on the FTFU 3024 and FTK 3072. If out of tolerance a non maskable interrupt is sent to the m pu.

7.3.3 Sensor monitoring

The FTFU 3024 carries out background tests on the correct operation of the sensor.

• Static monitoring is via measurem ent of the sensor’s current consum ption. When the consum ption i s in the

permitted range, StaticMonitorOK is set (=1) in the Status byte, otherwise reset (=0).

• Dynamic 2 out of 3 monitoring determ ines the deviati on between m easured values <AbsolutA>, <Absol utB> and

<AbsolutC> in comparison with a user definable max deviat ion. DynAOK, is set (=1) in the status byte when the deviation of the corresponding measured value is within defined lim its, ot herwise reset (=0).

• Dynamic 3 out of 3 monitoring works like Dynam ic 2 out of 3 m onitori ng when the three m easured values are

above max deviation. When they are under max deviation the 3 m easured values m ust be equal, otherwi se DynAOK, DynBOK and DynCOK will be reset (=0).

• Combination of static and dynamic m onitoring. SensorMonitorOK in the status byte is an AND function of

StaticMonitorOK and DynAOK and is available for relay control. The constituents of SensorMonitorOK can be

masked by software. When not otherwise defined, relay K2 on the FTFU 3024 is used to signal sensor moni toring. In the event of a fault (SensorMonitorOK = 0) the front panel green MO-LED goes out and the red NMO-LED lights

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7.3.4 System monitoring

The FTFU 3024 and FTK 3072 run background self tests on the most important CPU and EEPROM functions.

SelftestOK is set (=1) when no fault exists, otherwise reset (=0). SystemOK in the status byte is an AND function of SelftestOK, SensorMonitorOK and PSOK. The constituents of

SystemOK can be masked by software configuration. In the event of a fault (SystemOK = 0), the front panel green OK-

LED goes out and NOK-LED lights. During tests of an othwerwise fault free measuring chain, the green OK-LED blinks. All relay and analog output behaviour in the event of a system faul t is described i n paragraph 7.4.4.

7.3.5 Module OK message

ModulOK in the status byte is an AND function of SelfTestOK, SensorMonitorOK ans PSOK and is available for relay control. The constituents can be masked by software.

7.3.6 Fault condition

CmdOnFailure in the status byte is an AND function of SelfTestOK, PS1OK, PS2OK, PS1OK-OR-PS2OK and SensorMonitorOK. The constituents can be masked by software configuration. In the event of a fault (CmdFailure = 0), the limit values assume the condition defined in the parameter table for limit value control (influence on LED’s and relay control)

7.4 Direction of rotation discriminator

To establish direction of rotation, 2 or 3 suitable speed sensors can be positioned around a pole wheel such that their output signals are electrically phase shifted by 90 or 120 degrees. The sequence of signals then changes with pol e wheel direction.

An analysis of the signal phase relationships allows the direction to be determ ined. The required l ogic is on the FTFU 3024 in the ASIC’s. The direction is displayed on the front panel yellow LED’s FW (ForWard) and BW (BackWard). BW and FW in the status byte are available for relay control.

When 2 signals are present (S1 and S2 or S2 and S3 or S3 and S1), forward operation (FW on) is defined as S1 leading S2 or S2 leading S3 or S3 leading S1.

When 3 signals are present (S1, S2 and S3), forward operation (FW on) is defined as S1 leading S2 and S2 leading S3 and S3 leading S1.

The use of 3 sensors instead of 2 provides greater security against sensor failure since the internal logic provides correct discrimination even if one sensor fails.

The required direction display for a given phase relationship can be defined in the configuration. Direction can also be signalled via a relay.

Setting forward operation is via the corresponding binary input configured. Forward operation is then assum ed and the relay adopts the corresponding status.

The direction display following power up can be defined by software.

7.5 Relay control

Each of the 3 relays on the FTFU 3024 and 4 on the FTV 3090 can be assigned to one function from the following l ist. The selection is defined by software:

• Limit value

• ModulOK

• PSOK

• SensorMonitorOK

• FW

• BW

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• TestO

• PS1OK

• PS2OK

• Limit 1

• Limit 2

• CmdOnFailure

• FW Inverse

• BW Inverse)

• ON

• OFF

• Limit3

• Limit4

7.6 Test frequency generator

ASIC 3 (measurement channel C) on the FTFTU 3024 includes a frequency generator for test purposes, having 2 selectable frequencies. The output signal from the generator is taken to input F4 and can be routed to inputs F1, F2 or F3 on the speed monitor. The 2 frequencies are automatically derived from the predetermined parameters upper test value and lower test value (eg in rpm).

7.7 Test

Each of the 3 speed monitors can be allocated 2 configurable parameters, upper test value and lower test value.2 internal commands in the CommandByte, SpeedMonitorInputASelect and SpeedMonitorInputBSelect enable selection of one of the 3 speed monitors as follows:

SpeedMonitorInputBSelect SpeedMonitorInputASelect Selected monitor

inactive inactive None - no test inactive active Speed monitor 1 active inactive Speed monitor 2 active active Speed monitor 3

When UnderOverSelect in the CommandByte is set active (=1), the upper test value is selected, when reset inactive (=0), the lower. The command TestOn in the CommandByte then switches the test frequency to the chosen speed monitor.

With TestOn set active (=1) the test starts, with TestOn reset inactive (=0) testing is terminated. During testing the green LED OK flashes at 1Hz and TestOn is set active (=1) in the StatusByte and is available for

relay control. Testing is only possible if there is no system fault, a speed monitor has been selected and TestOn is set active. The status of internal commands SpeedMonitorInputASelect, SpeedMonitorInputBSelect, UnderOverSelect and TestOn

can be changed via configured binary inputs or FT 3000 PC commands.

7.8 Frequency outputs

3 frequency outputs are available. Frequency output 1 having common reference voltage wit h -V on the supply.

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Frequency output 2 having potential free, floating reference. Frequency output 3 controls the yellow front panel LED S. Every frequency output is programmable with one of 5 possibl e input signal s (None, F1, F2, F3, F4).

7.9 Lamp test

The lamp test switches on all FTFU 3024 and any FTV 3090 LED’s present. No relay status i s changed. Relays remain under the sole control of the m onitoring m odule. Lamp testing is active when LampTest is set active (=1) in the CommandByte.

7.10 Message acknowledgement

Whether the internal messages PS1OK, PS2OK, SensorMonitorOK and ModulOK must be acknowledged or not can be defined by software. Acknowledgement is via setting (=1) and resetting (=0) of ResetLatch in the CommandByte.

7.11 Binary inputs

Each of the 6 binary inputs can be allocated to one of the following functions:

• without None

• Reset messages via active hold function ResetLatch

• Reset max value memory ResetMaxMem

• Lamp test LampTest

• Set direction DirectionSet

• Select speed monitor to test SpeedMonitorASelect

• Select speed monitor to test SpeedMonitorBSelect

• Select 1 of 2 test frequencies UnderOverSelect

• Initiate test TestOn

An inactive binary input resets (=0) the allocated internal comm and. An active binary input sets (=1) the allocated command.

7.12 Parameter entry

The input of process and configuration parameters would normally be m ade by the m anufacturer or OEM per the order. Process and configuration parameters are configurable via PC software using the RS 232 interface and the FTK 3072 comms module (see section 7).

Where a micro terminal is installed, process parameters may be entered via this. Service parameters are reserved for the manufacturer. All parameters are stored in EEPROM and not lost if power fails.

7.13 Signal Monitoring

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The FTBU card is designed to combine different trip commands to provide global shutdown control within the IEC 61508 SIL 3 regime. The overspeed functionality of the FT3000 is SIL 3 certified. The FTBU extends this certification to encompass trip signals from other sources such as temperature, pressure etc alarms.

6 potential free change-over relay contacts (K1-6) are created from 6 opto-coupled inputs (IN1-6). The relationship between INi and Ki is 1:1. An additional output (OUT) comprises of two relays that each provide a change-over contact. These contacts allow 2 out of 3 voting in a three FTBU 3x34 card system. The OUT output is driven by a logical combination of the six inputs : OUT is active (deenergized) when the fol owing equation is t rue :

IN1.IN2 + IN3.IN4 + IN5 + IN6 where INi means an active input (low level). This function allows the FTBU card to provide optimum com bination of com m ands in t he trip chain and sim plify

system wiring. The card has an on board self-diagnostic unit, which drives the ALARM output. The power supply and the logical

correlation between the 6 inputs and the relay outputs are monitored. Spare contacts from the OUT relays are used for this purpose.

To periodically check the availability of the trip chain function a test input allows simulation of the OUT relays. The relay function must then checked by the user.

Eingang 1

I=6mA

10< I <13mA

I=6mA

10< I <13mA

I=6mA

10< I <13mA

I=6mA

10< I <13mA

I=6mA

10< I <13mA

I=6mA

10< I <13mA

Relais

Stand Eingang 1

Stand Eingang 2

Stand Eingang 4

Stand Eingang 5

Stand Eingang 6

Stand Eingang 3

Relais

ALARM

GLOBAL RELAIS

PS1 PS2 PS1 Negativ PS2 Negativ ERDE

18V<PS1<33V

18V<PS2<33V

Regler 24V/5V 1A

PS2 =1

"0" bei Relais im Ruhe zustand oder defekt

G R

LOGIK

FTBU3X34 Funktionsdiagramm

Strom verbrauch: c.a. 0.8 A / 5V --> Leistung au f 24V S eit e = 0.8 X 5 / 0.8 = c.a. 5W

PS1 =1

Eingang 2

Eingang 3

Eingang 4

Eingang 5

Eingang 6

Relais TEST

AND

Diagnostik Logik

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8 Installation

8.1 General

The equipment conforms to protection class 1 and requires the connecti on of protective earth. This must be connected to the designated terminal before any other connecti ons are made. The earth wire cross section must be at least the same size as the power cables.

NB: Any interruption of the earth connection outside or inside of the equipment affects the safety and noise im muni ty and may endanger personnel and/or equipment. Intentional disconnecti on of the earth connection i s forbidden.

The wired rack may only be used in a fixed installation. The m ains supply m ust be equipped wi th a suitabl e switch. Before switching the equipment on, verify that the PSU’s m atch t he mai ns supply provided. To ensure noise immunity, the sensor screens must be connected to the te rmi nals provided. To avoid external interference when switching loads, suitable suppression should be used. 19" rack connection diagram: Dwg nr. 3-110.536/... NB: There are capacitors charged to the supply voltage on the PSU’s.

8.2 IEC 61508-2-3 Specific Installation rules

The Ft3000 rack system must be installed in a key closed cabinet. Onl y trai ned people (service/ instal lat ion people) have allowed acces to the rack.

The signal cables and power supply cables must be installed separately on separate d paths.

No ventilator required for the system.

Avoiding common mode failures : No rack displacement during the working of the rack.

The integrator must preconfigure the process parameters for each channel before running the main process. This configuration check can be done by driving the overpeed proctection system without runni ng the m ain process.

The integrated overspeed protection system must be pre-tested before running the main process (See maintenance specification for this test : periodic test).

There is no specific specifications for the starting procedure of the main process. Theses procedures depends on the OSPS / Main process integration and is full dependent of the integrator philosophy. However the OSPS system must be started and ran when the equipment under controll is started.

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9 Setting parameters and operation

9.1 Software concept

The input of various parameters is covered in section 5.11 and is via a user friendl y operating sy stem . Various windows permit the selection of functions and parameters usi ng prepared menus.

9.1.1 Process parameter list

Using the PC software (Art. No.: 377A-72710) and the RS 232 interface on the FTK 3072 the following parameters can be configured.

Parameters and their values activated upon delivery are shown bold.

• Parameter input Absolute / percent

• Min measuring time 0.01 ... 1.00s

• Number of measurements 1 .. 4

• Machine factor input Machine factor / pulses per rev

• Machine factor 1...4 -9.9999 E+/-12 ... 1.0000 ... +9.9999 E+/-12

• Pulses per rev 1...4 1 ... 60 ... 65535

• Nominal speed 1...4 -9.9999 E+/-12 ... 1000.0 ... +9.9999 E+/-12

• Units 1...4 None / U/min / rpm / T/min

• Message acknowledgement Without / with acknowledgement

• Process name ( 8 characters )

• Lower set point 1...4 (Limit X low) -9.9999 E+/-12 ... 1.0000 ... +9.9999 E+/-12

• Upper set point 1...4 (Limit X high) -9.9999 E+/-12 ... 1.0000 ... +9.9999 E+/-12

• Analog output range 1...3 0/4...20mA

0/1...5mA 0/2...10V

• Measuring range start value -9.9999 E+/-12 ... 1.0000 ... +9.9999 E+/-12

• Measuring range end value -9.9999 E+/-12 ... 1000.0 ... +9.9999 E+/-12

• Sensor monitor (permissible deviation for -9.9999 E+/-12 ... 50.000 ... +9.9999 E+/-12

dynamic monitoring)

• Lower test value 1...3 -9.9999 E+/-12 ... 550.00 ... +9.9999 E+/-12

• Upper test value 1...3 -9.9999 E+/-12 ... 750.00 ... +9.9999 E+/-12

• Parameter enable - OEM H0, H1, H2, H3, H4, H5, H6, H7

•

Parameter enable - End user H0, H1, H2, H3, H4, H5, H6, H7

• Parameter enable - micro terminal H0, H1, H2, H3, H4, H5, H6, H7

• Password - manufacturer ******

• Password - OEM ******

• Password - End user ****

9.1.2 Configuration parameter list

The following configuration parameters are configurable via PC. (If a micro terminal is installed it can not be used to configurate these parameters.).

Parameters and their values activated upon delivery are shown bold.

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• Machine factor Global

• Input card E01 / E02 / E03

• Optional converter Without / with

• Converter type FTW 3013

• Relay card Without / with

• Relay card type FTV 3090

• Microterminal Without / with

• Configuration name ( 8 characters)

• Permissible module addresses 0 ... 15

• System monitoring (LED’s) System, PS1, PS2, PS1 OR PS2, Sensor Monitor 1

Sensor Monitor 2, Sensor Monitor 1 OR 2

• Module OK signalling (influence on relays) System, PS1, PS2, PS1 OR PS2, Sensor Monitor 1

Sensor Monitor 2, Sensor Monitor 1 OR 2

• Power supply monitoring PS1 , PS2

• Sensor monitoring Static, dynamic, majority, m ax value

• Analog output control 1...3 None, AbsolutA, AbsolutB, AbsolutC

FunctionABC, MaxMem

• Analog output 1...3 20mA/5mA/10V

• Time constant on analog o/p 0.0 ... 9.9s

• If analog output 1 ... 3 deviation Not off/off

• Limit control 1 ... 3 None/speed monitor/comparator

• Speed monitor limit control 1 ... 3 None/F1/F2/F3/F4

• Comparator limit control 1 ... 4 None/AbsolutA/AbsolutB/AbsolutC

FunctionABC/MaxMem

• Limit mode 1 ... 4 Normal/inverse

• Limit value table Table0/table1

When Table 0 and fault case, the limit state corresponds to limit set poi nt overgone

When Table 1 and fault case, the limit state corresponds to limit set point undergone

• Limit value 1 ... 4 LED’s Normal/inverse

• Time control - Limits 1 ... 4 Used/not used

• Function - limits 1 ... 4 One shot/flip-flop

• Time - limits 1 ... 4 10s

• Edge - limits 1 ... 4 Positive/negative

• Control - relay 1 (Motherboard) Limit1 / Limit 2 / Limit 3 / Limit 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - relay 2 (Motherboard) Limit1 / Limit 2 / Limit 3 / Limit 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - relay 3 (Motherboard) Limit1 / Limit 2 / Limit 3 / Limit 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - relay 1 (Relay card) Lim it1 / Limit 2 / Limit 3 / Lim it 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - relay 2 (Relay card) Lim it1 / Limit 2 / Limit 3 / Lim it 4 / Ok / PS / Mo / FW /

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BW / TestOn / PS1 / PS2

• Control - relay 3 (Relay card) Lim it1 / Limit 2 / Limit 3 / Lim it 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - relay 4 (Relay card) Lim it1 / Limit 2 / Limit 3 / Lim it 4 / Ok / PS / Mo / FW /

BW / TestOn / PS1 / PS2

• Control - binary inputs 1 ... 6 None/ResetLatch/ResetMax/LampTest/DirectionSet/

SpeedMonitorInputA_Select/SpeedMonitorInputB_Select/ UnderOver_Select, TestOn

• Input - frequency measurement A none/F1/F2/F3/F4

• Input - frequency measurement B none/F1/F2/F3/F4

• Input - frequency measurement C none/F1/F2/F3/F4

• Function output None/MajorVoteABC/MaxABC/MinABC/SigmaABC/

SigmaAB/SigmaBC/SigmaAC/DeltaAB/DeltaBC/ DeltaCA, Accel. 1,Accel. 2

• Max value memory None/AbsolutA/AbsolutB/AbsolutC/FunctionABC

• Frequency output 1 ... 3 None/F1/F2/F3/F4

• Standard direction None/FW/BW

• OnCmdSetDirection None/FW/BW

• OnPowerSetDirection None/FW/BW

9.1.3 Service parameter list

The detailed list of service parameters is available from JAQUET on request. Use of the service parameters is however reserved by the manufacturer and of no significance to end users.

9.2 PC communications

The FTK 3072 equipped with a RS 232 interface is required for communications between a PC and the various modules.

9.2.1 PC system requirements

386DX, 486DX or higher, equipped with Microsoft® WindowsÔ 3.11 or higher, with serial interface COM1 or COM2 available and not running any application programs other than the FT 3000. The PC to FT 3000 interface cable must be a screened D9 male to D9 female, connected 1:1. (See 9.4.2)

9.2.2 PC software installation

The FT 3000 software is supplied on 3.5" disk and is to be found under FT3000.EXE. The file FT3000.EXE must be copied to a suitable directory using File Manager, eg C:\FT3000. Using Drag and Drop it can then be installed in the Program Manager.

If another application is using the serial interface, the FT3000 program will display an error message when started. The interface would then be set as ‘none’.

Note: The first time the FT3000 program is used, the interface is set to ‘none’ and must be set up using the menu Settings and the command Interface.

Important: With operating system Windows 3.11, the Windows System File SYSTEM.INI under the (386Enh) section must be extended as follows:

COM1Buffer=8192 or COM2Buffer=8192 COM1FIFO=ON (

) COM2FIFO=ON

COMBoostTime=30 COMBoostTime=30

(

) With operating system Windows 95 or later, the FIFO of the serial interface has to be disabled.

The application will then be ready after Windows has been rebooted.

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9.2.3 Optimisation

Various settings can be made in the initialisation file FT3000.INI that is saved in the Windows directory for the FT3000 application the first time the program is exited. The following settings are made from the FT3000 application menu - ‘Settings’ and should not be altered with a text editor:

(Settings) CommPort=1 1 = COM1 CommDirControl=0 0 = DTR control line CommTimeOutEcho=20 Time out in ms if the PC does not receive an echo (irrespective of

data amount)

CommTimeOutEchoCharacter=5 Additional time out per character in ms if the PC does not receive an CommTimeOutResponse=200 Time out in ms if the PC does not receive an answer from the FT3000 CommTimeOut=50 Additional time out per character in ms if the PC does not receive an

answer from the FT3000 (dependent on data amount)

CommDelayTimeCommand=10 Minimum time in ms that the PC allows from receipt of one response

to sending a new command to the FT3000

DisplayInterval=2500 PC display interval for measured data Note: By reducing the times shown in bold the data transfer may be speeded up. However, t his increases the risk of a

data crash, especially when using an older or slower PC, since the FT3000 requires a minim um tim e to respond to PC commands.

9.2.4 Setting the display interval

The display interval of measured data and additional messages on t he PC can be set in the range

0.25 ... 10seconds. This cannot however be guaranteed due to the way Windows handles multi tasking.

9.2.5 Protection of configuration parameters

As standard, the configuration parameters are protected from being changed via PC password. An OEM password level is provided for changing parameters as defined in 9.3.6 and 9.3.7. The OEM should be aware that changing parameters can alter the whole FT3000 system that would i n principle correpond to changing the wiring.

9.2.6 Protection of process parameters

As standard, the process parameters are protected from being changed via PC password. A user password level is provided for changing parameters as defined in 9.3.6 and 9.3.7.

9.2.7 Reading and writing parameters

Reading or writing of parameters occurs after confirmati on in the dialogue box <C onfirm parame ter read/writ e>. When reading parameters, the configuration and process parameters per m odule shoul d always be read toget her.

If the configuration and process parameters are read into a new file, then the construction of the FT3000 m ust be defined. All FT3000 modules can then be automatically i nterrogated.

9.2.8 Parameter printout

FTFU 3024 configuration and process parameters are separately printed out for one m odule at a t im e. The module selected is shown in the PC window top left. Selection is vi a <- and -> scroll keys.

9.2.9 Display of current measured data

The display of current measured data is for one module at a tim e. M odule selection i s via <- and -> scroll key s.

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9.3 Setting parameters

Parameter configuration is via the FTK 3072 comms module, a RS 232 PC interface and the FT3000 application program.

Within the aforementioned range the parameters can be changed either ON-LINE (via comms module FTK 3072 and RS-232 PC interface) or OFF-LINE by selection of the corresponding menu and change of the desirred parameters.

OFF-LINE (without connected FT 3000-system):

1. With the FT 3000 command: < configuration: module on the unit .... > the modules inst alled m ust be

identified by means of activating the corresponding bush button on t he configuration di alogue <module on the unit> and confirming this with <OK>.

2. Only after step No.: 1 the dialogues for the configuration- and process-parameters can be called.

3. To change a parameter a password must be used (see 9.3.6 and 9.3.7) Attention: Each parameter change only becomes effective after the PC command FT3000 - write parameters is given

and the FT3000 has stored the new parameters.

There are 7 process parameter functions: <System settings>, <Sensor m onitor>, <Anal og outputs>, <Limit values>, <Test values>, <Parameter enable> and <Password>.

9.3.1 System settings

9.3.1.1 Parameter input

The parameters for <Sensor monitor>, <Analog outputs>, <Limit values> and <Test values> can be entered as absolute or percentage values of nominal speed.

9.3.1.2 Nominal speed

The nominal speed must be specified if parameters are inputed as percentage val ues. Please note the following if the nominal speed is changed:

• If parameter input is in absolute values, a change to the nominal speed will not result in recalculation of the absolute

values - Speed deviation, Analog measuring range, Limit set points, Test values.

• If parameter input is in percentage values, a change to the nominal speed will result in recalculation of the absolute

values - Speed deviation, Analog measuring range, Limit set points, Test values.

Whether recalculation takes place is based on the setting Absolute or % in the application program.

9.3.1.3 Units

When entering parameters in absolute values, a unit may be specified eg rpm.

9.3.1.4 Machine factor

The machine factor M = f/n where

• f Hz = sensor signal for a given speed

• n rpm = machine speed

In place of the machine factor, the number of pulses per rev (= nr. of poles on the gear wheel) can be entered. The machine factor is then automatically calculated as M = ppr/60.

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9.3.1.5 Measurement ( Min measuring time and number of measurements)

The min. measuring time determines the minim um period during which t he input frequency i s measured. The effective measurement time is terminated upon completion of the mi n measur ing tim e by the next positive edge of the input frequency.

A long min measuring time can be used to average out variances of the input frequency but it increases the output reaction time to step changes in speed.

The min measuring time can be set in increments of 10ms from 0.01 to 1.00 seconds. To suppress variances showing up in the measured data, 1 to 4 measurements can be averaged without the need to

increase the measuring time.

9.3.1.6 Message acknowledgement

‘With acknowledgement’, messages are stored until reset eg via configured binary inputs or PC command. Or ‘Without acknowledgement’, messages are not stored.

9.3.1.7 Process name

The process name (max 8 characters) serves to identify the application of indivi dual plug in m odules.

9.3.2 Sensor monitor

With 3 channel 2 out of 3 monitoring, the max permissibl e speed difference between 2 channels m ust be specifi ed.

9.3.3 Analog outputs

The following parameters can be independently set for each of the 3 analog outputs.

9.3.3.1 Measuring range start value

The value entered tells the FTW 3013 what frequency corresponds to, for example 0mA.

9.3.3.2 Measuring range end value

The value entered tells the FTW 3013 what frequency corresponds to, for example 20mA. For a falling characteristic the end frequency value must be smaller than the start value.

9.3.3.3 Output range

In standard FTW 3013 units this is set to normal (0...20mA or 0...5mA or 0...10V). Output range with zero suppression corresponds to 4...20mA or 1...5mA or 2...10V.

9.3.4 Limit values

The following parameters can be independently set for each of the 4 limit values.

9.3.4.1 Set point

The limit value can be defined with an upper and lower set point. If in the configuration <Limit value control> was defined as normal, exceeding the upper set point activates the lim it. It

then becomes inactive when the speed drops below the lower set point. If in the configuration <Limit value control> was defined as inverse, then when the speed drops below the lower set

point it is active. It then becomes inactive when the speed exceeds the upper set point.

9.3.4.2 Pulses

If during configuration <Limit value control> was specified as SpeedMonitor, t he number of pul ses to be used for the measurement must be defined.

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If during configuration <Limit value control> was specified as Comparat or, this entry is not required. Limit 4 is always defined as Comparator.

The FT 3000 Windows software will allow a minimum pulse value to be set, which is appropriate to the limit setting. In the event that trips occur at speeds apparently below the limits selected, then this may be the result of gear machining inaccuracies. The solution to this is to increase the number of pulses used to say 20% of the number of teeth on the gear.

9.3.5 Test values

If during configuration <Limit value control> was specified as SpeedMonitor, upper and lower test values are available for each limit. Internally generated square wave signals corresponding to the speed set points are fed to the respective speed monitor input during testing in place of the input signal. This is controlled by suitably configured binary inputs or via PC commands.

9.3.6 Parameter enable

The individual configuration and process parameters have the followi ng fixed hierarchy: H0 - Process 0 Absolute / %, ProcessName H1 - Process 1 Limit_Hi gh, Lim it_Low, SpeedMoni tor_Pulses, Analog_Full , Analog_Zero, H2 - Process 2 MachineFactor, NominalSpeed, PulsesPerRev, FixTim e, Num berOfMeasurement H3 - Config 0 LimitMode, LED-Mode, ConfigNam e H4 - Config 1 All configuration parameters excl. H3 - Confi g 0 and H5 - Config 2 H5 - Config 2 ModuleInstallationByt e H6 - Service ServiceParameter, Calibration H7 - Commands FT3000 commands (ReseM axMem , Lam pTest etc) The individual hierarchy levels can be enabled or disabled for the OEM and End User. To change the parameter enable for the End User, the OEM’s password is required. To change the parameter enable for the OEM, the manufacturer’ password is required. With the manufacturer’s

password, the End User parameter enable can also be changed. The password must be entered each time a parameter is changed, whereby OEM’s and End Users can only change

parameters that their passwords allow. If the password is accepted, then changes are allowed up until the configuration file is saved or the parameters are

written to the FT3000 module. For any further changes the password has to be re-entered. If the password is rejected, then no changes are possible.

9.3.7 Password

Following entry of a valid password, a new password may be defined. The OEM can change the End User’s password but not vice versa.

The successful password change must be written to all installed FT3000 compact modules using Write FT3000 Parameters and to the FTC file in the PC. Permissible password characters are A...Z, 0...9 and the characters - and _. Lower case letters are automatically interpreted as upper case.

Max password length is 6 characters. Note: Within one installation, all process parameters, with the exception of the password, are module specific;ie. they

may vary from one compact module to anot her. The passwords must however be t he same.

9.4 Operating behaviour

9.4.1 Power up

Analog outputs: After connecting the supply and until the first measurement, the output corresponds to the analog start value configured.

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Relay output: After connecting the supply the relays are initially inactive and then assume the state defined under <Limit value control>

The first positive edge of the signal input starts the first frequency measurement

• Upon completion of the first measurement relay s assigned to li mi t control assum e the stat e corresponding to the

measurement.

• If Comparator is configured and no input frequency exists, relays assi gned to lim it control assume t he state defined

as - speed below lower set point after 20 s.

• If Speed Monitor is configured and no input frequency exists, relays assigned to li mi t control assum e the stat e

defined as - speed below lower set point after a measurement tim e corresponding to Lim it x High.

9.4.2 Measurements

• A measurement starts with the positive edge of the input frequency. Following the Fixed Time, the next positive

edge terminates the measurement and starts another.

• The total resulting measurement time has a resolution of +/- 0.4μs.

• The calculation and control of the outputs occurs during the next imm ediate m easurem ent.

• The transfer to the PC and display of measurement values and status occurs within the display interval configured.

• If the analog ranges are exceeded, the output goes to the end values configured.

9.4.3 Response to sensor failure

• Should the input frequency suddenly and totally fail, the m easured value and analog out put follows an exponent ial

step function towards the start value as soon as the period of the new measurement is 2, 4, 8 ti mes l arger than the period of the last measurement.

• Should the input frequency suddenly and totally fail, m easured values below the lower set poi nts register speed

below lower limit.

• If the sensor’s current consumption exceeds the predifined limits the message ‘StaticMonitorFlag1' is set to 0.

9.4.4 Behaviour during system alarm

• If the module is in Config Mode (red NOK-LED on and green OK-LED flashing at 1Hz) or in Service Mode

(red NOK-LED on and green OK-LED flashing at 0.5Hz) the analog outputs go to 0mA (0V) and the relays are deenergised. All LED’s - BW, FW, LIMIT 1...4 are off.

• If the module is in Process Mode and Alarm Condition (red NOK-LED on and green OK-LED off), the analog

outputs go to 0mA (0V) and the relays assume the status corresponding to t he lim it value cont rol configurati on. The LED’s LIMIT 1...4 also assume the status defined under Limit value control.

• If the module enters Process Mode from Config Mode or Service Mode and an alarm conditi on occurs, the analog

outputs go to 0mA and the relays de-energise. All LED’s - BW, FW and LIMIT 1...4 are off.

9.4.5 Response to mains failure

• If the mains fails for longer than the permitted time, the analog outputs go to 0mA and the relays de-energise.

When the supply returns the unit goes through the power up routine (see 7.4.1)

• Should the internally stabilised supply drop below the minimum specified voltage, then this is detetected as mains

failure.

9.5 Frequency measurement calibration

The modules are calibrated at the factory and the data stored in EEPROM. There are no manual adjustments on the FTW 3013 converters for output current range. Eventual faults m ust be

corrected at the factory. There are no manual adjustments on the FTFU 3024 monitoring m odules. Eventual faul ts m ust be corrected at t he

factory.

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9.5.1 Calibration tools

• Frequency sources: Accurate frequency generator or generator with digital tachometer having accuracy better than 0.05% of the frequency

setting. Where a lower demand on the accuracy exists, calibration can take place on the machine. The sensors then act as the frequency source and would be measured by a digital tachometer. The machine factor M must be taken into account, ie. the relationship between frequency and machine speed.

• Measurement of output current/voltage: Precision instrument with an accuracy better than 0.05% or the integral meter. Errors in the integral meter are then

automatically calibrated out and the accuracy of the total system depends upon the accuracy of the frequency source.

9.5.2 Factors influencing accuracy

• Quartz crystal: Temp. Drift +/-10ppm over the total tem p. Range

Long term drift +/- 5ppm/year Failure rate < 15 fit

• Reference source: Temp. Drift +/-50ppm/ Deg. K

Long term drift typically +/- 1ppm/1000hrs Failure rate < 4.5 fit

• Precision resistors Temp. Drift +/-50ppm/Deg. K

Long term drift <+ 500ppm/year Failure rate < 0.7 fit

• Trimmers Temp. Drift +/-100ppm/Deg. K

Long term drift <+ 500ppm/year Failure rate < 100 fit

9.5.3 Calibration rules

During calibration the previously frequency sources and measuring instrum ents m ust be used. Measurements should be compared with calibration values and any variances noted.

• Calibration of the analog outputs:

Input frequency corresponding to configured start value: Actual value = start value

Analog output value = 0.00% (display only with FTW 3013)

Input frequency < ‘Min displayed measured value’ configured = display of 0000. FTW 3013 analog output corresponds to configured start value. Input frequency corresponding to configured end value:

Actual value = end value Analog output value = 100.00% (display only with FTW 3013)

FTW 3013 analog output corresponds to configured end value.

Input frequency in the middle of configured start and end values: Actual value = mid value Analog output value = 50.00% (display only with FTW 3013)

FTW 3013 analog output corresponds to mid value.

Display or output variances can, within limits, be adjusted at a suitably equipped work stati on.

• Set point calibration:

Operating status - on.

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When the frequency is raised past the upper set points, the relays configured ‘normal’ energise and those configured ‘inverse’ de-energise.

When the frequency drops back down to the lower set points, the relays configured ‘normal’ de-energise and those configured ‘inverse’ energise.

Limit value/relay status display: active - when energised

Inactive - when de-energised.

Inaccurate set points can only be adjusted at the factory.

9.6 Calibrating the sensor monitor

• Measurement of sensor current limit values:

Multimeter with an accuracy better than 0.1%

• Load resistor - 470 Ohm, 0.5W

• Variable resistor - 1 KOhm, 100mA, 0.5W

The 470 Ohm resistor is connected in series with the 1 KOhm to form a supply load l im ited to 25m A m ax.

• Variable resistor - 50 KOhm, 15mA, 0.5W

The 1 KOhm resistor is connected in series with the 50 KOhm to form a supply load l im ited to 12m A m ax.

9.6.1 Factors influencing accuracy

• Reference sources: Temp. Drift +/-10% over the total temp. Range

Long term drift < +/- 12mV/1000hrs Failure rate < 200 fit

Precision resistors: Temp. Drift +/-50ppm/Deg. K

Long term drift < + 500ppm/year Failure rate < 0.7 fit

9.6.2 Calibration rules

• Measurements should be compared with calibration values and any variances noted.

easure the sensor supply with no load and loaded to 25mA. If the supply is outside of tolerance this can only be adjusted at the factory. With a load exceeding 25mA the supply will dip.

• Measure the sensor supply current with various loads:

If the current falls outside of the Imax and Imin values configured, the sensor monit or led MO red goes on. At Imin + 0.4mA or Imax - 0.4mA the sensor m onitor is i nactive. Errors to the set points can only be adjusted at the factory.

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10 Mechanical construction

See also sections 3 and 4. Up to 21 19" rack modules of 4 unit width can be installed in one rack. Every m odule is fixed i nto the rack using sli des

and retained screws. The screws provide an earth connection to the module’s front panel. Every module consists of an electronic card fixed to the front panel along with event ual additional component s.

Electrical connections are via card connectors in accordance with DIN 41612. Auxiliary cards such as the FTW 3013 converter and FTV 3090 relay card are plugged onto the FTFU 3024

motherboard, with connections via the internal local bus. These cards can therefore only be plugged in or rem oved together despite having separate front panels.

The arrangement of auxiliary modules is such that the motherboard is always far left and any relay card is far right. A converter card would sit in between. The input card is also plugged onto the motherboard but without a front panel.

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11 Circuit description

Jaquet FT 3000 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual