Rockwell Automation T6200 User Manual
x
T6200
Ics triple
User’s Guide
__________________________________________________________________________ ___________________________
T6200
Compressor Anti-Surge and Capacity Controller
Issue 1
May 2004
Copyright 2004 ICS Triplex
Contents of this manual may not be reproduced
in any form without the written permission of ICS Triplex.
Printed in the United States of America.
Specifications are subject to change without notice.
A/S VIEW MOPS, and T6200
are trademarks of ICS Triplex,
Information furnished by ICS TRIPLEX is believed to be
accurate and reliable. However, no responsibility
is assumed by ICS TRIPLEX for its use.
T6200
USER’S GUIDE
ICS Triplex p/n 9001-0220
Issued May 2004
ICS Triplex, Inc.
4325 West Sam Houston Pkwy. North
Suite 100
Houston, Texas 77043-1219 USA
Phone: 713-353-2400 Fax: 713-353-2401
www.icstriplextmc.com
T6200
User’s Guide
TABLE OF CONTENTS
SECTION 1 – PRODUCT OVERVIEW
Design Structure.............................................................. ................................................................................1-3
Analog and Discrete Input/Output.................................. ................................................................................1-4
Line Power and Transmitter Power................................ ................................................................................1-5
System Security .............................................................. ................................................................................1-5
On Line Diagnostics........................................................ ................................................................................1-6
Configuration Security..................................................... ................................................................................1-6
Controller Redundancy................................................... ................................................................................1-6
Dual Non-Redundant Controller………………………………………………………………………………….1-6
SECTION 2 – INPUT/OUTPUT CIRCUIT DESCRIPTION
Analog Voltage Inputs..................................................... ................................................................................2-3
Analog Current Inputs..................................................... ................................................................................2-4
Analog Current Outputs .................................................. ....................................................... .........................2-4
Isolated Discrete Inputs .................................................. ................................................................................2-6
Discrete Inputs with Excitation from Controller.............. ................................................................................2-6
Discrete Outputs.............................................................. ................................................................................2-8
Discrete Outputs with Internal Power............................. ................................................................................2-8
Discrete Outputs with External Power............................ ................................................................................2-9
Active/Standby Logic....................................................... ................................................................................2-9
SECTION 3 – HARDWARE INSTALLATION/MAINTENANCE
Site Selection Considerations......................................... ................................................................................3-3
Access Considerations ................................................... ................................................................................3-3
T6200 Controller Mounting ............................................. ......................................................... .......................3-4
T6200 Controller Electrical Power Wiring...................... ................................................................................3-6
T6200R Subrack Electrical Power Connection ............. ................................................................................3-8
Input/Output Hardware Configuration ............................ ................................................................................3-9
Signal Wiring.................................................................... ...............................................................................3-10
Wiring and Jumper Placement for T6200C Channels 1-8............................................................................3-12
Wiring and Jumper Placement for T6200C Channels 9-16..........................................................................3-13
Wiring and Jumper Placement for T6200C Channels 17-22, 31, and 32.................................................... 3-14
Wiring and Jumper Placement for T6200C Channels 23-26 .......................................................................3-16
Wiring for T6200C Channels 27-30................................ ...............................................................................3-17
Wiring and Jumper Placement for T6200D Channels 1-26, 31, and 32 ......................................................3-17
Wiring for T6200D Channels 27-30................................ ...............................................................................3-19
Ethernet Communication Network ................................. ...............................................................................3-19
Network Security ............................................................. .................................................. .............................3-19
Ethernet Network Connectors………………………………………………………… ....................................3-19
Network Cabling.............................................................. ...............................................................................3-20
Non-Redundant Network................................................ ...............................................................................3-20
Redundant Network………………………………………………………………………………………………3-21
T6200R Subrack Ethernet…… .....................................................................................................................3-23
Operator Interface Installation ........................................ ...............................................................................3-24
Firmware Changes.......................................................... ...............................................................................3-27
Serial Communication Connection................................. ...............................................................................3-28
3
T6200
User’s Guide
SECTION 4 - SOFTWARE INSTALLANTION
The Micon OPC Server Compact Disc .......................... ................................................................................4-2
Install the Packet Driver Software .................................. ........................................................... .....................4-2
Install the Micon OPC Server and Related Components...............................................................................4-5
Ethernet Addresses......................................................... ................................................................................4-7
SECTION 5 - T6200 CONTROLLER OPERATION
Push to Activate Switch .................................................. ................................................................................5-5
System Start-up............................................................... ................................................................................5-6
Replacing Control Boards............................................... ................................................................................5-6
Loading Controller Configuration.................................... ................................................................................5-8
Watchdog Timer.............................................................. ................................................................................5-8
SECTION 6 – HMI-6200 OPERATOR INTERFACE
Preface............................................................................. ................................................................................6-2
Overview of HMI-6200 Features .................................... ................................................................................6-4
Event Information Processing......................................... ................................................................................6-6
Display Layout................................................................. ...............................................................................6-15
General Display Description........................................... ...............................................................................6-18
Graphic Displays Configuration...................................... ...............................................................................6-21
HMI Example – Single Stage Compressor.................... ...............................................................................6-22
Adaptation of Pre-Defined Displays ............................... .............................................................. .................6-25
Surge Curve Screens...................................................... ...............................................................................6-29
Custom Graphic Screens................................................ ...............................................................................6-30
Configuring the Security System.................................... ...............................................................................6-31
Communications.............................................................. ...............................................................................6-34
Downloading the Updated Application........................... ...............................................................................6-38
SECTION 7 – CONTROL PRIMER
Proportional (P) Action.................................................... ................................................................................7-4
Integral (I) Action… ......................................................... ................................................................................7-8
Derivative (D) Action ....................................................... ................................................................................7-8
Proportional-Plus-Integral (PI) Action……………………………………………………………………………7-9
Proportional-Plus-Derivative (PD) Action………………………………………………………………………..7-10
Proportional-Plus-Integral-Plus-Derivative (PID) Action………………………………………………………..7-11
Interactive and Non-Interactive Control………………………………………………………………………….7-12
Deadtime……………………………………………………………………………………………………………7-13
Cascade Control.............................................................. ................................................................................7-14
Ratio Control.................................................................... ................................................................................7-16
Damping........................................................................... ................................................................................7-16
4
T6200
User’s Guide
SECTION 8 – CONFIGURATION
Preface............................................................................. ................................................................................8-3
Configuration Studio........................................................ ................................................................................8-4
Running the FBD Configurator Workbench................... ................................................................................8-4
Function Block Diagram (FBD) Editor............................ ...............................................................................8-10
Miscellaneous Workbench Features.............................. ...............................................................................8-16
Adaptation of Pre-Defined Configuration....................... ...............................................................................8-22
MICON OPC Server Start-up........................................................................................................................8-39
SECTION 9 – SPECIFICATIONS
APPENDIX A – DATA STRUCTURES AND EXPRESSIONS
Tags................................................................................. ................................................................................A-3
Reserved Words.............................................................. ................................................................................A-6
Labels............................................................................... ................................................................................A-7
Data Types ...................................................................... ................................................................................A-7
Logical Operations .......................................................... ................................................... .............................A-7
Arithmetic Operations...................................................... ................................................................................A-8
Relational Operations...................................................... ................................................................................A-8
Unary Operations............................................................ ................................................................................A-8
Expression....................................................................... ................................................................................A-9
Truth Tables..................................................................... ...............................................................................A-11
Logic Evaluation Rules ................................................... ...............................................................................A-11
Boolean Logic Rules ......................................................................................................................................A-11
APPENDIX B – MODBUS INTERFACE – RS-232
Preface............................................................................. ................................................................................B-2
T6200 MODBUS Functions Supported………………………………………………………………………….B-2
T6200 MODBUS Configuration…………………………………………………………………………………..B-3
5
T6200
User’s Guide
6
Product Overview
Section One
1
Product Overview
Design Structure 3
Analog and Discrete Input/Output 4
Line Power and Transmitter Power 5
System Security 5
On Line Diagnostics 6
Configuration Security 6
Controller Redundancy 6
Dual Non-Redundant Controller 6
1-1
Product Overview
1-2
Product Overview
PRODUCT OVERVIEW
The T6200 Controller is made up of two parts: The Operator Interface and the T6200 Controller.
The Operator Interface with the Windows CE platform enables complete interaction with the T6200
Controller. Through the touch screen and LCD display users can change setpoints, outputs, start/stop
devices, scroll through trends, or acknowledge alarms. The T6200 Controller functions as a
multiapplication Controller or intelligent RTU capable of performing all data acquisition, continuous
control, batch control, logic control and RTU requirements. Each T6200 Controller includes 999
function blocks in which control/logic functions can reside. The integral input/output (I/O) section
of each T6200 Controller accommodates 32 I/O points. The large library of functions (over 100) and
the practically unlimited number of blocks allow for pre-configuration of a wide variety of strategies
by the factory and permits field application optim izat ion.
Design Structure
The Operator Interface is an embedded PC. It is independent of the T6200 Controller and it
communicates with the T6200 Controller via Ethernet.
The T6200 Controller consists of three physical parts: the control board/s (single or redundant), the
controller housing, and the termination panel. Refer to Figure 1-1. The termination panel may also
include a remote termination panel for the I/O connections.
The control boards are a single printed circuit board design. The board contains the microprocessor
circuitry, the memory chips, the communication interfaces, and the input/output conditioning
components. Primary and backup control boards are identical.
1-3
FIGURE 1-1.
T6200 Unit Controller
Product Overview
Analog and Discrete Input/Output
Analog inputs can be either current or voltage. High common mode (200 Volts) amplifiers are
utilized. Each input has a separate input amplifier. Also, each two wire transmitter input (4-20mA)
is provided with a separate internal 24 volt regulator. Analog outputs source up to 20 milliamperes
to the user’s receiver (load).
Most discrete inputs are opto-isolated (refer to specifications). The sample rate resolution of one
millisecond provides for first out sequence of events capability. Three of these inputs can be
1-4
TABLE 1-1 .
TABLE 1-1.
Input/Output
Channel Assignments
Product Overview
configured as frequency/pulse inputs. Discrete outputs are transistor configurations. A separate
internal 24 volt regulator is supplied for each input/output.
The internal I/O section of the Controller accommodates 32 I/O points. Refer to Table 1-1 for I/O
channel assignment information.
I/O Channel Numbers
Type
T6200C
T6200D
1 - 8 9 – 16 17 - 22 23-26 27 - 30 31 - 32
Analog
Input
Analog
or
Discrete
Discrete
I/O *
Analog
I/O
Analog
Output
Discr
I/O*
Input
Discrete I/O
Discrete
Input
Discr
I/O*
* Channels 22, 31 and 32 can also be configured as a frequency/pulse input. C hannel 32 can also be
configured as a frequency/pulse output.
The process signals supported by the T6200 Controllers are:
• Analog Inputs (4-20 mA, ±20 mA, ±10 Vdc) internally or ext ernally powered
• Analog Outputs (4-20 mA, 0-20 mA)
Discrete Inputs (On-Off contacts) internally or externally powered
Discrete Outputs - internally or externally powered
Pulse Inputs (up to 25 kHz)
Line Power and Transmitter Power
The T6200 Controllers operate on 26 Vdc power. The T6200R subrack supplies redundant AC to
DC power supplies or the 26 Vdc can be obtained from any other reliable power source. Terminal
blocks are provided on the termination panel for primary and secondary (redundant) 26 Vdc power
input. Power for field transmitters, I/Ps, field switches, etc., is distributed through the T6200
Controller eliminating separate input/output power supplies and circuitry.
Both power supplies operate continuously. If one unit fails, it is not necessary to switch to the other
power supply. Both of the 26 Vdc sources are diode-isolated in the T6200 Controller to prevent the
failure of one from affecting the other. The supplies feed redundant power distribution traces on the
termination panel.
System Security
The Controller maximizes its reliability and availability by a design incorporating complete
redundancy of memory, intelligence, communication, and power. The redundancy includes total
process input/output circuitry backup. And, since each termination panel can accommodate both the
primary and backup control boards, the architecture allows for simple plug-in of the redundant
control board. No wiring or cabling is required for redunda nt confi gurati ons.
The integral backup communication link of each unit assures that both control boards (primary and
backup) maintain the same data base. Each control board has its own on-line, sophisticated
1-5
diagnostics and also monitors the status of the other control board which provides for a reliable
transfer and redundancy scheme.
On Line Diagnostics
The T6200 Controller has on-line diagnostics designed to identify failures quickly. On all (primary
and backup) operator interfaces, highways, local communications, the Controller run diagnostics on
a continuous basis. These routines continuously check the status of critical device functi ons t o det ect
failures.
If a failure is detected an alarm is activated to inform the operator and the backup unit is enable d.
Configuration Security
The T6200 Controllers maintain identical configuration at all times. At startup, when both control
boards are powered up, the backup control board’s memory is always cleared, and the active control
board transfers the configuration to the backup control board through the backup serial link, if it has
a backup control board.
During operation (runtime), if new configuration is downloaded (to active control board), it
automatically goes to both the primary and the backup control board. Thus configuration integrity is
achieved and there are no mismatches.
Uninterrupted communication and control is provided by automatically transferring all configuration
and communications of the active control board to the backup redundant control board. There is a
complete transparency in the redundant control board. Apart from notification of failure, there is no
change in the operator interface.
Product Overview
Controller Redundancy
The T6200 Controller redundancy concept allows the user to simply plug-in a backup control board
side-by-side with the primary control board. The user has no installation or cable connection
requirements. Termination panel data links enable the backup to copy the input/output and control
configuration of the primary control board and to assume virtually immediately the input/output and
control functions in case of a primary malfunction.
Each control board contains, in addition to the input/output functions, an extensive library of control
algorithms. Thus, the T6200 Controllers can be configured as totally stand-alone intelligent
controllers or RTUs. This minimizes dependency on communications, resulting i n high reliabi lity.
Dual Non-Redundant Controller
The T6200 Dual Non-Redundant Controller concept allows the user to have two independent
controllers (a primary and a second controller) in one chassis thereby reducing the required panel
space by half. With this option, two T6200-C Controller cards or two T6200-D Controller cards or a
T6200-C and a T6200-D Controller card may be plugged into a single chassis. Two Rem ote I/O
Termination Panels (one for the primary controller and one for the second controller) are requi red
with this concept. The Dual Non-Redundant Controller option should onl y be used when c ontrol le r
redundancy is not foreseen as a requirement.
1-6
Input/Output Circuit Description
Section Two
Analog Voltage Inputs 3
Analog Current Inputs 4
Analog Current Outputs 4
Isolated Discrete Inputs 6
Discrete Inputs with Excitation from Controller 6
Discrete Outputs 8
Discrete Outputs with Internal Power 8
Discrete Outputs with External Power 9
Active/Standby Logic 9
Input/Output Circuit Description
2
2-1
Input/Output Circuit Description
2-2
Input/Output Circuit Description
INPUT/OUTPUT CIRCUIT
DESCRIPTION
Each control board in the T6200 Controller incorporates the µP, memory, communicat ions and I/O
circuitry. Separate I/O modules are not required.
Analog Voltage Inputs
Up to 20 channels in the T6200-C Controller can be configured with field changeable jumpers for
voltage inputs. In reference to Figure 2-1, the input amplifier does not have galvanic isolation but it
appears to have it in most applications because of its high common-mode voltage and its high input
resistance. The 100 volt transient absorbers on each input will allow up to 100 volts dc or 75 volts
ac (rms, sine wave) continuously or up to 104 volts impulse voltage to enter the amplifier. The
amplifier will continue to operate with up to 200 volt s on it s inputs.
Each input has a separate input amplifier. The output of each of these amplifiers passes to the
analog switch. Only one of these inputs is selected at one time. The selected signal continues to the
programmable gain amplifier (PGA). The microprocessor selects the optimum gain setting for the
PGA. The possible input full scale ranges that can be selected are 0.625, 1.25, 2.5, 5, and 10 volts.
Inputs may be either polarity.
The voltage input configuration can be used as a current input by putting a resistor between the “+”
and “-” input terminals. Use a 250 ohm resistor for a 4 to 20 milliampere loop and a 100 ohm
resistor for a 10 to 50 milliampere loop.
2-3
Input/Output Circuit Description
Primary Control Board
To ADC
FIGURE 2-1
Analog Voltage
Input
Analog
Voltage
Input
Termination
Panel
1A
100V
1A
100V
200 Volt
Common-mode
Amplifier
Analog
Switch
Programmable
Gain Amplifier
Analog Current Inputs
The current input is similar to the voltage input with 250 ohm resistor across the amplifier inputs. Field
changeable jumpers are used to select between voltage or current input. The maximum continuous input
current is 20 mA and 40 mA momentary. Refer to Figure 2-2. Also the gain is increased in the PGA by a
factor of two when a backup control board is present, to compensate for the decrease in voltage that the
additional 250 ohm resistor will cause.
When an isolated two-wire 4 to 20 milliampere transmitter is used, the circuit shown in Figure 2-3 m ay be
used. In this configuration a separate internal +24 volt voltage regulator is used for each transmitter. Each
voltage regulator has thermal, reverse voltage, and short-circuit protection. In this arrangement, one end
of the 250 ohm resistor is connected to circuit common. The two-wire 4-20 mA represents the standard
analog input jumper selection.
1A
100V
1A
100V
200 Volt
Common-mode
Amplifier
Analog
Switch
Programmable
Gain Amplifier
Backup Control Board
To ADC
Analog Current Outputs
The T6200 Controller can be configured from four to eight current out put s. The current out put will source
from 0 to 20 milliamperes to the user's receiver (load). The receiver must share the same circuit common
as the T6200 Controller. The maximum receiver resistance is 1000 ohms.
In reference to Figure 2-4, the digital to analog converter (DAC) receives a digital value from the
microprocessor and converts it to an analog voltage. The voltage to the current converter, combined with
transistor Q1 and the 50 ohm resistor, converts the voltage to a current signal.
The output of the primary and backup control boards are connected together on the Controller termination
panel. The output is only enabled in the active control board. The diode is used to block the current from
the active control board.
2-4
Input/Output Circuit Description
FIGURE 2- 2
Analog Current
Input
4-20 MA
Input
Termination
Panel
200 Volt
Common-mode
Amplifier
Analog
Switch
Primary Control Board
Program mable
Gain Amplifier
To AD C
FIGURE 2- 3
Two-Wire
Transmitter Input
200 Volt
Common-mode
Amplifier
Analog
Switch
Backup Control Board
Program mable
Gain Amplifier
To AD C
Primary Control Board
Voltage
Regulator with
short-circuit
protection
Programmable
Gain Amplifier
X2
Backup Control Board
Voltage
Regulator with
short-circuit
protection
Gain Amplifier
X2
To ADC
To ADC
Two-Wire
Transmitter
Input
Termination
Panel
1A
100V
1A
100V
1A
100V
1A
100V
24 VDC
250
OHM
24 VDC
250
OHM
Analog
Switch
Analog
Switch Programmable
+V
2-5
Input/Output Circuit Description
FIGURE 2-4.
Analog Current
Output
Analog
Current
Output
Termination
Panel
125mA
125mA
+25.2V
+25.2V
50
OHM
50
OHM
Voltag e to
Current
Converter
DAC
Reset
Active from Figure 2-9
Voltag e to
Current
Converter
Q1
DAC
Reset
Active from Figure 2-9
Primary Control Board
From
Microprocessor
Inhibit from Figure 2-9
Primary Control Board
From
Microprocessor
Inhibit from Figure 2-9
Isolated Discrete Inputs
The T6200-C Controller can be configured for up to 16 isolated discrete inputs. The T6200-D Controller
can be configured for up to 28 isolated discrete inputs in addition to the four internally power discrete
inputs. The resistor, in series with the input, is used to limit the maximum current to less than 6.5
milliamperes. In reference to Figure 2-5, the resistor across the opto-isolator is used to increase the
minimum input current to greater than one milliampere.
The opto-isolator provides electrical isolation between inputs and other circuits. Each input is protected
with fuses. A 100 volt transient absorber is provided on each input terminal to prevent arcing between
conductors on the circuit board. The maximum voltage that can be applied continuously is 38 volts dc or
30 volts ac (rms, sine wave). Discrete input channels 22, 31, and 32 can be used as frequency inputs, with
input frequencies up to 25 kHz. Other discrete inputs can be used as frequency inputs with input
frequencies up to 500 Hz.
Discrete Inputs with Excitation from Controller
The discrete input is similar to the isolated discrete input above, without the isolation. The input is
internally powered. In this configuration a separate internal +24 volt regulator is provided for each dry
contact input. Each voltage regulator has thermal, reverse voltage, and short circuit protection. The
regulator supplies up to five milliamperes.
A contact closure between + and – terminals will activate the input. Refer to Figure 2-6. The internally
powered discrete input represents the standard discrete input jumper selection. The T6200 Controller has
a minimum of four internally powered discrete inputs.
2-6
Input/Output Circuit Description
FIGURE 2- 5.
Isolated Discrete
Input
Power
Termination
Panel
1A
100V
1A
100V
1A
100V
1A
100V
1.8K
4.7K
1.8K
4.7K
Primary Control Board
Input to
Microprocessor
Backup ControlBoard
Input to
Microprocessor
FIGURE 2-6.
Discrete Input with
Excitation from
Controller
Termination
Panel
1A
100V
1A
1A
100V
1A
Voltage
Regulator
Voltage
Regulator
24 VDC
1.8K
4.7K
24 VDC
1.8K
4.7K
Primary Control Board
Input to
Microprocessor
Backup Control Board
Input to
Microprocessor
2-7
Input/Output Circuit Description
Discrete Outputs
The T6200-C Controller can be configured for up to eight discrete outputs. The T6200-D Controller can
be configured for up to 28 discrete outputs. A 100 volt transient absorber is connected on each terminal to
protect the output transistor and to prevent arching between conductors on the circuit board. Each
terminal is protected with a one ampere fuse.
The output transistor in the standby (not ACTIVE) control board is alway s open.
Discrete output 32 can be used as frequency output, with output frequencies up to 10 kHz. Other discrete
outputs can be used as frequency outputs with output frequencies up to 100 Hz.
Discrete Outputs with Internal Power
In reference to Figure 2-7, a separate internal +24 volt voltage regulator is provided for each output. Each
voltage regulator has thermal, reverse voltage, and short-circuit protection. The regulator can supply 24
Vdc power for a load up to 20 milliamperes continuously and 100 mill iam peres momentarily .
FIGURE 2-7
Discrete
Output with
Internal Power
LOAD
<20 mA
Termination
Panel
1A
100V
1A
100V
24 VDC
Voltage
Regulator with
short-circuit
protection
Active from Figure 2-9
Latch
RS
Primary Control Board
Output from
Microprocessor
Inhibit from Figure 2-9
1A
100V
1A
100V
24 VDC
Voltage
Regulator with
short-circuit
protection
Active from Figure 2-9
Latch
RS
Backup Control Board
Output from
Microprocessor
Inhibit from Figure 2-9
2-8
Input/Output Circuit Description
Discrete Outputs with External Power
In reference to Figure 2-8, the discrete transistor output with an external power source can sink up to 0.25
amperes continuously and one ampere momentarily. The maximum voltage that can be applied
continuously is 38 volts DC. The return (-) of the external power source must be connected to the “-”
input or “-” power terminal of the T6200 Controller.
Primary Control Board
Output fr om
Microprocessor
Inhibit from Figure 2-9
Backup Contr ol Board
Output fr om
Microprocessor
Inhibit from Figure 2-9
FIGURE 2-8.
Discrete Output
with External
Power
Load
<0.25A
T e rmination
Panel
1A
100V
1A
1A
100V
1A
Active from Figure 2-9
Latch
RS
Active from Figure 2-9
Latch
RS
Active/Standby Logic
The active/standby logic determines which control board (primary or backup) is active and if the outputs
are active. Only one control board can assume the active role at any given time. Refer to Figure 2-9.
The inhibit signal is true when the control board is not active and the system fail signal is true. The inhibit
signal when true will reset the analog outputs to zero and reset the discrete output latches causing the
output transistors to open.
The only time the inhibit signal can be true, in a primary control board that does not have a good control
board in its backup position, is the first 0.2 second after power is first applied. This will allow the outputs
to reset on power up and to freeze the outputs if the system fail signal should become true when the
control board is active and must remain active.
2-9
Input/Output Circuit Description
FIGURE 2-9
Termination
Panel
Primary Control B oard
Active/Standby
Logic
Active
Inhibit
Active
Inhibit
ACT
LED
OUT LED
ACT
LED
OUT LED
Power Up
Reset
System Fail
Activate
switch
Backup Control Board
Power Up
Reset
System Fail
Activate
switch
2-10
Section Three
Site Selection Considerations 3
Access Considerations 3
T6200 Unit Automating System Mounting 4
T6200 Controller Electrical Power Wiring 6
T6200R Subrack Electrical Power Connection 8
Input/Output Hardware Configuration 9
Signal Wiring 10
Wiring and Jumper Placement for T6200-C Channels 1-8 12
Wiring and Jumper Placement for T6200-C Channels 9-16 13
Wiring and Jumper Placement for T6200-C Channels 17-22, 31, and 32 14
Wiring and Jumper Placement for T6200-C Channels 23-26 16
Wiring for T6200-C Channels 27-30 17
Wiring and Jumper Placement for T6200-D Channels 1-26, 31, and 32 17
Wiring for T6200-D Channels 27-30 19
Ethernet Communication Network 19
Network Security 19
Ethernet Network Connectors 19
Network Cabling 20
Non-Redundant Network 20
Redundant Network 21
T6200R Subrack Ethernet 23
Operator Interface Installation 24
Firmware Changes 27
Serial Communication Connection 28
Hardware Installation/Maintenance
Hardware Installation/Maintenance
3
3-1
Hardware Installation/Maintenance
3-2
Hardware Installation/Maintenance
Hardware
Installation/Maintenance
`
Site Selection Considerations
The T6200 Controller requires following conditions during normal operation:
32 to 122º F (0 to 50º C)
5 to 96% Relative humidity
Protection from direct contact with water, chemicals, and conductive dust.
Protection from exposure to sulfur compounds, acid, other corrosive or reactive vapors or
fumes, dust, and lint.
For estimating heat load requirements, the T6200 Controller dissipates a maximum of 10 BTU/hr.
(or 24 KGM-CAL/Hr) to the inside of the control panel.
Access Considerations
There are very few restrictions on the mounting position of the T6200 Controller. The following should
be taken into consideration:
All electrical power and input/outputs are connected on the rear termination panel.
Because as many as 70 conductors and four cables can be terminated to each T6200 Controller
adequate wireway space should be provided.
The T6200 Controller is operated from the front of the unit with switches on the
bottom. The Operator Interface slides up 0.5 in. (12 mm) to remove.
3-3
The control boards slide out the front of the unit.
To ensure a proper viewing angle, the Controller should be installed approximately
64 inches (1.6 m) above the floor.
Outdoor installation is not recommended. However, for outdoor installations, the
face of the Controller should be shielded from direct sunlight, since bright light produces a
poor display contrast.
T6200 Controller Mounting
T6200 Controller Mounting
Figure 3-1 provides mounting dimensions for the T6200 Controller. Dimensions are shown in inches
(mm).
Remove Operator Interface by pushing up and pulling out at the bottom. Disconnect cable
from Operator Interface
Use the two Phillips head screws and clamps to mount the T6200 Controller in the user’s
panel.
When the T6200 Controller is positioned properly, hand-tighten both clamps in place. Note:
Do not exceed 15 in-lbs (17 cm-kgs) of torque on panel clamp screws.
The panel cut-out dimensions, as well as the Operator Interface front outline dimensions are shown in
Figure 3-2. The T6200 Controller would normally be mounted in a vertical posit ion.
Figure 3-3 provides mounting dimensions for the optional Remote I/O Termination Panel. The I/O
cable that connects the T6200 Controller to the Remote I/O Termination Panel is 6 ft. (2m) long.
Dimensions are shown in inches (mm). The Remote I/O Termination Panel can be snapped onto a user
supplied standard 35 mm DIN rail.
T6200R Subrack Mounting
Each T6200R Subrack Housing accommodates up to six redundant T6200 Controllers. The subrack
may also include two power supplies, Operator Interface, and two Ethernet hubs. Refer to Figure 3-4
for T6200R Subrack mounting dimensions. The subrack should be mounted in a EIA standard 19 inch
rack. Refer to Section Nine Specifications for more detailed physical dimensions.
Hardware Installation/Maintenance
3-4
FIGURE 3-1.
T6200
Mounting
Hardware Installation/Maintenance
FIGURE 3-2.
T6200 Controller
Panel Cutout
Dimensions
OPERATOR INTERFACE
PANE L CU TO U T
5.95 [151]
5.44 [138]
5.50 [139]
1.375 [35]
4.30 [109]
2.74 [69]
2.68 [68]
1.72 [44] MIN
3-5
FIGURE 3-3
Remote I/O
Terminal Panel
Mounting
Dimensions
Hardware Installation/Maintenance
T6200 Controller Electrical Power Wiring
The guidelines below should be followed when wiring the power to the T6200 Controlle r:
The maximum wire size is 16 AWG stranded.
All wiring should be multi-stranded annealed copper with insulation that meets the
requirements of all applicable electrical codes.
AC power wiring should be run in a separate conduit from the T6200 Controller power and the
I/O.
The stripped portion of the wire should be 3/16” (5 mm) long.
Wires should be inserted in the clamp type terminals until they touch the internal stops. The
terminal screw should be tightened while holding the wire in place. Check for proper clamp
pressure with a gentle tug on the wire.
Electrical power should be provided from a redundant, highly reliable, dedicat ed 26 Vdc power
source.
Power consumption is 15 watts for the T6200 Controller and 15 watts for the Operator
Interface, not including field devices.
The T6200 Controller has redundant 26 Vdc power supply connections.
3-6
FIGURE 3-4
T6200R Subrack
Mounting
Dimensions
Hardware Installation/Maintenance
Figure 3-5 shows the internal power distribution for the T6200 Unit Automation System. Connect 26
Vdc (18-32 Vdc) power to the 26V PRI (Primary) terminals and to the 26V SEC (Secondary)
terminals.
There is a jumper (W1) on the T6200 Termination Panel that connects the minus side of the 26 volt
supply to earth ground. This jumper may be cut if the power source is referenced to earth ground
somewhere else in the system.
3-7
FIGURE 3-5
Internal Power
Distribution
Hardware Installation/Maintenance
T6200R Subrack Electrical Power Connection
Once the T6200R Subrack is mounted, plug the included external power supply’s DC power cord into
the matching power jack on each of the Ethernet Hub’s rear panel. The Ethernet Hub shelf may be
removed to connect the power. Plug each of the power supply’s transformers into an AC receptacle that
is six feet (two meters) or less away. The green “Pwr” LED should light up.
Refer to the guidelines in T6200 Controller Electrical Power Wiring above and Figure
3-6 and connect AC power wiring to each of the 26 Vdc Power Supplies.
The 26 Vdc power to the T6200 Controllers and Operator Interface is usually prewired as shown in
Figure 3-6.
Figure 3-6
T6200R Subrack
Power Wiring
3-8
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