Symphony BRC-100, PBA-100 Instruction

Instruction

Harmony Series

Bridge Controller and Processor Bus Adapter

BRC-100 and PBA-100

Preface

The BRC-100 Harmony Bridge Controller is a high-performance, high-capacity process controller. It is a rack controller designed to interface with both Harmony I/O blocks and Harmony rack I/O in the Symphony Enterprise Management and Control System. The Harmony bridge controller is fully compatible with the INFI 90 munication and packaging. The Harmony bridge controller collects process I/O, performs control algorithms and outputs control signals to process level devices. It also imports and exports process data of other controllers and system nodes, and accepts control commands from operators and computers connected to the network.

This instruction provides information about how the Harmony bridge controller works, and how to install, configure, operate and troubleshoot the module.

OPEN system in functionality, com-

The Harmony bridge controller is designed for redundancy. This can be achieved while remaining connected to the Hnet, or without, using an optional BRC redundancy kit.

WBPEEUI230017B1

List of Effective Pages

Total number of pages in this instruction is 99, consisting of the following:

Page No. Change Date

Preface 04 December 2000

List of Effective Pages 04 December 2000

iii through x 04 December 2000 1-1 through 1-8 04 December 2000 2-1 through 2-8 04 December 2000 3-1 through 3-19 04 December 2000 4-1 through 4-5 04 December 2000 5-1 through 5-23 04 December 2000 6-1 through 6-4 04 December 2000 7-1 through 7-3 Original 8-1 04 December 2000

A-1 through A-8 Original B-1 through B-7 04 December 2000

Index-1 through Index-3 04 December 2000

When an update is received, insert the latest changed pages and dispose of the superseded pages.

NOTE: Changed text or tables are indicated by a vertical bar adjacent to the changed area. Changed figures are indicated by a vertical bar next to the figure caption. The date appears beside the page number.

WBPEEUI230017B1

Table of Contents

Section 1 Introduction ..................................................................................................1-1

Overview .................................................................................................................. 1-1

Intended User .......................................................................................................... 1-2

Hardware Description .............................................................................................. 1-2

Faceplate ............................................................................................................. 1-3

Circuit Board ....................................................................................................... 1-3

Hardware Application............................................................................................... 1-3

Features .................................................................................................................. 1-3

Instruction Content.................................................................................................. 1-4

How to Use this Instruction...................................................................................... 1-4

Glossary of Terms and Abbreviations........................................................................ 1-5

Reference Documents............................................................................................... 1-6

Related Nomenclatures ............................................................................................ 1-6

Specifications........................................................................................................... 1-6

Section 2 Description and Operation .........................................................................2-1

Introduction............................................................................................................. 2-1

Operation................................................................................................................. 2-1

Circuitry .................................................................................................................. 2-2

Microprocessor..................................................................................................... 2-2

Clock and Real-Time Clock ................................................................................... 2-2

Memory................................................................................................................ 2-2

Direct Memory Access .......................................................................................... 2-3

Controlway........................................................................................................... 2-4

Redundancy Link ................................................................................................. 2-4

Hnet Communication ........................................................................................... 2-5

I/O Expander Bus ................................................................................................ 2-5

I/O Section .......................................................................................................... 2-6

Serial Channels.................................................................................................... 2-6

Station Link ......................................................................................................... 2-6

Power................................................................................................................... 2-7

Section 3 Installation ....................................................................................................3-1

Introduction............................................................................................................. 3-1

Special Handling ...................................................................................................... 3-2

Unpacking and Inspection........................................................................................ 3-2

Dipswitches and Jumpers ........................................................................................ 3-3

Dipswitch SW5 - Module Address ......................................................................... 3-4

Dipswitch SW2 - Normal Operating Options.......................................................... 3-5

Dipswitch SW2 - Special Operations ..................................................................... 3-5

Dipswitch SW3 - Module Options ......................................................................... 3-8

WBPEEUI230017B1 iii

Table of Contents (continued)

Section 3 Installation (continued) ..........................................................................................

Dipswitch SW4 - Module Options ..........................................................................3-8

Jumpers ...............................................................................................................3-8

Module Mounting Unit Preparation ...........................................................................3-9

Module Slot Assignments ......................................................................................3-9

Dipshunts ..........................................................................................................3-10

Controlway Cable................................................................................................3-10

PBA Board Installation........................................................................................3-11

Mounting Bracket ...........................................................................................3-11

Cable and Terminator .....................................................................................3-12

Mounting ........................................................................................................3-13

BRC Redundancy Kit Installation ........................................................................3-16

Module Installation.................................................................................................3-18

Pre-Installation Check ........................................................................................3-18

Installation .........................................................................................................3-19

Section 4 Operating Procedures .................................................................................4-1

Introduction .............................................................................................................4-1

Startup.....................................................................................................................4-1

Module LEDs ............................................................................................................4-2

Front Panel LEDs..................................................................................................4-2

Red/Green Status LED .........................................................................................4-3

Stop/Reset Switch ....................................................................................................4-3

Modes of Operation...................................................................................................4-4

Section 5 Troubleshooting ..........................................................................................5-1

Introduction .............................................................................................................5-1

Error Codes ..............................................................................................................5-1

Flowcharts ...............................................................................................................5-5

Diagnostics ..............................................................................................................5-5

Overview...............................................................................................................5-5

Diagnostic Test Selection ......................................................................................5-8

LED Display .......................................................................................................5-11

Module Status Summary ........................................................................................5-12

Card Edge Connectors ............................................................................................5-17

Section 6 Maintenance .................................................................................................6-1

Introduction .............................................................................................................6-1

Preventive Maintenance Schedule .............................................................................6-1

Equipment and Tools Required .................................................................................6-1

Preventive Maintenance Procedures ..........................................................................6-2

iv WBPEEUI230017B1

Table of Contents (continued)

Section 6 Maintenance (continued) .......................................................................................

Printed Circuit Board Cleaning ............................................................................. 6-2

General Cleaning and Washing ......................................................................... 6-3

Edge Connector Cleaning.................................................................................. 6-3

Checking Connections .......................................................................................... 6-4

Section 7 Repair and Replacement .............................................................................7-1

Introduction............................................................................................................. 7-1

Module Replacement ................................................................................................ 7-1

PBA Board Replacement........................................................................................... 7-2

Section 8 Replacement and Spare Parts ....................................................................8-1

Parts........................................................................................................................ 8-1

Appendix A Online Configuration ..............................................................................A-1

Introduction.............................................................................................................A-1

Setup.......................................................................................................................A-1

Operation.................................................................................................................A-2

Backup Cycle ....................................................................................................... A-3

Primary Cycle.......................................................................................................A-6

Appendix B NTMP01 Termination Unit ...................................................................... B-1

Description ..............................................................................................................B-1

List of Figures

No. Title Page

1-1. Harmony Bridge Controller Architecture.................................................... 1-2

2-1. Functional Block Diagram ......................................................................... 2-3

3-1. BRC Module Layout ................................................................................. 3-3

3-2. Controlway Cable Installation ................................................................. 3-11

3-3. PBA Installation ...................................................................................... 3-14

3-4. PBA Connector Identification................................................................... 3-15

3-5. BRC Redundancy Kit Installation ............................................................ 3-17

3-6. Hood Connector Assembly Connector Identification ................................. 3-18

4-1. Front Panel ............................................................................................... 4-2

WBPEEUI230017B1 v

List of Figures (continued)

No. Title Page

5-1. Troubleshooting Flowchart (Serial Port) .....................................................5-6

5-2. Troubleshooting Flowchart (Status LED) ....................................................5-7

5-3. LEDs - Pass/Fail .....................................................................................5-12

A-1. Backup Cycle ........................................................................................... A-6

A-2. Primary Cycle ........................................................................................... A-8

B-1. DTE Jumper Configuration (NTMP01) ....................................................... B-2

B-2. DCE Jumper Configuration (NTMP01)....................................................... B-2

B-3. Nonhandshake Jumper Configuration (NTMP01)....................................... B-3

B-4. Loopback Jumper Configuration (NTMP01) ............................................... B-3

B-5. Jumpers J3 through J10 Configuration (NTMP01) .................................... B-4

B-6. NTMP01 Board Layout.............................................................................. B-5

B-7. NTMP01 Cable Connections (Redundant BRC Modules/PBA Boards) ........ B-6

B-8. Cable Connections (Redundant BRC Modules Using BRC Redundancy Kit) B-7

List of Tables

No. Title Page

1-1. Glossary of Terms and Abbreviations .........................................................1-5

1-2. Reference Documents ................................................................................1-6

1-3. Related Nomenclatures ..............................................................................1-6

1-4. Specifications ............................................................................................1-7

3-1. Dipswitch SW5 Settings (Operation)...........................................................3-4

3-2. Dipswitch SW5 Settings (Address)..............................................................3-5

3-3. Dipswitch SW2 Settings (Operating Options) ..............................................3-6

3-4. Dipswitch SW2 Settings (Special Operations) .............................................3-7

3-5. Dipswitch SW4 Settings (Module Options)..................................................3-8

3-6. Jumpers Settings (J1 through J4) ..............................................................3-9

5-1. Error Codes ...............................................................................................5-1

5-2. Status LED and Other Conditions..............................................................5-4

5-3. DSO and BRC Setup for I/O Expander Bus Test ........................................5-8

5-4. Diagnostic Dipswitch Settings....................................................................5-8

5-5. Diagnostic Tests ........................................................................................5-9

5-6. Status Report ..........................................................................................5-13

5-7. Status Report Field Descriptions..............................................................5-13

5-8. P1 Pin Assignments (BRC) .......................................................................5-17

5-9. P2 Pin Assignments (BRC) .......................................................................5-18

5-10. P3 Pin Assignments (BRC)1,2 ..................................................................5-18

5-11. P4 Pin Assignments (BRC) .......................................................................5-19

5-12. P1 Pin Assignments (PBA) ........................................................................5-19

vi WBPEEUI230017B1

List of Tables (continued)

No. Title Page

5-13. P3 Pin Assignments (PBA) ....................................................................... 5-20

5-14. P4 Pin Assignments (PBA) ....................................................................... 5-20

5-15. P5 Pin Assignments (PBA) ....................................................................... 5-21

5-16. P5 Pin Assignments (Hood Connection Assembly) .................................... 5-22

6-1. Preventive Maintenance Schedule.............................................................. 6-2

8-1. Miscellaneous Nomenclatures ................................................................... 8-1

8-2. Cable Nomenclatures ................................................................................ 8-1

8-3. Miscellaneous Parts .................................................................................. 8-1

A-1. Legend of Symbols ....................................................................................A-3

A-2. Backup Cycle ............................................................................................ A-3

A-3. Primary Cycle............................................................................................A-7

WBPEEUI230017B1 vii

Safety Summary

GENERAL

WARNINGS

SPECIFIC

WARNINGS

Equipment Environment

All components, whether in transportation, operation or storage, must be in a noncorrosive environment.

Electrical Shock Hazard During Maintenance

Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing.

Special Handling

This module uses electrostatic sensitive devices.

Disconnect power before installing dipshunts on the module mounting unit backplane. Failure to do so will result in contact with cabinet areas that could cause severe or fatal shock. (p. 3-9)

Disconnect power before installing the processor bus adapter mounting bracket on the module mounting unit backplane. Failure to do so will result in contact with cabinet areas that could cause severe or fatal shock. (p. 3-11)

Wear eye protection whenever working with cleaning solvents. When removing solvents from printed circuit boards using compressed air, injury to the eyes could result from splashing solvent as it is removed from the printed circuit board. (p. 6-1)

SPECIFIC

CAUTIONS

viii WBPEEUI230017B1

Never operate the BRC module with the machine fault timer circuit disabled (jumper pins connected). Unpredictable module outputs and configuration corruption may result. The unpredictable module outputs may damage control equipment connected to the BRC module.

To avoid potential module damage, evaluate your system for compatibility prior to module installation. This module uses connections to the module mounting unit backplane that served other functions in early Network 90 systems. (p. 3-16)

Support Services

ABB will provide assistance in the operation and repair of its products. Requests for sales or application services should be made to your nearest sales or service office. ABB can also provide installation, repair and maintenance contract services.

When ordering parts, use nomenclature or part numbers and part descriptions from equipment manuals. Parts without a description must be ordered from the nearest sales or service office. Recommended spare parts lists, including prices are available though the nearest sales or service office.

ABB has modern training facilities available for training your personnel. On-site training is also available. Contact your nearest ABB sales office for specific information and scheduling.

Additional copies of this instruction, or other instructions, can be obtained from the nearest ABB sales office at a reasonable charge.

WBPEEUI230017B1 ix

Trademarks and Registrations

Registrations and trademarks used in this document include:

® INFI 90 Registered trademark of ABB Process Automation. ® INFI-NET Registered trademark of ABB Process Automation. ® Network 90 Registered trademark of ABB Process Automation.

x WBPEEUI230017B1

Introduction

Overview

Section 1

The Harmony bridge controller is a stand-alone controller that can handle specific control and information processing applications in addition to multiple-loop analog, sequential, and batch control. It has the power to execute demanding process control applications that are data intensive, program intensive or both. The Harmony bridge controller supports multiple control languages which include function codes, C, Basic, Batch 90, and Ladder.

The Symphony system uses a variety of analog, control, and digital I/O devices to interface with the process. Control input/ output is available from I/O blocks using the Harmony communication network (Hnet) or from Harmony rack I/O modules using the I/O expander bus.

For added reliability, the BRC module has circuitry that supports redundancy. A backup BRC module waits in a standby mode while the primary module executes. If the primary goes offline for any reason, there is a bumpless transfer of control to the backup module. A processor bus adapter (PBA) board is required to support redundant BRC modules and redundant Hnet buses. When no Hnet and termination unit connection is needed, a BRC redundancy kit may be used to support redundant BRC modules.

IISAC01 Analog Control Stations can connect directly to the BRC module via a PBA board and termination unit. The BRC module also supports IISAC01 stations that are connected to a Harmony control I/O block (CIO-100/110) on the Hnet bus or a Harmony control I/O module (IMCIS12, IMQRS12) on the I/ O expander bus. The BRC module supports up to 128 SAC sta-

WBPEEUI230017B1 1 - 1

Intended User

tions communication at a 40-kbaud rate. Figure 1-1 shows the Harmony bridge controller architecture.

CNET

HARMONY RACK COMMUNICATION MODULES

CONTROLWAY

HARMO NY BRIDGE CONTROLLER

HNET

HARMONY I/O BLOCKS

REPEATER MOUNTING UN IT (R M U )

HNET

RMU

Figure 1-1. Harmony Bridge Controller Architecture

Intended User

Personnel installing, operating or maintaining the BRC module should read this instruction before performing any installation, operation, or maintenance procedures. Installation requires an engineer or technician with experience handling electronic circuitry. Formal training in Symphony system configuration (especially function codes) is helpful when configuring the BRC module.

HNET

HARMONY

I/O BLOCKS

REMOTE LOCATION

I/O EXPAN DER BUS

HARMONY RACK I/O M O D U L E S

PROCESS I/OPROCESS I/O PROCESS I/O

T0246 7A

1 - 2 WBPEEUI230017B1

Hardware Description

The Harmony bridge controller consists of a circuit board and a faceplate.

Faceplate

The BRC faceplate measures 35.56-millimeters wide by

177.80-millimeters high (1.4-inches wide by 7.0-inches high). Two latching screws, one at the top, the other at the bottom, lock the module assembly in a module mounting unit (MMU). A transparent window on the faceplate enables viewing the 16 CPU LEDs and the status LED. These LEDs display operating information. A small hole directly below the window provides access to the combination stop/reset pushbutton. Besides locking the module in place, the faceplate also protects the circuit components and promotes proper air flow within the enclosure.

Hardware Description

Circuit Board

The circuit board features state-of-the-art surface mount technology. On the board are nonvolatile random access memory (NVRAM), static random access memory (SRAM), flash memory (ROM), a microprocessor running at 32 megahertz, direct memory access (DMA) circuits, ABB Process Automation custom bus circuits, and various support circuitry. The board attaches to the faceplate with two screws. The module assembly occupies one slot in a module mounting unit.

A processor bus adapter board is required for connection to the Harmony I/O subsystem via Hnet. It also connects to a termination unit for two auxiliary serial I/O ports and IISAC01 stations. Redundant BRC modules and Hnet buses connect through redundant PBA boards.

Hardware Application

Because of the superior performance of the BRC module, applications that formerly required an external mainframe or minicomputer can now be handled in the Harmony control unit. The large memory space and on-board communication ports of the BRC module enable it to meet the sophisticated control

WBPEEUI230017B1 1 - 3

Features

application requirements of supervisory control, optimization routines, performance assessment, and process modeling.

The Harmony bridge controller retains all of the features of the INFI 90 OPEN multifunction processor modules. Additional features of the Harmony bridge controller include:

• Simultaneous Hnet bus and I/O expander bus communi-

cation supports both Harmony I/O blocks and Harmony rack I/O modules.

• Redundant Hnet bus.

• Online Hnet communication bus diagnostics and fault

isolation.

• Automatic downloading of Harmony I/O block

configurations.

• NVRAM battery power monitoring.

• Status output alarm monitoring.

• Two megabytes of on-board SRAM memory.

• Compatible with existing INFI 90 OPEN systems.

Instruction Content

This instruction consists of the following sections:

Introduction

Description and

Operation

Installation

Operating Procedures

Provides an overview of the module, a description of the hardware, a glossary of unique terms, and a table of physical, electrical and environmental specifications.

Uses block diagrams to explain the function of the key circuits.

Explains the handling, inspection, hardware configuration, and installation aspects of the module.

Discusses the front panel indicators and controls, and everyday operation.

Troubleshooting

1 - 4 WBPEEUI230017B1

Features detailed flowcharts and tables that enable quick diagnosis of error conditions and provides corrective actions.

How to Use this Instruction

Maintenance

Repair and

Replacement

Replacement and Spare

Parts

Appendices

Covers scheduled module maintenance.

Describes how to repair and replace the module.

Provides a list of part numbers and nomenclatures.

Provide quick reference information for NTMP01 hardware configuration and step-by-step instructions for performing online configuration.

How to Use this Instruction

Read this instruction in sequence. To get the best use out of this instruction, read it from cover to cover, then go back to specific sections as required. ABB strongly advises against putting the module into operation until the installation section has been read and performed.

1. Read and perform all steps in the installation section.

2. Thoroughly read the operating procedures section before applying power to the module.

3. Refer to the troubleshooting section if a problem occurs. This section will help to diagnose and correct a problem.

4. Go to the repair and replacement section for replacement part numbers and nomenclatures, and for instructions on how to replace the module.

Glossary of Terms and Abbreviations

Table 1-1 contains those terms and abbreviations that are unique to ABB or have a definition that is different from standard industry usage.

Table 1-1. Glossary of Terms and Abbreviations

Term Definition

Controlway High speed, redundant, peer-to-peer communication link. Used to transfer infor-

mation between intelligent modules within a Harmony control unit.

Hnet Communications path between Harmony controller and I/O blocks.

Executive block Fixed function block that determines overall module operating characteristics.

WBPEEUI230017B1 1 - 5

Reference Documents

Table 1-1. Glossary of Terms and Abbreviations

Term Definition

Function block The occurrence of a function code at a block address of a module.

Function code An algorithm which manipulates specific functions. These functions are linked

together to form the control strategy.

I/O block Generic name for a processor based Harmony input/output device: AIN-120,

AOT-150, CIO-100, DIO-400, etc.; comprised of an I/O module and a base.

I/O module Houses the I/O block circuitry; part of I/O block.

I/O expander bus

MFT Machine fault timer. Reset by the processor during normal operation. If not reset

MMU Module mounting unit. A card cage that provides electrical and communication

PBA Processor bus adapter.

Termination unit Provides input/output connection between plant equipment and the Harmony

Parallel communication bus between the Harmony rack controller and Harmony rack I/O modules.

regularly, the MFT times out and the module stops.

support for Harmony rack modules.

rack modules.

(continue d)

Reference Documents

Table 1-2 contains a list of documents referenced in this instruction that provide information on BRC firmware and related hardware.

Table 1-2. Reference Documents

Number Title

WBPEEUI200502?? Module Mounting Unit (IEMMU11, IEMMU12,

WBPEEUI210504?? Function Code Application Manual, Symphony

WBPEEUI230022?? Analog Control Station (IISAC01)

WBPEEUI240751?? Harmony Input/Output System

WBPEEUI240762?? IMDSO14 Digital Output Module

WBPEEUI260039?? NTMP01 Multifunction Processor Termination Unit

WBPEEUI270002?? Primary Interface, Composer

WBPEEUI270003?? Automation Architect, Composer

IEMMU21, IEMMU22)

1 - 6 WBPEEUI230017B1

Related Nomenclatures

Table 1-3 lists nomenclatures related to the BRC module.

Table 1-3. Related Nomenclatures

Nomenclature Description

Related Nomenclatures

IEMMU11, IEMMU12, IEMMU21, IEMMU22

IISAC01 Analog control station

NTMP01 Field termination panel

Module mounting unit

Specifications

Table 1-4 lists the specifications for the BRC module, process bus adapter board and BRC redundancy kit.

Table 1-4. Specifications

Property Characteristic/Value

Microprocessor 32-bit processor running at 32 MHz

Memory All memory has 32-bit data path

SRAM NVRAM

Total Available Total Available

2 Mb 1.57 Mb 512 kb 441 kb 1 Mb

Power requirements 5 VDC at 2 A; 10 W typical (BRC)

Flash ROM

Tot al

Station support 128 40-kbaud serial stations (IISAC01) or eight 5-kbaud serial stations

Redundant controller communication link

Programmability Function codes, C, Basic, Batch, Ladder, user-defined functions

Dimensions

BRC

PBA

Weight

BRC PBA

WBPEEUI230017B1 1 - 7

5 VDC at 100 mA; 0.5 W typical (PBA)

4 MHz per byte per second (normal operation)

35.56 mm wide, 177.80 mm high, 298.45 mm long (1.40 in. wide, 7.00 in.high, 11.75 in. long)

31.60 mm wide, 166.12 mm high, 102.62 mm long (1.24 in. wide, 6.54 in. high, 4.04 in. long)

0.70 kg (24.69 oz)

0.30 kg (10.6 oz)

Specifications

Table 1-4. Specifications (continued)

Property Characteristic/Value

Communication ports 2 RS-232-C or 1 RS-232-C and 1 RS-485,

1 SAC channel (128 SACs maximum

Ambient temperature 0° to 70°C (32° to 158°F)

Relative humidity 0% to 95% relative humidity up to 55°C (131°F) noncondensing

0% to 45% relative humidity at 70°C (158°F) noncondensing

Atmospheric pressure Sea level to 3 km (1.86 mi)

Certification CSA certified for use as process control equipment in ordinary

(nonhazardous) locations.

CE mark compliant for EMC directive and LV directive.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE.

)

1 - 8 WBPEEUI230017B1

Description and Operation

Introduction

This section explains the functionality of the Harmony bridge controller (BRC) using block diagrams and text. Block diagrams divide the operation of the Harmony bridge controller.

Operation

The BRC module incorporates the power of a second generation 32-bit microprocessor operating at 32 megahertz. This is coupled with 32-bit wide memory design with an optimized interface. The microprocessor supplies superior performance capable of supplanting the need for external mainframes or minicomputers.

Control input/output is available from I/O blocks using Hnet or from Harmony rack I/O modules using the I/O expander bus. The data within the BRC module may be exported to the Cnet communication network and to existing INFI-NET Plant Loop communication systems.

Section 2

and

In some processes, the effects of a control failure in the system can create dangerous situations or cause economic loss. To reduce the possibility of these problems occurring, redundant modules provide fail-safe control. Redundant BRC modules link directly to each other via the processor bus adapter (PBA) board or the BRC redundancy kit to keep the database in the backup module current. Each module uses a redundant high speed communication channel to accomplish this function. If the primary module fails, the backup module is waiting in standby mode and immediately takes over. The backup module has the same control strategy loaded in its memory as the primary BRC module and is ready to assume control. When operating in Hnet communication mode, the redundant communication channel insures that single point failures will not prevent the backup module from being in a state of readiness to take over.

While the BRC module is controlling a process, it also executes diagnostic routines. It is constantly checking the integrity of its

WBPEEUI230017B1 2 - 1

Circuitry

hardware and firmware during normal operation. If the diagnostic routines discover a module hardware or software problem, it makes that information available to the operator. The operator has access to this information through status LEDs on the module faceplate and through reports received on the human system interface (HSI) in module status bytes.

The BRC module uses a control I/O block (CIO) on Hnet to support a station link that can handle up to 128 IISAC01 stations and is compatible with the Symphony system.

Two auxiliary RS-232-C ports and a serial station link are available through a cable connection via the PBA board to an NTMP01 Multifunction Processor Termination Unit. This station link can handle up to 64 IISAC01 stations at a 40-kilobaud rate or eight stations at a five-kilobaud rate. Various handshake options are available via jumper configurations on the termination unit.

Circuitry

Microprocessor

The BRC module has all the needed circuitry to operate as a stand-alone controller. Direct memory access (DMA) operation is supported for the station link. Figure 2-1 shows a block diagram of the BRC circuitry.

The microprocessor is responsible for module operation and control. The BRC microprocessor is a 32-bit processor that runs from a 32-megahertz clock. The microprocessor executes synchronous access to long word memories and an asynchronous access to all byte ports. Since the microprocessor is responsible for module operation, it communicates with all blocks of the BRC circuitry. The microprocessor operating system instructions and the function code library reside in the read only memory (flash ROM). The microprocessor carries out all control responsibilities as it executes the control strategy set up in its function block configuration.

The microprocessor constantly triggers the machine fault timer (MFT) circuit. If the microprocessor or software fails, the MFT circuit times out, issues a board wide reset, and the status LED turns red. This condition is a fatal module error.

2 - 2 WBPEEUI230017B1

CLOCK

MACHINE

FA U LT

TIME R

MICROPROCESSOR

LEDs,

SWITCHES,

DATA BUFFERS

Circuitry

32 -B IT D ATA PAT H

ROM NVRAM SRAM

16 -B IT D ATA PAT H

REDUNDANT HNET BUS

REDUNDANCY

Figure 2-1. Functional Block Diagram

Clock and Real-Time Clock

DUAL

LINK

STEERING

DATA

LOGIC

DMA /PERIPHERAL CONTROL I/O

CONTROLWAY/

MODULE BUS

8-BIT DATA PATH

I/O

EXPANDER

BUS

SAC/ DCS

PROCESSOR

BUS ADAPTER

DUART RTC

T01272A

The clock section provides the clock signals to drive the microprocessor and associated peripheral devices. The clock/timer section also includes a real-time clock (RTC).

Memory

The BRC memory is made up of one megabyte of flash ROM memory, two megabytes of SRAM memory, and 512 kilobytes of NVRAM memory.

The flash ROM memory holds the operating system instructions for the microprocessor. The SRAM memory provides temporary storage and a copy of the system configuration. The NVRAM memory holds the system configuration (control strategy designed with function codes) and files for Batch, Basic, C,

WBPEEUI230017B1 2 - 3

Circuitry

and UDF applications. NVRAM memory retains whatever information it has, even when it loses power.

Direct Memory Access

The DMA section enables the various communication links to do direct data transfers to and from RAM memory without processor intervention. Communication links that support direct memory access are the I/O expander bus, the dual redundancy link, the station serial link, and Controlway. ABB-designed chips control DMA activity.

The DMA process greatly reduces the amount of work the microprocessor needs to do when making data moves. This greatly increases the speed of the BRC module by not overloading the microprocessor with the work associated with data moves. The microprocessor does not have to execute data moves and is free to do other tasks.

Controlway

The Controlway is a high speed communication bus between Harmony rack controllers. The BRC module uses this bus to communicate with other control modules within a Harmony control unit. It provides a one-megabaud, peer-to-peer communication link that can support up to 32 devices. The Controlway interface is provided by a custom integrated circuit that links the BRC module to the Controlway. It has full DMA capabilities (allowing for quicker operation), and two independent, redundant channels.

The redundant Controlway channels run through two paths on the module mounting unit backplane circuit. The BRC module transmits and receives data over both channels simultaneously. By receiving data through two channels, the BRC module can check its integrity. In this way, the Controlway minimizes the potential that a failure on a circuit board or backplane will cause loss of module communication.

The Controlway interface also allows the BRC module to run on module bus by operating in an 83.3-kilobaud mode (switch selectable). The module bus operation option is provided to support existing INFI 90 OPEN and Network 90 jumper allows the BRC module to be installed in systems using early Network 90 modules that require -30 VDC. The jumper

systems. A

2 - 4 WBPEEUI230017B1

Redundancy Link

Circuitry

disconnects -30 VDC from pin four of connector P2 on the BRC module.

The redundancy link is a dual parallel link between a primary and backup BRC module in redundant configurations. As the primary module executes, the backup module waits in standby mode and receives a copy of block outputs over this link. If for any reason the primary module fails, the backup takes over without any process interruption.

NOTE: Firmware revision levels must be the same in both primary and second-

ary BRC modules. If the firmware revision level is different and a failover

occurs, the redundant BRC module may operate erratically.

Two parallel channels of data and control signals connect by way of a processor bus adapter board. Each BRC module in a redundant configuration connect through PBA boards connected by redundant PBA cables. Both channels have parity protection.

If no Hnet or termination unit communication is needed, the primary and backup BRC modules connect by a BRC redundancy kit. The BRC redundancy kit contains two Harmony I/O hood connection assemblies and a redundant PBA cable. The connection assemblies replace the redundant PBA boards and connect to each other through the redundant PBA cable.

Hnet Communication

An Hnet interface enables communication with Harmony I/O blocks. All communication functions are handled by the Hnet application-specific integrated circuit (ASIC). Hnet is a 16-bit interface that operates via control registers in the I/O section of BRC module memory and a one-megabyte memory space for shared SRAM.

Hnet and I/O expander bus communication can be active simultaneously if enabled, allowing the BRC module to utilize both Harmony I/O blocks and Harmony rack I/O modules to control a process. Function code 90 (S3) controls what combination of I/O interfaces are active. Three selections are available: enable Hnet only, enable Hnet and I/O expander bus, and enable I/O expander bus only.

WBPEEUI230017B1 2 - 5

Circuitry

I/O Expander Bus

Physical connection is provided by a direct connection from the BRC module P3 connector to the processor bus adapter board P5 connector. The processor adapter board mounts on the rear of a module mounting unit with the proper adapter brackets installed. It uses cables to connect to the Harmony block mounting columns. The PBA board provides Hnet physical layer functions, termination, isolation relays, and BRC module redundancy link.

The I/O expander bus interface is implemented using an ABB-designed integrated circuit. The microprocessor can select one of two modes of operation: DMA or auto mode. The BRC software selects the mode of operation. Mode selection is based on optimizing the number of bytes to be transferred. In either mode of operation, the microprocessor does not need to wait for each byte to transfer (as in previous controllers).

I/O Section

Serial Channels

The BRC module connects to the I/O expander bus through the P2 connector on the module mounting unit backplane. It is an eight-bit parallel bus that provides the communication path for I/O data from Harmony rack I/O modules. The I/O expander bus supports 64 low power I/O modules.

The I/O section interface allows the microprocessor to read the switches that tell it how to operate and set the module address. This section also contains latches whose outputs connect to the status and error LEDs. This section monitors redundant modules and outputs a signal to the LEDs of the primary module. Upon failover, this output de-energizes and the output of the backup module energizes as it takes over. Additionally, the I/O section monitors the stop/reset pushbutton. When the pushbutton is pressed, the I/O section insures that the module completes any I/O functions before it stops the module.

Two independent serial channels (RS-485) are available on the BRC module. Both serial channels are dedicated for language support (C or Basic) or sequence of events recording. Clear to send (CTS) and request to send (RTS) handshake signals are supported. A DUART circuit on the processor bus adapter

2 - 6 WBPEEUI230017B1

Circuitry

board supplies the serial channels with handshaking signals. Clock signals for the baud rate generator are derived from an on-board, 7.3728-megahertz oscillator.

The PBA board connects to an NTMP01 Multifunction Processor Termination Unit. Input/output signals enter or leave the PBA board through a cable connection to the termination unit. An NKTU01 or NKTU11 cable connects an NTMP01 termination unit. Standard D-type connectors are available on the termination unit.

To provide better noise immunity, both channels transmit and receive differential serial signals based on the RS-485 standard. These signals are converted to normal RS-232-C voltage levels by the termination unit. Each channel is capable of supporting standard RS-232-C baud rates up to 38.4 kilobaud. The termination unit also provides optical isolation to eliminate the possibility of introducing ground loops into the system from improper cable shield grounding. Channel A (the terminal channel) can be selected to operate without the RS-485/ RS-232-C conversion allowing it to be used with differential terminals or programmable logic controllers (PLC).

Station Link

Station communication originates from a DUART circuit on the BRC module. This link controls the serial communication between the BRC module and the control stations. It has two modes of operation: Hnet transactions to a Harmony control I/ O block, or direct operation by the BRC module via a termination unit.

The Hnet-to-CIO block mode of operation allows stations to be placed at greater distances from the BRC module because the CIO block contains the physical interface to the station. The BRC module is capable of communicating with a total of 128 IISAC01 stations attached to a total of 64 CIO-100/110 blocks.

NOTES: The system station maximum of 128 stations assumes that only Hnet-

to-CIO block communication mode is used.

The BRC module can also directly connect to local IISAC01 stations. Eight stations can be supported at the five-kilobaud rate and up to 64 stations can be supported at the 40-kilobaud rate. The BRC module makes this direct local connection through the PBA board and appropriate termination hardware.

WBPEEUI230017B1 2 - 7

Circuitry

Power

Support for bypass stations requires a Harmony control I/O module (IMCIS12, IMQRS12) configured on the I/O expander bus.

Power requirements are 5 VDC for logic power and for line drivers/receivers. The Hnet interface derives all other power requirements from the 5 VDC logic power. Power for the module is supplied via the module mounting unit connection to the BRC module P1 connector. The PBA board receives 5 VDC logic power via its connection to the BRC module. The PBA board uses this power for Hnet termination, and to power the isolation relays.

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Installation

Introduction

Section 3

This section explains how to set up and install the Harmony bridge controller (BRC). Read, understand, and complete the steps in the order they appear before operating the BRC module.

The Harmony bridge controller requires a P-H-BRC-PBA1000 Processor Bus Adapter (PBA) board to support Hnet communication and BRC module redundancy. If no Hnet communication and termination unit is needed, a BRC redundancy kit may be used to support redundancy instead of the PBA boards. This section includes instructions for PBA board, BRC redundancy kit, and related cable installations.

NOTE: This module uses connections to the module mounting unit backplane

that served other functions in earlier Network 90 systems. To avoid potential

module damage, evaluate your system for compatibility prior to module instal-

lation. Earlier Network 90 systems applied -30 VDC to pins three and four of

the module connector P1. This voltage is not required for Symphony and

INFI 90 OPEN modules. In Symphony and INFI 90 OPEN systems, pin four is

used for the Controlway bus.

If the system contains modules that require -30 VDC, set jumper J3 to the

30 VDC position (jumper pins one and two). Doing so allows the installation of

the BRC module in a module mounting unit that uses -30 VDC and limits com-

munication to module bus. Refer to Table 3-6 for more information about setting

jumper J3.

WBPEEUI230017B1 3 - 1

Special Handling

Observe these steps when handling electronic circuitry:

1. Use Static Shielding Bag. shielding bag until you are ready to install them in the system. Save the bag for future use.

2. Ground Bag Before Opening. ing an assembly with semiconductors, touch it to the equipment housing or a ground to equalize charges.

3. Avoid Touching Circuitry. avoid touching the circuitry.

NOTE: Always use ABB's field static kit (part number 1948385?1 - consisting

of two wrist straps, ground cord assembly, alligator clip and static dissipative

work surface) when working with the modules. The kit grounds a technician

and the static dissipative work surface to the same ground point to prevent

damage to the modules by electrostatic discharge.

Use Static Shielding Bag. Keep the modules in the static

Use Static Shielding Bag. Use Static Shielding Bag.

Ground Bag Before Opening. Before opening a bag contain-

Ground Bag Before Opening.Ground Bag Before Opening.

Avoid Touching Circuitry. Handle assemblies by the edges;

Avoid Touching Circuitry.Avoid Touching Circuitry.

4. Avoid Partial Connection of Semiconductors.

Avoid Partial Connection of Semiconductors. Verify that all

Avoid Partial Connection of Semiconductors. Avoid Partial Connection of Semiconductors.

devices connected to the modules are properly grounded before using them.

5. Ground Test

Ground Test Equipment.

Ground TestGround Test

6. Use an Antistatic Field Service Vacuum.

Use an Antistatic Field Service Vacuum. Remove dust from

Use an Antistatic Field Service Vacuum.Use an Antistatic Field Service Vacuum.

the module if necessary.

7. Use a Grounded Wrist Strap.

Use a Grounded Wrist Strap. Connect the wrist strap to the

Use a Grounded Wrist Strap. Use a Grounded Wrist Strap.

appropriate grounding plug on the power entry panel. The grounding plug must be effectively connected to the earth grounding electrode system through the AC safety ground.

8. Do Not Use Lead Pencils to Set Dipswitches.

Do Not Use Lead Pencils to Set Dipswitches. To avoid con-

Do Not Use Lead Pencils to Set Dipswitches. Do Not Use Lead Pencils to Set Dipswitches.

tamination of dipswitch contacts that can result in unnecessary circuit board malfunction, do not use a lead pencil to set a dipswitch.

Unpacking and Inspection

Equipment.

Equipment.Equipment.

1. Examine the hardware immediately to verify that it has not been damaged in transit.

2. Notify the nearest ABB sales office of any damage.

3 - 2 WBPEEUI230017B1

3. File a claim for any damage with the transportation company that handled the shipment.

4. Use the original packing material and container to store the hardware.

5. Store the hardware in an environment of good air quality, free from temperature and moisture extremes.

Dipswitches and Jumpers

This section explains how to configure and install the BRC module. After installing the module, a function block configuration must be created to define the functions the module will perform.

The BRC module has four configurable dipswitches, and four jumpers. Each dipswitch has eight poles. Figure 3-1 shows the location of the dipswitches and jumpers on the circuit board.

Dipswitches and Jumpers

CR21

SW1

SW5

1 2 3 4 5 6 7 8

Figure 3-1. BRC Module Layout

Dipswitch SW5 sets the module address, bus speed, and operation mode (normal/diagnostic). Dipswitch SW2 sets module options, enables special operations, and enables diagnostic operations. Dipswitch SW4 sets module mounting unit and memory options. Dipswitch SW3 is not used.

SW2

SW 3

1 2 3 4 5 6 7 8

SW4

1 2 3 4 5 6 7 8

P10

P11 P9

T01274B

WBPEEUI230017B1 3 - 3

+ 74 hidden pages

Symphony BRC-100, PBA-100 Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual