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Symphony Plus S+ Control: NTDO02 Digital Output Termination Unit User Manual Symphony Plus

Symphony Plus

S+ Control: NTDO02 Digital Output Termination Unit User Manual

Symphony Plus

Symphony Plus S+ Control: NTDO02 Digital Output Termination Unit User Manual Symphony Plus

NOTICE

This document contains information about one or more ABB products and may include a description of or a reference to one or more standards that may be generally relevant to the ABB products. The presence of any such description of a standard or reference to a standard is not a representation that all of the ABB products referenced in this document support all of the features of the described or referenced standard. In order to determine the specific features supported by a particular ABB product, the reader should consult the product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intellectual property in the ABB products described in this document.

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product has been designed to meet the requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC. See the Spec- ifications section in this manual for status of agency certifications

TRADEMARKS

All rights to copyrights, registered trademarks, and trademarks reside with their respective owners. Copyright © 2012 ABB. All rights reserved.

Release:

August 2012

Document number:

2VAA001694

Preface

The NTDO02 Digital Output Termination Unit is a Harmony rack I/O device that is part of the Symphony Plus Control System. It provides a signal path between a SPDSO14 Digital Output Module and digital control devices such as annunciator panel lamps, motors, and fans.

This user manual explains the NTDO02 termination unit specifications and operation. It details the procedures necessary to complete setup, installation, maintenance, repair, and replacement of the termination unit.

NOTE: The NTDO02 termination unit is fully compatible with existing INFI 90 OPEN and Symphony Control systems.

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 through 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.

Trademarks and Registrations

Registrations and trademarks used in this document include:

INFI 90®

Registered trademark of ABB.

Symphony™ Plus

Trademark of ABB S.p.A.

TABLE OF CONTENTS

TABLE OF CONTENTS

Safety Summary

1

About This Book

3

Document Conventions

3

Information and Tip Icons

3

1. Introduction

1-1

1.1 Overview

1-1

1.2 Description

1-1

1.3 Mounting Hardware

1-2

1.4 Intended User

1-2

1.5 User Manual Content

1-2

1.6 How to Use this Manual

1-2

1.7 Document

Conventions

1-3

1.8 Reference

Documents

1-3

1.9 Related Nomenclature

1-3

1.10 Specifications

1-3

2. Installation

2-1

2.1 Introduction

 

2-1

2.2 Special Handling

2-1

2.3 Unpacking and Inspection

2-1

2.4 Setup/Physical

Installation

2-1

2.4.1 Dipshunt Configuration

2-1

2.4.2 Fuse Installation

 

2-5

2.4.3 Relay Installation

2-5

2.5

Termination Unit Installation

2-5

2.5.1 Mounting

 

2-5

2.5.2 Cable Connection

2-6

2.5.3 Power Wiring

2-7

2.5.4 Terminal Block Wiring

2-8

2.6

Installation

Complete

2-8

3. Maintenance

3-1

3.1 Introduction

3-1

3.2 Preventive Maintenance Schedule

3-1

3.3 Equipment and Tools Required

3-1

3.4 Preventive Maintenance Procedures

3-1

3.4.1

Printed Circuit Board Cleaning

3-2

TABLE OF CONTENTS

3.4.2 Checking Connections

4. Repair and Replacement

3-2

4-1

4.1 Introduction

4-1

4.2 Fuse Replacement

4-1

4.3 Relay Replacement

4-1

4.4 Termination Unit Replacement

4-2

LIST OF TABLES

LIST OF TABLES

Table 1-1

Reference Documents

1-3

Table 1-2

Related Nomenclature

1-3

Table 1-3

NTDO02 Termination Unit Specifications

1-3

Table 1-4

Relay and Fuse Specifications

1-4

Table 2-1

Dipshunt XU01 and XU02 Normal Operation Settings

2-2

Table 2-2

Dipshunt XU03 through XU10 Settings

2-4

Table 2-3

Fuse and Relay Ratings

2-5

Table 2-4

Cable Applications

2-6

Table 3-1

Preventive Maintenance Schedule

3-1

Table 4-1

Parts List

4-1

LIST OF TABLES

LIST OF FIGURES

LIST OF FIGURES

Figure 1-1

Harmony Rack I/O Architecture

1-1

Figure 1-2

Mounting Hardware

1-2

Figure 2-1 Termination Unit Layout

2-2

Figure 2-2 Dipshunt Socket XU01 and XU02 Internal Circuitry

2-3

Figure 2-3

Example Configuration Using Dipshunts

2-3

Figure 2-4 Example Configuration Using Adapter Plugs

2-4

Figure 2-5

Termination Unit Installation

2-6

Figure 2-6

Cable Connections

2-7

Figure 2-7

Terminal Assignments

2-8

LIST OF FIGURES

Safety Summary

The following table categorizes the various safety precautions to be followed when using the NTDO02 digital output termination unit:

Safety Precaution

Description

 

Electrostatic Sensitive Device

Devices labeled with this symbol require special handling precautions as described in section 2- Installation

Devices labeled with this symbol require special handling precautions as described in section 2- Installation of this user manual.

GENERAL WARNINGS

Equipment Environment All components, whether in transportation, operation or storage, must be in a non-corrosive environment.

Electrical Shock Hazard During Maintenance Disconnect power or take precautions to insure that contact with energized parts is avoided when servicing

SPECIFIC WARNINGS

Verify the main power, field power, and power entry panel circuit breakers/switches are turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, retrofit, upgrade, or wiring procedures are complete. (Refer to sub-section 2.5.3- Power Wiring of this user manual, where this specific warning statement is applicable)

Never clean electrical parts or components with live power present. Doing so exposes you to an electrical shock hazard. (Refer to sub-section 3.4.1- Printed Circuit Board Cleaning of this user manual, where this specific warning statement is applicable)

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. (Refer to sub-section 3.4.1- Printed Circuit Board Cleaning of this user manual, where this specific warning statement is applicable)

There are exposed AC and DC connections inside the cabinet. These exposed electrical connections present a shock hazard that can cause injury or death. (Refer to sub-section 3.4.2- Checking Connections of this user manual, where this specific warning statement is applicable)

If input or output circuits are a shock hazard after disconnecting system power at the power entry panel, then the door of the cabinet containing these externally powered circuits must be marked with a warning stating that multiple power sources exist. (Refer to sub-section 3.4.2- Checking Connections of this user manual, where this specific warning statement is applicable)

Safety Precaution

Description

SPECIFIC CAUTIONS

Use only the CSA certified fuses and relays specified in this user manual. Use the correct fuse for the selected relay. Failure to use the correct relay and fuse could cause damage to equipment. (Refer to sub-sections 2.4.2- Fuse Installation and 4.2- Fuse Replacement of this user manual, where this specific caution statement is applicable).

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module. Refer to sub-sections 2.5.2- Cable Connection and 4.4- Termination Unit Replacement of this user manual, where this specific caution statement is applicable).

About This Book

About This Book

Document Conventions

Microsoft Windows conventions are normally used for the standard presentation of material when entering text, key sequences, prompts, messages, menu items, screen elements, etc.

Information and Tip Icons

This publication includes Information and Notes where appropriate to point out important information or useful hints to the reader. The corresponding sections should be interpreted as follows:

Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a
Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a
Information alerts the reader to pertinent facts and conditions Warning indicates the presence of a

Information alerts the reader to pertinent facts and conditions

Warning indicates the presence of a hazard which could result in a plant shutdown.:

Caution indicates the presence of a hazard which could result in personal or hardware module damage.

NOTE

Note indicates advice on, for example, how to design your project or how to use a certain function

About This Book

1. Introduction

1.

Introduction

1.1 Overview

Overview

The NTDO02 Digital Output Termination Unit is a Harmony rack I/O device that is part of the Symphony Plus Control System. It provides up to eight solid state relay outputs. The controller configuration determines the output state of the NTDO02 termination unit relays.

The NTDO02 termination unit interfaces with an SPDSO14 Digital Output (DSO) Module through a cable connection. Each DSO module can have up to 16 output signals for relay control. Each of the 16 output signals can control up to nine relays via the NTDO02 termination unit. The DSO module can control up to 18 NTDO02 termination units. If more than one termination unit is used, the additional termination units are interconnected.

The following figure (Figure 1-1) shows the Harmony rack I/O architecture. A Harmony area controller and the Harmony rack controllers can use the rack I/O module and termination units for I/O interface.

rack I/O module and termination units for I/O interface. Figure 1-1 Harmony Rack I/O Architecture 1.2

Figure 1-1 Harmony Rack I/O Architecture

1.2 Description

The NTDO02 termination unit is a seven-by-seven inch square printed circuit board. The board contains:

• 10 dipshunt sockets.

• Two terminal strips.

• Eight fuse holders (for relays).

• Eight relay sockets.

• Two cable sockets.

• 24 VDC faston connector.

• DC common faston connector.

• One fuse (24 VDC power).

Mounting Hardware

1. Introduction

There are three types of relays available, each with different output capabilities. The relay type used depends on the current and voltage rating of the controlled device. Relays are not provided with the termination unit.

Each relay output is fused. The fuse (F1 through F8) value required for each relay depends on the current capability of the relay type used. Fuses F1 through F8 are not provided with the termination unit. Power (24 VDC) to switch the solid state relays is also fused (provided with termination unit).

1.3 Mounting Hardware

Harmony termination units mount in standard ABB enclosures. An NFTP01 Field Termination Panel is used for termination unit mounting (Figure 1-2). The panel attaches to the side rails in standard 438-millimeter (19-inch) enclosures.

side rails in standard 438-millimeter (19-inch) enclosures. Figure 1-2 Mounting Hardware 1.4 Intended User Personnel

Figure 1-2 Mounting Hardware

1.4 Intended User

Personnel installing, operating, or maintaining the NTDO02 termination unit should read this user manual before performing any installation, operation, or maintenance procedures. Installation requires an engineer or technician with experience in handling electronic circuitry. Personnel working with the NTDO02 termination unit must have experience working on it and know the precautions to take around AC/DC power. Knowledge of the Symphony system and electronic principles is also mandatory.

1.5 User Manual Content

The user manual consists of the following four sections:

Introduction:

This section provides an overview of the NTDO02 termination unit.

Installation:

This section explains the physical installation, wiring and cable requirements, dipshunt settings and handling of the termination unit.

Maintenance:

This section describes the maintenance schedule.

Repair and Replacement:

This section explains how to replace the fuses, relays and termination unit.

1.6 How to Use this Manual

Make sure to read this user manual in sequence. It is important to become familiar with the entire contents of the user manual before using the module.

This user manual is organized to enable quick information retrieval:

1. Introduction

Document Conventions

1. Perform the steps in the Installation section.

2. Refer to the Maintenance section for scheduled maintenance requirements.

3. Refer to the Repair and Replacement section to replace a termination unit.

1.7 Document Conventions

The ‘?’ in the nomenclature or in a part number indicates a variable for that position (e.g., IMMFP1?).

1.8 Reference Documents

The following table (Table 1-1) lists ABB instructions for equipment that is referenced in this user manual:

Table 1-1 Reference Documents

Number

Document

2VAA002157

Module Mounting Unit (IEMMU21, IEMMU22)

WBPEEUI200505??

Site Planning Guidelines

2VAA001623

SPDSO14 Digital Output Module

1.9 Related Nomenclature

The following table (Table 1-2) lists the nomenclature related to the NTDO02 termination unit:

Table 1-2 Related Nomenclature

Nomenclature

Description

IEMMU21, IEMMU22

Module mounting unit

SPDSO14

Digital output module

NFTP01

Field termination panel

NKTU01

PVC termination cable

NKTU11

Non-PVC termination cable

1.10 Specifications

The following table (Table 1-3) details the NTDO02 termination unit specifications:

Table 1-3 NTDO02 Termination Unit Specifications

Property

 

Characteristic/Value

Power requirements

+

24 VDC at 268 mA maximum

Cable insulation PVC (UL rating PLTC) Non-PVC (UL rating PLTC)

80°C (176°F) at 300 V 90°C (194°F) at 300 V

Mounting

Mounts on the field termination panel

Overvoltage category (ANSI/ISA S82.01-1994 and IEC 61010)

I for power

II

for outputs

Specifications

1. Introduction

Table 1-3 NTDO02 Termination Unit Specifications (Continued)

Property

Characteristic/Value

Environmental

 

Ambient temperature

0° to 70°C (32° to 158°F)

Relative humidity

5% to 95% up to 55°C (131°F) (non-condensing) 5% to 45% at 70°C (158°F) (non-condensing) Pollution degree: I

Altitude

Sea level to 3 km (1.86 mi)

Air quality

Noncorrosive

Cooling requirements

No cooling is required when used in ABB cabinets and operated within environmental limits

Installation category

III

Certifications

 

Canadian Standards Association (CSA)

Certified for use as process control equipment in an ordinary (non-hazardous) location.

Factory Mutual (FM)

Approved as nonincendive equipment for use in Class I; Division 2; Groups A,B,C,D; hazardous locations.

CE Mark

CE Mark EMC Directive 2004/108/EC & Low Voltage Directive

2006/95/EC

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

The following table (Table 1-4) details the relay and fuse specifications:

Table 1-4 Relay and Fuse Specifications

Property

 

Characteristic/Value

Relay type

 

120

VAC (ABB part number 1947684?32)

Fuse rating

4

A slo blo (60 A for one cycle surge)

Output (load) voltage range

12

VAC to 280 VAC

Output (load) current

3

A RMS maximum from 15° to 25°C (59° to 77°F)

1.2

A RMS maximum at 70°C (158°F)

Load frequency

47

to 63 Hz

Off-state leakage current

0.75 mA RMS maximum

One cycle surge capability

 

85

A PEAK maximum

Relay type

 

120

VAC (ABB part number 1947803?1 1 )

Fuse rating

4

A slo blo (60 A for one cycle surge)

Output (load) voltage range

24

VAC to 280 VAC

Output (load) current

3.5

A RMS maximum from 0° to 30°C (32° to 86°F)

1.75 A RMS maximum at 70°C (158°F)

Load frequency

 

47

to 63 Hz

Off-state leakage current

4

mA RMS maximum

One cycle surge capability

80

A PEAK maximum

1. Introduction

Specifications

Table 1-4 Relay and Fuse Specifications (Continued)

Property

 

Characteristic/Value

Relay type

 

24

VDC (ABB part number 1947685?31)

Fuse rating

3

A

Output (load) voltage range

5

VDC to 60 VDC

Output (load) current

3

ADC maximum from 15° to 25°C (59° to 77°F)

1.2

ADC maximum at 70°C (158°F)

Inductive loads should be diode suppressed

Off-state leakage at 60 VDC

 

10

ADC maximum

One second surge capability

5

ADC maximum

Relay type

 

125

VDC (ABB part number 1947684?32)

Fuse rating

1

A

Output (load) voltage range

10

VDC to 200 VDC

Output (load) current

1

ADC maximum from 15° to 25°C (59° to 77°F)

400

mADC maximum at 70°C (158°F)

Inductive loads should be diode suppressed

Off-state leakage at 200 VDC

 

10

ADC maximum

One second surge capability

1.5

ADC maximum

Certification

All relays are CSA approved. All DC relays pass IEEE-472-1989 test for surge and withstand capability.

NOTE:

1. Use this relay for AC applications requiring IEEE-472-1989 surge withstand capability.

SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

Specifications

1. Introduction

2. Installation

2.

Installation

Introduction

2.1

Introduction

This section explains NTDO02 termination unit installation. Do not proceed with operation until the steps are read, understand, and performed in the order in which they appear.

2.2

Special Handling

Observe these steps when handling electronic circuitry:

1. Use Static Shielding Bag: Keep an assembly in its static shielding bag until ready to install it in the system. Save the bag for future use.

2. Ground Bags before Opening: Before opening a bag containing an assembly with static sensitive devices, touch it to the equipment housing or ground to equalize charges.

3. Avoid Touching Circuitry: Handle assemblies by the edges; avoid touching the circuitry.

4. Avoid Partial Connection of Semiconductors: Verify that all devices connected to the module are properly grounded before using them.

5. Ground Test Equipment:

6. Use an Antistatic Field Service Vacuum: Remove dust from assemblies if necessary.

7. Use a Grounded Wrist Strap: Use the ABB field static kit (part number 1948385A1 - consisting of two wrist straps, ground cord assembly, alligator clip, and static dissipative work surface) when working with modules. The kit grounds a technician and the static dissipative work surface to the same ground point to prevent damage to the circuitry by electrostatic discharge. Connect the wrist strap to the appropriate grounding plug on the power supply or to an unpainted portion of the enclosure with the alligator clip. The wrist strap must be effectively connected to the earth grounding electrode system through the AC safety ground.

8. Do Not Use Lead Pencils to Set Switches: To avoid contamination of switch contacts that can result in unnecessary circuit board malfunction, do not use a lead pencil to set a switch.

2.3

Unpacking and Inspection

Follow the given steps to unpack and inspect the termination unit:

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

2. Notify the nearest ABB Sales Office of any such damage.

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.

2.4

Setup/Physical Installation

Set the dipshunts, install the fuses, and install the relays before installing or operating the NTDO02 termination unit. Figure 2-1 shows the layout of the termination unit.

2.4.1

Dipshunt Configuration

There are 10 dipshunts on the termination unit. Figure 2-1 shows the locations of the dipshunts. Dipshunts XU01 and XU02 determine the I/O module relay control. Configure a dipshunt by either cutting straps or leaving straps uncut in certain sequences. Cut the dipshunt straps using a standard shunt cutting tool. Always cut straps completely. Install the configured dipshunt into the desired socket on the termination unit. To install a dipshunt, align the end of the dipshunt identified with the

Dipshunt Configuration

2. Installation

silver dot to the end of the socket having an identification mark and push the dipshunt into the socket. Be careful not to bend any pins during insertion.

socket. Be careful not to bend any pins during insertion. Figure 2-1 Termination Unit Layout 2.4.1.1

Figure 2-1 Termination Unit Layout

2.4.1.1 Normal Operation (XU01 and XU02)

Normally each I/O module output controls one relay on the termination unit. The I/O module has 16 outputs divided into two groups. Outputs one through eight belong to group A and outputs nine through 16 belong to group B. Group A controls outputs one through eight on a termination unit connected to the I/O module. The termination unit can be interconnected to a second termination unit. Group B controls the second termination unit.

The following table (Table 2-1) shows the settings for dipshunts XU01 and XU02 for normal operation:

NOTE: To control the termination unit using I/O module group A (one through eight) outputs, install dipshunt XU01. To control the termination unit using I/O module group B (nine through 16) outputs, install dipshunt XU02. Do not install both dipshunts (XU01 and XU02) on the same termination unit.

Table 2-1 Dipshunt XU01 and XU02 Normal Operation Settings

XU01 Dishunt

XU02 Dipshunt

Function

Configuration

Configuration

I/O module group A (outputs 1 - 8) controls termination unit outputs 1 - 8.
I/O module group A (outputs 1 - 8) controls termination unit outputs 1 - 8.

I/O module group A (outputs 1 - 8) controls termination unit outputs 1 - 8.

I/O module group B (outputs 9 - 16) controls termination unit outputs 1 - 8.
I/O module group B (outputs 9 - 16) controls termination unit outputs 1 - 8.

I/O module group B (outputs 9 - 16) controls termination unit outputs 1 - 8.

NOTE: 0 = open or cut strap, 1 = intact or shorted strap.

2.

Installation

Dipshunt Configuration

2.4.1.2 Advanced Applications (XU01 and XU02)

In advanced applications, a single output from the I/O module can control up to nine relays. Each I/O module can control up to 18 interconnected termination units.

The following figure (Figure 2-2) shows the internal circuitry of dipshunt sockets XU01 and XU02:

the internal circuitry of dipshunt sockets XU01 and XU02: Figure 2-2 Dipshunt Socket XU01 and XU02

Figure 2-2 Dipshunt Socket XU01 and XU02 Internal Circuitry

There are two ways to configure the NTDO02 termination unit. Use either dipshunts or insert an adapter plug (part number 1947690?16) into the dipshunt socket. Figure 2-3 and Figure 2-4 show two configuration examples.

The following figure (Figure 2-3) shows an I/O module with each output controlling a relay:

) shows an I/O module with each output controlling a relay: Figure 2-3 Example Configuration Using

Figure 2-3 Example Configuration Using Dipshunts

The following figure (Figure 2-4) shows an example of an I/O module controlling 27 relays through four termination units using adapter plugs:

• I/O module output one (group A) controls nine relays.

• I/O module output two (group A) controls three relays.

• I/O module output 10 (group B) controls eight relays.

Dipshunt Configuration

• I/O module output 11 (group B) controls seven relays.

2. Installation

output 11 (group B) controls seven relays. 2. Installation Figure 2-4 Example Configuration Using Adapter Plugs

Figure 2-4 Example Configuration Using Adapter Plugs

When using the adapter plugs, jumper the I/O module outputs to the appropriate relays by soldering wire (22 to 30 AWG) on the adapter plug and then insert the adapter plug into the dipshunt socket (XU01 or XU02).

2.4.1.3 I/O Module Selection (XU03 Through XU10)

Dipshunts XU03 through XU10 determine the type of I/O module used. Dipshunts XU03 through XU10 must be configured identically for each relay being used on all termination units connected to a particular I/O module.

The following table (Table 2-2) shows the settings for dipshunts XU03 through XU10:

NOTE: To use any output on interconnected termination units, the corresponding dipshunt must be configured and installed on all preceding interconnected termination units.

For Example: If there are three interconnected termination units, then XU09 on all three termination units must have a configured dipshunt installed to use output seven on the last interconnected termination unit. Install a configured dipshunt in XU09 and XU10 to use output eight on any NTDO02 termination unit. Configuring XU09 connects 24 VDC to XU10.

Table 2-2 Dipshunt XU03 through XU10 Settings

Dipshunt Configuration

Dipshunt Configuration Function SPDSO14 module

Function

SPDSO14 module

NOTE: 0 = open or cut strap, 1 = intact or shorted strap.

2.

Installation

Fuse Installation

2.4.2

Fuse Installation

Use only the CSA certified fuses and relays specified in this instruction. Use the correct

Use only the CSA certified fuses and relays specified in this instruction. Use the correct fuse for the selected relay. Failure to use the correct relay and fuse could cause damage to equipment.

 

The eight outputs on the termination unit are protected by a fuse (F1 through F8). Output one is protected by fuse F1, output two by fuse F2, etc. Fuses F1 through F8 are not provided with the termination unit. Install the correct fuse for each relay type.

The following table (Table 2-3) shows the corresponding fuses and relays:

 

NOTE: The fuse rating may be higher than the relays current capabilities. The fuse is rated to protect the output device from damage due to a short circuit. These fuse ratings allow short duration surge currents to pass while providing protection for normal current operation.

 

Table 2-3 Fuse and Relay Ratings

 
   

Relay

 

Fuse

 

Output

Part Number

Description

Part Number

120

VAC

1947684?32, 1947803?1 1

4

A (slo blo)

194776?24001

24 VDC

1947685?31

3

A

194776?13001

125

VDC

1947685?32

1

A

194776?11001

NOTE:

 
 

1. Use part number 1947803?1 for AC applications requiring IEEE-472- 1989 surge and withstand capability.

 
 

Fuse F9 (part number 194776_15000) is an input fuse for 24 VDC to the termination unit. Fuse F9 is used by the I/O module output switch and the solid state relay input voltage circuit. Fuse F9 is rated at 500 milliamperes. Verify that fuse F9 is installed in the termination unit. If there are interconnected termination units, only the first termination unit (the one cabled directly to the I/O module) requires a fuse.

2.4.3

Relay Installation

The solid state relays must be installed in the termination unit. Select relays and fuses from Table 2-3. Each relay controls one output. The relay type installed depends on the application. Use the appropriate fuse with the relay per the listing in Table 2-3. Insert the relay into the socket on the termination unit by aligning the pins with the socket. The relay has offset pins to insure proper installation. Do not bend the pins on the relay. Secure the relay to the board by tightening the captive hold-down screw in the relay. Do not overtighten the screw.

2.5

Termination Unit Installation

 

The termination unit is ready for installation when the dipshunts are properly installed and configured, and the relays and fuses are in place. The termination unit mounts on a standard NFTP01 panel as shown in Figure 1-1.

2.5.1

Mounting

Follow the given steps to mount the NTDO02 termination unit to the field termination panel:

1. Remove the safety shield.

Cable Connection

2. Installation

2. Insert the tabs of the circuit board into the proper slots of the termination panel standoff as shown in Figure 2-5 and slide the circuit board into position.

in Figure 2-5 and slide the circuit board into position. Figure 2-5 Termination Unit Installation 3.

Figure 2-5 Termination Unit Installation

3. Secure the termination unit circuit board to the field termination panel with two No. 10 thread-forming screws (Figure 2-5).

2.5.2 Cable Connection

After mounting the termination unit to the field termination panel, install the termination cables.

The following table (Table 2-4) lists the cables, their applications, connector assignments and maximum length restrictions:

Table 2-4 Cable Applications

Nomenclature/Description

Application

NTDO02

Max. Length

Connector

m (ft)

NKTU01 (PVC)

NTDO02 to module

P1

30 (100)

NKTU11 (non-PVC)

termination cable

NKDO01 (PVC) NKDO11 (non-PVC) interconnection cable

NTDO02 to NTDO02

P1 and P2

1.5 (5.0)

2. Installation

Power Wiring

The following figure (Figure 2-6) shows a diagram of cable connections to the I/O module and termination unitt

of cable connections to the I/O module and termination unitt Figure 2-6 Cable Connections Follow the

Figure 2-6 Cable Connections

Follow the given steps to install the termination unit cable:

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module.the given steps to install the termination unit cable: 1. Install the J2 connector of the

1. Install the J2 connector of the NKTU01 or NKTU11 termination unit cable in the module mounting unit backplane slot assigned to the I/O module.

2. Insert the J1 connector of the NKTU01 or NKTU11 termination unit cable into P1 of the termination unit.

NOTE: When using interconnected termination units use an NKDO01 or NKDO11 interconnection cable.

Follow the given steps to install the interconnection cable:

1. Connect the 24-pin connector of the interconnection cable to P2 of the first interconnected termination unit.

NOTE: The first interconnected termination unit is connected to the I/O module.

2. Connect the 36-pin connector of the interconnection cable to P1 of the second interconnected termination unit.

3. Repeat for all interconnected termination units (up to 18).

2.5.3 Power Wiring

There are two terminals that provide power and ground connections. Refer to Figure 2-1 for terminal locations. Terminal E1 is the 24 VDC power connection. Terminal E2 is the I/O common connection.

Follow the given steps to connect the power wiring:

Verify the main power, field power, and power entry panel circuit breakers/switches are turned off before starting installation, retrofit, upgrade, or wiring procedures. Failure to do so could result in severe or fatal shock. Do not turn the power on until the installation, retrofit, upgrade, or wiring procedures are complete.Follow the given steps to connect the power wiring: 1. Attach a 14 AWG wire from

1. Attach a 14 AWG wire from the 24 VDC power distribution source to the E1 terminal on the termination unit.

2. Attach a 14 AWG wire from the I/O common to the E2 terminal of the termination unit.

NOTE: All interconnected NTDO02 termination units derive 24 VDC power for their outputs from the E1 connector on the first termination unit. Therefore, when connecting 24 VDC power and I/O common to interconnected termination units, connect 24 VDC power and I/O common to the first termination unit only.

Terminal Block Wiring

2.5.4

Terminal Block Wiring

2. Installation

Refer to Figure 2-7 for terminal block assignments and terminal polarity. Field wiring requirements will depend on the application. Refer to the Site Planning Guidelines instruction for specific information on field wiring installation requirements (i.e., spacing, isolation, etc.). Connect the wiring from the terminals to the output devices. Proper wiring polarity is required for relay signals.

2.6

Installation Complete

The termination unit is ready for operation when:

• The fuses are installed.

• The relays are installed.

• The dipshunts or plug adapters are installed.

• The termination unit is installed on the field termination panel.

• The cables are connected.

• Power wiring is connected and applied to the termination unit.

• Terminal block wiring is connected to the termination unit and field device.

• The safety shield is installed.

termination unit and field device. • The safety shield is installed. Figure 2-7 Terminal Assignments 2-8

Figure 2-7 Terminal Assignments

3. Maintenance

3.

Maintenance

3.1 Introduction

Introduction

The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB recommends that all equipment receive preventive maintenance which will keep the equipment operating at an optimum level.

This section presents procedures that the customer should be able to perform on site. These preventive maintenance procedures should be used as a guideline to assist in establishing good preventive maintenance practices.

Personnel performing preventive maintenance should meet the following qualifications.

• Qualified electrical technicians or engineers who have proper knowledge of using test equipment.

• Knowledge of module mounting unit

• Knowledge of field termination panel

• Experience working with process control systems and knowing what precautions to take when working on live AC and/or DC systems.

3.2 Preventive Maintenance Schedule

The following table (Table 3-1) details the preventive maintenance schedule for the NTDO02 termination unit; where the preventive maintenance tasks in groups according to their specified maintenance interval. Instructions for tasks that require further explanation are covered under sub-section 3.4- Preventive Maintenance Procedures of this user manual.

NOTE: The preventive maintenance schedule is for general purposes only. Application may require special attention.

Table 3-1 Preventive Maintenance Schedule

Task

Frequency

Check cabinet air filters. Clean or replace them as necessary. Check the air filter more frequently in excessively dirty environments.

3 months

Check cabinet and termination unit for dust. Clean as necessary using an antistatic vacuum.

Check all termination unit signal, power and ground connections within the cabinet. Verify that they are secure. Refer to procedure.

Check termination unit circuit board, giving special attention to power contacts and edge connectors. Clean as necessary. Refer to procedure.

12 months

Complete all tasks in this table.

Shutdown

3.3 Equipment and Tools Required

Following are the tools and equipment required for maintenance procedures:

• Antistatic vacuum.

• Screwdriver (medium length).

• Isopropyl alcohol (99.5 percent electronic grade).

• Distilled water.

• Compressed air.

• Foam tipped swabs.

• Lint-free cloths.

• Nonabrasive eraser.

3.4 Preventive Maintenance Procedures

This section covers the following tasks from Table 3-1 that requires specific instructions or further explanation:

• Cleaning printed circuit boards and edge connectors.

Printed Circuit Board Cleaning

• Checking signal, power and ground connections.

3. Maintenance

3.4.1

Printed Circuit Board Cleaning

Never clean electrical parts or components with live power present. Doing so exposes you to

Never clean electrical parts or components with live power present. Doing so exposes you to an electrical shock hazard.

 

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.

 

There are several circuit board cleaning procedures in this section. These procedures cover circuit board cleaning and washing, cleaning edge connectors and circuit board laminate between edge connectors. Use the procedures that meet the needs of each circuit board. Remove all dust, dirt, oil, corrosion or any other contaminant from the circuit board.

Perform all cleaning and handling of the printed circuit boards at static safe work stations. Always observe the steps under sub-section 2.2- Special Handling of this user manual when handling printed circuit boards.

3.4.1.1

General Cleaning and Washing

If the printed circuit board needs minor cleaning, remove dust and residue from the printed circuit board surface using clean, dry, filtered compressed air or an antistatic field service vacuum cleaner.

Follow the given steps to wash the printed circuit board:

 

1. Clean the printed circuit board by spraying or wiping it with isopropyl alcohol (99.5% electronic grade).

2. Wipe the circuit board with a form tipped swab.

3. Remove excess solvent by using compressed air to blow it free of the circuit board.

3.4.1.2

Edge Connector Cleaning

Follow the given steps to clean the edge connector:

 

1. Use a solvent mixture of 80% isopropyl alcohol (99.5% electronic grade) and 20% distilled water.

2. Soak a lint-free cloth with the solvent mixture.

3. Work the cloth back and forth parallel to the edge connector contacts.

4. Repeat with a clean cloth that is soaked with the solvent mixture.

5. Dry the edge connector contact area by wiping with a clean lint-free cloth.

 

Follow the given steps to clean tarnished or deeply stained edge connector contacts:

 

1. Use a nonabrasive eraser or equivalent to remove tarnish or stains.

NOTE: Fiberglass or nylon burnishing brushes can also be used.

2. Minimize electrostatic discharge by using the 80/20 isopropyl alcohol/water solution during burnishing.

NOTE: Do not use excessive force while burnishing but use only enough force to shine the contact surface.

3. Inspect the edge connector after cleaning, to assure no loss of contact surface.

4. Wipe clean with a lint-free cloth.

3.4.2

Checking Connections

NOTE: Power to the cabinet must be off while performing this preventive maintenance task.

There are exposed AC and DC connections inside the cabinet. These exposed electrical connections present a shock hazard that can cause injury or death.be off while performing this preventive maintenance task. If input or output circuits are a shock

If input or output circuits are a shock hazard after disconnecting system power at the power entry panel, then the door of the cabinet containing these externally powered circuits must be marked with a warning stating that multiple power sources exist.

Check all signal wiring, power and ground connections within the cabinet to verify their integrity. When checking connections, always turn a screw, nut or other fastening device in the direction to tighten only. If the connection is loose, it is tightened. If the connection is tight, the tightening action verifies that it is secure. There must not be any motion done to loosen the connection.

3. Maintenance

During check connections:

Checking Connections

• Verify whether all power connections within the cabinet are secure.

• Verify whether all wiring connections to the termination unit are secure.

Checking Connections

3. Maintenance

4. Repair and Replacement

4. Repair and Replacement

4.1 Introduction

Introduction

This section explains the repair and replacement procedures for an NTDO02 termination unit.

4.2 Fuse Replacement

for an NTDO02 termination unit. 4.2 Fuse Replacement Use only CSA certified fuses and relays specified

Use only CSA certified fuses and relays specified in this user manual. Use the correct fuse for the selected relay. Failure to use the correct and fuse could cause damage to equipment.

If a fuse opens, replace it with a fuse having an equivalent rating. Table 4-1 describes the fuses and lists the ABB part numbers.

Follow the given steps to replace a fuse:

1. Turn off power to the cabinet.

2. Remove the safety shield.

3. Remove the blown fuse from its holder.

4. Replace the blown fuse with an equivalent fuse.

5. Install the safety shield.

6. Turn on power to the cabinet.

Table 4-1 Parts List

Part Number

Description

Part Number

Description

1946715?8

Dipshunt

194776?13001

Fuse, 3 A, 250 V

1947684?32

Relay, 120 VAC

194776?15000

Fuse, 500 mA, 250 V

1947685?31

Relay, 24 VDC

194776?24001

Fuse, 4 A, 250 V (slo blo)

1947685?32

Relay, 125 VDC

1947803?1 1

Relay, 120 VAC

1947690?16

Plug adapter

NFWAB17010

0.19-16 (no. 10) x 5/8 in. Phillips-head thread forming screw

1947691?16

Plug adapter cover

NTLAC19000

0.19 in. (no. 10) external tooth lock washer

194776?11001

Fuse, 1 A, 250 V

   

NOTE:

1. Use part number 1947803?1 for AC applications requiring IEEE-472-1989 surge and withstand capability.

4.3 Relay Replacement

If a relay fails, replace it with an equivalent relay. Table 4-1 describes the relays and lists ABB part numbers.

Follow the given steps to replace a relay:

1. Turn off power to the cabinet and the field device.

2. Remove the safety shield.

3. Remove the failed relay from the termination unit.

4. Replace the failed relay with an identical relay.

NOTE: Refer to Table 4-1 for ABB part numbers.

5. Install the safety shield.

6. Turn on power to the cabinet and the field device.

Termination Unit Replacement

4.4 Termination Unit Replacement

4. Repair and Replacement

If it is determined that the termination unit is faulty, then replace it with a new one. Do not try to repair the unit; replacing components may affect the unit performance and certification. When replacing a termination unit, observe the special handling guidelines listed in section 2- Installation of this user manual.

NOTE: Turn off power to the field devices before removing the cables from the termination unit.

before removing the cables from the termination unit. Remove a module from its assigned slot before

Remove a module from its assigned slot before installing or removing a cable assigned to that slot. Failure to do so could result in damage to the module.

Follow the given steps to replace the termination unit:

1. Turn off power to the cabinet and remove the safety shield.

2. Disconnect the 24 VDC and I/O common wiring from the E1 and E2 faston connectors of the termination unit.

3. Mark the wires according to the terminal assignment when removed.

4. Disconnect the interconnection cable from the P1 or P2 connector on the termination unit, if it is connected.

5. Mark the cable according to its connector assignment.

6. Remove the second interconnection cable from P1 or P2 and mark the cable accordingly, if the termination unit is interconnected between two termination units.

7. Pull the I/O module out of its cable connection on the module mounting unit backplane, if the termination unit is connected to an I/O module.

8. Disconnect the termination cable from the P1 connector on the termination unit, if a termination cable is connected.

9. Mark the cable according to its connector assignment.

10. Turn off power to the field devices.

11. Disconnect I/O wiring from the terminal blocks.

12. Mark the wires according to the terminal assignment.

13. Remove the two mounting screws and the termination unit from the field termination panel, when all cables and wires are removed from the termination unit,

14. Verify whether the dipshunts (the plug adapters, if used) on the replacement termination unit are the same as the dipshunt settings on the faulty termination unit.

15. Verify that the fuses (F1 - F9) are installed on the replacement termination unit.

16. Verify that the relays are installed on the replacement termination unit.

17. Secure the replacement termination unit circuit board to the field termination panel with the two mounting screws.

18. Connect the termination unit cables to their assigned connector on the termination unit.

19. Connect the I/O wiring to the terminal strips.

20. Connect the 24 VDC and common wiring to the E1 and E2 faston connectors of the termination unit.

21. Push the faceplate of the I/O module to fully insert it into its module mounting unit slot.

NOTE: The I/O modules must be seated in the termination unit cable at the rear of the module mounting unit when fully inserted.

22. Install the safety shield and return power to the field devices, after all cables and wiring are replaced.

23. Return power to the cabinet.

C

Checking connections 2 Cleaning Edge connectors 2 Printed circuit boards 2 Conventions, documents 3

D

Dipshunt Adapter plugs 3 Advanced applications 3 Normal operation 2

F

Field static kit 1 Fuse Installation 5 Replacement 1

H

How to use this instruction 2

I

I/O terminal assignments 8 I/O wiring 8 Installation Cables 6 Fuse 5 I/O wiring 8 Power wiring 7 Relay 5 Termination unit 5

M

Maintenance 1 Schedule 1 Tools required 1 Mounting hardware 2

P

Parts list 1 PCB cleaning 2 Power wiring 7 Preventive maintenance Checking connections 2 Schedule 1 Tools and equipment 1

R

Relay Installation 5 Replacement 1 Replacement Fuse 1 Relay 1 Termination unit 2

S

Setup/physical installation 1 Special handling 1

T

Termination unit Cables 6 Description 1 Dipshunt configuration 1 Installation 5 Mounting 5 Replacement 2

U

Unpacking and inspection 1 User qualifications 2

INDEX

INDEX

Document Number: 2VAA001694

ABB Ltd. Business Unit Power Generation P.O. BOX 8131 8050 Zürich SWITZERLAND Phone: +41 (0) 43 317-5380 Fax: +41 (0) 43 317-5382 www.abb.com/powergeneration

Notice The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license. This product meets the requirements specified in EMC Directive 2004/108/EC and in Low Voltage Directive

2006/95/EC.

Copyright © 2012 by ABB. All rights reserved. Release: August 2012