Symphony Plus

S+ Turbine Control: SPFCS01

Frequency Counter Module
User Manual

Symphony Plus
Symphony Plus

S+ Turbine Control: SPFCS01

Frequency Counter Module
User Manual
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 meets the requirements specified
in EMC Directive 2004/108/EC and in Low Voltage Directive 2006/95/EC.

TRADEMARKS
Symphony is a registered or pending trademark of ABB S.p.A.

All rights to copyrights, registered trademarks, and trademarks reside with their respective owners.
Copyright © 2012 ABB.
All rights reserved.
Release: December 2012
Document number: 2VAA002472
Preface
The SPFCS01 Frequency Counter Module is a Harmony rack I/O module that is part of the Symphony Enterprise
Management and Control System. It provides a single channel frequency input for a Harmony controller to calculate turbine
speed.

This user manual explains the SPFCS01 module specifications and operation. It details the procedures necessary to
complete setup, installation, maintenance, troubleshooting, and replacement of the module.

NOTE: The SPFCS01 module is fully compatible with existing INFI 90® OPEN Strategic Enterprise Management
Systems.All references to the FCS01 module in this user manual apply to both the INFI90 and Symphony Plus versions
of these products (IMFCS01 and SPFCS01) respectively.
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 Application...........................................................................................................1-1
1.3 Intended User ......................................................................................................1-1
1.4 User Manual Content ..........................................................................................1-2
1.5 How to Use this Manual ......................................................................................1-2
1.6 Document Conventions ......................................................................................1-2
1.7 Reference Documents.........................................................................................1-2
1.8 Related Nomenclature ........................................................................................1-3
1.9 Glossary of Terms and Abbreviations...............................................................1-3
1.10 Specifications ......................................................................................................1-4

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

2.1 Introduction .........................................................................................................2-1
2.2 Module Description .............................................................................................2-1
2.3 Control Loop Operation......................................................................................2-1
2.3.1 FCS01 Module .................................................................................................2-1
2.3.2 HSS03 Module.................................................................................................2-2
2.3.3 Controller .........................................................................................................2-2
2.4 Operation .............................................................................................................2-2
2.5 Module Circuitry ..................................................................................................2-3
2.5.1 Input Signal Conditioning .................................................................................2-3
2.5.2 Microprocessor ................................................................................................2-4
2.5.3 Data Storage ....................................................................................................2-4
2.5.4 Sequencing Logic ............................................................................................2-4
2.5.5 Watchdog Timer...............................................................................................2-5
2.5.6 Module Status ..................................................................................................2-5
2.5.7 I/O Expander Bus Interface..............................................................................2-5
2.6 Mounting Hardware.............................................................................................2-5

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

3.1 Introduction .........................................................................................................3-1
3.2 Special Handling .................................................................................................3-1

2VAA002472 i
TABLE OF CONTENTS

3.3 Unpacking and Inspection..................................................................................3-1

3.4 Termination Unit Installation ..............................................................................3-1
3.5 I/O Expander Bus Address (SW1) ......................................................................3-2
3.6 Module Installation ..............................................................................................3-2
3.7 Configuration.......................................................................................................3-3

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

4.1 Introduction .........................................................................................................4-1
4.2 Startup ..................................................................................................................4-1
4.3 Operation .............................................................................................................4-1

5. Troubleshooting............................................................................................. 5-1
5.1 Introduction .........................................................................................................5-1
5.2 Procedure.............................................................................................................5-1
5.3 Startup Failures ...................................................................................................5-1
5.3.1 Configuration Error...........................................................................................5-1
5.3.2 Hardware Failure .............................................................................................5-1
5.4 Online Failure ......................................................................................................5-4
5.5 Connector Pin Assignments ..............................................................................5-5

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

6.1 Introduction .........................................................................................................6-1
6.2 Preventive Maintenance Schedule ....................................................................6-1
6.3 Equipment Required ...........................................................................................6-1
6.4 Preventive Maintenance Procedures.................................................................6-2
6.4.1 Checking Connections .....................................................................................6-2
6.4.2 Printed Circuit Board Cleaning.........................................................................6-2

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

7.1 Introduction .........................................................................................................7-1
7.2 Module Replacement ..........................................................................................7-1
7.3 Termination Unit Replacement...........................................................................7-1

A. NTDI01 Termination Unit ............................................................................... A-1

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

ii 2VAA002472
 LIST OF TABLES

LIST OF TABLES

Table 1-1: Reference Documents .............................................................................. 1-2

Table 1-2: Related Nomenclature .............................................................................. 1-3
Table 1-3: Glossary of Terms and Abbreviations ....................................................... 1-3
Table 1-4: Specifications ............................................................................................ 1-4
Table 3-1: I/O Expander Bus Address (SW1) - Example Settings ............................. 3-2
Table 5-1: Startup Failures ......................................................................................... 5-3
Table 5-2: Online Failures .......................................................................................... 5-5
Table 5-3: P1 Module Power Pins .............................................................................. 5-5
Table 5-4: P2 I/O Expander Bus Pins ........................................................................ 5-6
Table 5-5: P3 I/O Pins ................................................................................................ 5-6
Table 6-1: Preventive Maintenance Schedule ............................................................ 6-1
Table A-1: NTDI01 Dipshunt Configuration ................................................................A-1

2VAA002472 iii
LIST OF TABLES

iv 2VAA002472
 LIST OF FIGURES

LIST OF FIGURES

Figure 1-1: Harmony Rack I/O Architecture ................................................................ 1-1

Figure 2-1: Turbine Speed Control Loop..................................................................... 2-1
Figure 2-2: Functional Block Diagram ......................................................................... 2-3
Figure 2-3: Input Signal Conditioning Circuit............................................................... 2-4
Figure 2-4: Mounting Hardware................................................................................... 2-6
Figure 3-1: Switch SW1 - I/O Expander Bus Address ................................................. 3-2
Figure 5-1: Hardware Failure Troubleshooting Flowchart (1 of 2)............................... 5-2
Figure 5-2: Hardware Failure Troubleshooting Flowchart (2 of 2)............................... 5-3
Figure 5-3: Online Failure Troubleshooting Flowchart ................................................ 5-5
Figure A-1:NTDI01 Dipshunt ...................................................................................... A-1
Figure A-2:NTDI01 Terminals..................................................................................... A-2

2VAA002472 v
LIST OF FIGURES

vi 2VAA002472
Safety Summary

The following table categorizes the various safety precautions to be followed when using the FCS01 module:

Safety Precaution Description

Electrostatic Sensitive Device
Devices labeled with this symbol require special handling
precautions as described in section 3- 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 Disconnect power before installing dipshunts on the MMU
backplane. Failure to do so will result in contact with
cabinet areas that could cause severe or fatal shock.
(Refer to sub-section 3.6- Module Installation 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 6.4.1- Checking Connections 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
6.4.2- 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
6.4.2- Printed Circuit Board Cleaning of this user manual,
where this specific warning statement is applicable)

2VAA002472 1
2 2VAA002472
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 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

2VAA002472 3
 About This Book

4 2VAA002472
Introduction Overview

1. Introduction
1.1 Overview
The FCS01 Frequency Counter Module is a Harmony rack I/O module that is part of the Symphony Enterprise Management
and Control System. It provides a single channel frequency input for a Harmony controller.

The FCS01 module conditions, converts, and processes pulse inputs from a magnetic pickup attached to the front standard
of a steam or gas turbine. The converted digital data represents a count of the input pulses and the period of the count. The
controller uses the data to calculate frequency and consequently turbine speed. The FCS01 module provides exceptional
frequency counting accuracy required by steam or gas turbine control systems. In most applications, the FCS01 module
works with the HSS03 Hydraulic Servo Module.

NOTE: The FCS01 module is fully compatible with existing INFI 90® OPEN Strategic Enterprise Management
Systems.

The following figure (Figure 1-1) shows the Harmony rack I/O architecture with the FCS01 module and HSS03 module. A
Harmony area controller or Harmony rack controllers can use these rack I/O modules for I/O interface.

Figure 1-1: Harmony Rack I/O Architecture

1.2 Application
One application of the FCS01 module is turbine speed control. The FCS module converts pulse inputs from a magnetic
sensing device on a turbine into digital data and sends the data to the controller through the I/O expander bus (Figure 1-1).

The controller calculates turbine speed using the data the FCS01 module provides. The configuration within the controller
uses the calculated speed to control servo valve outputs according to the user-defined control strategy.

In most applications, the FCS module works with the HSS03 module. The HSS module allows the operator to position
(manual or automatic) a hydraulic actuator using a servo valve. The hydraulic actuator positions a gas turbine fuel valve or
steam turbine governor valve. As the valve opens or closes, it regulates the fuel or steam flow to the turbine thus controlling
the turbine speed.

1.3 Intended User

Personnel installing, operating, or maintaining the FCS01 module 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 frequency counter module 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.

2VAA002472 1-1
User Manual Content Introduction

1.4 User Manual Content

This user manual consists of seven sections and one appendix:
• Introduction
This section provides an overview of the FCS01 module and its specifications.

• Description and Operation:

This section explains the FCS01 module operation though major functional blocks using schematics, block
diagrams, and text.

• Installation:
This section covers field wiring, switch settings, and configuration.

• Operating Procedures:
This section explains how to startup and operate the FCS01 module.

• Troubleshooting
This section provides corrective actions for system startup and operational problems.

• Maintenance
This section provides a list of maintenance procedures.

• Repair and Replacement:

This section provides procedures that explain how to replace the FCS01 module and its termination unit.

• Appendix A: NTDI01 Termination Unit:

This appendix provides NTDI01 dipshunt settings, and also shows the NTDI01 terminal assignments and cable
connections.

1.5 How to Use this Manual

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

This user manual is organized to enable quick information retrieval as follows:

1. Read the Operating Procedures section before installing the module.
2. Perform the steps in the Installation section.
3. Refer to the Troubleshooting section to resolve problems if they occur.
4. Refer to the Maintenance section for scheduled maintenance requirements.
5. Refer to the Repair and Replacement section to replace a module.

1.6 Document Conventions

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

1.7 Reference Documents

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

Table 1-1: Reference Documents

Doc ID Document Name

2VAA002157* S+ Control: IEMMU21/IEMMU22- Module Mounting Unit User Manual

2VAA000844* Symphony Plus Function Code Application Manual

1-2 2VAA002472
Introduction Related Nomenclature

Table 1-1: Reference Documents (Continued)

Doc ID Document Name

2VAA002394 S+ Turbine Control: SPHSS03- Hydraulic Servo Module User Manual

2VAA001693 S+ Control: NTDI01 - Digital Input Termination Unit User Manual

2VAA000813 S+ Engineering: Composer Harmony Automation Architect Manual

1.8 Related Nomenclature

The following table (Table 1-2) lists nomenclature related to the FCS01 module.

Table 1-2: Related Nomenclature

Nomenclature Description

IEMMU21, IEMMU22 Module mounting unit

NFTP01 Field termination panel

1.9 Glossary of Terms and Abbreviations

The following table (Table 1-3) contains the terms and abbreviations that are unique to ABB Automation or have a definition
that is different from standard industry usage:

Table 1-3: Glossary of Terms and Abbreviations

Term Definition

Cnet Symphony system advanced data communication highway.

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

information between intelligent modules within a Harmony control unit.

Function code An algorithm which manipulates specific functions. These functions are linked
(FC) together to form the control strategy.

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

Module mounting A card cage that provides electrical and communication support for Harmony
unit (MMU) rack modules.

Termination unit Provides input/output connection between plant equipment and the Harmony
(TU) rack modules.

2VAA002472 1-3
Specifications Introduction

1.10 Specifications
The following table (Table 1-4) lists the FCS01 module specifications:

Table 1-4: Specifications

Property Characteristic/Value

Power requirements
Operating voltage 5 VDC at 241 mA typical
+15 VDC at 6.88 mA typical
–15 VDC at 5.39 mA typical
Power dissipation 1.2 W (5 VDC)
185 mW (±15 VDC)

Input 1 frequency input channel

Voltage range 300 mVPP to 120 VRMS (150 mVP to 170 VP)
Frequency response 1 Hz to 12.5 kHz

Accuracy ±0.25 Hz at 1 Hz to 5 kHz

±0.50 Hz at 5 kHz to 10 kHz
±0.63 Hz at 10 kHz to 12.5 kHz

A-to-D resolution 24 bits

Module time base

Frequency 1 MHz
Accuracy 0.005%
Count ±1 of time base

Resolution 24 bits

Mounting Occupies a single slot in a standard module mounting unit.

Surge protection Meets IEEE-472-1974 surge withstand capability test.

Environment
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: 1
Altitude Sea level to 3 km (1.86 miles)
Air quality Noncorrosive

CE Mark declaration This product, when installed in a Symphony cabinet, complies with the
(pending) following directives/standards for CE marking.
EMC96 Directive EN50082-2 Generic Immunity Standard - Part 2: Industrial Environment
2004/108/EC EN50081-2 Generic Emission Standard - Part 2: Industrial Environment
Low Voltage Directive EN61010-1 Safety Requirements for Electrical Equipment for
2006/95/EC Measurement, Control and Laboratory Use - Part 1: General Require-
ments

Certifications
Canadian Standards Certified for use as process control equipment in an ordinary (nonhaz-
Association (CSA) ardous) location.
Factory Mutual (FM) Approval for the following categories:
Non-incendive for:
Class I Division 2, Groups A,B,C,D
Class II, Division 2, Groups F,G

SUBJECT TO CHANGE WITHOUT NOTICE

1-4 2VAA002472
Description and Operation Introduction

2. Description and Operation

2.1 Introduction
This section explains the operation of the FCS01 module. It gives an overview of the frequency counter (FCS) module and
related modules within a process control system and explains the operation of the module circuitry.

2.2 Module Description

The FCS module is an intelligent I/O module with microprocessor, memory, and communication circuitry. The FCS module
consists of a single printed circuit board that occupies one slot in a module mounting unit (MMU). Two captive latches on
the module front panel secure it to the module mounting unit.

The FCS module has three card edge connectors for external signals and power: P1, P2 and P3. P1 connects to the supply
voltages. P2 connects the module to the I/O expander bus, over which it communicates with the controller. Connector P3
carries the I/O from the termination cable plugged into the termination unit (TU). The terminal blocks for field wiring are on
the termination unit.

2.3 Control Loop Operation

The FCS module, hydraulic servo (HSS) module, and Harmony controller form the controlling segment of a closed loop
control system. The controller directs the control process. The FCS and HSS modules interface the process to the
controller.

The following figure (Figure 2-1) shows a diagram of the turbine speed control loop and the control signals to and from the
process:

Figure 2-1: Turbine Speed Control Loop

2.3.1 FCS01 Module

The FCS module detects turbine speed by counting pulses it receives from a magnetic pickup on the turbine shaft.
Additionally, it keeps a 24-bit timer value corresponding to the period of the pulse count. It stores these values in a buffer
and sets a data available status bit to notify the controller that it has current data. FCS module operation is automatic; it
continuously updates the count and holds it for the controller.

2VAA002472 2-1
HSS03 Module Description and Operation

For the controller to work with the FCS module, it requires FC 145 in its configuration. FC 145 defines the module address,
high/low speed alarms, and high/low rate of change alarms. The block output is frequency of input pulses in hertz. The FCS
module continuously checks itself and notifies the controller if a failure occurs.

2.3.2 HSS03 Module

The HSS module provides control of throttle valve position in a turbine speed control system. The controller sends data to
the HSS module, which directs the control of a hydraulic actuator (through a servo valve or I/H converter). By sending a
position demand to the HSS module, the controller initiates a change in turbine speed. The position demand travels over
the I/O expander bus to the HSS module. An onboard microprocessor reads the demand and loads it into a digital-to-analog
(D/A) converter. The resulting analog value drives the servo valve. The servo valve loads hydraulic fluid to one side of a
double acting hydraulic actuator. As the hydraulic actuator opens or closes the throttle valve, the turbine speed changes.

The controller requires FC 55 (or FC 150) in its configuration to direct the operation of the HSS module. FC 55 defines the
module address, mode of operation (calibration or normal), calibration cycle time, and stores calibration data. The 10 output
blocks include actuator position, digital-to-analog converter output, servo valve coil output current, and status outputs for
the module and process equipment.

A linear variable differential transformer (LVDT) measures actuator position. The HSS module supplies a 400 to 15,000
hertz excitation voltage (selected through FC 55) to the LVDT primary. A zero in the LVDT frequency specification of
function code 55 enables an excitation voltage for a DC LVDT. A dipswitch on the HSS module selects the excitation voltage
amplitude ranging from 1.08 volts peak to 9.0 volts peak.

The LVDT secondary develops a differential voltage proportional to the position of the hydraulic actuator. The HSS module
converts the differential voltage to digital data and sends it to the controller. Using the data the controller stores (during
valve calibration) in its configuration specifications (S18 through S21), it translates the LVDT secondary differential voltage
into actuator position feedback. The HSS module is self-checking and notifies the controller if a failure occurs.

The HSS module initiates manual control of the turbine throttle valve if an HSS module communication failure with the
controller occurs (or the controller goes into configuration mode). The HSS module provides inputs that are hard wired to a
24 VDC source. External inputs (i.e., push buttons, contacts, etc.) direct the HSS module to raise or lower the actuator.
Also, a trip bias circuit on the HSS module drives the fuel throttle valve to the closed position if necessary.

2.3.3 Controller
The controller directs the control loop and controls turbine speed according to its control strategy (i.e., function block
configuration). The controller requests data from the FCS module to calculate turbine speed. If the FCS module has data
available, it sends it to the controller. If there is no data available the controller must make another request. If the turbine
speed goes above or below the speed set point in the controller configuration, the controller will send a position demand to
the HSS module to adjust the throttle valve. This process repeats continuously at the cycle time of the controller.
The turbine speed limits and high/low speed alarms are set during configuration of the controller and I/O modules.

Additionally, the user calibrates the hydraulic actuator and LVDT transformer and also initiates auto tuning of the
demodulator gain. Proportional gain is tuned manually (demodulator gain can also be tuned manually). The controller sends
data, module status, and alarms to a human system interface during normal operation. The operator can monitor system
operation and initiate automatic or manual control through a human system interface such as a workstation running
Conductor software.

2.4 Operation
The FCS module interfaces the controller to a steam or gas turbine, providing the controller with turbine speed data. The
FCS microprocessor carries the work load. It is able to perform multiple tasks with the help of the module support circuitry.
The microprocessor provides the intelligence (firmware) needed to count and time input pulses, update process data
buffers, do self check diagnostics, and give module status information. The controller retrieves data from the FCS module
without interrupting the counting and updating process; therefore, the most current values are available.

Following are the several functional blocks of the module, as shown in the following figure (Figure 2-2):

2-2 2VAA002472
Description and Operation Module Circuitry

Figure 2-2: Functional Block Diagram

• Microprocessor.
• Input signal conditioning.
• Module status.
• Watchdog timer.
• Doubled buffered and latched data storage areas.
• Sequencing logic.
• I/O expander bus address.
• I/O expander bus interface.

All the blocks of the support circuitry help the microprocessor direct module activity such as conditioning the input, timing
the input, writing to buffers, and communicating with the controller. Power enters the module by way of the module
mounting unit backplane. The I/O expander bus interface provides I/O module communication with the controller.

The input enters the module via the P3 connector. The input signal conditioning circuit chops and squares the AC input into
TTL digital levels, making it electrically compatible with the microprocessor. This digital signal is fed to the microprocessor
interrupt. As the microprocessor detects pulses, it increments the event counter and memorizes the count in an internal
timer. After a 20 millisecond period, the microprocessor writes the count and time interval value to the double buffered
storage area and sets a status bit to tell the controller that data is currently available. The data is double buffered such that
the microprocessor will not overwrite current data when the controller is reading that data.

The controller clocks the data from the doubled buffered storage area to the I/O expander bus interface when it is ready to
receive count and timer information. The sequencing logic prevents the microprocessor and controller from accessing the
storage area simultaneously. The microprocessor posts the module status in the module status buffer. Module status is
always available to the controller through the I/O expander bus interface.

2.5 Module Circuitry

The following sub-sections explain the operation of the functional blocks that make up the FCS module.

2.5.1 Input Signal Conditioning

The FCS module receives the input signal through its cable connection to the termination unit. The incoming signal is an
analog waveform. The input signal conditioning circuit changes the analog input into a digital input usable by the
microprocessor.

2VAA002472 2-3
Microprocessor Description and Operation

The following figure (Figure 2-3) shows the input signal conditioning circuit and how the circuit converts input signals into a
digital waveform:.

Figure 2-3: Input Signal Conditioning Circuit

Figure 2-3 is a typical example of a sinusoidal input signal (E1). Diodes clip the input signal at ±10 V limiting the input
amplitude to 20 Vp-p (E2). Resistors limit the inrush current. This circuit can process input signals that range from 300
millivolts (peak-to-peak) to 120 VRMS at frequencies in the range of one hertz to 12.5 kilohertz.

The comparator works as a zero crossing circuit. It converts the input signal to a digital waveform (E3). A high frequency
filter removes noise from the input signal before reaching the comparator (operational amplifier).

The NAND gate provides gating for the input enable function. No input signal can pass until the microprocessor is ready to
count and process data from the field.

2.5.2 Microprocessor
The microprocessor is responsible for collecting data, timing the data, and communicating with the controller. Residing in
the module is the firmware that directs the FCS operation. The microprocessor counts pulses at the interrupt level. When
the microprocessor interrupt is ready to receive input pulses, it enables an input gate to allow data to pass. An internal
program in the microprocessor compiles the count and formats it for the controller. The microprocessor sends the count and
timer information to the double buffered storage area.

Data from the microprocessor goes to the first set of buffered latches. A data request from the controller transfers data from
the buffered latches to the I/O expander bus interface.

Status bits set by the microprocessor control the transfer of information and inform the controller of module status. If the
input signal is lost, the microprocessor tells the controller by generating a status bit. The microprocessor sends the bit to the
module status block. The controller reads the module status block for the FCS status. The microprocessor generates a data
available status bit when it has data for the controller. It also provides the 20 millisecond clock to reset the machine fault
timer. Additionally, the microprocessor performs checksum diagnostics as a background task.

2.5.3 Data Storage

There are two 32-bit (4-byte) buffered latch storage areas. Their function is to hold and stage data that is available for the
controller. The double buffer allows the controller to retrieve data without interrupting the microprocessor from the counting
process. The double buffer insures that the data being read is current; not a mixture of the previous count and the current
count. The microprocessor loads the first buffer one byte at a time. When the data transfers to the second buffer, all four
bytes of data move in a group.

2.5.4 Sequencing Logic

The sequencing logic block controls the transfer of data in the buffers. There are four bytes of data latched in the storage
area. The controller transfers data from the second buffered latch to the I/O expander bus interface by requesting bytes in a
logical sequence. The microprocessor continues to clock new data into the buffered latches. The sequencing logic prevents
the second buffer from receiving data from the first buffer when the controller is clocking data to the I/O expander bus. It
monitors controller activity (I/O expander bus communication) and transfers data to the second buffer when there is no
activity on the I/O expander bus.

2-4 2VAA002472
Description and Operation Watchdog Timer

2.5.5 Watchdog Timer

The watchdog timer verifies the status of the module. As long as the microprocessor is processing code internally it outputs
a 20 millisecond clock. The timer must sense the 20 millisecond clock from the microprocessor or it expires and sets a
status bit, warning the controller of a microprocessor failure. The controller automatically resets the FCS module if operation
stops because of a watchdog time-out.

2.5.6 Module Status

The module status block handles all module status messages from the microprocessor and holds them in a buffer on the I/O
expander bus interface for the controller to read.

The three module status bits are:

• Data available
• Data loss
• Watchdog time-out

• Data available: The microprocessor sends the data available status bit to the module status block when it has data
for the controller. When the controller reads the status block and sees the data available bit set, it can send a data
request to the FCS module.
• Data Loss: The microprocessor communicates to the status block that the input signal is lost. The controller knows
that there is no data available when it reads this status bit. The input signal may be temporarily lost when an abrupt
change in the input signal frequency occurs or the input frequency drops below one hertz. Operation returns to the
beginning of the process cycle and repeats until the microprocessor recovers the signal.
• Watchdog Time-Out: This status bit warns the controller of a microprocessor failure. The watchdog timer
constantly monitors the 20 millisecond clock from the microprocessor. The status bit is set when the clock fails to
reset the watchdog timer.

2.5.7 I/O Expander Bus Interface

The I/O expander bus interface block provides the circuitry that enables communication between the controller and the FCS
module. An ABB Automation designed integrated circuit provides a data bus for interfacing the storage area and the module
status buffer to the controller. This block follows the ABB Automation designed protocol for controller and I/O module
communications. It performs address compare, read/write strobe generation, and contains bus drivers and receivers.

The I/O expander bus address is selected by setting a dipswitch on the FCS module. The address byte precedes every data
transfer between the FCS module and the controller. The I/O expander bus integrated circuit enables the address buffer
and does an address comparison before allowing data to transfer to the I/O expander bus. If the addresses match, the
controller can strobe data to the I/O expander bus.

2.6 Mounting Hardware

Harmony rack I/O modules and termination units mount in standard ABB Automation enclosures (CAB-01, CAB-04, CAB-
12). The number of modules that can be mounted in a single cabinet varies.

An IEMMU21 or IEMMU22 module mounting unit and an NFTP01 field termination panel (FTP) are used for module and
termination unit mounting respectively (Figure 2-4). The mounting unit and termination panel both attach to the side rails in

2VAA002472 2-5
Mounting Hardware Description and Operation

standard 483-millimeter (19-inch) enclosures. Front mount and rear mount MMU versions are available to provide flexibility
in enclosure mounting.

Figure 2-4: Mounting Hardware

A module mounting unit is required to mount and provide power to rack-mounted modules. The unit is for mounting
controllers, I/O modules, and communication interface modules.

The MMU backplane connects and routes:

• Controlway.
• I/O expander bus.
• Logic power to control, I/O, and interface modules.

The Controlway and I/O expander bus are internal cabinet, communication buses. Communication between rack controllers
and communication interface modules is over Controlway.

2-6 2VAA002472
Installation Introduction

3. Installation
3.1 Introduction
This section covers the FCS01 module installation and configuration. Read and perform the steps in this section before
placing the module into operation.

3.2 Special Handling

NOTE: Always use the ABB Automation field static kit (part number 1948385A1), consisting of two wrist straps, ground
cord assembly, alligator clip, and static dissipating work surface when working with static sensitive devices. The kit is
designed to connect the technician and the static dissipating work surface to the same ground point to prevent damage
to the static sensitive devices by electrostatic discharge.

Use the static grounding wrist strap when installing and removing modules. Static discharge may damage static sensitive
devices on modules in a cabinet. Use grounded equipment and static safe practices when working with static sensitive
devices.

Follow the given steps when handling the module:

1. Use Static Shielding Bag: Keep the module in its static shielding bag until you are 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 Static Sensitive Devices: Verify that all devices connected to the modules are
properly grounded before using them.
5. Ground Test Equipment.
6. Use an Antistatic Field Service Vacuum: Remove dust from the cards if necessary.
7. Use a Grounded Wrist Strap: Connect the wrist strap to the appropriate grounding plug.
8. Do Not Use Lead Pencils to Set Dipswitches: To avoid contamination of switch contacts that can result in
unnecessary circuit board malfunction, do not use a lead pencil to set a dipswitch.

3.3 Unpacking and Inspection

Follow the given steps to unpack and inspect the module:
1. Examine the hardware immediately to verify that 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.

3.4 Termination Unit Installation

For information about installing process wiring and the NTDI01 Digital Input Termination Unit ,refer to the appropriate
termination unit user manual. Appendix A: NTDI01 Termination Unit contains quick reference information for the termination
units.

Follow the given steps to install the termination unit:

1. Install the magnetic pickup according to the manufacturer's directions.
2. Configure the dipshunt on the termination unit. (Refer to Appendix A: NTDI01 Termination Unit of this user
manual for more details, if required)
3. Install the termination unit on the termination mounting panel and secure into place.
4. Connect the wiring from the magnetic pickup to the termination unit.
(Refer to Appendix A: NTDI01 Termination Unit of this user manual for more details, if required.)
5. Connect the hooded end of the NKTU01 cable to the rear of the module mounting unit (MMU) slot for the FCS
module.
6. Connect the other end of the NKTU01 cable to the P1 connector on the termination unit.

2VAA002472 3-1
I/O Expander Bus Address (SW1) Installation

3.5 I/O Expander Bus Address (SW1)

The FCS module must have its I/O expander bus address set to be able to communicate with the controller. Set the FCS
module I/O expander bus address to any unused binary address from zero to 63. The address is set with dipswitch SW1.
Dipswitch S1 is an eight-pole dipswitch (Figure 3-1).

Figure 3-1: Switch SW1 - I/O Expander Bus Address

Dipswitch poles one and two must be in the closed position for normal operation. Use poles three through eight to set the
address.

The following table (Table 3-1) lists examples of I/O expander bus address dipswitch settings. Record the I/O expander bus
address in the user setting column.

Table 3-1: I/O Expander Bus Address (SW1) - Example Settings

Dipswitch Pole
Example (Binary Value) User
Address Setting
1 2 3 4 5 6 7 8
(128) (64) (32) (16) (8) (4) (2) (1)

15 0 0 0 0 1 1 1 1

32 0 0 1 0 0 0 0 0

63 0 0 1 1 1 1 1 1
NOTE: 0 = closed or on, 1 = open or off.

3.6 Module Installation

Follow the given steps to install the FCS01 module into the module mounting unit:
1. Verify the module mounting unit slot assignment for the module.
Disconnect power before installing dipshunts on the MMU backplane. Failure to do so will
result in contact with cabinet areas that could cause severe or fatal shock.

2. Check the I/O expander bus dipshunt socket on the backplane of the module mounting unit.

NOTE: The dipshunt must be installed with all pins shorted. There must be a communication path from the
controller to the I/O module.

3. Align the top and bottom edges of the circuit card with the top and bottom rails of the assigned slot in the module
mounting unit.
4. Slide the module into the slot.
5. Push until the module is seated in the backplane connector.
6. Turn the two thumbscrews on the faceplate ½-turn until the module locks in place.

3-2 2VAA002472
Installation Configuration

3.7 Configuration
The controller must have FC 145 in its configuration to communicate with the FCS module. Configure the controller before
attempting to operate the FCS module. Refer to the Symphony Plus Function Code Application Manual for information on
how to configure FC 145. It lists the function code specifications, output blocks, and configuration information.

2VAA002472 3-3
Configuration Installation

3-4 2VAA002472
Operating Procedures Introduction

4. Operating Procedures
4.1 Introduction
This section contains information about FCS01 module operation. The FCS module requires no operator interaction.
Complete the instructions in section 3- Installation of this user manual to assure successful startup and operation.

4.2 Startup
FCS module startup is fully automatic. When the FCS module comes online, the controller establishes communication with
it. At the segment cycle time, the controller polls the FCS module for information. If the FCS module has data available, then
the controller can request that information.

4.3 Operation
The onboard microprocessor controls the FCS module operation. There are no user actions required during normal
operation. Operation is fully automatic.

The controller continuously monitors the FCS module status. The following situations result in bad status for the FCS
module:
• Sudden loss of the pulse input source.
• FCS microprocessor fails.
If either of the two situation occurs, then the controller generates a module problem report accessible from a human system
interface. Refer to section 5- Troubleshooting of this user manual for troubleshooting information, if the FCS01 module fails
to start and come online.

2VAA002472 4-1
Operation Operating Procedures

4-2 2VAA002472
Troubleshooting Introduction

5. Troubleshooting
5.1 Introduction
This section contains information about troubleshooting FCS01 module failures. It explains troubleshooting procedures
using text, flowcharts, and reference documents.

5.2 Procedure
The operator can effectively troubleshoot a failure by using the flowcharts provided in this section to isolate the failure. After
locating the failure, refer to the text or other instructions for more information about the failure and the corrective action.
Contact the manufacturer for information about the magnetic pickup.

The first part of this section covers installation and startup failures. If the failure is preventing module startup, refer to sub-
section 5.3- Startup Failures of this user manual for details on troubleshooting procedure. The second part covers failures
during operation. If the failure occurs during operation, then refer to sub-section 5.4- Online Failure of this user manual for
details on troubleshooting procedure.

5.3 Startup Failures

There are two types of startup failures:
• Configuration error
• Hardware failure

5.3.1 Configuration Error

This sub-section details startup failures that occur as a result of module configuration errors.

If the FCS01 module fails to come online after completing the installation, then look for configuration errors by checking the
controller status. Refer to the appropriate instruction for the controller for a list of error codes and corrective actions.

If the FCS module continues to fail to start and there are no configuration errors, then refer to sub-section
5.3.2- Hardware Failure of this user manual for information on how to troubleshoot this error.

5.3.2 Hardware Failure

This sub-section details the startup failures that do not appear as configuration errors and how to troubleshoot those
failures. Hardware failures are a result of incomplete or incorrect installation of the related FCS hardware or a failure of the
FCS module.

The human system interface displays an error message, if there is a hardware failure. A module problem report (MPR)
accessible from the human system interface gives a not responding indication, if there is a hard failure or if the controller
receives a bad quality indication from the FCS01 module.

Follow the given steps to troubleshoot a hard failure:

2VAA002472 5-1
Hardware Failure Troubleshooting

1. Use the following flowcharts (Figure 5-1 and Figure 5-2) to find the location of the hard failure.

Figure 5-1: Hardware Failure Troubleshooting Flowchart (1 of 2)

5-2 2VAA002472
Troubleshooting Hardware Failure

Figure 5-2: Hardware Failure Troubleshooting Flowchart (2 of 2)

2. Refer to Table 5-1 for corrective action.

Table 5-1: Startup Failures

Problem Cause Action

FCS fails to start Controller not in Place the controller in execute mode.
execute mode

Configuration error Check the human system interface for error

messages and indications.

2VAA002472 5-3
Online Failure Troubleshooting

Table 5-1: Startup Failures (Continued)

Problem Cause Action

FCS fails to start and Controller not in
there are no configura- execute mode
tion errors.
Improper installation
Place the controller in execute mode.
Verify proper installation of FCS module and
related hardware.
1. Check the I/O expander bus dipshunts. All the
dipshunt pins should be shorted.
2. Check the I/O expander bus address setting on
SW1 of the FCS module. SW1 should be the same
value as S1 of function code 145.
3. Reinsert the module in the module mounting
unit.
4. Check the termination unit cable.
5. Verify the correct dipshunt configuration on the
termination unit.
6. Verify the magnetic pickup is connected to the
correct terminals on the termination unit.
7. Check the magnetic pickup installation.

Magnetic pickup Check the input signal from the magnetic pickup.
failure
1. Connect an oscilloscope to the input terminals
on the termination unit. Verify there is a signal from
the magnetic pickup.
2. If there is no signal from the magnetic pickup,
then check the continuity of the cables connecting
the pickup to the termination unit.
3. Replace any open cable or cables having an
unusually high impedance.
4. Replace the magnetic pickup if there is no input
signal and the cable continuity checks good.

FCS fails to start and FCS module failure Replace the FCS module.
the related hardware
installation is correct
with no configuration
errors.

Replacement FCS fails — Contact ABB Automation technical support for

to start and all other assistance.
areas check good.

3. Replace the module, if there are no configuration errors or hard failures and the FCS module continues to fail to
start.
4. Contact ABB technical support for assistance, if replacing the module does not correct the problem.

5.4 Online Failure

This part of the section covers failures that occur while the FCS module is online and how to troubleshoot those failures.
Online failures are a result of hardware failure, loss of input signal, bad quality, or the input signal is outside of the operating
specifications. Refer to Figure 5-3 for an online troubleshooting flowchart. Table 5-2 lists error messages, causes, and
corrective action.

Follow the given steps to correct an online failure:

1. Use a human system interface to monitor for error messages by checking the module problem report.
2. Follow the corrective actions inTable 5-2 that apply to the error messages.

5-4 2VAA002472
Troubleshooting Connector Pin Assignments

3. Monitor FC 145 output block N+3.

NOTE: A one in output N+3 indicates bad quality while a zero indicates good quality.

4. Refer to Table 5-2 to find bad quality in the Cause column, and follow the corrective action listed in it.

Figure 5-3: Online Failure Troubleshooting Flowchart

Table 5-2: Online Failures

Error Message Cause Corrective Action

Not responding Bad quality Re-seat the FCS module.

Watchdog timeout Replace the FCS module.

Out of range Loss of input due to No action.

abrupt change of signal
The FCS module should adjust to change as it
continues to cycle. The FCS automatically
recovers the signal.

5.5 Connector Pin Assignments

Table 5-3 through Table 5-5 details the pin assignments for the module connectors.

Table 5-3: P1 Module Power Pins

Pin Signal Pin Signal

1 + 5 VDC 2 + 5 VDC

3 Unused 4 Unused

5 Common 6 Common

7 + 15 VDC 8 - 15 VDC

2VAA002472 5-5
Connector Pin Assignments Troubleshooting

Table 5-3: P1 Module Power Pins (Continued)

Pin Signal Pin Signal

9 PFI 10 PFI

11 Unused 12 Unused

Table 5-4: P2 I/O Expander Bus Pins

Pin Signal Pin Signal

1 Data Bit 1 2 Data Bit 0

3 Data Bit 3 4 Data Bit 2

5 Data Bit 5 6 Data Bit 4

7 Data Bit 7 8 Data Bit 6

9 Clock 10 Sync

11 Unused 12 Unused

Table 5-5: P3 I/O Pins

Pin Signal Pin Signal

1 Input + A Input -

2 NC B NC

3 NC C NC

4 NC D NC

5 NC E NC

6 NC F NC

7 NC H NC

8 NC J NC

9 NC K NC

10 NC L NC

11 NC M NC

12 NC N NC

13 NC P NC

14 NC R NC

15 NC S NC
NOTE: NC=not connected

5-6 2VAA002472
Maintenance Introduction

6. Maintenance
6.1 Introduction
The reliability of any stand-alone product or control system is affected by the maintenance of the equipment. ABB
recommends that all equipment users practice a preventive maintenance program that 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.

Maintenance personnel performing preventive maintenance should meet the following qualifications.
• Qualified electrical technicians or engineers who have knowledge and proper usage of test equipment.
• Familiarity with the FCS01 module
• Familiarity with the module mounting unit
• Experience working with process control systems
• Knowledge of what precautions to take when working on live AC/DC systems.
• Knowledge of turbine shutdown and startup, and plant operating procedures.

6.2 Preventive Maintenance Schedule

The following table (Table 6-1) is the preventive maintenance schedule for the FCS01 module. The table lists the preventive
maintenance tasks in groups according to their specified maintenance interval. Some tasks in Table 6-1 are self
explanatory. Instruction for tasks that require further explanation are covered under sub-section
6.4- Preventive Maintenance Procedures of this user manual.

NOTE: The preventive maintenance schedule is for general purposes only. The application can require special
attention.

Table 6-1: Preventive Maintenance Schedule

Task Frequency

Check the FCS module and module mounting unit for dust. Clean as necessary using 3 months
an antistatic vacuum.

Check all signal, power, and ground connections associated with the FCS module
and its termination unit. Refer to appropriate procedure.

Inspect the FCS module and associated termination unit, giving particular attention to 12 months
power supply contacts and edge connectors. Clean as necessary. Refer to appropri-
ate procedure.

Complete all tasks in this table. Shutdown

6.3 Equipment Required

Following are the tools and equipment required for the maintenance procedures:
• Antistatic vacuum.
• Screwdriver (medium length).
• Isopropyl alcohol (99.5 percent electronic grade).
• Distilled water.
• Compressed air.
• Foam-tipped swabs.
• Eberhard Faber® (400A) Pink Pearl® eraser.
• Fiberglass burnishing brush.
• Lint-free cloths.
• Small needle nose pliers.

2VAA002472 6-1
Preventive Maintenance Procedures Maintenance

6.4 Preventive Maintenance Procedures

This sub-section covers tasks from Table 6-1 that require specific instructions or further explanation:
• Checking signal, power, and ground connections.
• Cleaning printed circuit boards and edge connectors.

6.4.1 Checking Connections

NOTE: Power to the cabinet should 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.

Check all signal wiring, power, and ground connections for the FCS module and its associated termination unit. When
checking connections, always turn a screw, nut, or other fastening device in the direction to tighten only. If the connection is
loose, then it is tightened. If the connection is tight, then the tightening action verifies that it is secure. There must not be any
motion done to loosen the connection.

During connections check:

1. Check module cable connections.
2. Verify that all wiring connections to the termination unit are secure.

6.4.2 Printed Circuit Board Cleaning

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
cleaning 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 3.2- Special Handling of this user manual when handling printed circuit boards.

6.4.2.1 General Cleaning and Washing

If the printed circuit board needs minor cleaning, then 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).

NOTE: Use a foam-tipped swab to wipe the circuit board.

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

6.4.2.2 Edge Connector Cleaning

Follow the given steps to clean edge connector contacts:

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 an Eberhard Faber (400A) Pink Pearl eraser, or equivalent to remove tarnish or stains.

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

6-2 2VAA002472
Maintenance Printed Circuit Board Cleaning

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.

6.4.2.3 Cleaning Female Edge Connectors

Follow the given steps to clean the female edge connectors:

1. Use a foam-tipped swab or a lint-free cloth wrapped over a piece of scrap circuit board.
2. Soak the swab or cloth in electronic grade isopropyl alcohol.
3. Insert the swab of cloth covered circuit board into edge connector and work it back and forth to clean the
contacts.
4. Rinse the edge connector contacts by spraying with isopropyl alcohol.
5. Remove excess alcohol and dry using compressed air.

2VAA002472 6-3
Printed Circuit Board Cleaning Maintenance

6-4 2VAA002472
Repair and Replacement Introduction

7. Repair and Replacement

7.1 Introduction
This section explains the replacement steps for the FCS01 module. Special tools are not required to replace the module.

7.2 Module Replacement

If the FCS01 module is faulty, then replace it with a new one. Do not try to repair the module; replacing components can
affect the module performance. Modules can be removed while system power is supplied.

Follow the given steps to replace a module:

1. Push and turn the two front panel captive latches one half turn to unlatch the module.

NOTE: The module is unlatched when the slots on the latches are vertical and the open end of the slots face
away from the center of the module.

2. Slide the module gently out of the module mounting unit.

3. Configure the replacement module switch and jumper settings per the same settings of the original module.
4. Align the replacement module with the guide rails in the module mounting unit in the same slot assignment as
the original module
5. Slide the module gently in until the front panel is flush with the top and bottom of the MMU frame.
6. Push and turn the two captive latches on the module faceplate one half turn to the latched position.

NOTE: The module is latched when the slots on the latches are vertical and the open ends face the center of
the module.

7. Return to normal operation.

7.3 Termination Unit Replacement

To replace the NTDI01 termination unit, refer to the repair and replacement procedures in the Digital Input Termination Unit
(NTDI01) user manual. These instructions contain step by step replacement procedures.

2VAA002472 7-1
Termination Unit Replacement Repair and Replacement

7-2 2VAA002472
NTDI01 Termination Unit Introduction

A. NTDI01 Termination Unit

A.1 Introduction
The FCS01 module uses an NTDI01 for termination. Dipshunts on the termination unit configure a frequency input from the
process. The FCS01 module can input a voltage of 300 millivolts (peak-to peak) to 120 VAC at a frequency range from one
hertz to 12.5 kilohertz.

The following figure (Figure A-1) shows an NTDI01 dipshunt without strapping, and the signal path from the field device to
the FCS01 module..

Figure A-1: NTDI01 Dipshunt

The following table (Table A-1) determines the dipshunt strapping to configure the NTDI01 termination unit:

Table A-1: NTDI01 Dipshunt Configuration

Application/Signal Type Dipshunt Configuration

Analog Inputs 0.3 Vp-p to 120 VAC

2VAA002472 A-1
Introduction NTDI01 Termination Unit

The following figure (Figure A-2) shows the terminal assignments and polarities for the input signal. Refer to this figure
when connecting field wiring to the NTDI01 termination unit

Figure A-2: NTDI01 Terminals

A-2 2VAA002472
 INDEX

INDEX

A Mounting Hardware 5
Application, module 1 Mounting hardware 5

C N
Checking Connections 2 NTDI01 1
Cleaning Female Edge Connectors 3 NTDI01 Termination Unit 1
Configuration 3
Configuration Error 1 O
Connector Pin Assignments 5 Online Failure 4
Control loop 1 Operation 2, 1
Controller 2 Controller 1
FCS01 1 Startup 1
HSS03 2
Control Loop Operation 1 P
Preventive Maintenance Schedule 1
D Printed Circuit Board Cleaning 2
Data Storage 4
Data storage 4 R
Description 1 Replacement
Circuitry 3 Module 1
Operation 2 Termination unit 1
E S
Edge Connector Cleaning 2 Sequencing Logic 4
Sequencing logic 4
F Special handing 1
FCS01 1 Special Handling 1
FCS01 Module 1 Startup Failures 1
Frequency Counter Module 1
Function code 3 T
Termination unit 3, 1
H Termination Unit Installation 1
Hardware Failure 1 Termination Unit Replacement 1
HSS03 Module 2 Troubleshooting 1
Configuration error 1
I Hardware failure 1
I/O expander bus Online failure 4
Address 5, 2
Interface 5 U
I/O Expander Bus Interface 5 Unpacking and Inspection 1
Input Signal Conditioning 3
Input signal conditioning 3 W
Installation 1 Watchdog Timer 5
Module 2
Termination unit 1
Content 2
Conventions 2
How to use 2
Intended user 1

M
Maintenance 1
Microprocessor 4
Module Circuitry 3
Module Description 1
Module mounting unit 3
Module Replacement 1
Module Status 5
Module status 5

2VAA002472 1
INDEX

2 2VAA002472
ABB Ltd.
Business Unit Power Generation
P.O. BOX 8131
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SWITZERLAND
Phone: +41 (0) 43 317-5380
Fax: +41 (0) 43 317-5382
www.abb.com/powergeneration
Notice
Document Number: 2VAA002472
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: December 2012