Documente Academic
Documente Profesional
Documente Cultură
Symphony Plus
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 89/336/EEC and in Low
Voltage Directive 72/23/EEC.
Copyright 2010 by ABB.
All rights reserved.
Release: Dec 2010
Document number: 2VAA000341
TRADEMARKS
All rights to other trademarks reside with their respective owners.
8BOverview
Overview ..............................................................................................................8
1.2
1.3
Terminology .........................................................................................................9
1.4
2.
INTRODUCTION............................................................................................ 10
2.1
2.4
3.
INSTALLATION............................................................................................. 12
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
4.
CONFIGURATION......................................................................................... 15
4.1
2VAA000341
8BOverview
4.2
5.
OPERATION.................................................................................................. 33
5.1
5.2
Functions ...........................................................................................................35
2VAA000341
8BOverview
6.
MAINTENANCE............................................................................................. 41
6.1
Preventive Maintenance....................................................................................41
6.2
Troubleshooting ................................................................................................42
6.4
Diagnostics ........................................................................................................43
6.5
Module Replacement.........................................................................................43
7.
SPECIFICATIONS ......................................................................................... 45
7.1
8.
2VAA000341
8BOverview
The Operation section describes the various start modes and operating modes available for each installation.
The Maintenance section focuses on detecting faults using built-in diagnostics. It explains system status displays in
operator stations and LEDs on modules.
In the Specifications section you will find a data sheet that lists the capacities of all of the components of the MCM800
module.
2VAA000341
A tip icon indicates advice on, for example, how to design your project
or how to use a certain function.
Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or
property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance, leading to personal injury or death. Therefore, comply fully with all
Warning and Caution notices.
1.3 Terminology
The following is a list of terms associated with the MCM800 that you should be familiar with. The list contains terms and
abbreviations that are unique to ABB or have a usage or definition that is different from standard industry usage.
Term
Description
MPM810
TBU850
VAC
VDC
Description
2VAA000341
12BProduct Overview
1BINTRODUCTION
2. INTRODUCTION
This documentation contains the description of the Machinery Condition Monitoring Module MCM800, which provides a
complete set of functions for comprehensive Rotating Machinery Diagnostics. These functions include:
Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.
The MCM800 system is part of a distributed modular I/O system. The MCM800 components provide easy installation
and reliable performance using advanced control technology.
2.1
Product Overview
The MCM800 is comprised of a Processing Module (MPM810) and a Termination Mounting Unit (TBU850).
Its main function is to provide rotating machinery monitoring and protection capability independent from any master
DCS or PLC. This independence results in higher reliability and faster response time.
The MCM800 system implements widely used monitoring and protection algorithms available in the industry. Each
function also has a set of software configuration parameters.
The MCM800 system has a built-in Profibus-DP Communication Interface to facilitate integration with external control
systems or other Profibus compatible devices.
2.2
MCM800 Details
2.3
10
2VAA000341
1BINTRODUCTION
2.4
15BProduct Features
Product Features
Danger
DIP Switches
Profibus Address
Option Switch
Profibus termination
2.4.2 Communication
RS-485
Profibus DP V1
Modbus
Reporting Values.
Ethernet
10/100 BaseT TCP/IP
RS-232
Debug
Note: a special cable is required.
2VAA000341
11
16BCabinet Installation
on
2BINSTALLATION
3. INSTALLATION
3.1
Cabinet Installation
Refer to the ABB Site Planning Guide (3BUA000258R5001) and the MCM800 Installation Guide for more information
about cabinet installation.
3.2
3.3
A standard Profibus or Modbus connector for line A (PA1) is connected on the left side of the unit and line B
(PB2) on the right side. The TBUs are designed to connect together passing the communication through the
system and out the opposite port.
The RJ-45 connector on the front of the unit provides proprietary Ethernet communication using TCP/IP protocol.
3.4
Module (MPM810)
Install module by aligning the connectors of the TBU and module, and then pushing the units together.
Ensure that the module is fully engaged into the TBU. Partial engagement may
produce unexpected results
After connection to the TBU, lock the I/O module in place using the I/O Module Locking device.
12
2VAA000341
2BINSTALLATION
3.5
20BModule Interconnection
Module Interconnection
On each side of the TBU are two DSBU9 connectors. The TBU is designed to plug together. Place the TBUs on the
DIN rail and slide the TBUs together until they are fully engaged. Use a screwdriver to turn the latch to secure the TBUs
in place.
3.6
Terminal
Description
13
3.7
2BINSTALLATION
3.8
2VAA000341
3BCONFIGURATION
FIGURATION
4. CONFIGURATION
4.1
4.2
Terminal
Description
Transducer Common
Transducer Signal
2VAA000341
15
25BTermination Base
e Units
3BCONFIGURATION
The Event Marker Terminal is used for the once per revolution phase marker. It is intended to be used with proximity
probes as the input sensor. This signal is common to each of the four input channels used to determine the various
orders calculations of vibration and it is used to report the speed of the shaft. The signal may be daisy chained to other
MCM800 modules or may drive a TTL signal for third part devices that can not handle proximity probe inputs.
Terminal
Description
Transducer Common
EM Signal (out)
EM Common (out)
EM Signal (in)
EM Common (in)
Terminal
Description
Alert Common
Danger Common
16
2VAA000341
3BCONFIGURATION
2VAA000341
17
3BCONFIGURATION
18
2VAA000341
3BCONFIGURATION
2VAA000341
19
4.3
3BCONFIGURATION
Switch
2345678
Profibus
Address
Switch
2345678
Profibus
Address
Switch
2345678
Profibus
Address
Switch
2345678
Profibus
Address
0000000
0010000
16
0100000
32
0110000
48
0000001
0010001
17
0100001
33
0110001
49
0000010
0010010
18
0100010
34
0110010
50
0000011
0010011
19
0100011
35
0110011
51
0000100
0010100
20
0100100
36
0110100
52
0000101
0010101
21
0100101
37
0110101
53
0000110
0010110
22
0100110
38
0110110
54
0000111
0010111
23
0100111
39
0110111
55
0001000
0011000
24
0101000
40
0111000
56
0001001
0011001
25
0101001
41
0111001
57
0001010
10
0011010
26
0101010
42
0111010
58
0001011
11
0011011
27
0101011
43
0111011
59
0001100
12
0011100
28
0101100
44
0111100
60
0001101
13
0011101
29
0101101
45
0111101
61
0001110
14
0011110
30
0101110
46
0111110
62
0001111
15
0011111
31
0101111
47
0111111
63
20
2VAA000341
3BCONFIGURATION
URATION
Setting Description
0
Normal Mode
Diagnostic Mode
Calibration Mode
Configuration Retention
Switch 3 determines if the MCM800 retains its configuration on restart or resets all configurations to the default settings.
Switch 3 Description
0
Reset IP Address
To reset the IP address to the default (192.168.222.111) set Switch 3 to 0 and the Address switch (S1) to 127 and the
redundancy to 0 (S1 = 01111111).
2VAA000341
21
3BCONFIGURATION
Switch 4 Description
0
Switch 1 Description
0
38400 Baud
19200 Baud
4.3.5 MPM810
There are no configurable settings on this board.
22
2VAA000341
3BCONFIGURATION
4.4
Range
Units
Type
IP Address NNN.xxx.xxx.xxx
0 to 255
None
IP Address xxx.NNN.xxx.xxx
0 to 255
None
IP Address xxx.xxx.NNN.xxx
0 to 255
None
0 to 255
None
0 to 255
None
0 to 255
None
0 to 255
None
0 to 255
None
English/Metric EU
0, 1
None
-360 to 360
Degrees
0 to 15
Volts
0,1
None
0,1
None
IP Address and Subnet Mask The IP Address and Subnet Mask is required for the module to communicate over
Ethernet. It is a unique address for a specific network. The default values are 192.168.222.111 and 255.255.0.0. The
configuration tools will allow a new address to be set. Once set the user must switch to the new address for proper
communication.
English/Metric Set this value to a 0if the engineering units are English and a 1 if they are in metric.
Angular Position of Event Marker probe This value is the angular position of the Event Marker from a fixed
reference point, typically vertical.
Event Marker Detect Voltage This value is the minimum pulse height (pk-pk) of the Event Marker pulse.
2VAA000341
23
3BCONFIGURATION
Normal Alert/Danger relay state Set to 0 for Normally De-energized (energize to activate relay), and 1 for Normally
Energized (de-energize to activate relay).
24
Description
Range
Units
Type
Channel type
This value specifies the operation of the channel.
0 = None (Valid for all channels)
1 = Vibration (Channels 1-4 only)
2 = Eccentricity (Channels 1-4 only)
3 = Thrust (Rotor) Position (Channels 1-4 only)
4 = Differential Expansion (Channels 1-4 only)
5 = Case Expansion (Channels 1-4 only)
6 = Dual Probe - Relative (Channels 1 & 3 only)
7 = Dual Probe Seismic (Channels 2 & 4 only)
8 = Dual Probe Absolute (Channels 5 & 6 only)
For channel 5, channel 1 must be set to Relative (6), and
channel 2 must be set to Seismic (7).
For channel 6, channel 3 must be set to Relative (6), and
channel 4 must be set to Seismic (7).
9 = SMAX (Channels 5-7only)
For channel 5, channel 1 & 2 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 6, channel 3 & 4 must be set to Vibration (1)
and Probe Type must be Eddy Current (1) for channels 1
& 2.
For channel 7, channels 5 & 6 must be set to Dual Probe
Absolute.
10 = Complementary Position (Channels 5 & 6 only)
For channel 5, channel 1 & 2 must be set to Thrust (3) or
Differential Expansion (4).
For channel 6, channel 3 & 4 must be set to Thrust (3) or
Differential Expansion (4).
0 to 10
None
0 to 5
None
Probe type
Type of probe (valid for channels 1 - 4 only).
0 = None.
1 = Proximity Probe.
2 = DC LVDT.
3 = Accelerometer.
4 = Moving Element velocity probe.
5 = Piezoelectric velocity probe.
0 to 8
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Probe Sensitivity
Sensitivity of the probe in mv/EU (valid for channels 1 - 4 only)
Full
mv/EU
Integration
Sets the type of integration (valid for channels 1-4 only).
0 = None.
1 = Velocity to displacement (velocity probes only).
2 = Acceleration to velocity (accelerometers only).
0 to 2
None
-360 to 360
Degrees
0 to 90
Degrees
-24 to +24
Volts
-24 to +24
Volts
3 to 10
None
0,1
None
Angular Position of probe This value is the angular position of the probe from a fixed reference point, typically
vertical.
Ramp Angle This value specifies the ramp angle for ramped differential expansion.
Probe DC Voltage High/Low Failure Thresholds This value is the voltage beyond which the module will report bad
quality for that channel. The High Failure Limit should be set to approximately one volt less than the upper limit of the
linear range. Likewise, the Low Failure Limit should be set to approximately one volt greater than the lower limit of the
linear range.
2VAA000341
25
3BCONFIGURATION
Note: Non-Linear Correction X1-X5, Y1-Y5 are pairs of values are used to correct for non-linearity effects of probes are
for Future Use.
26
Description
Range
Units
Type
0,1
None
0,1
None
0,1
None
0,1
None
Full
EU
Full
EU
Full
EU
Full
EU
Alert Delay
Determines the delay in seconds the condition must exist before
activating Alert status. Note: If the value exceeds the Danger set
point before the Alert delay expires, the module will immediately
set the Alert status. (Valid for all channels).
0.1 to 300
Seconds
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Danger Delay
Determines the delay in seconds the condition must exist before
activating Danger status. Note: If the value exceeds the Danger
set point before the Alert delay expires, the module will
immediately set the Alert status. (Valid for all channels).
0.1 to 300
Seconds
Alert Enable
Enables the alert action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.
0,1
None
Danger Enable
Enables the danger action. (Valid for all channels).
0 = Action disabled.
1 = Action enabled.
0,1
None
1 to 1,000
Hz
30 to
15,000
Hz
Full
EU
-24 to +24
Volts
0,1
None
Waveform Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
0,1
None
Run-up Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
0,1
None
2VAA000341
27
3BCONFIGURATION
Description
Range
Units
Type
Rundown Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
0,1
None
Event Capture
When the values changes from 0 to 1 the specific waveform file
will be captured for analysis. Refer to the Waveform Historian
manual for more information.
0,1
None
28
Description
Range
Units
Type
Module Alert
Indicates the Alert alarm status.
0 = Normal.
1 = Alert / Danger Active.
0,1
None
Module Danger
Indicates the Danger alarm status.
0 = Normal.
1 = Alert / Danger Active.
0,1
None
0,1
None
0,1
None
0,1
None
0,1
None
Dual Vote Alert Ch 5&6 Indicates if both channels are active when
Dual Voting is enabled.
0 = Normal.
1 = Alert / Danger Active (Both channels).
0,1
None
0,1
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
MCM Mode
Reflects the operational mode of the MCM800 based on Dipswitch
S2.
0 = Normal.
1 = Low Speed.
0,1
None
Calibration Active
Calibration status.
0 = Not calibrating (Normal).
1 = Module is calibrating.
0,1
None
Diagnostic Error
Indicates the diagnostic status.
0 = Diagnostics successfully passed.
1 = Diagnostics failed.
0,1
None
Orders Active
Orders are being calculated.
0 = Orders are not being calculated.
1 = Orders are being calculated.
0,1
None
0,1
None
0,1
None
Invalid IP Address
Indicates if the IP address or subnet mask is invalid.
0 = IP Address and Subnet mask are valid.
1 = IP Address or Subnet mask is invalid.
0,1
None
Profibus Active
Indicates a Profibus Master is communicating.
0 = Profibus not communicating.
1 = Profibus is communicating.
0,1
None
0 to 255
None
0 to 255
None
0 to 255
None
0 to 255
None
Speed
The current speed in RPM.
0 to 30,000
RPM
Overall Output
The overall movement or position in Engineering Units according
to channel type. (Valid for all channels).
Full
EU
2VAA000341
29
30
3BCONFIGURATION
Description
Range
Units
Type
DC Voltage
The current DC component of the output value in Volts. (Valid for
channels 1 - 4).
-24 to +24
Volts
DC Relative Gap
The current DC component of the output value in Engineering
Units according to channel type. (Valid for channels 1 4,
Ethernet Only).
Full
EU
Full
EU
0 to 359
Degrees
Order 1x Amplitude
First Order Vibration component in Engineering Units. (Valid for
channels 1 6, Vibration only).
Full
EU
Order 1x Phase
First Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order 2x Amplitude
Second Order Vibration component in Engineering Units. (Valid
for channels 1 6, Vibration only).
Full
EU
Order 2x Phase
Second Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Order Nx Amplitude
Indicates the Nth Order Vibration component in Engineering Units.
(Valid for channels 1 6, Vibration only).
Full
EU
Order Nx Phase
The Nth Order phase angle in degrees. (Valid for channels 1 6,
Vibration only).
0 to 359
Degrees
Full
EU
0 to 359
Degrees
Critical Error
Any module error detected by the system.
0 = Normal.
1 = Error.
0,1
None
Configuration Error
A channel is configured improperly.
0 = Normal.
1 = Error.
0,1
None
0,1
None
2VAA000341
3BCONFIGURATION
Description
Range
Units
Type
Bad Data
The overall value is out of the specified limits.
0 = Normal.
1 = Bad Quality.
0,1
None
Suspect Data
The Overall value is within 5% of the specified limit.
0 = Normal.
1 = Suspect Quality.
0,1
None
Alert Active
The Overall value has exceeded the specified range.
0 = Normal.
1 = Alert.
0,1
None
0,1
None
0,1
None
Danger Active
The Overall value has exceeded the specified range.
0 = Normal.
1 = Danger.
0,1
None
0,1
None
0,1
None
0,1
None
0,1
None
0,1
None
2VAA000341
31
Description
Time Waveform Rundown Active
The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.
Time Waveform Event Log Active
The MCM800 is actively capturing respective waveform data.
0 = Normal.
1 = Active.
32
3BCONFIGURATION
Range
Units
Type
0,1
None
0,1
None
2VAA000341
4BOPERATION
28BGeneral Description
5. OPERATION
5.1
General Description
The MCM800 system is part of ABBs Symphony Plus technology platform. Data exchange occurs between the
controller and the module. However, the MCM800 operates independently from the main DCS controller using its builtin processors. The functions of the MCM800 provide dedicated monitoring and protective features, including:
Vibration Monitoring.
Eccentricity.
Thrust (Rotor) Position.
Differential Expansion.
Case Expansion.
The MCM800 System is comprised of an MPM810 and a TBU850. The TBU850 conditions the field signals and passes
the conditioned signals to the MPM810 controller. The MPM810 uses the field data in the execution of its functions.
In the next sections of this manual, the MCM800 system is divided into three main functional areas for analysis
purposes:
I/O Functions
Protective Functions
Testing Functions.
5.2
33
4BOPERATION
NX.
34
2VAA000341
4BOPERATION
5.3
30BFunctions
Functions
The MCM800 System provides all the common rotating machinery diagnostic functions. These functions can be
individually configured for maximum flexibility. The sections below list typical parameter settings for the various
functions. Some parameters are application specific and may deviate from those listed. Not all parameters are used for
every function and are ignored. For those parameters, the default setting is recommended.
5.3.1 Vibration
This function measures shaft vibration.
Probe Type
Probe Sensitivity
Integration
1 = Vibration
0 = Peak-to-Peak
1 = Peak
2 = RMS
3 = Average
4 = Calculated Peak-to-Peak
5 = Calculated peak
1 = Proximity Probe
3 = Accelerometer
4 = Moving Element velocity probe
5 = Piezoelectric velocity probe
Millivolts / EU
0 = None
1 = Velocity to displacement (velocity probes only)
2 = Acceleration to velocity (accelerometers only)
Angular Position
of Probe
High Failure
Threshold
Low Failure
Threshold
2VAA000341
Typical settings
Proximity Probe = -0.5
Accelerometer = 20.0
Moving Element velocity probe = 20.0
Piezoelectric velocity probe = 20.0
Typical settings
Proximity Probe = -20.0
Accelerometer = 0.5
Moving Element velocity probe = -20.0
Piezoelectric velocity probe =0.5
3 10 (User specified)
User defined (recommendations listed below)
Proximity Probe = 1
Accelerometer = 10
Moving Element velocity probe = 10
Piezoelectric velocity probe = 10
Integrated signals with low frequency noise = 40
35
30BFunctions
4BOPERATION
Shaft Rotation
Direction
5.3.2 Eccentricity
This function measures shaft eccentricity.
2 = Eccentricity
0 = Peak-to-Peak
1 = Proximity Probe
Millivolts / EU
Angular Position
of Probe
High Failure
Threshold
Low Failure
Threshold
3 = Thrust
1 = Proximity Probe
6 = Complementary proximity probe
Millivolts / EU
2VAA000341
4BOPERATION
30BFunctions
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage
Probe Sensitivity
Ramp Angle
4 = Differential Expansion
1 = Proximity Probe
2 = DC LVDT
6 = Complementary proximity probe
7 = Ramped Complementary proximity probe
Millivolts / EU
High Failure
Threshold
Low Failure
Threshold
Null Position in
Engineering Units
Null Position
voltage
Non-linear
Correction
2VAA000341
10
15
20
37
30BFunctions
4BOPERATION
5 = Case Expansion
1 = Proximity Probe
2 = DC LVDT
Millivolts / EU
Proximity Probe = -0.5
DC LVDT = probe dependent
Proximity Probe = -20.0
DC LVDT = probe dependent
User defined.
Set by user.
Probe
Sensitivity
Integration
Seismic (2/4)
Absolute (5/6)
6 = Relative
0 = Peak-to-Peak
1 = Proximity Probe
7 = Seismic
0 = Peak-to-Peak
4 = Moving Element
velocity probe
5 = Piezoelectric
velocity probe
Millivolts / EU
8 = Absolute
0 = Peak-to-Peak
N/A
Millivolts / EU
N/A
0 = None
1 = Velocity to
displacement
N/A
Angular
Position of
Probe
High Failure
Threshold
Low Failure
Threshold
45
-45
N/A
N/A
N for Nth
Order
Filter Low
Cutoff
Frequency
3 10 (User specified)
Same as relative
Filter High
Cutoff
Frequency
38
Relative (1/3)
User defined
(recommendations
listed below)
1 to 10 Hz
User defined
(recommendations
listed below)
Low Speed (< 1000
User defined
(recommendations
listed below)
5 to 10 Hz
Same as relative
N/A
N/A
2VAA000341
4BOPERATION
30BFunctions
RPM) = 200
Medium Speed (10005000 RPM) = 300 to
1000
High Speed (> 5000
RPM) = up to 2000
Highest speed of
interest in Hertz times
10
5.3.7 SMAX
This function measures shaft vibration using two probes in an X/Y configuration.
displacement of the shaft by trigonometrically combining the two signals.
The SMAX application combines an X (channel 1) with a Y (channel 2) producing an SMAX signal (channel 5).
Likewise, channel 3 (X) and channel 4 (Y) produces channel 6 (SMAX). In addition, if two Dual Probes are placed in an
X/Y configuration SMAX is calculated using channel 7.
The X and Y designators are arbitrary. What is more important is the probe angles and direction of rotation.
Typical SMAX Configuration (valid channels 5 - 7)
Configure the X and Y channels as vibration channels or dual probes.
Channel Type
Output Select
9 = SMAX
0 = Peak-to-Peak
1 = Peak
10 = Complementary Position
2VAA000341
39
30BFunctions
4BOPERATION
The value of the Complementary output depends on the quality of each of the two hardware inputs. The quality is
based on the High and Low failure voltages. Refer to the section that explains the Probe Failure Voltage setting.
The two probes can be mounted in such a way that the probes are either overlapping or non-overlapping as shown
below. It is preferred to mount the probes such that their ranges overlap. If this is not possible due to longer shaft
movement the range in the middle of the shaft movement will report bad quality, as shown below.
40
2VAA000341
5BMAINTENANCE
31BPreventive Maintenance
6. MAINTENANCE
6.1
Preventive Maintenance
Periodically (every six months) or during a plant shutdown, inspect modules and clean any dust accumulation with a
static safe vacuum cleaner.
6.2
Hardware Indicators
Description
R/F
Health LED. If module is OK the LED is GREEN. On failure, the LED is either RED or OFF.
During startup this LED may flash GREEN and RED while going through diagnostics.
RxTxA Profibus Bus A communication. The LED is AMBER if the module is communicating over Bus A.
RxTxB Profibus Bus B communication. The LED is AMBER if the module is communicating over Bus B.
The LED is GREEN when running normally, completed diagnostics, or completed calibration. It
STATUS is AMBER during startup, running diagnostics or calibration. It is RED if the module failed
startup, diagnostics or calibration
CH1
Channel 1 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH2
Channel 2 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH3
Channel 3 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH4
Channel 4 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH5
Channel 5 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH6
Channel 6 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
CH7
Channel 7 status. GREEN means the channel is operational and not in alarm. Solid AMBER
means the channel is in Alert. Solid RED means channel is in Danger condition. Blinking
AMBER means configuration error. OFF means channel is not configured.
Table 6-1 MPM810 LEDs
2VAA000341
41
33BTroubleshooting
6.3
5BMAINTENANCE
Troubleshooting
Symptom
Possible Causes
Module is not plugged in correctly.
Loose or disconnected.
Profibus not properly terminated.
Signal noise.
Poor connection.
Improper shielding.
Incorrect sensitivity.
Improper calibration.
Malfunctioning hardware.
42
Corrective Action
Re-adjust the module to fit properly.
Check Profibus Address Dipswitch.
Check Ethernet IP address.
Check option Dipswitch.
Replace the module.
Check +24 & -24 volt power supplies
and connector.
Re-adjust the module to fit properly.
Replace the module.
Re-adjust the module to fit properly.
TBU850 Power Failure.
Replace the module.
Check Profibus master and
configuration and addressing.
Check module Profibus address.
Check the cable for proper fitting.
Check Profibus termination Dipswitch
S3.
If LED does not turn green after
several minutes the module may be
faulty. Replace module.
Replace MPM810.
Replace MPM810 or TBU850.
Replace TBU850.
Check configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
This is usually a normal condition.
However, it could be caused by a
noisy signal or an improper
configuration.
Check configuration.
Configure channel using configuration
tool.
Re-configuration channel and set
dipswitch to save parameters.
The possible corrective actions are
just as numerous, some are listed
below.
Recalibrate TBU850.
Replace MPM810 or
TBU850.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
Check cables for any faults. This
may be an infrequent occurrence that
can not be easily identified and
corrected.
Replace the module.
2VAA000341
5BMAINTENANCE
6.4
34BDiagnostics
Diagnostics
The R/F LED will flash RED according to the table below if an error is detected. A Channel LED will light RED if the
corresponding component test fails.
Test
TBU850 Test
R/F
LED
X
Channel
LED
Error
Code
Faulty Voltage(s)
on TBU850
Faulty CPU
Solid RED
Stack RAM
Faulty access or
data
Faulty data
FPGA Load
Faulty FPGA
6.5
Status
LED
Faulty Test
Repetitive RED
Flashes
2 Repetitive
Flashes
4 Repetitive
RED Flashes
5 Repetitive
RED Flashes
Continuous
Flashing RED
Flash Test
Faulty access or
data
Bad CRC
Solid RED
Processor Test
Faulty CPU
Solid RED
FPGA Test
Faulty Signature
Solid RED
DSP Test
Faulty DSP
Solid RED
NVRAM Test
Faulty Parameters
Solid RED
Undefined
Program failure
Solid RED
Solid RED
Module Replacement
6.5.1 General
All I/O modules are designed for long, trouble-free service. If it is determined that the module is faulty, replace it with a
new one. DO NOT try to repair the module as replacing components may adversely affect the module's performance
and void the warranty. If it becomes necessary to replace any parts, contact the ABB Customer Service Department.
All I/O modules can be exchanged on-line with the process power supply connected. However, it is important to
understand the consequences of a module exchange on-line and how it affects the process. Replacement of an I/O
module affects all channels on the module. It sometimes also indirectly affects the outputs, via some application
function, on another module.
6.5.2 Replacement
Replace faulty or suspect I/O modules in the following way:
Provide access to the module by loosening the module locking device.
Grip the module firmly and extract the module.
Store extracted modules in envelopes.
Insert the new module carefully and completely.
Ensure that the module contacts mate properly with the contacts in the TBU and activate the locking
mechanism in place.
Modules initialize automatically and will begin to execute in a few seconds.
2VAA000341
43
36BFirmware Upgrade
5BMAINTENANCE
6.6
Firmware Upgrade
Occasionally firmware upgrades of the MCM800 will be available at which time an upgrade procedure will be available
with the firmware release.
44
2VAA000341
6BSPECIFICATIONS
7. SPECIFICATIONS
7.1
Microprocessors
System Communications
Profibus DP V1
Modbus RTU (Output Only)
Ethernet 10/100 Base T, TCP/IP
I/O Termination
TU Terminal Blocks
24A/250V
Positive Power
Negative Power
Constant Current
2A @ 24 VDC
ELECTRICAL
Module Operating
Module Consumption
Field I/O
2VAA000341
45
7BREVISION HISTORY
ENVIRONMENTAL
This product, when installed in a cabinet, was designed to comply with
the following Directives/Standards for CE Marking.
Emissions:
EN61000-6-2:2005
CIS 11:2003+A2:2006,EN55011:2007+A2:2007
EN61000-3-2:2006,EN61000-3-3:1995+A1:2001+A2 :2005
Immunity:
EN61131-2 :2007,
EN61000-4-2 :1995+A1 :1999+A2 :2001, EN61000-4-3 :2006,
EN6111-4-4 :2004, EN61000-4-5 :2005,EN61000-4-6 :2007 ,
EN6100-4-8 :1993+A1 :2001, EN61000-4-11 :2004
CE Mark
EMC Directive
2004/108/EC
Safety Requirements
Ambient Temperature
0 to 55 C (32 to 131 F)
Humidity
Atmospheric Pressure
Air Quality
Non-corrosive
Installation Category
8. REVISION HISTORY
Rev.
5.1
46
Date / Initial
Updated for the Version 5.1 release
05/2010 KD
2VAA000341
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 89/336/EEC and in Low Voltage Directive
72/23/EEC.
Copyright 2010 by ABB.
All rights reserved.
Release: June 2010
47
ABB Ltd.
Business Unit Power Generation
P.O. BOX 8131
8050 Zrich
SWITZERLAND
Phone: +41 (0) 43 317-5380
Fax:
+41 (0) 43 317-5382
www.abb.com/powergeneration